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BMW sees potential of 3D printing in new business models

BMW sees potential of 3D printing in new business modelsAudrey LaForest"We believe that additive manufacturing might change the way that we could produce our cars or components in the future in a dramatic way," said Dominik Rietzel, BMW Group's head of additive manufacturing in the non-metals division.Detroit — As additive manufacturing matures, improvements in the technology can help companies to create economies of scale, but only if material costs are low.That was a point made by Dominik Rietzel, head of additive manufacturing in the non-metals division at BMW Group, during a keynote presentation at the Rapid + TCT trade show, held May 20-23.The German automaker identified eight important topics that are transforming automotive production such as smart data and analytics, automation, lightweight construction, electrified powertrains and, of course, additive manufacturing."We believe that additive manufacturing might change the way that we could produce our cars or components in the future in a dramatic way," Rietzel said.BMW has been innovating in the field of prototyping for decades and is using 3D printing to produce foam-like prototype parts that mimic the real foam parts used in seats and dashboards, he said."Every engineer on our site can upload this dashboard with this foam component. He can choose the foam type he needs to improve the manufacturing process or to improve the product, and we put the geometry in there directly," Rietzel said. "In this way, we want to mimic the behavior of the layer of foam in an ideal way, so that we can really improve the assembly process."But for series production, especially in automotive, "reliability is key," he said. "Our cars are driven in very rough conditions. We need to rely on every component in them."That's part of the reason why BMW developed its own additive manufacturing readiness levels, which is essentially a "generic approach" to utilizing the technology and validating 3D printed parts, Rietzel said. It's also something BMW openly shares with its suppliers."We don't want to keep all the [intellectual property] on our side," Rietzel said. "We want to share it with the community, so that everybody can really improve their processes and supply us with parts in the future."Strong, long-term partnerships with additive manufacturing firms such as HP Inc. and EOS GmbH has helped the automaker achieve those types of product innovations in additive manufacturing.But tech startups also play a role in this. Through BMW's venture capital fund — BMW i Ventures Inc. — the company is staying on the forefront of the latest advancements in technology."For us, the most important thing is to work closely together with them and understand the [key performance indicators] of such a new technology before they release the product," Rietzel said of BMW's access to startups.Changing the processAdditive manufacturing is not only changing the way companies think about products, Rietzel said, but also how they create their business models.A prime example of this is BMW's Mini Yours Customized project, where consumers are able to customize and personalize various components, such as side scuttles and cockpit fascias, that are then 3D printed by the automaker."Imagine having such a process in a big corporation that you can just upload something on your iPhone, and we can print it for you and send it directly to you," he said. "This isn't normal in this industry."For the project, Rietzel said BMW is using an automated production cell with two robots and two M2 printers from Carbon. With automation, the company can produce 504 pieces per week on each machine vs. 120 pieces in a manual production setup."If you have a fast technology waiting, it doesn't help. … We automate where it makes sense and that means we are pretty lean now in the production process," he said.The research that went into automating that process is part of a big-picture view for how BMW is working to improve additive manufacturing for applications in the future. Rietzel said the automaker has started an initiative on additive manufacturing across the whole group, including production, design, engineering and IT departments.BMW has also identified four key topics to focus on for additive manufacturing within the organization: functional safeguarding for the approval process, individualization for all the different products offered, series production only where it makes sense and spare parts production where it is needed.In terms of BMW's corporate research, the automaker has identified technology development and the improvement and development of materials as two areas that still need to be addressed to take additive manufacturing to the next level."You will always have to pay for it," Rietzel said of materials as a baseline cost. "This price will always be in those parts."source : www.plasticsnews.com
Editor 2019-06-02
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Symbio JV to push fuel cell technology

-Symbio JV to push fuel cell technologySymbioA Symbio fuel cell system.French auto suppliers Fauecia SA and Michelin are working together to accelerate automotive fuel cell technology.The two companies signed a memorandum of understanding to create a joint venture in Symbio, previously a subsidiary of Michelin, according to a Michelin spokesman. The company will develop, produce and market hydrogen fuel cells for light and utility vehicles and trucks, as well as for other applications.Fabio Ferrari, Symbio founder and CEO, started the company about 10 years ago with a goal for commercializing fuel cell technology after working with the French Alternative Energies and Atomic Energy Commission (CEA) to find the right market for the product, he said."They have been developing fuel cell systems for about 30 years now. They're really good at the technology, and they were looking for ways to put it into the market," Ferrari said. "I worked with them for about one year to define where are the right market segments to start, and at the end of the study, I decided to create the company."The company worked alongside Michelin for several years before Michelin came in as a shareholder