A Prototype System for Molding Virgin and Recycled Discontinuous Long-Fiber Reinforced Plastic Composites into Commericial Products

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Continuous-fiber reinforced plastics are superior mechanically to short-fiber reinforced plastics. However, components fabricated from continuously reinforced plastics are labor-intensive, time consuming and expensive. In phase I and in response to industrial demand, an innovative system to mold quality, discontinuous long- fiber, reinforced plastic products to net dimension was developed. Results of the American Society of Testing Materials test specimens molded from either virgin or virgin/recycled materials and scanning electron microscope and ashing data, substantiate the advantageous mechanical/physical performance of such composite components. The mechanical advantages were achieved without sacrificing the design and processing flexibilities or economical advantages of using short-fiber composites. The use of recycled feed-stock also has favorable environmental implications. In phase II the pioneer equipment will be developed into a prototype system for its commercialization and that of its products. The use of other virgin and recycled feed-stock materials will be evaluated and process optimization for molding various materials into industrial products will be conducted.