CMT Materials, Inc.

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As the world leader in the manufacturing and sales of syntactic foam plug assist materials, CMT continuously develops innovative new products, techniques and information relative beneficial to the thermoforming market.  Check back frequently for the latest news.

CMT Materials' New HYTAC® Syntactic Foams Provide
Low-Scratch, Reduced Cost Alternative for Plug-Assist
 Forming of Transparent PP Sheet

ATTLEBORO, Mass., November 7, 2011 – HYTAC-FLX and FLXT copolymer syntactic foams from CMT Materials Inc., a leading supplier of plug-assist materials for the thermoforming industry, have emerged as highly viable alternatives to engineered solid polymer thermoplastics for production of deep-draw transparent polypropylene (PP) packaging. CMT’s new plug-assist materials optimize material distribution and offer easier machining, better optical properties, and lower cost than solid engineered polymers such as polyetherimide (PEI) and polyetheretherketone (PEEK).

"These new materials give thermoformers new more cost-effective options," said Kathleen Boivin, Materials Engineer for CMT Materials. "FLX and FLXT offer a smoother surface than traditional syntactic foams – closely mirroring solid polymers – thus providing better transparency and minimal scratching while maintaining the benefits and lower cost of syntactic foam."

HYTAC-FLX is a toughened copolymer syntactic foam. The enhanced formulation is easy to polish and results in minimal to no scratches with transparent PP sheet. The material has been designed to minimize chilling of the sheet and bring more material into the sidewall, resulting in improved distribution. Meanwhile, HYTAC-FLXT is a PTFE-containing syntactic foam that boasts even less scratching, less haze, higher transparency, and better release capability for sticky materials.

Both HYTAC-FLX and FLXT are easy to machine/polish, thus minimizing any chance of plug marks. Both materials are being used globally by thermoformers for production of clear PP drink cups and other packaging.

CMT now supplies cutting tools!

Machining of HYTAC materials
Customer feedback from the recently updated HYTAC machining guidelines continues to be overwhelmingly positive and includes one common, but new theme… “Simplify the tool selection process and provide the specific tools and best practice settings for machining HYTAC syntactic foam.” 

We listened, and we continued developmental work with the largest manufacturer of appropriate cutting tools in the US.  We are pleased to announce that CMT now supplies cutting tools with specific geometry for the machining of HYTAC materials.

Please click here for the latest HYTAC Machining Guide, now updated to provide part numbers, chip load and depth of cut factors specific to each tool. Standard size tools are available from immediate stock.

Machining of METAPOR materials
Along with testing of tools designed to cut syntactic foam, CMT has also worked to identify the best tools and methods for the machining of METAPOR Air Permeable Composites.  Please click here for the latest METAPOR Machining Guide, now updated to provide part numbers, chip load and depth of cut factors specific t each tool.  These guidelines are specific to METAPOR materials.  (PROTOBLOCK is best machined following HYTAC Machining Guidelines.)

New HYTAC Inserts Provide Effective, Secure Base Attachment
CMT has long recommended the use of scored inserts bonded in to syntactic foam as opposed to threaded inserts. While both types of inserts fail at similar average pull-out values, threaded inserts result in catastrophic failure of the plug and destroy the attachment area of brittle epoxy syntactic foams. Scored and bonded inserts provide secure attachment yet will break free of the plug, generally requiring only a reapplication of adhesive, if a screw is over tightened. CMT now sells scored inserts for ¼-20 thread screw attachment (insert diameter 0.5") or for 6mm screw attachment (insert diameter 12mm) for customer use. See our insert guidelines for procedures.