TPF Process Review

In 2002, the Metis Design Corporation was commissioned by Envirokare Tech, Inc. to perform a thorough engineering review of the Thermoplastic FlowForming (TPF) process. TPF is a proprietary process developed by Thermoplastic Composite Design Inc. (TCD) that "enables the manufacture of large structural parts using long-fiber reinforced thermoplastic resins." As 3rd-party unbiased composite experts, MDC's role was to report on the value-added utility and cost-effectiveness of the TPF process.

MDC's review of the TPF process involved consideration of many factors including material properties and cost, infrastructure costs, cycle time and production costs and process usability. As part of our review, coupons of material formed by the TPF process were tested to determine strength and stiffness, as well as the length of the glass fibers present in the processed material. The final report prepared for Envirokare (link to press release), validated their claim that the TPF process could enable manufacturers to mass produce long-fiber reinforced plastic pieces at high rates and labor efficiencies that favorably compare with many current production techniques, while retaining accuracy and ability to utilize low molding pressures. Another advantage highlighted by MDC was the ability of the TPF material deposition process to allow complex ribbing on both sides of the molded part. Envirokare continues to license the TPF process to companies around the world to enable solutions to complex composite molding problems.

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