Plastics &

Engineered
Materials
For more information on partnering
with the Kansas City Plant, contact:
Ofce of Business Development
1.800.225.8829
customer_inquiry@kcp.com

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Ceramics &
Glass

Ceramics and glasses are used in a variety of

applications from structural materials to highvoltage capacitors. The Kansas City Plant has
ceramic process capabilities such as powder
formulation and continuous form tape casting.
We have extensive experience in working with
industry and centers of excellence in both the
development and transfer of ceramic and glass
processes. Listed below are several examples
of how we use ceramic materials and
processes to support internal and external
customer needs.

Features

Ceramic Tape Casting

We have developed the capability to fabricate ceramic devices such as capacitors and
insulators utilizing tape casting processes
and equipment. Tape casting of ceramics is
a proven technology used to form high-quality, uniform layers for multi-layer devices. With

in-plant blanking, lamination and screen print

operations, the Kansas City Plant offers a
complete processing solution for ceramic,
multi-layer device needs.
Capabilities currently exist to cast
continuous sheets of tape that are up to 13
wide and 2 to 6 mils thick unfired
Thin, ceramic sheets have been used to
manufacture ceramic capacitors with a wide
range of geometries, dimensions and
electrical performance requirements. For
example, the Kansas City Plant has
manufactured a 1.6 uF segmented ring
capacitor designed for 6 kV applications and
capable of fitting around a cylindrical device.
We are currently developing slurry formulas
utilizing a variety of ceramic materials
including nano-sized ceramic powders
and low-temperature co-fired ceramic

(LTCC) material
We are also working with university partners
to develop ceramic materials and processes
with improved performance and reliability

Multi-layer ceramic
capacitors fabricated
from dielectric tape
cast at the Kansas City
Plant

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Ceramics &
Glass

Joining and Sealing

To support hermetic sealing applications, the
Kansas City Plant has developed ceramic-tometal joining capabilities including active metal
brazing and Mo/Mn metallization processes.
In addition, our engineers have experience in
the characterization, testing, modeling and
failure analysis of glass-to-metal seals.
Because unique ceramic processing
methods require a specific furnace
atmosphere, Kansas City Plant has a
1,500 C furnace that can perform high-
vacuum, partial-pressure or positiveHydrogen furnace work zone
pressure hydrogen processing with a
controlled dewpoint
We perform in-plant lightning arrestor cable
ceramic granule fabrication and testing
In conjunction with our analytical sciences
lab, equipment such as a variable pres-
sure SEM has been used to characterize
the material-process relationship of dense or
porous ceramic components, joint interfaces
and MEMs devices

Applications

Capacitors
High-voltage, high-energy density capacitors
are made for applications where fast rise time,
short pulse width and low equivalent series
resistance are critical to performance. Ceramic
capacitors also have the advantage of being
capable of operating and existing in extreme
environments where other materials fail, such
as in high temperatures or near radioactive
material.
Insulators
We use tape casting processes and thick film
printing to produce high-performance ceramic
insulators for advanced weapon systems such
as lasers and firesets. High-performance

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Multi-layer
insulators
fabricated at
the KCP from
commercially
available LTCC
tape

insulators have non-weapon applications as

well, such as medical devices and linear
accelerators.
Joining and Seals
Ceramic-to-metal joining and glass-to-metal
seals are typically used for hermetic and
electrically insulating seals. They are typically
used as electrical feed-throughs and
insulating mounts in instruments, gauges,
electronic devices and vacuum systems.
Low-Temperature Co-Fired Ceramics
LTCCs make custom packaging of
microelectronics possible. Please see the
LTCC information in the Microelectronics
section of this catalog.

