Processing Success with DYLARK Resins

DYLARK resins are a preferred material for use in instrument panel applications. Beyond the performance benefits that DYLARK is noted for, it can also be easily processed. DYLARK resins exhibit superior flow characteristics when compared to most competitive glass-filled resins.

DYLARK resins deliver numerous advantages to manufacturers, such as processing ease, faster cycle times, elimination of material drying and product quality and consistency. NOVA Chemicals is dedicated to assisting our customers to improve productivity, reduce costs and produce a quality finished product. Below are a few elements to consider while designing the IP system with DYLARK resins. These tips will optimize the design and molding processes and help eliminate trouble-free molding down the road:

Design Stages

  • It is recommended to maintain a design that incorporates uniform wall thickness throughout the part. For areas that need to be more robust (i.e. airbag openings) consider utilizing ribbing versus adding additional wall stock. This will help minimize part distortion due to effects of differential cooling, as well as improve the ability to run overall faster cycle times.
  • DYLARK resins are notch sensitive. All ribs, bosses, attachments and wall transitions should incorporate radii to help improve strength, part performance and overall handling in the plant.

Tooling Stages

  • Typically there are areas in an IP design that will be difficult to cool. Review design enhancements that will improve these conditions and observe cooling line placement. In some cases, the use of a beryllium alloy will help to maximize the cycle.
  • Selection of the gating type: DYLARK is successfully used in all types of manifold systems with most gating styles. However, in utilizing DYLARK materials, it is not recommended to use “cashew” type gating.
  • Proper venting of molds is important to eliminate localized burning and mold damage, improve weld line integrity and allow for easier filling of parts. Whenever possible, fill parts with material flow going outward to allow for best condition in venting to atmosphere.

Molding Stages

  • Molding equipment is a key factor in processing success. DYLARK resins are processed on all types of injection molding machines utilizing general-purpose screw designs. Injection units should be capable of delivering fast fill times due to the quick setting characteristics of the material. Clamp requirements generally range from 2–3 tons per square inch with 2.5 tons per square inch commonly used for IP applications.
  • Since most DYLARK grades are glass-filled, it is important to consider screw, barrel and mold wear resistant treatments/coatings to help extend the overall life.

NOVA Chemicals offers a variety of computer-aided engineering (CAE) services to enable our customers to optimize performance and processing for DYLARK resins. For more information on optimizing your manufacturing and design processes, please visit our online design manual at www.DYLARK.com or contact a NOVA Chemicals technical representative at 800-233-6461.