in 2014.With Michelin's concurrent sustainable mobility research, the two companies found a stride working together, especially on projects aimed at boosting the flexibility of electric vehicles, he said.Ferrari said Michelin bought Symbio in February, introducing it as a subsidiary of the group. The company will be owned equally by Faurecia and Michelin through the JV.Faurecia, a French automotive systems supplier, found common ground with Michelin in hydrogen as a solution for powering vehicles, according to Eric Fohlen-Weill, head of corporate communications for Faurecia."Both companies believe that hydrogen will be complementary to battery electric vehicles," Fohlen-Weill said.While battery electric vehicles are useful for various applications, the system doesn't adapt well for trucks as an example, he said. Trucks see regular, intense use for long distances, and can't be left charging for 2-3 hours."Those two key elements are already available with hydrogen solutions," Fohlen-Weill said. "You can have more than 1,000 kilometers of autonomy with a hydrogen solution, and the refueling time is three to five minutes. So hydrogen is a suitable solution for light commercial vehicles and delivery vehicles."Hydrogen is additionally useful because even after a day full of making deliveries, "at the end of the tailpipe, it's only water. It's a zero-emission solution," Fohlen-Weill said.A hydrogen system uses more simplified architecture and reduces price, Ferrari said. A fuel cell typically uses a polymer film at its center, while fuel cell systems rely on plastics and other lightweight materials for housings, cables and cooling systems."It's four times smaller and five times lighter if you compare a battery to fuel cells," he said.One drawback is a lack of widespread refueling stations, but as the system becomes more popular, those will be easier to sustain, Ferrari said. Because of their regular routes, light commercial vehicles such as fleet vehicles can make a good choice for hydrogen systems."The good thing is that you're not going to holiday with this vehicle, so they come back to the parking lot every night, so it's easy to put in the right position, and to optimize the business model for this working condition," Ferrari said."As this common vision appears, we say, the markets need to receive a strong signal from OEMs," he said. "If two worldwide leading companies, manufacturers, say they both invest and believe in fuel cell technology, it will give a very good, positive signal to the rest, and to the market."Fohlen-Weill said fuel cells are a mid- to long-term solution for the automotive industry, but the time to develop the technology is more immediate as manufacturers are planning future vehicles."We believe that competitive fuel cell systems will be on order around 2025, so companies like Symbio need to be a backbone to strong shareholders who are able to finance those kinds of activities until it is happening," he said. "With companies like Faurecia and Michelin, it's possible. We really believe in this energy vector."Faurecia will bring the knowledge and work it's done with the CEA to develop a new generation of hydrogen tech, and Michelin will provide all the activities that Symbio has done, Fohlen-Weill said.Michelin also will provide research and development and production activities, according to the company spokesman.Both companies will help the developing Symbio gain access to the right people to spur reach into the automotive market who will be able to sell the solution as a viable option, Ferrari said."Of course we will be able to take some competencies from Michelin and Faurecia to more rapidly grow in the right direction," Ferrari said.Symbio already has several staff members at the sales and technical level coming from Michelin, and Ferrari hopes to have some employees joining from Faurecia as well once the final agreement is signed, he said.Ferrari is working on the next steps for Symbio's process through the JV, which includes planning for the new build of the company "to be compatible with the objectives I have now in terms of market and production," he said. Symbio has a capacity to produce about 1,000 fuel cell systems per year and plans to scale up to producing more than 100,000 per year."It's a huge step for us," Ferrari said. "The market is forecasting for that, so we have to go that direction for sure."Growth of that magnitude means a requirement for expansion of the company's facilities, starting with its production facility near Lyon, France, Ferrari said. As demand increases, there could be continued development near that facility. Symbio has its headquarters and R&D at its location in Montagny, France.Symbio, which has 120 employees, also will need to bring on a larger staff, though the goal total is still being established, he said."I think we will at least double the size of the company in the next year, because we have large objectives," he said. "It all depends on how we see the growth and how we want to invest, at what pace we want to invest, to be exact." Details about investment surrounding the JV were not disclosed.His objective is to have some results for the structure of the JV going forward by June, but it could reach into September. The new company still needs to undergo scrutiny through antitrust regulations. With that goal in mind, Ferrari would like to have the first phase of production with the new plant underway by the end of next year."The market is really starting now," Ferrari said. "We really want to be ready for this market, so we really have to accelerate. It's a huge exercise to grow like that in a short time frame, but it's mandatory. It's a good goal to set."To obtain reprints or copyright permissions:E-mail: pnreprints@crain.comVisit: Reprintssource : https://www.plasticsnews.com
Editor 2019-04-26
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Biomedical market sees 
in-mold printed electronics

-Biomedical market sees 