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Fiber-Reinforced
Composites

Composites fabricated with two or more

distinct materials provide unique physical
properties in products that are used to protect
critical internal weapon components and
ancillary secure electronics. The Kansas City
Plant manufactures a wide variety of these
products. Our secure fabrication facility
specializes in molding fiber-reinforced epoxy
composites using autoclave processing, resin
transfer molding and filament winding
processes. Carbon, glass and aramid fibers
are processed in the form of dry fabrics,
prepreg fabrics and continuous filaments.
Products in a wide variety of shapes and sizes
can be molded to size or molded to nearnet-shape and final-machined.

Features

The Kansas City Plants composite

facility processing capabilities
include:
Vacuum-bag, autoclave curing capacities up
to 5 diameter by 10 long
Circumferential winding of tape and tow
materials in sizes up to 2 diameter by 4
long
Steel rule die-cutting of thin materials up to
18 by 26
Programmable, automated cutting of
prepregs and film materials up to 6 wide by
12 long
Vacuum impregnation and vacuum-assisted
resin transfer molding processes
Curing in walk-in and cabinet ovens up to
650 F
High-voltage, low-leakage testing located in
a secure, humidity-controlled environment
A 30-ton heated compression molding press
Plasma cleaning in oxygen, argon and
zero-air atmospheres
Machining in an adjacent low-humidity,
non-lubricant area with several computer
numerically controlled 4 and 5-axis mills and
lathes

Graphite composite packaging

for secure electronics module

Automated
cutting
machine

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Fiber-Reinforced
Composites

Applications

Composites offer significant flexibility in design

and fabrication, which translates into parts that
are lighter, stronger and have unique
properties to fit specialized applications.
Fibers can be oriented to provide maximum
directional properties while resin matrix
materials can be selected based on other
requirements such as toughness, electrical
properties, chemical resistance and the use
environment. Extensive experience exists for
hand-layup of materials in several types of
custom-made tooling including metal, RTV
rubber and molded graphite.

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Autoclaves

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Hydrogen
Getters

Hydrogen is known to be harmful to

components inside hermetically sealed
electronic devices and can severely jeopardize
their performance. Hydrogen is also known
to react with and weaken certain metals. To
combat this, the Kansas City Plant has put
over 25 years of experience into developing
expert hydrogen getter systems that effectively
remove this gas from sealed assemblies.

radioactive environments but at a 20% less

capacity than DPB.

Both the DPB and DEB getter systems:

Cause a gas-solid irreversible reaction with
reaction rate as a function of hydrogen pres-
sure, temperature and getter surface area
Are unaffected by the presence of air or
water vapor
Operate without the need for oxygen
Effectively remove hydrogen to measured
values of 1 ppm or less
Come in a variety of forms, including pow-
Two types of getter systems are available:
der, granular, pellet and combined in a
An organic-based getter produced from a moldable polymer matrix (i.e., silicones,
catalyzed crystalline acetylenic hydrocarbon polyethylene and urethanes)
that irreversibly reacts with molecular
Army tritium
hydrogen and its isotopes
getters made
An inorganic system that combines the
from DEB
reactive capabilities of a metal oxide with a
composites
desiccant and a silicone polymer to create a
getter capable of meeting the hydrogen
reduction needs of communication hybrid
microcircuits (HMCs). In addition to hydro-
gen this inorganic system is also capable of
DEB/DPB
converting detrimental carbon monoxide into
getter
the less reactive species: carbon dioxide.
products
Both of these getter systems can be implemented into a variety of devices and will function under the most demanding conditions to
protect sensitive components from the detrimental effects of hydrogen.

Features

Organic Getters
The Kansas City Plant manufactures two types
of organic getter systems. The names of these
two materials are DPB and DEB. Material
selection depends on operating conditions and
capacity requirements; however, both of these
organic getters provide the same hydrogen
protection. The DEB material can operate at
substantially higher temperatures and work in

A DEB
H1616
container
getter

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Hydrogen
Getters

ventional organic getters in its ability to:

