Molds and Composite Tooling Materials

Tooling system stable up to 400°C (750°F) for advanced thermoplastic and thermoset carbon fiber reinforced plastics

When it comes to molding composites that require processing at high temperatures (e.g. thermoset or thermoplastic matrices cured at 250°C and higher), choosing a tooling material becomes difficult. Machinable tooling blocks and conventional composite tools made of organic polymers will not resist the elevated temperatures, and metal tools often exhibit excessive expansion, while remaining impractical for large parts, due to their weight.

PyroTool^®, a tooling material under development at Pyromeral Systems, aims exactly at resolving these problems by providing a solution for the molding of carbon-fiber reinforced plastics (CFRP) with thermoset and thermoplastic matrices cured between 150°C (300°F) and 400°C (750°F). It offers a very low coefficient of thermal expansions (CTE), as low as 1.5x10^-6 /K, and also enables the design of temperature-controlled tools (heating/cooling).

In order to accommodate a wide range of processes, dimensions and materials, PyroTool is being developed in different formats: machinable tooling blocks and tooling materials made of carbon fibers and inorganic polymers.
- PyroTool Machinable Tooling Blocks provide a durable and dimensionally stable alternative to conventional tooling blocks made of organic polymers. This system specifically aims at providing a machinable solution for up to 350°C (660°F) while reducing the coefficient of thermal expansion (CTE) to offer better control on the dimensions of the parts. With their inherent heat-resistance PyroTool tooling blocks are also expected to allow longer production runs.
- PyroTool Tooling Materials made of carbon fibers and inorganic polymers are being developed for large parts, and specifically for tools where a solution based on tooling blocks would not be practical due to weight constraints. PyroTool tooling materials are designed to be stable up to 400°C (750°F) while maintaining a low CTE over its entire working range.

Looking for new options for the production of advanced carbon-fiber composites processed at high temperatures? Please, contact us to find out how PyroTool can simplify your processes.

Product Information

PyroTool is currently being developed for the construction of conventional and heated tools for the lay-up of carbon-fiber composites with matrices such as:

• PEEK
• PA12
• CBT/PET
• PP
• BMI
• Polyimide

PyroTool Advantages

• Lightweight, high-temperature alternative to metal tools (e.g. Invar) and standard tooling materials,
• Ideal for the lay-up of advanced CFRP processed at high temperatures,
• Low coefficient of thermal expansion,
• Compatible with large tools,
• Compatible with heated tools,
• Available in different formats and designs to best suit the size and shape of the part to manufacture.