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The KyronMAX™ series from Mitsubishi Chemical Advanced Materials - Engineered Solutions is a unique combination of a proprietary high pressure molding technology, coupled with a state-of-the-art material technology to produce high strength structural components.

Strongest Moldable Thermoplastic Materials Available

Composite plastic materials are generally broken down into two categories: composite plastics that can be injection molded and composite polymers that are produced with pre-preg lay-ups. Although injection molded composite plastics are inherently less expensive than their lay-up counterparts, because they can be high volume molded, they traditionally have considerably lower mechanical properties. Lay-up composite polymers are much stronger but require very expensive and laborious processing which limits their applications. The KyronMAX materials bridge the gap between the two technologies and allow parts to be high volume injection molded with strengths that approach lay-up composite polymers.

Metal Replacement

Generally speaking even the strongest moldable plastics are nowhere near the strength of metals so the metal part geometry must be altered and re-engineered to utilize plastic materials. This often involves adding much more material volume of the plastic which can increase the weight and cost of the part. KyronMAX polymers offer mechanical properties which meet, and in some cases, exceed metals. The resulting component design can more easily replicate the original metal design, reducing material volume, while realizing all the benefits of the plastic material.

Product Features

  • Tensile strength to weight ratio - Higher than steel.
  • Weight - Almost 75% lighter than steel and almost 40% lighter than aluminum.
  • Higher product performance due to better knit line strength - Lower filler levels reduce the knit line effect and increase the strength of the molded part.
  • Better "practical toughness" due to lower filler loadings - Lower filler content increases the material's elongation at yield which results in the ability for the part to yield and not fracture.
  • Lower filler loadings than traditional thermoplastic compounds - Lower filler levels promote a larger processing window and reduce weight.

 

KyronMAX S Series

KyronMAX ES Series

KyronMAX XS Series

Tensile StrengthUp to 50,000 psi/
(345 MPa) 
50,000 - 75,000 psi/
(345-517 MPa)
75,000 - 120,000 psi/
(517-827 MPa)
Tensile ModulusUp to 5 million psi/
(35 GPa)
5 - 8 million psi/
(35-55 GPa)
8 - 12 million psi/
(55-83 GPa)
FillersMAX FibersMAX Fibers, 
Glass, Carbon
MAX Fibers, 
Glass, Carbon
PolymersPEEK, PPS, PEI, PPA, PAPEEK, PPAPEEK, PPA
Metal ReplacementAluminum, 
Cast Iron, Magnesium
Steel, Aluminum, 
Cast Iron, Magnesium
Titanium, Stainless Steel, Steel, Aluminum, Cast Iron, Magnesium

Targeted Industries

  • Aerospace
  • Automotive
  • Industrial
  • Food Processing
  • Medical
  • Oil & Gas
  • Electronics
  • Chemical

Application: Molded Screws

Problem
For years aerospace OEM's have requested Mitsubishi Chemical Advanced Materials - Engineered Solutions develop an injection moldable thermoplastic composite bolt that exhibits metal-like strength. These end users have been looking at plastic fasteners to replace traditional titanium metal fasteners for weight savings but were unable to find a polymer with enough mechanical performance or that was economically viable.

Solution
Mitsubishi Chemical Advanced Materials - Engineered Solutions molded one of the KyronMAX thermoplastic polymers into a standard #10-32 bolt and was able to meet both the strength and the cost target requirements for the application while reducing the weight of the incumbent titanium bolt by approximately 60%! 

Property

Molded Screws Target
Minimum Strength

KyronMAX XS

Tensile Load650 lbs (295 kg)741 lbs (336 kg)
Double Shear Strength1,600 lbs (726 kg)1,890 lbs (857 kg)

 

 

Property

Molded Screws Target
Minimum Strength

KyronMAX XS

Stainless Steel

Steel

Titanium

Weight0.04 oz 
(1.20 grams)
0.03 oz 
(0.95 grams)
0.27 oz 
(7.60 grams)
0.26 oz 
(7.41 grams)
0.15 oz 
(4.28 grams)
Density0.08 lb/in3
(2.25 g/cm3)
0.07 lb/in3
(1.79 g/cm3)
0.29 lb/in3
(8.00 g/cm3)
0.28 lb/in3
(7.80 g/cm3)
0.16 lb/in3
(4.50 g/cm3)
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