Perform in a wider range of temperatures,
The DPB material:
from -67 F to 392 F, due to its non-organic
Can achieve a hydrogen capacity of up to makeup (no vapor pressure)
303 cm3-atm/g at standard temperature Function in a vacuum or in the presence of
and pressure
an inert gas, oxygen, air and/or water vapor
Operates effectively at temperatures ranging Be easily formed into a variety of shapes or
from -65 F to 120 F
films for easy bonding into electronic
Can be pressed into a density of 1.3 g/cm3 enclosures as a lining
without loss of reaction rate
Scavenge excess water produced by the
The DEB material:
getters reaction with hydrogen
Can achieve a hydrogen capacity of up to Operate without desorbing any materials
241 cm3-atm/g at standard temperature beneficial to the application
and pressure
Maintain a hydrogen capacity as high as
Operates effectively at temperatures ranging 30 cm3-atm/g at standard temperature and
from -65 F to 175 F
pressure
Operates best at a density of less than 1.1
g/cm3
HMC getter
Hydrogen capacity is unaffected by typical
products
mixed-waste-generated gases, such as
ammonia, nitrous oxide and carbon
monoxide
Will not radiolytically decompose; DEB is
tritium stable and will function at radiation
levels as high as 1 Grad. Note: The
above-mentioned polymer matrices are not
suitable for high-radiation uses.
Kansas City Plant getter systems can be used
Inorganic Getters
in a variety of situations to protect electronics
The inorganic HMC getter is a highly effective
and mechanical systems under demanding
system that removes both hydrogen gas and
conditions. Some of these include:
water vapor from hermetically sealed hybrid
Microcircuit devices that perform in harsh
microcircuits. This system involves an oxidized
environments, such as in outer space,
platinum group metal that converts hydrogen
military and marine functions
to water, a desiccant that removes the water
Protection from the hydrogen-desorbing
and a gas-permeable binder that allows the
effects of radio frequency absorbers and
system to be molded into unique shapes or
special alloy metals
films. We can design the getter for needed
Sealed enclosures (electronic packages)
hydrogen applications, but the manufacture
Personnel protection when used as a
of this material has been licensed to Cookson
secondary confinement for tritium source
Semiconductor Materials. The Kansas City
lighting
Plant, however, manufactures this inorganic
Filtration of hydrogen in flowing gas streams
getter to provide carbon monoxide mitigation.
Mixed waste hydrogen mitigation
The advanced HMC getter goes beyond con Nuclear fuel rod storage protection

Applications

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Metals

Our experience with and knowledge of metals

ranges from aluminum to zinc. Kansas City
Plant materials experts offer engineering
solutions to material problems from the design
and specification stage to processing and
fabrication, and we cover field performance
support including diagnostic and failure
analysis of components and piece parts as
well.

Features

Primary activities in metallurgical engineering

are divided into several categories, including:
Nuclear Grade Steel (NGS)
NGS steels have more stringent
requirements than typically used in industry
These materials require controlled
chemistry and microstructural features that
are not traditionally specified. Our engineers
work with metal suppliers to establish the
requirements, develop and monitor their
processing, and ensure that the finished
mate rials meet the customers needs.

Stages in forging

These materials require traceability, and

the Kansas City Plant has established an
electronic system of tracking the properties
and inventory from an individual bar to the
heat from which it came
Forgings
Forging is the high-temperature
deformation of metals to obtain specific
grain flow and geometry
Commercial forgings are typically heat treated to achieve certain mechanical
requirements. However, because of the
material systems that are typically used at
the Kansas City Plant, most forgings require
mechanical properties to be obtained in the
as-forged condition. Our materials engineers
work with suppliers to develop the forging
processes that will ultimately meet the
shape, grain flow and mechanical property
requirements.
Verification testing of the design
requirements utilizes our analytical science
laboratorys state-of-the-art capabilities to
measure and document the material
properties of the forgings

