Clearlux® (MABS) is primarily processed through injection molding, but any process suitable for thermoplastic molding compositions may also be used.

Predrying

Clearlux pellets can absorb small amounts of moisture under adverse conditions of storage or transport. This can cause surface defects to arise during processing, taking the form of streaks, lines or bubbles. We therefore recommend that Clearlux is pre-dried for about 2 hours at about 70°C before processing.

Compatibility with other thermoplastics

Clearlux should not be mixed with other thermoplastics; even small amounts of other plastics, including transparent ones, cause irreversible clouding.

Reprocessing

Clearlux may be reused as regrind if it has been processed as specified and has not been contaminated or thermally degraded. Since regrind has a larger surface area than pellets and therefore absorbs moisture more rapidly, it must be dried before being reused. Virgin pellets should always be used for parts, which are subject to high quality requirements.

Clearlux® (MABS) can be processed on any commercially available injection molding machine.

Injection unit

Universal screws are highly suitable. Guide values for proven screw designs are as follows:

Total length: 18 – 22 D (compression ratio 2 – 2,5)  Feed section: 0,5 L  Compression section: 0,3 L  Metering section: 0,2 L

 where D = screw diameter; L = total length.

 

Gate and mold design

It is generally possible to use any of the usual types of gating. Molds with hot-runner systems can also be used.

Mold temperature control

Shrinkage and, to some extent, the thermal and mechanical properties of the part can be influenced via the mold temperature. Higher mold temperatures provide better weld line strength and lower internal stresses, and therefore also reduce warpage. Mold temperatures which have proven successful in practice are between 50 – 75°C.

Processing temperature

Melt temperatures of 220 – 250°C give optimum transparency. Excessively high melt temperatures and long residence times may cause slight yellowing. The highest part transparency is achieved when the mold surface is highly polished.

Flow behaviour

Clearlux is a high flow injection molding type and for example can be used for difficult parts with a long flow paths/wall thickness ratio or is also suitable for multi-cavity tools.

Mold release

Injection moldings made from Clearlux exhibit good mold release properties. Drafts of 0.5 – 1° are generally sufficient. For textured surfaces, the draft depends on the depth of the texture and should be greater than the values given.

Shrinkage

The shrinkage of the part typically ranges from 0.4 – 0.7%. Post-shrinkage is negligible. Shrinkage not only depends on the type of material used, but also on the design of the part and the processing conditions.

No adverse health effects on processing personnel have been observed where processing of the products is carried out correctly and suitable ventilation is provided in production areas. Further information is given in our Clearlux safety data sheet.

 

Disposal

Under German regulations MABS is classified as polystyrene waste. Solid plastic wastes of this type are exempt from the monitoring which applies to other types of waste, and normally it can be landfilled (cf. Clearlux safety data sheets). Clearlux wastes are inert in landfills. In Germany Clearlux is classified as not hazard zo water.  Subject to official regulations, Clearlux may also be incinerated in a suitable incinerator, e.g. a domestic waste incinerator. Further information is given in our Clearlux safety data sheet.

Recovery

Wastes, whether melt or used parts, consisting solely of Clearlux can be recovered, i.e. can be fed back to the process as regrind (cf. Reprocessing, above). Depending on the age and wear of the used parts to be recycled, certain properties may have changed. It is therefore important to check whether the recycled material is suitable for the intended application.