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The Valyi surface finishing/compression molding process (SFC) has successfully been used to produce large structural panels with Class A finishing films under low pressure using short glass/carbon fiber reinforced materials and engineering materials. The material used in the SFC process must meet certain performance requirements in order to fully exploit the capability of the process. This paper reports the mechanical properties and rheological properties of short and long glass and carbon fiber reinforced materials. The fiber distribution in the parts produced by SFC have been compared to that from conventional injection molding. The long fiber reinforced PP resins show enhanced stiffness and impact strength. The methods of improving appearance due to long fiber read through have been investigated in this paper.

Class “A” automotive parts with a 1.6 square meter surface area were produced using a new process of surface finishing/compression molding SFC (The Valyi SFC™ Process (1). In the process a precut Class “A” film finish blank was placed over the mold cavity of a vertical press. Molten plastic was extruded onto the film, reinforcing layers added, and the mold was closed. In this SFC process, the melt, deposited directly onto the film-backing layer, heats the film finish and causes it to become pliable for forming. This process eliminates the need for painting and produces large parts at low clamp forces. This paper reports the materials and process that were used to produce full sized development parts that demonstrate the capability for production of large structural panels such as roof tops, hoods, or trunk lids. In order to achieve the strength and stiffness requirements, continuous fiber reinforcements were moled into the parts.

“Paint Film” material and process technology have progressed to a new level of development for finishing injection molded plastics in-the-mold. 3M and Rexam have combined forces (Cooperative agreement announced at the 1995 SAE meeting in Detroit) to develop a systems application approach for paint film production, part and mold design and film finishing in the molding process definition. This paper will review film finish material design, part and mold design and the molding and part handling process.