in-mold printed electronicsMatthew Rubinberg PhotographyKarthik Gopalan, a fourth-year doctorate candidate and researcher at the University of Clifornia Berkeley seaks at the In-Mold Decorating Association's annual symposium.San Diego — Karthik Gopalan discussed the use of printed, flexible and in-mold electronics for biomedical applications.The fourth-year doctorate candidate and researcher at the University of California, Berkeley’s electrical engineering and computer sciences department compared the value of additive printing — “one step for patterning and deposition” — vs. multi-step photolithography.For wound monitoring, inkjet-printed electrode arrays can map tissue impedance and detect wounds such as pressure ulcers before they become visible, Gopalan said, citing two 2015 technical papers.Impedance mapping can extract unique electrical signatures in healthy and damaged tissue, he noted in remarks at the IMDA symposium.InkSpace Imaging Inc., a spinoff from the UC Berkeley laboratory of professor Ana Claudia Arias is making technology strides. Arias is advising Gopalan.Startup InkSpace of Moraga, Calif., can use additive processing in making patient-customized lightweight magnetic resonance imaging surface-receive coils that can increase patient comfort and the speed of examinations.InkSpace’s manufacturing method uses printed electronics to make extremely lightweight, flexible and low-cost MRI coils.In particular, printed coils can benefit pediatric patients and limit the use of general anesthesia.“The mission is to make body coils to fit any patient’s size, shape or body part,” Gopalan said.InkSpace’s MRI surface technology adds to the functionality of organic optoelectronics for pulse oximetry from suppliers such as Cambridge Display Technology Ltd. of Godmanchester, England, or Intel Corp. of Santa Clara, Calif. An oximeter measures the oxygen saturation of arterial blood in a subject.An adaptable model 300XQ vacuum forming machine from Formech International Ltd. of Harpenden, England, is used in processing plastic sheet modeled on a grid of points with finite mass. Adjacent points are coupled with “springs,” infinite friction is set between the plastic and the mold and the vacuum force is proportional to the area of each triangle, Gopalan said, quoting from two other technical papers.“You need to predistort the plastics before the cloth is draped over,” Gopalan said.Project leaders aim to enter a production phase in mid-2019 in conjunction with custom injection molder Sussex IM Inc. of Sussex, Wis.For the technology developments, the National Science Foundation has awarded two Small Business Innovation Research grants to InkSpace: $224,980 in 2017 and $750,000 in 2018.Gopalan acknowledged technical contributions from others at UC Berkeley for scanning, ink selection and spray coating support; Xerox Corp.’s Palo Alto Research Center for help with electro-less plating; Formech for research and technical assistance; and Massachusetts General Hospital.source : 
Editor 2019-02-16
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Growth, new products and technology: Highlights from LSR 2018 in Anaheim

Growth, new products and technology: Highlights from LSR 2018 in AnaheimPhoto by Roger Renstrom, Plastics NewsEngel Machinery Inc.'s west technical center in Corona, Calif., welcomed more than 100 people from the LSR 2018 conference for an open house with live demonstrations.Anaheim, Calif. — LSR processing, materials and markets underwent thorough reviews during the second international conference on advances in liquid silicone rubber and related thermosetting polymers.Amos Golovoy, organizing committee chairman, said 197 people attended LSR 2018. Golovoy is president of AG Research in Canton, Mich.Here are notes from some of the 28 presentations at the LSR 2018 conference and details from the live demonstrations at the related technical center visit.LSR’s evolutionMark Bonifacio described LSR as an amazing young technology in his keynote address.“Silicone is in the early stages … on the 10-yard line,” said Bonifacio, president of Boston-based Bonifacio Consulting Services LLC.Bonifacio said global LSR market sales were $1.5 billion in 2015 and are on target to reach $3.29 billion by 2025, according to a report from Grand View Research Inc. of San Francisco.Bonifacio described the raw thermoset material — he called it “goop” — as high-purity two-part platinum-cured silicone. Others described the raw material as “sticky” or “paste.”The markets in the Asia-Pacific region and for medical and health care applications “are the biggest growth areas” for LSR, Bonifacio said. Among the principle drivers, processors “use silicone when other materials don’t perform as well.”Bonifacio said LSR contract processors face challenges when major customers merge. He cited the Abbott Laboratories acquisition of St. Jude Medical Inc. in January 2017 and the Medtronic Inc. acquisition of Covidien plc in January 2015.Square expandingDuring the fourth quarter of 2018, Shenzhen Square Silicone Co. Ltd. plans to complete a 6,000-metric-ton-per-year expansion project in Zhejiang province in eastern China.“Square will be able to produce 12,000 metric tons per year” and expects to replace Dow Corning as China’s largest LSR supplier, said YanMin Lee, chairman and founder of the Shenzhen-based Square.“China’s increasingly stringent environmental policies have put pressure on siloxane producers,” Lee said. “The facilities are relatively backward, resulting in equipment maintenance rates becoming significantly higher than international rates. The increase of environmental protection policies has also increased production costs.”Differentiating DowSilJacob Steinbrecher, applications engineer in electronics and lighting with Dow Corning, differentiated the recently rebranded DowSil moldable optical silicones from traditional LSR materials.“Silicone resins impart strength and stability” in moldable optical silicones, he said. In comparison, “silica and/or other fillers impart strength and stability in traditional LSR.”Steinbrecher said the DowSil products are “optically transparent, highly reflective [and] translucent.”Particular applications include diffusers, protective covers, total-indicator-runout, Fresnel and free-form lenses; engineered diffusers, light guides, white reflectors and mixing chambers.Experimental silica gainsVictor Lifton said Evonik Corp.’s newly developed EXP 107-2 experimental hydrophobic precipitated silica “shows unexpectedly positive influence on the behavior of the RTV-2 system at elevated temperatures.” Evonik of Piscataway, N.J., has ongoing tests of the LSR.“Special grades of structure-modified fumed silica enable high loading levels without sacrifices in processability,” said Lifton, Evonik technical market manager.Among the benefits: “low thickening effect and excellent processability at more than 20-percent loading levels, excellent reinforcement [and] no post-thickening effect,” Lifton noted. Moisture levels remain a concern and “optical properties are not as high as with fumed silica.”Roembke 
