The use of syntactic foam materials as plug assist tooling replacing conventional materials such as aluminium, wood or felt has become increasingly popular in the thermoforming industry. Syntactics, the combination of hollow glass microspheres in a polymer matrix, have many unique properties which make them ideal candidates for these applications, for example:

  • Low thermal conductivity and specific heat
    This translates to low heat transfer reducing warm-up time and virtually eliminating material sticking to the plug
  • Excellent temperature resistance
    NEWTAC 104 is specially formulated with epoxy resin which maintains a high modulus at elevated temperatures
  • Easily machined
    NEWTAC 104 can be easily machined to any size or shape using conventional equipment
  • Dimensionally stable
    The low coefficient of thermal expansion means the plug maintains its shape over a wide temperature range
  • Lightweight
    This increases the life of capital equipment due to reduced wear and tear on moving parts
  • Variety of shapes and sizes
    The material is provided in standard size rods or sheets but may be custom moulded to meet your specific requirements

NEWTAC 104 may be used in a wide variety of applications on sheet-fed or in-line machines. It may also be used with most commonly thermoformed materials as well as some of the more exotic materials available today. NEWTAC 104 may be used as a direct replacement for the other epoxy syntactic materials.

  • Tooling
Product Features
  • 3D fabrication
  • Dimensional stability
  • High temperature applications
  • Low weight
  • Wide temperature range
  • Industrial

Typical properties

Product Property Value Test Method
Colour White
Density (kg/m3) 670
Thermal conductivity (W/m.K) 0.12
Specific heat 2.09 kJ/kgºC
Coefficient of thermal expansion (CTE) 31 x 10(-6) m/m/ºC
Compressive strength (MPa) 45
Compressive modulus (GPa) 2.33
Temperature (ºC) 180