High-Temperature Syntactic Foam and High-Slip Plug Materials for Thermoforming

Developer and supplier of plug-assist materials for the thermoforming industry CMT Materials, will launch a new Hytac syntactic foam with high-service temperature and high friction at the K 2022. The company will also highlight a new developmental higher slip plug material that eliminates the use of PTFE. These product developments represent the latest in toughened copolymers that are easy to use and extend the performance range to fill challenging market needs, according to CMT Materials’ managing directorTerry Woldorf. They are also the culmination of collaborative work with leading thermoforming companies to optimize plug-assist material choices.

The new Hytac-HTF-- available in a variety of sheet and rod size, is a syntactic foam capable of high service temperature performance (450 F) based on a toughened copolymer formulation. It is easily polished to a mirror-like surface while maintaining optimal friction properties, making it an ideal choice for use with sticky barrier films to minimize plug buildup. Such copolymer plug materials reportedly also provide dust-free machining and high strength. Reportedly, Hytac syntactic foam is used by the majority of toolmakers and thermoforming processors around the world. Thin-gauge thermoformed parts such as drinking cups, coffee capsules, fruit trays, barrier trays, horticultural parts, and many more are formed with plug-assisted pre-stretching.

Meanwhile, a developmental high-slip plug assist has been developed in response to market concerns over polyfluorinated alkyl substances (PFAS) in such formulations. While laboratory “set-off” testing by the Intertek Health, Environmental and Regulatory Services Chemical Management Team has confirmed there is no material transfer when using the incumbent Hytac-FLXT, CMT understands the preferable approach will be to completely eliminate PTFE or any other PFAS “forever chemicals” as an ingredient.

Hytac-FLXT is widely used when forming PP, various multilayer and other challenging materials. The new developmental high-slip plug material is expected to provide the same high performance as Hytac-FLXT with easy material release, excellent forming properties, and ease of polishing. The developmental grade is expected to be commercialized by late fall.