emphasizes turnkeyAdam Shaal underscored the value of a turnkey system in leveraging design, build, test and support phases of a LSR project.“We see more customers wanting to utilize turnkey systems for their production,” said Shaal, business development manager for Roembke Mfg. & Design Inc. of Ossian, Ind.Roembke’s Asia-Pacific main office is located at the Hong Kong site of Everfinest Engineering Co. Ltd. In 2015, Everfinest cooperated with Roembke to introduce LSR tool, flashless and runnerless rubber mold and cold-runner valve-gate and open-gate systems to the Southeast Asia and China markets.Hybrid mesh
 for simulationPlastics simulation software provider Moldex3D says a new hybrid mesh — boundary layer meshing — is being used more frequently than the traditional voxel-type mesh for advanced LSR simulation technologies.BLM validation with an end user confirmed the capability of the surface mesh to capture curvatures when necessary, said Jay Vang, customer success engineer with the Moldex3D North America Inc. unit in Farmington Hills, Mich.The latest simulation technology for LSR molding leads to higher resolution, lower element count and faster simulation times, Vang said.Users “need to capture precisely to measure viscosity differences,” said Torsten Kruse, president of Kruse Analysis Inc. in Naples, Fla., and a Moldex3D collaborator.CoreTech System Co. Ltd. of Chupei, Taiwan, does business as Moldex3D.Protecting electronicsMichael Kou successfully placed his iPhone in a container of water to demonstrate LSR’s capability to protect consumer electronics.“The advent of LSR made ingress protection possible,” said Kou, U.S. market director for Singapore-based Synergy Hanil Precision Polymer Technologies Co. Ltd.“Nothing is water proof, only water resistant,” Kou said. A fine-mesh ingress-protection design “allows air and sound to pass [and] keeps dust and water out” of a device’s audio jack, pressure vent, speaker, charging port, home button and microphone.Future ingress-protection technologies such as ISO 20653-certified IPX9K will have the capability to withstand high-temperature water jets, outdoor and harsh environments and steam-autoclave sterilization applications.Onward to high volumeRick Ziebell discussed how fast LSR prototyping can allow speed-to-market responses and provide functionally-capable 3D printed parts.Pairing Dow Performance Silicone’s new Evolv3D-brand technology and German RepRap GmbH printers can “provide ease of use and scalability to high-volume LSR injection molding,” said Ziebell, technology fellow with R.D. Abbott Co. Inc. of Cerritos, Calif.GRR’s new liquid additive manufacturing printer frame enables the use of silicone and support material for more complex shapes, he said. The LAM is based on GRR’s X400 fused deposition modeling 3D printer.The LAM printer’s improved software print control and expanded nozzle size option can yield finer print definition, Ziebell said.R.D. Abbott, celebrating its 70th anniversary with roots in the rubber industry, has built an expertise in elastomers with premium products, testing laboratories and warehouses throughout the U.S. and Mexico.ACH in FloridaACH Solution USA Inc. has established an 800-square-foot sales office and 2,500-square-foot technical center in Sarasota, Fla., according to Steven Broadbent, general manager. The entity expects February delivery of a 120-ton Engel injection molding press with an integrated Viper linear robot.The Florida operation is the newly formed U.S. unit of Christian Hefner’s Fischlham, Austria-based ACH Solution GmbH. The parent firm does more than 50 percent of its business in the U.S. and reported 2017 global sales of about 13 million euros ($15.6 million).Broadbent was in technical sales positions with Engel Machinery Inc. of York, Pa., for 10 years before officially joining ACH on July 1.Photo by Roger Renstrom, Plastics NewsPlastics processing engineer Steven Sheely shows polycarbonate medical specimen containers being molded during live demonstrations at Engel Machinery Inc. west technical center in Corona, Calif.Engel demonstrationsIn live demonstrations, LSR 2018 attendees saw production of eyeglass lenses, a radial seal and a medical specimen container during a tour at Engel Machinery Inc.’s west technology center in Corona, Calif.A tie-barless 55-ton Engel Victory LSR machine with an integrated Engel Viper 6 robot produced the Wayfarer eye glasses using Shin-Etsu Silicones clear optical-grade x34-1972-3 on a one-cavity Roembke mold with 40-second cycles. 2KM North America Inc. supplied a SilcoStar e-flow 20 metering system.An Engel 55-ton e-Mac LSR machine ran the radial seal using Momentive Performance Materials Inc.’s self-lubricating Silopren LSR 3286/50 on a four-cavity ACH mold with a 20-second cycles. Fluid automation specialist Graco Inc. supplied an F4 dosing system, and PolyOne Corp.’s GSDI Specialty Dispersions Inc. provided the colorant.A Wintec 100-ton e-Win machine with a pick-and-place Engel viper linear robot ran the 13-gram polycarbonate in-development specimen container on a two-cavity Roembke mold on a 30-second cycles. Moretto USA Inc. supplied the feeder and dryer, and Lenzkes Clamping Tools Inc. provided the clamps. Engel designs and engineers the servo-electric high-precision Wintec product lines in Europe and manufactures the sister brand of Engel in Changzhou in China’s Jiangsu province.More than 100 people attended the Engel open house.Engel North America opened its 7,300-square-foot California technical center in 2009. Parent firm Engel Austria GmbH is based in Schwertberg, Austria.LSR 2018 conference presentations took place Sept. 11-12 in Anaheim, and the Engel technical center event occurred Sept. 13 in Corona.