Forging furnace

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Metals

Failed gear post analyzed with scanning electron microscopy

to find the crack initiation site

Solder Analysis and Characterization

Solders are metal alloys with a melt
temperature less than 842 F that are used
to join materials
Solders can form a conductive pathway in
electronic circuits, a hermetic seal for
electronic packages and a relatively
environmentally stable joining material
The Kansas City Plant has the ability to
replicate production solder joints through
lab-scale soldering techniques
Through analytical characterization tools,
our materials engineers can examine
solder joints for life-impacting features
such as intermetallic compound growth and
fatigue cracking
Materials engineers can also evaluate solder
durability, sources of failure and aging
response
Our specialized solder equipment includes
a Sikama belt reflow furnace, which makes
uniform and reproducible solder joints. In
addition, aging and environmental test
chambers are available with a range
of relative humidity and temperature control
options
Failure Analysis
Kansas City Plant materials engineers play a
lead role in failure analysis, whether a
component or material fails in service, during
manufacturing or in production processing
In conjunction with our analytical sciences
lab,our materials experts routinely analyze
materials and components from a wide
range of parts and processes to identify the
failure mode, failure site, failure mechanism
and root cause
Analysis is performed on failures from
processes such as heat treating, welding,
plating and soldering

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Molded
Desiccants

Water vapor from leaks or reactions can be

extremely problematic in hermetically sealed
environments. The Kansas City Plants specialty desiccant products, however, provide
an effective way to mitigate the effects of
unwanted water vapor. With over 35 years of
experience, we can custom design desiccant
systems based on product requirements so
they provide the maximum protection for vessels and containers.

Features

Our desiccant products all contain a zeolite as

the active material. Zeolites are manufactured
inorganic ionic compounds that trap water vapor and other gases inside a molecular cage.
The common name for this type of material is
a molecular sieve. Molecular sieves are added
to various molding polymers to produce a
desiccant part that can either be molded to
shape or machined to size. The selection of
the polymer is determined by the ultimate use.
The Kansas City Plant identifies the desiccant
type by the binder system that is used. Each
binder system has unique properties with
advantages and limitations. We design desiccant systems based on product requirements
including:
Water capacity
Operating temperature
Desired absorption rate
Polymeric properties (i.e., flexibility and
compressive strength)
Space limitations (part location in an
assembly)

Available binder types that are molded with

molecular sieve desiccants include:
Epoxy
- High moisture capacity (contains 80%
desiccant by weight)
- Can be molded into basic shapes only
does not lend itself to a molded to size
definition
- Parts are easily machinable with standard
dry cutting methods
- Final product is tough and is only brittle in
thin cross sections
- Material is bondable; typical adhesives
used are silicones and epoxies
- Moisture pick-up rate is self-controlled by
diffusion through the epoxy
- Activation at 350 F in vacuum required
before use

Molded and machined epoxy

Molded polymide ring

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Molded
Desiccants

Polyimide
- Medium moisture capacity (contains up to
58% desiccant by weight)
- Glass microballoons up to 12% by weight
can be added for density reduction
- Can be molded into annular rings and
shapes with curved sections
- Side details must be dry-machined into
the molded part
- Part is extremely brittle until parylene
coating is applied for strength and
moisture rate control
- Part requires handling strategy to
minimize breakage
- Bonding is not recommended
- Activation at 350 F in vacuum required
before use

-

-

Parylene coating of the part is

recommended for moisture rate control
Activation at 350 F in vacuum required
before use

Polyurethane
- Medium moisture capacity (contains up to
55% desiccant by weight)
- Parts can be molded to most contour
shapes with molded-in features
- Molded parts are durable but can be
broken or damaged by handling
- Moisture pick-up rate is very slow
- Activation at 320 F in vacuum required
before use

