SunForce™ is a highly functional material with unprecedented design possibilities.
Initial Cost Reductions (Mold Cost)
A mold is required to form plastic products. Molds are made of metal to withstand the injection of plastic at high temperatures and pressures. Metals used in the molds require high resistance to abrasion since plastics often include glass and minerals for reinforcement. Manufacturing cost of metal molds have a major effect on product cost. The effect of mold fabrication costs is therefore significant, particularly in small lot production (less than 10,000 units).
SunForce employs the same steam molding as ordinary polystyrene foam, however the pressure inside the mold is only a few hundredths of that required with injection molding. The low pressures used permit the use of aluminum molds. Aluminum is characterized by its ease of working, and molds can therefore be manufactured very cheaply.
Compared to metal plastic injection molds of the same shape, aluminum molds can be manufactured at 10% – 20% of the cost. Products of complex shape can therefore be readily manufactured, even in small lots.
Total Cost Reductions
The use of SunForce permits mold fabrication at low-cost, and dramatically reduces the amount of resin used, and consequently enables total cost reduction,.
Particularly for components requiring thermal insulation and light weight, SunForce is a material that is cost-effective in terms of reducing the number of components required, reducing man-hours, and in reducing labor.
A comparison of lots of 10,000 components manufactured from SunForce and an injection resin product is shown below.
SunForce™ BE - Automotive Application
Automotive industry (exterior and interior parts, structural battery parts)
(airplane components, train components, railway infrastructure, electrical parts,
Other industries (E-wave applications)