Editor 2018-12-25
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SPE names Automotive Innovation Award winners

▲ Ford took home top honors as both the grand winner and powertrain category winner with its vacuum generation system for brake assist on the 2017 F-150 pickup.Automakers, suppliers, engineers and plastics experts once again gathered to celebrate a handful of industry firsts and lightweight parts applications Nov. 7 at the automotive division of the Society of Plastics Engineers’ 48th annual Automotive Innovation Awards Gala.Nine category winners were announced as well as one grand winner. This year’s Hall of Fame award and Lifetime Achievement Award winners were also honored.Ford Motor Co. took home the top award for its entry in the powertrain category: the all-plastic vacuum generation system for brake assist on the 2017 F-150 pickup. The thermoplastic part achieves a 40 percent weight reduction and a 25 percent cost savings over current pump systems. Dayco Products LLC is the Tier 1 supplier. MacLean-Fogg Component Solutions and Engineering Plastics Co. are the processors. Materials are from DowDuPont Inc.SPE honored Honda Motor Co. Ltd. with this year’s Hall of Fame award for what the society said is the first injection molded thermoplastic rear energy absorber for a vehicle bumper system. The polycarbonate/polybutylene terephthalate energy absorber is on the 2003 Honda Element compact crossover. The PC/PBT part replaced an expanded polypropylene foam version, requiring less package space at a lower cost with better damageability performance.As previously reported by Plastics News, Rose Ryntz, formerly the vice president of advanced development and material engineering at International Automotive Components Group, was recognized as the society’s 2018 Lifetime Achievement Award winner. Ryntz resigned from her position at IAC Oct. 31.Other category winners are as follows:Body ExteriorFiat Chrysler Automobiles NV for the thermoplastic liftgate on the 2019 Jeep Cherokee. The thermoplastic liftgate replaces the steel design and enables a 28 percent mass reduction in addition to a 50 percent tooling and capital investment savings.The automaker said it is an industry-first use of conformal infrared welding behind the molded-in-color grain Class A surface. Magna International Inc. is the Tier 1 supplier, with materials from Trinseo SA and LyondellBassell NV. Tycos Tool & Die Co., a division of Magna Exteriors, supplies the tooling.Body InteriorFord for the integrated modular pelvic bolster on the 2018 Lincoln Navigator SUV. The application combines two side-impact bolster designs into one and integrates the part into the door trim map packet.The consolidated design offers an estimated cost savings of $100,000 in tooling and a 10 percent weight reduction. Faurecia supplies the system, using polypropylene material from LyondellBassell. Roush Industries Inc. supplies the tooling.Chassis/HardwareFiat Chrysler for the high-strength, self-tapping composite nut on the 2016 Chrysler Pacifica minivan. The composite nut has self-healing properties that allow it to maintain sufficient torque and clamp load even after being stripped.Estimated cost savings are $3.25 per vehicle. ITW Deltar Fasteners supplies the system, using material from Asahi Kasei Corp. and tooling from Maple Mold Technologies Inc.EnvironmentalFord for the use of sustainable hybrid composites on the 2018 Lincoln Continental luxury sedan. The automaker said the industry-first application of composites combining cellulose fiber from trees with long glass fiber in a polypropylene matrix results in a $2 million cost savings achieved by reducing weight by 24 percent and shortening cycle times by 20-40 percent.Summit Polymers Inc. is the Tier 1 supplier and toolmaker. The composite materials are from Celanese and International Paper Co.MaterialsHyundai Motor Co. for its use of electromagnetic interference shielding compounds developed for high-voltage junction box upper covers on the 2019 Nexo SUV.The material — nylon with a hybrid conductive carbon filler from Hanwha Compound — replaces conventional die-cast aluminum for reduced weight and manufacturing costs. Yura Corp. supplies the system, with tooling from Hyundai.Process/Assembly/ Enabling TechnologiesFiat Chrysler for the integrated tire carrier, rear camera and brake light assembly on the 2018 Jeep Wrangler. The hybrid composite technology uses magnesium injection molding for higher structural strength and reduced weight as well as polymer overmolding for better impact and corrosion resistance.The new design also eliminates the need for a steel bracket. Grammer AG’s Toledo Molding & Die Inc. is the Tier 1 supplier. Tooling is from Leggera Technologies LLC. DowDuPoint supplies the material.SafetyFord for the interlocking mechanism design for side impact on the 2019 Transit Connect van. The patent-pending design, which prevents the fracturing or separating of components that could cause sharp edges, replaces the need for metal bracket reinforcements. Faurecia is the Tier 1 supplier, with tooling from Meymol SL. Trinseo supplies the ABS material.
