Suburban Machine has developed a proprietary high-pressure molding technology that yields near-net shape acoustic foams with minimal porosity, voids or sinks. The near-net-shape method molds the part closely to its final shape so there is minimal machining needed to complete the final part.

This greatly reduces the time and cost to produce the parts, and reduces waste generated by up to 67%. The process, which utilizes molding equipment designed and developed by Suburban Machine, allows us to mold dampening material to specific dimensions with the required acoustic properties.

Benefits

• Reduced cost of finished parts
• Reduced machine time
• Reduced waste / Eco-Friendly
• Suitable for large parts up to 20 lbs
• Complex customization

SADM Disk

SADM is a plastic–composite material perfectly suited for use in sonar arrays, which require optimal acoustic performance. It consistently delivers a high level of echo reduction and insertion loss over the 10 kHz–100 kHz range, both at ambient pressures and at operating depth.Many types of SADM material are available for applications ranging from broadband use to improved performance at specific frequency ranges.

Suburban Machine specializes in the design and manufacture of near-net molded parts incorporating SADM for use in transducer arrays. The unique properties of SADM require proper tool speeds, feed rates, and material handling protocol. Drawing from Bruce St. Hilaire’s experience in machining heavy metals, our CNC equipment has been specially modified to work with SADM, employing strict quality control measures and hazardous material handling procedures at every stage of our process.

Read about our work with National Geographic and underwater exploration with ‘Critter Cams’ here!

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Reduce cost of acoustic foam parts with near-net molding

A major reason for developing the new technology was to reduce cost and waste when machining finished parts from acoustic material containing heavy metals and unique polymers. “The molds are inexpensive, since we are only molding a near-net shape that will be machined after molding,” said Bruce St. Hilaire.

Raw Molded Part

After Machining

Before/After Machining

Finished Product

The technology allows Suburban Machine to offer small batch runs of these acoustic foams. This in turn allows Suburban Machine to offer foams with different compositions and different application methods, such as Tactically Distributed foams and Direct Application foams. There is no need to settle for off the shelf materials when Suburban Machine can create the perfect material to result in a superior final product.

The process is suitable for large parts and weights of up to 20 pounds per blank, with large and varying wall thicknesses and complex geometries. Near-net shape is effective for parts that cannot be efficiently produced using standard machining methods due to the greatly reduced machining time.

Greener production process is eco-friendly

“Because it’s close to the final part, a near-net shape requires less machining. Less machining means less waste, which is an important consideration for green and sustainable programs.

With ever changing regulations it is more important than ever to find ways to produce parts in a way that produces less waste and minimizes environmental impact.

To learn more about Suburban Machine’s near-net molding process call 978.392.9100 or contact us via email.