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The DODGE Composites thermoplastic composite thermoforming process is distinguished by its low cost tooling and versatility.
Companies with low volume production requirements will be interested in Dodge’s capabilities as a supplier. Dodge is making its machine time available to a limited number of customers.
Companies who have higher volume needs or who are making large parts would be interested in acquiring machinery and technology licensing from DODGE Composites.
Perfect Storm Sports Technology (PSST) president and co-founder Dave Dodge said “I’ve been in the composites business my entire career. One of the difficulties for anyone using thermoformed composite construction is finding a turn-key manufacturing process. We couldn’t find one when we started our ski boot manufacture so we had to invent it. I’m proud to say this is a tried-and-true process with turn-key machinery so anyone can get up to speed right away at a modest cost.”
Tooling costs are a fraction of those typically found in other composite molding processes, with the average mold cost being less than $1000.
Processing time is also very quick, with a heating/molding cycle of only a minute or less.
The PSST machinery and process is suitable for a wide variety of thermoplastic composites utilizing resins including TPU, nylon, polypropylene, polyethylene and fibers of carbon, Kevlar, fiberglass and others. PSST has been successfully using the process to manufacture the world’s only carbon fiber composite alpine ski boot for over 5 years utilizing a TPU/carbon/glass material.
Another important part of the Dodge Composites process incorporates the use of a robotic laser for final part trimming.
The entire process, from raw material to finished part takes less than 3 minutes.