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Feature – Rapid Manufacturing- Closer to reality?
· New composites offer high strength, toughness and dimensional stability
· Long term affects of oxygenated fuels in plastics
Construction - Composites are now in decking
· Biodegradable disposable food service
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Rapid manufacturing- Closer to reality?
Several years ago we did a study to understand the potential for rapid prototyping, rapid tooling and manufacturing. We predicted that there existed a $500MM-$1B market for rapid tooling and manufacturing. This was comprised of applications where:
We felt that the number of rapid machines could easily be twice what they were in1997 which was 2250 machines. However, at the time there were some serious deficiencies in the industry. Some of these were:
It looks like 2001 is bringing this closer to reality.
Rapid Prototyping could replace injection molding for some lower volume, high-priced parts. DTM Corp, 3D Systems and Stratasys (leading rapid prototyping equipment suppliers) are all working on new materials that could make direct manufacturing possible in the near future.
The trend toward mass customization also is pushing rapid prototyping into the world of production. Align Technologies, a company in Santa Clara, Ca. has purchased 10 3D Systems SLA 7000 machines. They pioneered polycarbonate braces to straighten teeth. Rapid prototyping machines used to create one of a kind forms, used to make the final braces. Several hearing aid manufacturers are also looking at a variation on this technique.
In March at the Design Show in Chicago, both DTM and 3D Systems displayed technology that moves rapid prototyping machines a step closer to direct manufacturing of parts and metal molds.
Getting more strength and toughness into polypropylene compounds is being examined in an effort to keep part costs down while improving performance. Several compounders have long fiber-reinforced grades of PP. Now Ticona is going a step further with its line of Compel LFRTs (long fiber-reinforced thermoplastics) by adding PP composites with one-to- two-inch long glass fibers.
The new composites offer high strength, toughness and dimensional stability, particularly in automotive applications such as instrument panels, bumper beams, seat bases and automotive front-end systems.
According to Ticona, its Compel line of LFRTs is typically processed using compression molding where it offers time and labor saving advantages over glass-mat reinforced thermoplastics. The Compel pellets are plasticized and can be extruded directly into a compression mold, eliminating the need to cut and size GMT (glass mat-reinforced thermoplastics).
Compel LFRT grades are also available in nylon 6, nylon 6,6, PPS, PC, acetal copolymer, TPU and polyethylene, flow easily into the mold and are suitable for molding parts with thin walls where they exhibit excellent toughness and stiffness.
Ticona has conducted a study of the long-term affects various oxygenated fuels have on several polymer products and the company has concluded that testing for many plastics used in automotive fuel systems should be extended to 5,000 hours, rather than the 500 hours or less that is commonly done for plastics.
Ticona included Celcon and Hostaform acetal PPS, nylon 6/6 and high temperature nylon in tests conducted by an independent third party. Three methanol blends, three ethanol blends, an ethanol/methanol blend, isooctane/toluene (Fuel C) and isooctane/toluene/peroxide (Fuel CAP) were used in the tests based upon SAE J1681 fuel standards
Ticona says the results of the test, which update a study it performed in 1991, reflect the nature of the new generation of auto fuels, the extension of auto design life to 15 years or 150,000 miles, and the many changes being made in regulations affecting fuel system emissions.
Most of the plastics tested retained their integrity through the study with the exception of acetal homopolymer, that may not be suitable for extended life with certain aggressive fuels. Nylon 6/6 had the poorest performance in all fuels at the higher temperature, while linear PPS offered the best performance at elevated temperatures
Ticona gathered physical and mechanical data, including changes in weight, dimensional stability, tensile strength and tensile modulus at 65C (149F) and at 121C (250F).
A descriptive brochure entitled "Plastics and Aggressive Auto Fuels" is available on Ticona's web site at www.ticona-us.com/Literature/documents/Fuel Brochure 01 300res72dpi.pdf.
For more information contact Dwight Smith at the Ticona Automotive Technical Center at 765 478-4826 or Dwight.smith@ticona.com .
Three million decks are built, replaced or repaired in the United States each year and right now, most of them are made of wood. North American demand for wood/plastic composites is pegged at 700 million pounds in 2000, and decking accounts for about 60 percent of the total. Composite decks are virtually maintenance free thus the composite decking market is expected to grow 25 percent this year.