Aeyoung Park 2018-11-20
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Finalists named for 2018 SPE Automotive Innovation Awards

▲ This 3D printed window alignment fixture is 30 percent lighter and cheaper to produce than a traditional welded fixture, according to Ford Motor Co. (ⓒSociety of Plastics Engineers)The Society of Plastics Engineers’ Automotive Division has selected the finalists for the 2018 Automotive Innovation Awards.Nine category finalists and one grand award winner were chosen during an Oct. 5 Blue Ribbon judging round. The winners will be announced during the society’s 48th annual Automotive Innovation Awards Gala Nov. 7 at Burton Manor in Livonia, Mich.This year’s finalists are:Additive Manufacturing• Ford Motor Co. for a 3D printed venting insert on the 2019 Ranger pickup. To improve venting, the 3D printed insert is designed with integrated venting channels that allow gas to escape into the atmosphere. Ford said manufacturing time is reduced by 70 percent for the 3D printed part compared with steel. The design also eliminates the need for a separate grille. Faurecia Interior Systems Inc. is the Tier 1 supplier, with Hi-Tech Mold & Engineering Inc. supplying the tooling. The thermoplastic polyolefin (TPO) material is from Advanced Composites Inc.• Ford for the window alignment fixture on the 2017 Mustang convertible. The 3D-printed fixture, made with a carbon fiber-reinforced nylon from Stratasys Ltd., is 30 percent lighter and cheaper to produce than the traditional welded fixture. Stratasys supplies the system, material and tooling for the part.• Ford for a 3D printed lift assist used in assembly for the 2018 Escape SUV and Fusion sedan. The updated lift assist, which carries anything from a half shaft to an instrument panel, has a 222-pound weight savings over a traditional steel welded or machined lift assist. Ford said the 3D printed version also costs 50 percent less to manufacture. Stratasys supplies the system and materials, with Eckhart Inc. supplying the tooling.▲ Fiat Chrysler Automobiles NV's thermoplastic liftgate on the 2019 Jeep Cherokee replaces a steel design. (ⓒSociety of Plastics Engineers)Body Exterior• Groupe Renault for the first thermoplastic composite guide rails for a sunroof module on the 2016 Scenic MPV. The composite guide rails, made from a glass fiber, ABS and styrene maleic anhydride blend, reduce production from seven steps to two. Sunroof installation on the assembly line is also reduced to a one-step, top-loaded process, resulting in a 20 percent cost savings. Webasto SE supplies the system. The ARRK Group’s Shapers supplies the tooling.• Fiat Chrysler Automobiles NV for the thermoplastic liftgate on the 2019 Jeep Cherokee. The thermoplastic liftgate replaces the steel design and enables a 28 percent mass reduction in addition to a 50 percent tooling and capital investment savings. The automaker said it is an industry-first use of conformal infrared welding behind the molded-in-color grain Class A surface. Magna International Inc. is the Tier 1 supplier, with materials from Trinseo SA and LyondellBassell NV. Tycos Tool & Die Co., a division of Magna Exteriors, supplies the tooling.• Fiat Chrysler for the injection molded rear bumper step reinforcement on the 2019 Ram 1500 pickup. The one-piece glass fiber-reinforced polypropylene part replaces an all-metal rear bumper assembly. The plastic rear bumper maintains a chromed metal shell and achieves an 8-pound weight savings. Flex-N-Gate Corp. supplies the system, with material from Celanese Corp. Integrity Tool & Mold Inc. supplies the tooling.• General Motors Co. for a bumper bracket on the 2019 Chevrolet Silverado pickup. The glass fiber-reinforced polypropylene bumper bracket replaces a stamped steel design. The plastic bracket allows for the integration of fog lamp mounting in the design and mass savings. Flex-N-Gate and its Ventra Plastics division supply the system, with tooling from Integrity Tool & Mold. Mitsui Chemicals Inc. and Lotte Advanced Materials Co. Ltd. supply the material.Body Interior• PSA Group for the lighted headliner on the 2013 Peugeot 2008 SUV. The decorative application of ambient lighting utilizes the integration of a planar light guide with LEDs embedded in a flexible cable. This is done in a wet polyurethane compression molding process. Common tooling from Grupo Antolin, which also supplies the system, allows for vehicle upgrades compatible with standard versions. Oroglas supplies the acrylic.• SAIC General Motors Corp. Ltd., GM’s Chinese joint venture, for the door trim panel on the 2016 Buick LaCrosse sedan. The injection molded part is produced via chemical foaming with a core-back process and achieves a 26 percent weight savings vs. a comparable industry standard application. Cycle time is also reduced by about 20 percent. Yanfeng Automotive Interiors supplies the system and tooling. Suzhou Runjia Engineering Plastics Ltd. Co. and Mitsui Chemicals supply the material.• Geely Automobile Holdings Ltd. for what it says is the first instrument panel with long glass fiber on a visual surface on the 2019 FE-6 sedan. The new design integrates polished and grained areas into one part with one tool, resulting in overall weight reduction and a cost savings of $2.20 per vehicle. SH Global Co. Ltd. supplies the system, with tooling from Taizhou Huangyan Tianhui Mould Co. Ltd. Materials are from Celanese.• Ford for the integrated modular pelvic bolster on the 2018 Lincoln Navigator SUV. The application combines two side-impact bolster designs into one and integrates the part into the door trim map packet. The condensed design offers an estimated cost savings of $100,000 in tooling and a 10 percent weight reduction. Faurecia supplies the system, using polypropylene material from LyondellBassell. Roush Industries Inc. supplies the tooling.Chassis/Hardware• Fiat Chrysler for the hybrid control arm with an integral ball joint on the 2019 Ram 1500. The automaker said this is the first usage of engineered plastic in the structure of a control arm for a high-volume production, light-duty full-size truck. The glass fiber-reinforced nylon part is injection molded over a welded steel stamping assembly, resulting in a 13 percent weight reduction and improved fuel economy. Iljin Group supplies the system, with materials from BASF Corp.• Ford for the integrated window regulator system on the 2019 Focus. The system features integrated organo fibers overmolded in a plastic material. The application achieves a 30 percent cost reduction as well as weight savings. Brose North America Inc. supplies the system and tooling. Materials are from Lanxess AG and Borealis AG.