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A range of load-bearing, cosmetically appealing structural components for furniture represent a new market thrust for compression molded long-glass composites of nylon 6 and PP. Herman Miller in Zeeland, Mich., is adopting these materials because of their mechanical properties and the cost-effectiveness of an in-line compounding and molding method called Direct Feed Thermoplastic (DFT) processing. DFT was developed by Composite Products Inc. (CPI) in Winona, Minn. Its in-line system is said to reduce costs by about 30-50% versus precompounded long-glass pellets or glass-mat reinforced sheet.
One application is the support foot for Herman Miller's Red Rocket Desk. It is molded of 40% glass-filled nylon 6. Material cost per table is less than half that for an equivalent aluminum part. The part has molded-in color, while the aluminum alternative would require painting. The compound offers strength and stiffness (1.7 million psi flexural modulus) enough to anchor the table, and sufficient dimensional stability to ensure easy assembly and firm fit of the foot to the desk legs.
Benefits of the DFT approach are being extended to 40% long-glass PP materials for other furniture products. Use of PP cuts part weight and cost even further. An example is the six legs of Herman Miller's Grasshopper Table. The tapered parts incorporate complex ribs to add strength and also include a threaded metal insert for attaching the legs to the table base. In another case, Herman Miller's Red Orbiter table uses long-glass PP in truss and gusset parts intended to provide both style and stability.
From: Plastics Technology, October 2001
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