When researching processes to produce one-piece, hollow composite parts which have complex internal and/or external geometry, consider CoreTech Systems' (CTS) "lost-core" plastic molding process. Trade named Metal Core Technology (MCT) this plastic manufacturing discipline is the premiere, production proven plastic molding process utilized to produce high quality, dimensionally accurate, one-piece, hollow plastic parts which have complex internal and/or external geometry. The process has found merit with numerous plastic molding processes including plastic injection molding; resin transfer molding; filament winding; hand lay-up; as well as many other methods.

CoreTech's MCT process provides a competitive edge in most applications by simplifying the plastic manufacturing process, and yielding economic benefit over other production methods including gas assist, foam cores, adhesive bonding, soluble polymers, and welding.

The MCT process has proven beneficial for plastic parts manufacture in numerous industries

The MCT "lost-core" molding process has found merit in applications where:

• Consolidation of multi-piece plastic components into one part;
• Integration of multiple plastic parts into one part; and/or, rotation from metal or other materials, into one plastic component.

The MCT process permits increased flexibility in the design of hollow complex shaped parts, often permitting manufacture, including injection molding, of parts once considered too complex for a single-piece molding or otherwise impossible to manufacture by any other method. Since its introduction in the mid '70's the MCT process has proven beneficial in the manufacture of numerous plastic parts in many industries, including automotive (air intake manifolds, water pumps, thermostat housings, steering reservoirs, air ducts); aerospace/aircraft (struts, fans, blades, thrust reverses, housings); recreational goods (bicycle wheels/frames; paddles/oars; tennis/other racquets); plumbing (faucets) and pumps (industrial impellers and fans), and other general industries.

CoreTech's engineering staff offers optimum parts design expertise

CoreTech's engineering staff provides support to achieve optimum part design, with the highest consideration to meet performance and manufacturability requirements. CTS will conduct a Preliminary Engineering Evaluation of any component to determine the viability of using the MCT process to produce the part. Following this, a more formal Application Analysis Study (AAS) can be commissioned. This study generates valuable information from which the client can make a "go"/"no-go" decision to proceed with the development of the part. The AAS includes a complete engineering analysis of the part, costs to complete prototyping of the part; projections for in-house production equipment costs; and for those not seeking to manufacture the part themselves, an estimated "piece price" for the supply of the part utilizing CTS's sub-contracted production facility.

The MCT "lost-core" molding process involves the use of a low melting temperature metal core, which is then loaded into a plastic molded tool, over molded and then melted-out after the part is formed. Standard plastic molding practices are utilized. Most resins can be accommodated.

Environmentally friendly, the MCT process recovers 99.9% of the metal core alloy and reuses it repeatedly to make new metal cores. A wide temperature range of proprietary metal alloys are available to serve in most resin over-molding applications. High quality smooth core surface and tight, repeatable dimensional accuracy supports molding of parts to the strictest of dimensional tolerances, normally 0.0015" per dimension. Control of wall thickness is consistently met.

MCT can help you achieve lower component manufacturing costs

CoreTech's process has helped numerous clients achieve lower component manufacturing costs derived from materials savings, process simplicity and reduction in secondary/finishing operations.

For more information about CoreTech Systems, our MCT technology and our moldings expertise, please contact by email, telephone (401-884-8808) or fax (401-884-8848).