Applications

Kansas City Plant desiccant systems provide

efficient water vapor control in hermetically
RTV Silicone
sealed vessels and containers. In addition, all
- Medium moisture capacity (contains up to
desiccant products are reversible and can be
50% desiccant by weight)
reactivated for additional use.
- Glass microballoons up to 5% by weight
can be added for density reduction
- Parts can be molded to shape to any
feature size compatible with RTV silicone
- Molded parts remain flexible
- Moisture pick-up rate is self-controlled by
diffusion through the silicone
- Additional coatings are not recommended
- Activation at 350 F in vacuum required
before use
Silicone Foam
- Medium moisture capacity (contains up to
55% desiccant by weight)
- Part density range is 0.6 to 0.75 g/cm3
- Parts can be molded to most contour
shapes with molded-in features
Epoxy desiccant with getters and pads
- Molded parts remain moderately flexible
- Moisture pick-up rate is very fast

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Plastic, Foam &

Composite
Machining

Complex plastic, foam and composite parts

require special machining techniques to meet
dimensional requirements and provide acceptable surface finishes. At the Kansas City Plant,
all plastic machining operations are performed
in humidity- and temperature-controlled environments without the use of cutting fluids or
other lubricants. This ensures the dimensional
stability, physical integrity and appearance of
easily damaged polymer materials.

Standardized tooling and machining pro-

cesses for various types of plastic materials
are being established. This activity includes
the use of diamond-coated end mills, drills
and turning inserts for improved durability
and surface finish when machining
extremely abrasive materials.

Features

Numerically controlled multi-turret slant bed

lathes are used for turning operations that
require precision cuts with close tolerances.
Tolerances on soft polymeric materials are
routinely held to less than 0.005"
Numerically controlled 4-axis and 5-axis
milling equipment is used for close tolerance
milling of slots, holes and other unique
features on parts and complex assemblies.
Tolerances can be held to less than 0.005".
A numerically controlled 5-axis laser is used
for cutting and trimming polymer compos-
ites as well as sheet stock in complex 3D
shapes. The laser is also used for inscribing
delicate parts with any required identification
or marking.
Uniquely designed vacuum and mechanical
fixtures are used to support easily damaged
and delicate polymeric materials during
machining operations
Traditional turning, milling, drilling, sawing
and sanding operations can also be per-
formed on engine lathes and manual milling
equipment without the use of cutting fluids
Debris collection systems are used on all
equipment to protect operators and
maintain cleanliness within the department

Protective end cap machined from nylon block

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Applications

Plastic, Foam &

Composite
Machining

Polyurethane foam assemblies, compres- Laser cutting of Kevlar and other composite
materials to make parts without the usual
sion-molded composites and injection mold ed parts made from varying polymer fuzzy edges associated with conventional
materials are machined to exacting finish machining is performed. Parts with complex
3D shapes made from vacuum-formed
dimensions
Metal assemblies containing polymer materi- thermoplastic materials are cut on the laser.
als are machined to final configuration or The laser is also used for the marking of
machined to allow rework or removal of parts and assemblies.
valuable components within the assembly
Machining of components from plastic rod,
plate, foam billets, extrusions or sheet stock
is performed to provide precise high-quality
parts and assemblies
NC mill used for machining plastics, foams and composites

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Kansas City Plant scientists are involved in all

aspects of polymer and specialty materials
production, from fundamental research and
scale-up to process refinement and production. Our facilities are equipped to manufacture a wide array of custom chemicals and
resin systems, but it is our thorough understanding of these materials that makes us a
leading source of customized material solutions.

Polymers,
Adhesives &
Foams

In addition to the production aspects of the

facility, we have the capability to analyze
materials with our on-site test equipment and
the complement of our full analytical sciences
department. Our scientists provide the
expertise to bring your ideas to full production.

We have a variety of reactor sizes and

processing equipment to support batch sizes
ranging from one liter to 500 gallons. Our
assets include:
Five chemical reactors
- From 15-liter to 500-gallon vessels
- All glass-lined except the 500-gallon
vessel
- Heat to approximately 450 F, vacuum
capable, pressure to 125 psi
Extensive complement of processing
equipment
- Ross sigma blade mixers
- Vacuum dryer (tray style)
- Cake filter
- Powder grinding and sieving

Features

500 gallon chemical reactor

Our polymer production facility currently manufactures over 100 different materials that are
impossible or difficult to acquire commercially.
Our products include:
Polyurethane foams and adhesives
Polyether and polyester resins
Specialty adhesives
Epoxies
Bismaleimides
Molded large foam billets: 2 to 60 lbs/ft3

densities
15 gallon chemical
Other specialty adhesives
reactor
The Kansas City Plant has developed specifications for hundreds of different chemical
formulations utilized throughout the nuclear
weapons complex.

