Mitsubishi Chemical Advanced Materials has the unique capability of casting nylon to custom mill shapes, cast blanks, near net shapes or cast to size finished parts. Using this technology, many designers have reduced the total cost to manufacture engineered components. Custom cast nylon parts often effectively replace machined plastic parts, sand cast metal parts, and multipart metal assemblies.
Custom casting offers a manufacturing alternative that bridges the plastic fabrication methods of machining from stock shapes and injection molding of thermoplastic parts. It is ideal for small and medium quantity production runs of parts too large or too costly to injection mold. Part size and production quantities most often custom cast are found in Figure 28.
Nylatron® and Monocast® (MC®) cast nylons produce tough, strong, resilient, and highly wear resistant parts that cost effectively replace bronze, brass, iron, steel and aluminum in many heavy-duty industrial applications.
Custom cast parts are made by a proprietary monomer casting process in which liquid monomer is directly polymerized into nylon polymer in the mold. Parts of virtually unlimited size and thickness, retaining internal soundness can be produced by Custom Casting. Eleven ft. tall slide bars and six feet diameter dryer gear rings that weigh 250 lbs. are just a few of the very large parts Mitsubishi Chemical Advanced Materials has produced using Custom Casting. Four inch bearings, bottle handling cams, and gear blanks cast over steel cores are also cost-effectively cast to a near net size, saving machining and assembly time and material costs.
Custom sizes of rod, sheet, tubular bar.
Castings of close to finish dimensions, supplied sufficiently over size for finish machining.
Castings the part to complete or nearly finished dimensions. Parts may require no machining, or machining only on critical dimensions.
Nylons can absorb up to 7% (by weight) water under high humidity or submerged in water. This can result in dimensional changes up to 2% and a corresponding reduction of physical properties. Proper design techniques can frequently compensate for this factor.