Molding Technology Reinvented by X2F

X2F’s revolutionary Controlled Viscosity Molding (CVM) equipment is based on a proprietary technology, offering a game changing alternative to traditional molding. CVM is a radical innovation, enabling high-value advancements in multiple industries that have been limited by complex material processing challenges. CVM addresses these challenges with patented technology, developed over a 15-year period, that performs complex molding using difficult-to-mold materials.

Controlled Viscosity Molding (CVM) Technology

Our patented CVM technology precisely modulates polymer viscosity and material flow into the mold cavity at 70% to 90% lower pressure compared to standard injection molding. Because CVM equipment is designed to mold at very low pressure it is a significantly less harsh and abrasive molding process compared to injection molding, and dramatically reduces the risks of unwanted defects, molded-in-stresses and damage to sensitive components during overmolding.

How it Works

CVM is self-tuning, utilizing internally embedded electric heaters, sensors, and control-loop feedback mechanisms with programmable logic controller (PLM) and advanced software algorithms that carefully modulate temperature, material viscosity and the movement of the extrusion screw.

CVM gradually builds to optimal mold-fill conditions through a multi-step “pulse-packing” approach that rotates the extrusion screw in two directions, creating our proprietary pack, hold and repack process. CVM builds up to final pack pressure as the cavity fills and packs it out at the final set point.

Multiple patents cover the entire machine, but the control system is a very important piece of the patented technology. The machine’s control system is intelligent, interpreting what is happening with the plastic throughout the molding process by sensing pressures and the torsional load on the screw such that CVM can flow virtually any resin without abusing the polymer in the process.

And there is no gate freeze-off because CVM maintains a dynamic load at the gate, continuing to add material as it shrinks and fills the mold.

Molded parts background

Materials and Fillers

Our revolutionary CVM technology easily molds ultra high-performance polymer composite materials. Because of the advantages CVM technology offers, we are garnering a lot of interest in the plastics industry. X2F currently has partnerships in place with several global materials companies, distributors and brand owners, including Covestro, Krayden, and R-Tek Thermal, just to name a few.

CVM can mold a wide variety of challenging materials including:

  • Ultra High Molecular Weight Polyethylene (UHMWPE)
  • Carbon Fiber Filled Polymers (e.g. Nylon, Polypropylene, PEEK, etc.)
  • Highly Filled Glass Polymers
  • Metal & Ceramic Filled Thermally Conductive Polymers
  • Makrolon® Thermally Conductive Polycarbonate by Covestro
  • Keratherm® Thermally Conductive Granulate by Kerafol
  • Polycarbonate Composites with Dense Graphite Filler
  • Bio-based and Bio-mixed resins

Tooling

Lower operating pressure also means more flexibility in the materials that can be used to make the molds. They don’t all need to be made of steel. Aluminum molds work quite well with CVM technology and can be produced quicker and cheaper than those made of steel.

3D printed molds can also be used with CVM technology, especially for prototyping. These molds can be created rapidly, providing the advantage of extremely fast prototype turnaround times. We are currently using 3D printed mold core and cavity inserts produced by stereolithography (SLA) type printers which provides us with the capability to go from design to physical parts on our customer’s desk in 10 business days.

Automated Manufacturing

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CVM easily scales from prototype to high-volume production needs and can be fully automated due to the machine’s intelligent control system. And CVM equipment is easy to operate. No plastics experience is required.

The entire CVM workflow from front to back is more efficient and cost effective compared to standard injection molding, conformal coating and potting. From smaller footprint and reduced power consumption to lower labor costs and enhanced material flexibility options, CVM enhances the entire economic picture.