In the realm of injection molding, certain materials pose unique challenges that require expertise and precision. One such material is Isoplast. Its high hygroscopicity makes it a daunting task for many molders, leading to a scarcity of reliable suppliers. However, at HARBEC, we have mastered the art of injection molding Isoplast for DAVCO, A Clarience Technologies Company. With our controlled environment and extensive experience, we proudly serve as the second-largest consumer of Isoplast in the country, if not the world. In this blog post, we’ll delve into the process, materials used, and our commitment to quality.

Leading the Way in Fuel Filtration:

In the world of diesel engines, Davco stands as the North American leader in fuel/water separators and fuel filtration systems. Their cutting-edge solutions ensure clean fuel and optimal engine performance. For over three decades, HARBEC has been a trusted partner, providing precision-molded plastic parts for Davco’s fuel filtration products.

Davco’s reputation as an industry leader in fuel filtration stems from their advanced technology that effectively removes water and contaminants from diesel fuel. Their comprehensive range of fuel filtration systems caters to various diesel engine applications, preventing costly engine repairs and minimizing downtime.

The Fuel Pro^® Series and HARBEC’s Contribution:

At the core of Davco’s product lineup is the Fuel Pro^® Series, comprising a filter bowl and pressure relief valve assembly. This vital component, responsible for filtering and separating water and contaminants from diesel fuel, is manufactured by HARBEC. With their expertise in injection molding, HARBEC ensures the production of high-quality, precision-molded plastic parts that meet the stringent standards set by Davco.

 

 

 

What is Isoplast?

Isoplast is a high-performance thermoplastic material that is known for its exceptional mechanical properties, chemical resistance, and dimensional stability. It is a brand name for a type of thermoplastic polyurethane (TPU) produced by the global chemical company, Dow Chemical Company.

Isoplast is engineered to exhibit a unique combination of strength, toughness, and rigidity, making it suitable for a wide range of demanding applications. It offers excellent impact resistance, high tensile and flexural strength, and good resistance to chemicals, oils, and solvents. Isoplast is also known for its dimensional stability, which means it maintains its shape and size even under varying environmental conditions.

Isoplast finds application in various industries, including automotive, aerospace, medical, electronics, and consumer goods. It is commonly used for components such as structural parts, housings, gaskets, seals, and medical devices that require durability, strength, and resistance to harsh environments.

The Challenge of Isoplast:

Isoplast is known for its high hygroscopicity, meaning it has a strong affinity for moisture absorption. This poses significant challenges during the injection molding process, as moisture can lead to issues like dimensional instability and part defects. Many molders are reluctant to handle Isoplast due to these complexities. However, at HARBEC, we have established a controlled environment that significantly aids in overcoming these challenges.

Our state-of-the-art facilities are equipped with advanced humidity and temperature control systems, ensuring optimal conditions for molding Isoplast. By carefully regulating the moisture content in our production environment, we mitigate the risks associated with this material and deliver superior results to our valued partner, Davco.

Isoplast usually carries a 30% scrap rate due to its challenging nature during the injection molding process. However, HARBEC’s dedication to continuous improvement has led to significant advancements in the production of Isoplast parts. Over the years, HARBEC has fine-tuned the process, implementing innovative techniques such as dedusting the fine resin to reduce imperfections. As a result, the waste generated from Isoplast molding has been reduced to single digits, showcasing HARBEC’s commitment to efficiency and sustainability.

In addition to their dedication to process optimization, HARBEC demonstrated their adaptability by introducing Thermoplastic Polyurethane (TPU) for the filter bowls in response to COVID-related supply chain challenges. This decision showcased their commitment to customer satisfaction and the ability to swiftly adopt alternative materials while maintaining high product standards.

   

 

Materials Utilized:

In the manufacturing of Davco units, we employ various materials, each chosen for its specific properties and suitability for the application. The primary materials we utilize include:

• Isoplast 101 and 302: Isoplast offers exceptional strength, impact resistance, and chemical compatibility. These properties make it an ideal choice for demanding applications where durability and performance are critical.
• Glass-Filled Nylon: Glass-filled nylon enhances the strength and rigidity of the molded parts, making it suitable for applications that require high structural integrity.
• Nylon: Nylon is a versatile material known for its excellent mechanical properties, toughness, and wear resistance. It is commonly used in a wide range of applications due to its durability and reliability.

 

In-House Assembly and Tool Manufacturing:

At HARBEC, we believe in maintaining control over every aspect of the manufacturing process to ensure the highest standards of quality and efficiency. That’s why we not only handle the injection molding of Isoplast for Davco, but we also carry out the assembly in-house. This integrated approach allows us to closely monitor the entire production process, from mold making to assembly, ensuring seamless execution and timely delivery.

 

 

Conclusion:

HARBEC’s expertise in injection molding Isoplast for Davco positions us as industry leaders in tackling the challenges associated with this material. Our controlled environment, commitment to quality, and in-house assembly capabilities allow us to deliver exceptional products to our partners. As the second-largest consumer of Isoplast, we take great pride in our ability to mold this material with precision and reliability. Through our dedication to mastering the art of injection molding, we continue to drive innovation and provide solutions that meet the most demanding requirements of our valued customers.