The wood composite market has lured brand-new players into the plastics industry. Lumber companies and wood fabricators generate waste fibers and sawdust. That cellulosic material is combined with plastic -- usually polyethylene, PVC or polypropylene -- to make the weatherproof "lumber." Either recycled or virgin plastic can be used.
Some manufacturers of composite decking include: Louisiana-Pacific Corp., Certainteed and Composite Building Products of Canada, Timbertech Ltd. (OH), and USPL of Boca Raton, FL. Not all manufacturers use wood fibers. In Canada, Composite Building Products International Inc. blends flax and rice hulls with high density PE to make their decking material.
Santa Barbara, Calif.-based EarthShell Corp., who just won a regional contract to supply McDonalds with new biodegradable clamshell packaging for hamburgers and has signed an agreement with DuPont's Polyester unit to jointly develop and market additional forms of biodegradable food packaging.
According to EarthShell, it will collaborate with DuPont in developing sandwich wraps and protective coatings for biodegradable disposable food service packaging, including cups, plates and hinged- lid containers. DuPont will contribute its Biomax hydrobiodegradable polyester coatings and films technology to the project.
New products resulting from the cooperative effort are expected to be introduced by the fall of this year.
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For the second time in less than a month, Japanese filmmaker Mitsubishi Plastics has won a contract to supply polylactic acid-based biodegradable film for a new packaging application.
The company announced earlier this month that it would produce film made from Cargill Dow's NatureWorks PLA for use in a golf ball package for Dunlop. This is PLA’s first wide-scale consumer application.
Now Mitsubishi reports that it has also won a contract to supply biodegradable film for NTT DoCoMo and Sony Corp. The company didn't identify what the film would be used for other than to say that Sony would use the film to package radios. Both orders represent about 100 tons of PLA a year. The company said that growing popularity of the film has led to plans for an expansion of capacity next year.
Key considerations, beyond its biodegradability, were PLA’s high clarity, high gloss, UV stability and dead fold properties.
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NOVA Chemicals recently introduced a "cleaner" version of its high molecular weight, high-density polyethylene (HMW-HDPE) resin specially designed for blow molding industrial containers for high-purity chemicals. This product development was prompted by the electronics industry, which has some of the most-stringent requirements for purity that extend to the packages for their chemical products.
NOVAPOL® HB-W555-AC resin has a flow rate of 5.0 g/10 minutes, a density of 0.955 g/cm3, environmental stress crack resistance (ESCR) of over 500 hours, a flexural modulus of 205,000 psi (1,400 MPa) at one-percent secant and a tensile impact strength of 200 ft-lbs./in2 (42 J/cm2).
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NOVA Chemicals also announced the commercial availability of eight grades of low volatile expandable polystyrene (EPS). Low volatile EPS products, those with a pentane level of 4.5% or less, help molders comply with the regulations of the Clean Air Act, which mandate a reduction in Volatile Organic Compounds (VOC’s) in non-attainment areas. Pentane is used as a blowing agent to expand a polystyrene bead.
Low volatile EPS can be used in a variety of applications such as Insulated Concrete Forms (ICF’s) and high performance packaging.
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NOVA Chemicals announced a new grade of polyethylene for rotationally molding large parts. NOVAPOL® TR-0242-U/UG, a high density, hexene copolymer, provides the durability and stiffness required for rotationally molding large tanks while processing as easily as other rotomolding resins with similar melt indices.
TR-0242-U/UG is characterized by a wide processing window (Ed.- see enclosed chart) and no sticking to the mold. With its high stiffness, excellent ESCR and strength, this product can be substituted for cross-linked polyethylene, fiberglass, steel and concrete in parts such as large agricultural and chemical storage containers and water tanks, and also for boats, kayaks and canoes.
For more information, please contact: Del Fischer -(412) 490-4292 or fischeda@novachem.com
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GE recently introduced a new product, an alloy of PPE and PP. GE brings these two formerly incompatible resins together with patent-pending alloying technology that incorporates the PPE particles in matrix of PP called Noryl PPX. The initial product line consists of two unfilled grades as well as 30% and 40% glass-filled grades.
With mold shrinkage values around 0.010 inch/inch and creep resistance closer to an engineering thermoplastic, PPX alloys exhibit better overall dimensional stability than either of its two ingredients.