• Ford for the sonic welded fog lamp and air curtain bracket on the 2018 Mustang. The one-piece, sonic welded bracket features a living hinge that is molded into the bracket, forming the duct for the air curtain. The application enables an annual weight savings of 0.2 pounds per vehicle and the elimination of 1.6 million fasteners. Flex-N-Gate supplies the system, with tooling from Omega Tool Corp. Saudi Basic Industries Corp. (Sabic) supplies the TPO material.• Fiat Chrysler for the high-strength, self-tapping composite nut on the 2016 Chrysler Pacifica minivan. The composite nut has self-healing properties that allow it to maintain sufficient torque and clamp load even after being stripped. Estimated cost savings are around $3.25 per vehicle. ITW Deltar Fasteners supplies the system, using material from Asahi Kasei Corp. and tooling from Maple Mold Technologies Inc.Environmental• Ford for the foamed extension dash panel on the 2019 Edge SUV. The dash panel is made with recycled polypropylene sourced from carpet backing and filled with recycled tire rubber and 20 percent glass. The part is injection molded with MuCell foaming, enabling a weight savings of 0.52 pounds and a cost reduction of 28 percent. Ford said 11.9 million square feet of carpet and more than 26,000 pounds of tire material were recycled for the application. Windsor Mold Inc. supplies the system. Materials are from Wellman Advanced Materials LLC and Lehigh Technologies Inc.• Ford for the use of sustainable hybrid composites on the 2018 Lincoln Continental luxury sedan. The automaker said the industry-first application of composites combining cellulose fiber from trees with long glass fiber in a polypropylene matrix results in a $2 million cost savings achieved by reducing weight and cycle times by 20-40 percent. Summit Polymers Inc. is the Tier 1 supplier and toolmaker. The composite materials are from Celanese and International Paper Co.• Ford for what it says is the first-time use of recycled, molded-in-color TPO for Class A components on the 2019 Transit van. Materials, supplied by Canuck Compounders Inc., include recycled polypropylene from automotive regrind and FDA-approved plastics. Magna is the Tier 1 supplier.▲ Hyundai Motor Co. is using conductive plastic compound materials for EMI shielding on high-voltage covers on the 2019 Nexo SUV. (ⓒSociety of Plastics Engineers)Materials• Hyundai Motor Co. for its use of EMI (electromagnetic interference) shielding compounds developed for high-voltage junction box upper covers on the 2019 Nexo SUV. The material, from Hanwa Compound, replaces conventional die-cast aluminum for reduced weight and manufacturing costs. Yura Corp. supplies the system, with tooling from Hyundai.• Ford for the use of lightweight elastomeric material on the 2017 Lincoln Continental. The ethylene propylene diene monomer (EPDM) and thermoplastic vulcanizate (TPV) material from Cooper Standard Automotive Inc. offers automakers a 30 percent mass reduction vs. dense EPDM and a 10 percent mass reduction vs. dense TPV.• GM for the thick polycarbonate light bar for unique LED styling in headlamps on the 2019 GMC Sierra 1500 pickup. The automaker used Covestro LLC’s crystal polycarbonate and a proprietary multishot injection molding process to achieve a floating C-shape and sculptured ice appearance. Proper Group International Inc. is the toolmaker. Valeo Lighting Systems is the Tier 1 supplier.Powertrain• Ford for the all-plastic vacuum generation system for brake assist on the 2017 F-150 pickup. The lightweight, low-cost system is designed to assist with braking feel and function. The thermoplastic part achieves a 40 percent weight reduction and a 25 percent cost savings over current pump systems. Dayco Products LLC is the Tier 1 supplier. MacLean-Fogg Component Solutions and Engineering Plastics Co. are the processors. Materials are from DowDuPont Inc.• Ford for the industry-first, cost-neutral application of graphene-reinforced polyurethane foam on the 2018 F-150. The under-the-hood application is used for pump and rail covers. Eagle Industries Inc. is the Tier 1 supplier and toolmaker. XG Sciences Inc. supplies the graphene-reinforced polyurethane foam.Process/Assembly/Enabling Technologies• Fiat Chrysler for the integrated tire carrier, rear camera and brake light assembly on the 2018 Jeep Wrangler. The hybrid composite technology uses magnesium injection molding for higher structural strength and reduced weight as well as polymer overmolding for better impact and corrosion resistance. The new design also eliminates the need for a steel bracket. Grammer AG’s Toledo Molding & Die Inc. is the Tier 1 supplier. Tooling is from Leggera Technologies LLC. DowDuPoint supplies the material.• Ford for the modular seat bushing on the 2018 Focus Active crossover hatchback. The rear seat mounting bracket and pivot system self-locates and self-retains, and replaces a royalty-fee design that requires tools for service and removal. Ford is the Tier 1 supplier. DowDupont supplies the nylon material. The toolmaker is Prevent TWB GmbH & Co. KG.• Ford for faux stitch-and-ditch features on the 2019 Focus. The stitching aesthetics are added to the in-mold grain and lamination and replace cast-vinyl and spray polyurethane processes. Faurecia supplies the system, with tooling from GS Engineering. The TPO skin is from Benecke-Kaliko AG.Safety• Ford for the interlocking mechanism design for side impact on the 2019 Transit Connect van. The patent-pending design, which prevents the fracturing or separating of components that could cause sharp edges, replaces the need for metal bracket reinforcements. Faurecia is the Tier 1 supplier, with tooling from Meymol SL. Trinseo supplies the ABS material.• Ford for the use of a new proprietary material for driver airbag covers on the 2019 F-150. The automaker said the TPE material — replacing TPO injection molding methods — offers better deployment performance at extreme temperatures as well as improved cosmetic appearance and a lighter weight design that enables 10 percent weight savings. The material is from Sumitomo Chemical Co. Ltd. The Tier 1 supplier and toolmaker is ZF Friedrichshafen AG.• American Honda Motor Co. Inc. for what it says is the first-known all-plastic autonomous milliwave radar bracket on the 2019 Acura RDX. The bracket features a pedestrian impact breakaway function to improve safety upon impact. Nifco America Corp. supplies the system and tooling. DowDuPont supplies the material.
