For example, if the plug has narrow ribs or posts it is not a good idea to use a brittle material like some epoxy syntactics.
It should be noted that this method cannot be used for thermoplastic-based syntactics.
Some materials, such as thermoplastic-based syntactics, are extremely durable and can withstand direct threading.
Solid polymers and syntactic foams are most commonly used in thin-gauge applications.
The rapid setting, high-strength epoxy syntactics from Huntsman Advanced Materials are supplied in four colors (light blue, orange, black, and gray); the lightweight materials are said to be self-extinguishing and halogen-free.
Epocast 1633 syntactic epoxies are extrudable and easy to dispense from dual-barrel cartridges that contain premeasured amounts of resin and hardener.
Epoxy-based syntactics are entry-level materials that provide good material distribution at a lower cost but are dusty to machine and have lower abuse resistance.
Copolymer syntactic is a new material that offers improved toughness and durability versus standard epoxy syntactics.
Plug assists made of syntactic foam can be used in various ways with both positive and negative tooling to alleviate these issues.
Compared with other common plug/pusher materials such as wood and felt-covered wood, syntactic foam results in minimal plug mark-off and improved plug durability.