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Case Study 4

Part name: Phenolic insulator

Material: Grade CE garolyte natural phenolic

Thickness: .062

Challenge: To produce a small part with a relatively large thickness (for its length and width), with holes with depth-to-diameter ratios of more than one, in a very brittle plastic material.

Solution: This part was produced complete on a compound die, through which strips (rather than coil stock) were fed to produce a complete part.

To prevent cracking, the strips were heated to approximately 150 degrees F just prior to entering the die. In-process QC measurements had to allow for thermal expansion of the phenolic material. The temperature was closely monitored to avoid damage to the matrix of the material, which could have resulted in embrittlement.