Reaction calorimeter

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Polymers,
Adhesives &
Foams

Other capabilities include:

Customized repackaging capabilities, which
reduce waste and meet exact customer
packaging requirements, ranging from a 10-
cc syringe to a 500-pound cylinder and up
to tank-car capacity
Reaction calorimetry equipment that allows
rapid scale-up from laboratory to production
quantities
Reverse engineering and polymer
deformulation that allow material duplication
and production of discontinued commercial
polymer materials

Applications

The Kansas City Plant has manufactured special materials for the NNSA to support a variety
of needs, including providing materials for Operation Iraqi Freedom within a condensed time
schedule. We have also developed classified
formulations to customers for special applications.
Polyurethane Foams
When commercially manufactured polyurethane foams cannot meet the stringent requirements needed for electronics packaging,
we develop and manufacture custom potting
and encapsulating formulations. Our foams
can also be used as:
Precursors for carbon materials for
rechargeable batteries
Precursors for carbon materials for super
capacitors
Insulation materials
Filter materials

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Adhesives
Our polymer scientists have formulated adhesives with the high-level fracture resistance
needed for weapon electromechanical device
manufacturing. These engineered adhesive
formulations are suitable for similar atypical
requirements.
Adhesives are also ideal for joining plastic and
microelectronic components to help reduce
size and weight in assemblies. Additionally,
adhesives can be used for:
Electrical assemblies and electronics
manufacturing
Structural assemblies
Optical systems
Ultraviolet adhesives for assembly and
coating
Automobiles, trucks, trailers and rapid
transit vehicles
Medical devices
Resins
Our scientists have also developed low-toxicity, high-temperature thermoset resins for
high-strength structural foams with improved
processing characteristics.
Polymer components

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Rigid
Plastics

Rigid plastics are manufactured at the Kansas

City Plant using several molding capabilities.
These involve applying variations of heat and
pressure to a material to obtain a predetermined part configuration defined by a mold.
The processes we use are injection molding,
transfer molding, compression molding and
thermoforming molding.

Features

Several of our presses are supported by a

computer-controlled mold heating and
cooling system. This system facilitates the
cycling of a mold temperature to establish
a repeatable profile controlled within two
degrees of a temperature ranging from
100F to 500 F.
Precise mold temperature control allows
for parts to be produced with a tolerance
of 0.001 as part shrinkage, warping and
internal stresses are controlled
Mold designs are developed using the
Moldflow Evaluation Program. This program
allows pre-fabrication mold analysis to opti-
mize design, which results in the production
of high-quality parts.

A part manufactured
by compression
molding

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Rigid
Plastics

The processes we offer include:

Injection molding
A homogenous thermoplastic polymer is injected under pressure into a closed mold and
cooled to retain the final shape. This capability
consists of five machines that vary in shot size
from 0.5 to 28 ounces and vary in clamp force
from 15 to 450 tons.
Transfer molding
Thermoset material is forced under pressure
into a closed, heated mold and maintained
until material polymerization is complete. We
use six machines that vary in clamp force from
50 to 400 tons and transfer force from 15 to
25 tons.
Compression molding
A thermoset material is placed in an open
mold and part configuration is achieved by
closing the heated molded under pressure.
This process uses six presses that vary in
clamp force from 150 to 750 tons.
Thermoforming
Polymer sheets are heated and placed over a
cool mold, and a vacuum draws them onto the
mold to achieve the final shape. The thermoforming capability consists of one machine that
can vary the sheet size from 12" x 12" to
44" x 44".

