High Performance Thermoplastic Composites for Medical Applications

1. HighPerformance ThermoplasticComposites for Medical Applications Cutting Dynamics Avon OH May 29, 2013

2. Why Thermoplastic Composites? High strength, stiffness, lower weight vs metallic components Maintains high precision tolerances through numerous autoclave sterilizations Radiolucent Tough, durable, excellent fatigue resistance Shape has the potential to be tailored on site if needed Green, recyclable product Excellent chemical resistance

3. Continuous Compression Molding • Process • Lay up tape in predetermined orientation • Process thru CCM flat machine- 24” wide max • Process thru CCM Shape Machine-5 x 5 sq max • Cut on 5 axis, WJ or Robot

4. CONTINUOUS COMPRESSION MOULDING MECHANICAL DEPICTION 2-step or 2D process 1-step or 1D process

5. Stamp Forming • Process Description • Material Layup- manual or FF • Continuous Compression Mold-Flat-24” wide • Stamp Form in Press- 40” x 48” • Trim on 5 axis WJ or machine Type Lay-up of multiaxial panels • Full automatic process control • Maximum part size 40" x 40" • Maximum speed 5 minutes/part • Maximum thickness not limited • Status in Service

6. 3-Dimensional Stamp Forming Process • Full automatic process control • Nominal compression force 4000 kN • Maximum width 40" • Maximum part size 28" x 40" • Maximum speed 5 minutes/part • Maximum temperature 752 °F • Maximum thickness 0.2" • Capacity 3-shift 8,500 parts/year • (5 minutes/part) • Status in Service Production unit for 2D and 3D stamp forming Medium parts

7. 5 Axis Robotic Trimming

8. Profile Machine • Maximum width 4" (100 mm) • Maximum Cross section 4" x 4" (100x100 mm) • Maximum feed 150 ft/h (30 m/h) • Maximum temperature 770 °F (410 °C) • Maximum thickness 0.4"(10 mm)

9. Prototype and Series Production of CCM Parts

10. Typical Weight Reduction Application • These typical parts could be made from one CCM then smaller parts removed then trimmed and formed. • 4.1926 lb alum • 2.366 lb CCM • 1.8266 weight savings X 2 (RH + LH) 3.6532 • Use click-bond & delete rivets

11. 3D Molded Shapes • Extrusion of IM7 reclaimed and Pure PPS • Fibers are Random- ½” to 1” long • 40% Fiber, 60% PPS • 70-80% of strength of uni- tape • Add unidirectional tape in areas of high stress for additional strength

12. Injection Molding and Overmolding Continuously Reinforced Components Can be Enhanced with Detailed Features by the Injection Overmolding Process • Enhanced Properties vs Injection Molding • Incorporation of Complex Features Without Subsequent Machining • Lower Cost • Metal Replacement Opportunities for Reduced Weight

13. Injection Molding Properties • Weight and cost reductions vs metal and compression molded parts Metal-like Properties Can be Achieved with Novel TP Matrix

14. Summary • Thermoplastic Composites are demonstrated, high performance materials for medical applications • Lightweight, high performance radiolucent material • Maintains precision tolerances through numerous sterilizations • High temperature usage • Wide variety of forms available • We are interested in working on support and development of medical applications.

15. Thank you! For more information, please contact: Michael Favaloro Sales Manager mfavaloro@cuttingdynamics.com Phone: 978-270-6011 Bill Carson President bcarson@cuttingdynamics.com Phone: 440-249-4165 Fax: 440-937-4742 Cutting Dynamics, Inc. 980 Jaycox Road Avon, OH 44011