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Metapor porous aluminum materials provide an alternative to conventional mold materials and offer increased performance and design flexibility when compared to aluminum and epoxy materials.

For most thermoform programs, developing the highest quality components in the shortest period of time is crucial. Currently, mold-makers have many options of mold materials to utilize based upon the project type and required time frame. Materials such as epoxy, billet aluminum and cast aluminum are industry mold standards. Depending upon the desired quality, most thermoform tooling is constructed from either cast or machined aluminum for the materials flexibility and durability. Porous aluminum mold materials offer alternative advantages over these standard materials and in many cases offer performance and cost benefits that aluminum mold development cannot offer. Porous aluminum materials eliminate the need for vacuum holes which results in shorter development time frames.

METAPOR, was originally introduced in 1994 by Portec Ltd. Of Winterthur, Switzerland. The material was first introduced to the European chocolate manufacturers for the thermoforming of thin-gauge product packaging. The porous aluminum performed well due to ease of machining and the open porosity over the surface of the mold. This allowed the original users of these materials to produce each mold in a shorter time and allowed the designers to develop more intricate packaging. The open porosity of the material allows for greater detail and accuracy.

Unlike similarly performing sintered metals, porous aluminum materials can be machined without compromising material porosity. Since Metapor is a composite material, it can be machined in less time with high-speed carbide cutting tools, and without coolants as compared to aluminum. Metapor machining qualities are similar to that of a hardwood.

Machineable Metapor porous aluminum is manufactured in block form with a cubic dimension of 500mm x 500mm x 400mm. Tooling Technology cuts and stocks ready-to-machine slabs of Metapor in various thickness.

For mold requirements that exceed the 500mm x 500mm, Metapor can be bonded together without witness lines after machining. Since Metapor can be easily bonded together for size flexibility, the Metapor mold can be easily repaired in the event of damage by the same bonding procedure. For a porous aluminum repair, the damaged area is removed and a Metapor plug is inserted. After the "plug" is inserted and bonding agent is cured, the repaired area is then refinished. The resulting repair should not affect part quality or performance. Porous aluminum mold repair times can be substantially less than conventional aluminum molds damages. Most Metapor mold damage can be repaired within hours of the incident. The porous aluminum technology provides manufacturers with a mold material option that can allow improved thermoform part detail, shorter development time, and a reduction of overall mold development cost when compared to cast or billet aluminum.

In thermoform manufacturing of plastic products, porous aluminum mold materials offer a high-performance alternative to the conventional materials currently being utilized. METAPOR provides many performance benefits that enable manufacturers to produce better components in a shorter period of time. With the unique air-permeability of Metapor porous aluminum, larger volumes of air can be evacuated from between the plastic sheet and the mold surface resulting in improved cycle times and superior finished part detail.