Applications

Structural components
Housings
Containers
Electrical contacts
Detonator components
Switch blocks
Protective shipping packages

Typical transfer molded parts;

Note electrical contacts molded
into some of the parts

Multi-featured part
produced by the
injection molding
process

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Silicone
Products

At the Kansas City Plant, we manufacture

parts made of room-temperature vulcanized
(RTV) blown foam, solid RTV and cellular silicone, all also referred to as elastomer cushion products. As the name indicates, these
products are of a softer nature and are used
in cushioning applications. Silicone materials
can be used to compensate for manufacturing tolerances and can function as gap fillers
to allow for thermal excursions. They also
mitigate shock between adjacent components
in assembly. Such materials are required to
exert specific compressive forces at specified
maximum and minimum assembly gaps.

Solid RTV
To manufacture solid RTV, a resin and a catalyst are mixed, and the mixture is placed under
a vacuum to remove trapped air. Solid RTV
has a longer pot life than RTV blown foam.
The material is injected into a room-temperature mold of variable contours and shapes.
Following molding, the parts are post-cured
and trimmed.

Features

RTV Blown Foams

Parts based on this material can be molded
in flat or contoured shapes
Part thickness vary from 0.02 to 1.5
Load capabilities are variable depending on
material density
Density is determined by the amount of
material placed in the mold
Molding operations include three fast-acting
compression presses having approximately
15 tons of pressing capacity
Post-curing operations are performed in
forced air convection walk-in ovens
Steel rule die-cutting operations are
available for flat slabs

RTV resin

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Silicone
Products

Cellular Silicone
Cellular silicone is the term used to denote a
family of silicone compounds that contains
urea prills, which are approximately 0.025 in
diameter and uniformly dispersed in a siliconebased compound. The urea is water-soluble
and is removed during the leaching operation
following molding. After leaching, the part is
post-cured to the desired configuration.
Part density is controlled by the amount of
urea compounded into the material. Current
porosities available are 47%, 50%, 57%,
60%, 63% and 77%
Material can be molded in flat slab or
contoured parts
Part thickness ranges from 0.04 to 1.5
Load capabilities are variable depending on
material density
Material mixing capabilities include: a
screener, intensive mixer, extruder and two
2-roll mills
Compression molding can be performed
at presses ranging from 140- to 2,000-ton
capacity and having heated platens
The leaching of the urea filler is performed in
specially designed, automatic L-tanks utiliz-
ing up to 275 gallons of 200 F, RO/DI water
Post-curing operations are performed at
400 F in forced air convection walk-in
ovens
Steel rule die-cutting operations are
available for flat slabs
Material Testing Capabilities
Our current material testing capabilities
include:
An Instron for tensile and compression
testing
A Tinious Olsen for compression testing
Two stress/strain Gilmore testers

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Applications
Silicone materials provide mechanical properties for various applications. Their flexible behavior allows the material to cushion components to alleviate shock and allow for thermal
excursions between components.

Parts manufactured from cellular silicone

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Structural
Foams

Foams serve a vital role in protecting

specialized electronic and mechanical
components. They absorb mechanical shock,
prevent jarring and insulate parts from
overheating and thermal degradation. At the
Kansas City Plant, we offer a wide range of
foam products that can be molded to virtually
any size or shape.

Features

We manufacture both polyurethane and

syntactic foams.

and filer materials can be incorporated into a

design to achieve the desired physical
properties
Possible microsphere materials include:
Phenolic
Carbon (used for applications where greater
thermal conductivity is desired)
Glass
Metallic coated glass
In addition, our foam formulas use a unique
resin binder manufactured exclusively by the
Kansas City Plant. This specialized resin has a
liquid phase, making it possible to manufacture
molded-to-shape parts rather than machining
to shape.

