Foam cylinder with metal plate inside

[Oseania]

I need to produce a closed cell plastic foam cylinder of height about 6 mm and diameter 2 mm. The trick is that we would need to insert a aluminium plate inside this cylinder (width 1.5 mm and height 4 mm).

I have considered two options:
1. Find a company that can put these plates inside the cylinder during their foam process
2. Use two half-cylinders and somehow combine (how?) the parts when the plate is between them.

I haven't considered gluing as we need to produce tens of thousands of these cylinders. If someone can guide me to a manufacturing company or process that can handle these requirements, it would help me a lot.

 

[Pud]

Must it be closed cell foam? How about say, PP or PE with a good dose of blowing agent in it? If so, could easily be injection moulded, either robot insertion of parts into a multi-cavity tool or manually (at added cost, I guess, unless low-wage area!)

H

http://www.tynevalleyplastics.co.uk

 

[patprimmer]

With a name like Oseania, it sounds like you could be Aussie or Kiwi.

I know a moulder in Sydney who already over moulds steel bar with foamed PP to encapsulate the steel to reasonably accurately controlled thickness.

I can put you in contact if you are interested.

Regards
Pat
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[Oseania]

Thanks. I am talking to couple of manufacturers and hopefully someone is able to coat the plate with foam. Unfortunately the foam has to be closed cell.

 

[loughnane]

I know Reiss Industries (in watertown Wisconsin) does that kind of "overmold" of foam. I've seen it in an application for an OB-GYN stirrup... they needed the strength of the metal, but the softness (and with the external skin... the chemical resistance) of a closed cell foam.

They don't have a website which i balked at, but after visited their facility I can see that they're legit.

If you want something with a website, maybe check out Bergad.

Chris Loughnane - Product Design

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