Heat-activated foaming core rapidly achieves net-shape 3D parts

L&L Products (Bruce Township, Mich., U.S.) showcases the combined expertise in materials science, advanced engineering and manufacturing process optimization for customers to develop solutions that deliver structural reinforcement, substrate bonding, static sealing and acoustic improvement for automotive, aerospace, commercial vehicle, construction and consumer products applications. This knowledge has taken the form of InsituCore foaming core structural technology, a family of one-component, heat-activated foaming structural materials that can be used to create foam core composites.

Placed in a heated tool, the material foams to fill the mold cavity and form net-shape parts without time-consuming machining processes or costly press equipment. With InsituCore, internally generated pressure can be used to create net-shape, lightweight and strong 3D parts in a simple, clean process. These materials can enable faster cycle times, a reduction in waste material and optimized production processes by eliminating secondary machining and assembly operations. With a wide range of volumetric expansion (800% to 4,000%), InsituCore can enable lightweighting over traditional materials. Moreover, the technology is free of isocyanates, unlike polyurethane foams.

Additionally, L&L is showcasing Phaster A-K700, a rapid cure adhesive designed to provide optimal adhesion and peel strength to a variety of metal, ceramic, cementitious and polymeric substrates without the need for extensive surface preparation. The product features no pungent odors and contains biorenewable carbon content. Based on the company’s polyhydroxy ether phosphate ester (PEPE) chemistry, the Phaster A-K700 is designed to enable rapid bonding of a wide variety of substrates for composite assemblies. A-K700 offers high peel strength up to 10 times compared to commercially available products, L&L notes, and is also free of isocyanates.

Attendees can speak with L&L Products representatives and try out the InsituCore pickleball paddle at the company’s mini court, as well as perform an A-K700 T-peel test. Attendees can also see the process of making a composite part in three steps at the Composites One demo area.

Today, L&L has more than 1,200 employees worldwide, 10 manufacturing facilities and locations in 15 countries.