Polyurethane Foams
We have four polyurethane foam machines
for production and process development
support. One machine is dedicated
to TDI (toluene diisocyanate) polyurethane A desiccant can also be added to the syntactic
mixture to improve water absorption
foam products, and the other three are
dedicated to PMDI (polymeric diisocyanate) capabilities.
polyurethane foam products.
A part constructed out of polyurethane foam
These rigid polyurethane foams are water-
blown systems with densities that range
from 2 to 60 lbs/ft3 (0.032 to 0.96 g/cm3)
Product sizes range from less than a centi-
meter to nearly a meter in cross-section
Product weights can range from less than a
gram to 25 kilograms or more. The stable
use temperature of polyurethane foams is
approximately 250 F (121.1 C).
Our dimensional tolerance capability
requirements are typically three times tighter
than the industry standard
Nearly all features can be molded-to-shape.
Syntactic Foam
Syntactic foam is any material system comprising hollow spherical particles
(microspheres) dispersed in some form of
binder. Depending upon the application,
various types of microspheres, resin binder

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Structural
Foams

Applications
Polyurethane Foam
Polyurethane foams are primarily used as
housings or mechanical supports for
electrical and mechanical components to
mitigate shock load and provide insulation and
thermal protection.
Syntactic Foam
These foams are typically used in applications
that take advantage of their very high specific
properties, pore structure, energy absorption
characteristics and flame-retardant properties.
They provide superb encapsulation for lowdensity (0.3g/cm3), heat-resistant/transmitting
structural components.

Glass syntactic foam

A part constructed
out of carbon
syntactic foam

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Surface
Coatings

Surface coatings are an important part of

production, whether theyre applied for
appearance, protection or both. The Kansas
City Plant offers a full range of high-quality
surface coatings for aluminum, stainless steel,
titanium and many other materials. Our
production facilities adapt easily to everchanging environmental requirements in the
coating industry. Were continually developing
new, low-volatile organic compound (VOC)
paints, zero-VOC paints and dry film lubricants
to increase environmental and associates
safety and provide our customers with a better
product.

Liquid coating

Features

Processes
Powder coating
- Primers (epoxies, polyesters)
- Topcoats (epoxies, urethanes, polyesters,
thermoplastics)
Liquid applications
- Surface pretreatments (chromate
conversion, wash primers)
- Primers (epoxies)
- Topcoats (enamels, urethanes, epoxies)
Ultraviolet (UV) coatings
Dry film lubricant application

Dry film coating

Powder coating

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Surface
Coatings

Equipment
Small-batch powder booth enables powder
coating of small parts and allows easy color
changeability
Walk-in powder booth supports processes
for larger product
Cross-flow paint booth for liquid applications
allows processing of parts up to 12 tall and
8 wide
Down-flow paint booth supports liquid
applications and features a conveyor system
and attached drying room to maintain
cleanliness of coated products
Four bench-top air circulating ovens enable
curing of coatings on small parts
Walk-in oven allows curing of large
liquid and powder-coated items in an
air-circulating environment
Infrared oven supports curing of
powder-coat products
UV curing chamber required for curing of UV
coatings
Dry film lubricant spray booths enable both
manual and automatic spray application of
dry film lubricants on small parts
Wet abrasive blasting equipment supports
dry film lubricant applications
Ultrasonic cleaning capabilities
Surface pretreatment wash booth
Explosion-proof mixing area and flammable
storage room for mixing and storage of
flammable coatings
Environment, Safety & Health
Temperature- and humidity-controlled
environment
Conveyor system, lifting and transportation
devices available to safely maneuver
products of various sizes
Updated exhaust systems
Personal protective equipment for operators

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Applications

Powder coating is the paint of the future; it is

rapidly replacing liquid paint in many industries,
including automobiles, agricultural equipment
and home appliances. The Kansas City Plant
uses powder coating on production items
such as weapon components and on fixtures
such as racks, stands and cabinets. These
processes can be performed on products
ranging from miniature components to large
cases, structural supports and trailer
componets.

Semitrailer paint booth