Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Four Main Areas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Obtain Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Strategy Theory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Defects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Angel Hair. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Burns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Delamination. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Dimension – Small . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Dimension – Large . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Distortion / Deformation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Flash. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Jetting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Plate-Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Short Shot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Sink . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Splay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Surface Finish. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Gate Vestige. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Voids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Warpage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Weld Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 The Injection Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Non-Return Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Nozzle Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Important Advice. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 The Clamping Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Mold Design Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Determining Cooling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Cooling Line Spacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Bibliography. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Acknowledgments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Design Guide 5 CHAPTER 1 | PRODUCT SUMMARY GRAVI-TECH™ DENSITY MODIFIED FORMULATIONS High-Performance Alternative to Lead and Other Traditional Metals PRODUCT DESCRIPTION Gravi-Tech™ polymer-metal composites offer a high-performance thermoplastic-based alternative to lead and other traditional dense metals. KEY CHARACTERISTICS The primary features and benefits of Gravi-Tech formulations are: • Customized density, offering a wide range of specific gravities from 1.5 to 11 gm/cm3 • Broad modulus range, from very flexible to very rigid grades • Corrosion resistance, withstanding oxidation for long-term use and benefit • Chemical resistance, withstanding fuels, oils and other harsh chemicals Additional features include: • Design flexibility and processing ease • Good impact strength • Elevated heat deflection temperature 6 Gravi-Tech Design Guide 7 CHAPTER 2 | PROCESS SETTINGS Density Modified Formulations Gravi-Tech™ polymer-metal composites are high-density materials developed as thermoplastic-based alternatives to lead and other traditional metals. These materials have been formulated using select metallic fillers and engineered thermoplastic resins to have densities similar to actual metals, while also providing the design flexibility and processing ease of conventional thermoplastics.

Impact modified Product Code - - - PP5920 PP5935 PP5940 B131 PP5950 Reinforcement Type - - - Glass/Mica Glass/Mica Glass/Mica Glass/Mica Reinforcement % - % - 20 35 40 50 Specific Gravity 73°F (23°C) - ASTM D792 1.05 1.17 1.25 1.34 Tensile Strength Yield psi ASTM D638 7000 9000 10,000 12,800 MPa ISO 527 Tensile Elongation Break % ASTM D638 6 5 5 2 Flexural Modulus 73°F (23°C) psi ASTM D790 550,000 780,000 870,000 1,300,000 MPa ISO 178 3900 5500 5800 9000 Notched Izod Impact 73°F (23°C) ft-lb/in ASTM D256 0.7 0.9 1.3 1.5 kJ/m2 ISO 180 4.0 5.0 7.0 8.0 Heat Deflection 66 psi °F ASTM D648 304 315 310 315 °C ISO 75 151 157 154 157 264 psi °F ASTM D648 225 298 290 310 °C ISO 75 107 148 143 154 Maxxam™ XST Thermoplastic Olefins (TPO) Offers exceptional stiffness to impact balance including excellent cold temperature impact resistance.

We supply fluoropolymer and high-temperature thermoplastics-based colorant and additive concentrates and compounds, dispersed pigments for coloring PTFE, functional additives such as laser marking, foaming agents, conductive, antistatic, radiopaque, reinforced, and cross-linked grades, as well as a full range of printing, striping, and marking inks.

In this study, Avient’s Trilliant™ HC8900 and Edgetek™ ET8900 thermoplastics were tested alongside competitive materials used for various medical and consumer device enclosures.

HAMMERHEAD™ MARINE COMPOSITE PANELS APPLICATION & INSTALLATION GUIDE PRODUCT DESCRIPTION FEATURE BENEFIT Exceptional strength-to-weight ratio Lightweight yet strong structural performance and increased payloads Resistance to UV light, chemicals, moisture degradation and rot Resistance to harsh marine conditions Tough and impact resistant Durability and long product life Dimensionally stable Consistent performance in extreme temperature and humidity fluctuations Strong adhesive properties Easy bonding to various materials FEATURE BENEFIT Ready-to-install Fewer parts & reduced scrap Large format Improved aesthetics with seamless designs Made via continuous-fiber manufacturing process Consistent quality in every panel PERFORMANCE ADVANTAGES MANUFACTURING ADVANTAGES Hammerhead™ Marine Composite Panels are made from continuous glass- fiber reinforced thermoplastic face sheets and polyester foam cores.

available from Avient POLYMERS • PET • Polyolefins • PVC COLOR TYPES* • Tints • Translucents • Opaques • Special effects • Additive additions (functional colors) PROCESSES • Injection Stretch Blow Molding (ISBM) • Injection molding • Extrusion Blow Molding (EBM) • Extrusion Sheet, Fiber, Film Avient ColorMatrix has pioneered the development of liquid color dispersions since the 1970s and is now considered the leading global innovator and supplier of liquid colorants for thermoplastic and silicone applications.

available from Avient POLYMERS • PET • Polyolefins • PVC COLOR TYPES* • Tints • Translucents • Opaques • Special effects • Additive additions (functional colors) PROCESSES • Injection Stretch Blow Molding (ISBM) • Injection molding • Extrusion Blow Molding (EBM) • Extrusion Sheet, Fiber, Film Avient ColorMatrix has pioneered the development of liquid color dispersions since the 1970s and is now considered the leading global innovator and supplier of liquid colorants for thermoplastic and silicone applications.

Polystrand establishes us with an immediate leadership position in new, next generation thermoplastic composites that combine high strength characteristics of a thermoset with the design freedom of thermoplastics."

CHAPTER 1 | APPLICATION SUMMARY Design Guide 5 GT5200-0013 GT6000-0004 GT7300-0006 GT5200-5003 GT6000-5002 GT7300-5007 Specific Gravity* 2.0 3.0 2.0 2.5 2.6 2.2 Color Options* Various Various Black to Grey Black Various Various Electroplating No Possibly Yes Possibly Possibly Yes Base Resin PP PA6 ABS PP PA6 ABS FDA Compliant* Yes Yes Yes Yes No Yes Region Produced North America North America North America Europe Europe Europe Full Name X GT5200-0013 PT White X GT6000-0004 PT White X GT7300-0006 PT Black GT7300-5003 Black FD GT6000-5002 EI White 1 GT7300-5007 X2 White FD *Please contact Avient for additional information 6 Gravi-Tech CHAPTER 2 | PROCESS SETTINGS Density Modified Formulations Gravi-Tech™ polymer-metal composites are high-density materials developed as thermoplastic- based alternatives to metals. These materials have been formulated using select metallic fillers and engineered thermoplastic resins to have densities similar to actual metals, while also providing the design flexibility and processing ease of conventional thermoplastics.

MULTIPURPOSE COLORANTS Polyethylene 1% Polypropylene 1% GP Polystyrene 1% HI Polystyrene 1–2% Acrylics (Opaque) 1% PBT Polyester 1% PET Polyester 1% Polyurethane 1–2% Polyamide (Nylon) 1% Acetal 1% SAN 1% ABS 1–3% PVC 1–3% Polycarbonate 1% Thermoplastic 1–3% Alloys & Blends 1–3% EVA 1% Filled Polymers 1–3% RECOMMENDED ADDITION RATES CONCENTRATE SELECTION Omnicolor colorants are generally selected because of their versatility where a wide range of polymers are processed and their availability for sale in small quantities.