The new alloys target a variety of applications, including automotive bumper fascia power tool and fluid-engineering components. Instrument panels, front-end modules, seat backs, load decks, and under-hood components might be other potential fits for PPX.
The new alloys are aimed primarily at an automotive segment looking for system cost reduction. A PPX bumper fascia, for example, can be 20-25% thinner than a comparable TPO fascia.
PPX also supports the automotive industry's growing plastic recycling efforts, as well. For more information, see www.geplastics.com
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In the marine industry, the use of closed molding is discussed as the next technology but until now, talk has not led to much action. The process has not been used cost-effectively, and has required more capital outlay than some smaller fiberglass-fabrication shops can afford.
Internal and government-induced pressure could be changing that notion. The Environmental Protection Agency has proposed tougher regulations governing the emission of hazardous air pollutants, called HAPs, from plants. The rules are part of the Clean Air Act, which was upheld in February in a U.S. Supreme Court decision.
Styrene monomer, a leading cluprit in those emissions is found in the production of fibergalss boat hulls and frames and in the tooling resin and gelcoats. According to a July EPA draft, styrene emissions can cause eye and mucous-membrane irritation. Longer-term exposure could affect the central nervous system, kidneys and blood, the report stated. Much of the potential problems come from the open molding process where the gelcoat is applied to the hold and then the polyester resin composite is layed-up.
The use of closed molds solves the hazardous air pollutant problems. The closed mold process typically seals two halves of a mold, then the unsaturated polyester resin with a reactive styrene diluent is injected into the mold. This step captures any unwanted emissions before they hit the atmosphere. Through VEC technology Inc. subsidiary, Genmar is using the process on its Glastron and Larson boats, which primarily are 17-20 feet long. The process combats the slowness and messiness of hand laid-up boat hulls. VEC Technology is in Greenville, PA and Little Falls, MN.
The technology reduces emissions by about 90% and is about at least eight times faster than open molding. This process has potential application in applications other than boat hulls, e.g., truck cabs, bulkheads, and outdoor tables.
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As manufacturers design more and more parts with hard-soft combinations, the future of two- and even three-component molding appears to be healthy and meeting new challenges One of the biggest trends in injection molding since 1990 has been 2-component production.
Automotive is using the technology because of the importance of appearance and the need for tactile surfaces for certain applications.
Two-component molding is growing in other areas as well. TPE manufacturer, GLS Corporation recently issued a news release on a customer project that required the overmolding of a TPE over a polypropylene handle for a toy called the Fascination Station.
GLS developed a new TPE for the overmolding that offered good adhesion to the PP part and was compounded to meet FDA and medical product applications. The toy is designed to be resistant to infant teething on the soft portion of the handle, but still provides a soft touch. GLS says the Fascination Station has won numerous awards for its innovative design.
Production of mobile phones is popularizing three-component molding as manufacturers strive to cut costs and increase functionality of key/button elements. When used in conjunction with film inserts it is possible to differentiate the product with color and other effects.
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Dow Chemical of Midland, MI and Mobius of Grass Valley, California entered into an agreement slightly more than a year ago to collaborate on the development of a flexible polyurethane foam recycling technology that Mobius had pioneered. While technologies exist to recycle most other types of polyurethane, flexible foam has proven very difficult and the Mobius technology is the first to show any promise.
Dow obviously believes the technology shows promise and has signed an agreement to promote the Mobius recycling technology to its flexible foam customers. Dow and Mobius will jointly market equipment and Dow's polyols and isocyanates as part of the deal.
The Mobius process pulverizes scrap foam to a microscopic powder and reintroduces it as an additive into the new foam manufacturing process. The European auto industry has been most interested in developing the technology to meet end-of-life vehicle requirements. A typical automobile interior contains 7-10 kg of flexible polyurethane foam, making them good candidates for PU recycling.
For more information on Mobius Technologies, visit their web site at www.mobiustechnologies.com .
Nypro, a global injection molder, announced recently initiatives in 3 areas:
· They have announced an alliance with Conferos, an on-line design collaboration service offering their customers a secure web-site dedicated to the design and product development team
· Strategic alliance with Commerx providing connectivity to suppliers – services to improve supply chain connectivity
· Web-based customer service offering customers access to daily schedule, order status, A/R and the shipping log
To our knowledge, this is a first in the custom molding community.
For more information contact www.nypro.com.