Our PERFECAST NYLON-6 product line is extremely wear resistant and impact resistant cast nylon-6 (also called Monomer Cast Nylon-6/ Mono-Cast Nylon-6/ MC Nylon/ Cast Polyamide/ PA-6-G) a partially crystalline thermoplastic which is produced by means of anionic polymerization of the raw material Caprolactam, supplied in flakes and transformed into liquid form and then into Cast Nylon 6 semi-finished products in plate, rod or tubular bars with its melting point above 220°C. In a pressureless casting process the liquid monomer is polymerized via a controlled chemical reaction directly to a semi-finished product. The ease of mixing the catalyzed resin makes nylon 6 convenient to use and highly economical for cast-in-piece components for low-volume or super-large-scale production of components outside the customary production facility.
Certain products that cannot be fabricated by extrusion or injection molding can be cast using the monomer nylon-6. PERFECAST NYLON-6 Casting is usually economical for large parts, up to 500 kg, but is generally not practical for production of small parts; less than 500g. Pure/ unfilled/ plain cast nylon 6 is used in applications such as heavy-duty bearings, gears, and propellers. Complex near-net shapes can be molded with multipart molds that can be disassembled for removal of the product. The moderate temperatures involved allow fabrication of small and moderate-size items that use ordinary materials for molds and melting vessels. Parts of virtually unlimited size and thickness, retaining internal soundness can be produced by Custom Casting.
The use of high quality resins, chemicals and a range of polymerization conditions with active chemistry allow Perfect Polymers to optimize the production of high quality products with the desired properties and results in products that reach the highest level of industry standards. Further modifications can be achieved through copolymerization of Caprolactam with Laurinlactam to produce Cast Nylon-6/12 and the use of a wide range of additives and fillers. The varying additives used during the casting process help determine the final performance and attributes of an engineering plastic.
We cure the material by the means of Annealing (a process used to relieve any residual stress in the material during polymerization) which improves the performance of material exhibiting better life of the material. Internal stresses are minimized as it is produced at temperature below the melting point of the polymer.
The unique process of monomer casting of Nylon-6, Nylon-6/12 Nylon-12 developed for producing this line of PERFECAST NYLON has resulted in highest quality exhibiting high strength at high hardness, its good abrasion resistance and its high damping capacity.
Under the influence of moisture absorption, the mechanical properties change. The material becomes tougher and more resistant to impact, the modulus of elasticity declines. Depending on the environmental atmosphere, the temperature and the period of moisture absorption, only the surface layer is affected by alterations of property to a certain depth. On thick-walled parts, the center area remains unaffected.
PERFECAST NYLON-6 produced by means of this process exhibit:
• Low internal stress
• Very High Molecular Weight
• Very good sliding properties with High heat and aging Resistance
• Can be machined to almost any form
• Can be manufactured as semi-finished products or custom cast parts
• Can be manufactured in almost unlimited weights and dimensions.