REV has introduced MAXComposite in two thickness options, making this high performance material accessible to everyone. MAXComposite is designed for applications requiring strength, impact resistance, and abrasion resistance, all while being 25% lighter than polycarbonate. Its exceptional chemical resistance ensures compatibility with Loctite and similar adhesives. MAXComposite is laser cuttable, allowing for fast and precise production of custom parts.
MAXComposite is made from self-reinforced polypropylene (SRPP), a pure thermoplastic material combining two molecular weights of polypropylene with different melting points. During production, polymer chains are stretched and aligned into individual sheets, which are stacked and heat pressed under precisely controlled temperature, time, and pressure. This causes only the lower melting point polypropylene to bond, forming a matrix that secures the unmelted fibers (thus “self-reinforced”). The result is an exceptionally strong and rigid sheet with significantly higher strength than standard polypropylene.
Processing
For rapid and accurate part fabrication, CO₂ laser cutting is the most efficient method. Proper settings are essential to achieve clean cuts in a single pass, preventing overmelting or rebonding. The laser also seals the edges, locking the layers and preventing delamination. Adequate ventilation is required during cutting due to moderate smoke production.
To minimize material waste, prototyping with 5mm (0.196in) plywood is recommended before finalizing designs with MAXComposite. When resizing sheets for laser cutter bed sizes, conventional tools like table saws, bandsaws, or jigsaws can be used, though care should be taken to avoid overheating and rapid air cooling which can jam higher speed tools.
Drilling is straightforward with sharp drill bits; a 4mm (0.157in) hole allows #10-32 screws to self-tap. MAXComposite can also be formed with heat but fixturing may be needed for proper results. For painting, a quality plastic primer ensures optimal results.
Features
- Offers excellent stiffness, impact toughness, and abrasion resistance
- Approximately 25% lighter than polycarbonate
- Loctite safe
- High chemical resistance
- Laser cuttable for precise and efficient processing
- 100% recyclable
Specifications
- Material: Self-Reinforced Polypropylene (SRPP)
- Density: 0.9g/cm^3 (0.033lb/in^3)
- Tensile Strength: 174MPa (25200psi)
- Sheet Size: 1194mm x 584mm (47in x 23in)
- MAXComposite Sheet - 0.1in (REV-21-3098)
- Thickness: 2.5mm (0.10in)
- Weight: 1621g (3.57lb)
- MAXComposite Sheet - 0.2in (REV-21-3095)
- Thickness: 5.1mm (0.20in)
- Weight: 3264g (7.20lb)
Tested Performance
REV has extensively tested SRPP materials from domestic and international suppliers, including Tegris from Milliken, to deliver the highest quality. Partnering directly with a manufacturer, REV offers MAXComposite as the premier choice for demanding applications requiring advanced material performance.
