Using long fiber thermoplastic composites as substitutes for metal: design considerations

Long fiber thermoplastic (LFT) composite design studies often emphasize fiber content but are sketchy on fiberorientation, fibermatrix interface, and mold design. At PlastiComp we use an all-inclusive approach to successfully deploy LFT materials in metal replacement applications. Examples show how long carbonfiber compounds were successfully substituted for die-cast magnesium by redesigning the application for injection molding production, achieving tailored fiber architectures at key stress locations through strategic gate locations, as advised through finite element analysis (FEA) and mold flow analysis (MFA), and maximizing mechanical properties through optimized molding processes.