Aeyoung Park 2018-11-07
기사제목

FRP pushing boundaries in lightweight applications

The requirements of modern lightweight applications can no longer be met by conventional materials, but can only be achieved by optimum solutions with innovative materials. Fiber reinforced plastic (FRP) is becoming the material of choice for lightweighting thanks to its extremely strong and lightweight properties.Weight reduction is one of the most important development trends in numerous sectors such as automotive, aerospace, construction, sports and leisure, etc.As technologies advances, in order to facilitate lightweight design and structural parts construction without sacrificing performance, more efforts are focusing on composite materials engineering, such as the development of FRP in high volume production.FRP is a composite material made of a polymer matrix reinforced with fibers. The fibers generally used now are carbon fibers and glass fibers.Carbon fiber reinforced plastic (CFRP) is an advanced non-metallic composite material composed of carbon fibers embedded in a polymer resin, in which the carbon fibers function as the reinforcement material and the polymer resin functions as the matrix to hold the fibers.CFRP has the advantages of many superior performances, such as high strength, lightweight, no corrosion and excellent fatigue resistance.CFRP is a key growth driver within the overall fiber reinforced lightweight materials market, according to a report published by Carbon Composites e.V. and AVK (Federation of Reinforced Plastics) based in Germany.The global demand for CFRP reached 101,000 metric tons in 2016, representing an increase of 11% when compared to previous year. Meanwhile, the total turnover for CFRP worldwide increased 14% to US$13.23 billion in 2016 from previous year.For the coming years, steady and continued, double-digit growth rates between 10% and 13% are expected.Automotive sector drives strong demand of lightweight compositesOne of the innovation drivers for the development of FRP is the automotive sector. It is very clear when considering a 100 kilogram lighter car consumes around 0.5 litres less fuel per 100 km.Many chemical suppliers have been introducing FRP for the automotive sector. For example, Solvay has expanded its portfolio of solutions for the automotive thermal management modules and multi coolant valves.The company’s new Amodel A-89XX series of glass fiber reinforced PPA grades ranges from 30-50% glass-filled loading, offering improved dimensional stability, lower moisture uptake and enhanced chemical resistance. Targeted applications include thermostat housings, multi-coolant valves, water inlets/outlets and cross overs, and other under-the-hood components.Asahi Kasei North America has also launched the Thermylene P11, a next-generation family of glass-reinforced PP compounds with unprecedented strength. As introduced, it provides a 40% improvement in measured tensile strength at 80°C and 120°C compared to conventional glass-filled PP.The new Thermylene P11 family expands the performance envelope for conventional glass-reinforced PP design and opening opportunities for thinwall molding of interior and exterior automotive parts.With special design of layers and high level of function integration, FRP provides more solutions for lightweighting and safety in the automotive sector.Lanxess’ Tepex dynalite continuous fiber reinforced, semi-finished thermoplastic composites have found new applications in vehicle interiors such as the backseat system.The center backseat is equipped with a load-through that enables the backrest of each seat to be folded down individually. This load-through component is produced by shaping and back-injecting Tepex dynalite.The new component is said to be more than 40% lighter than its steel counterpart. At the same time, this safety-relevant component withstands all load scenarios, because the orientation of the continuous fiber layers in the only two millimeter-thick semi-finished product was designed to bear the mechanical stress.Reinforced composites evolve to stay ahead in aerospace sectorThe aerospace sector was one of the earliest and most significant adopters of CFRP. Apart from lightweighting, the ability to add functionality to a composite part is also the added value for the performance.Driven by their superior strength and stiffness-to-weight ratio, composites can account for more than 50% of the structural parts in the latest models of civil aircrafts.The Airbus A350 XWB is one of the aircrafts with the highest weight ratio for CFRP. It is built of 52% CFRP, including wing spars and fuselage components.It was also one of the first commercial aircrafts to have the wing spars made from composites. Its central wing-box, trailing edge, along with the rear bulkhead, empennage and un-pressurized fuselage are made of CFRP.Composites have not exhausted their innovation avenue, according to the report “Additive Manufacturing and Lightweight Materials for Aerospace and Defense 2018–2028” by IDTechEx.Many new processes are re-inventing this class of material and advancing more than just mechanical properties, says IDTechEx. There are many progressions to improving the lightweight performance of a composite part. This includes next-generation prepreg materials and the rise of high-performance thermoplastics, the report notes.One recent development gaining increasing attention is thin-ply composites from spread-tow fibers. This involves spreading the fibers for a reduced density (typically below 75 gsm) and a stronger homogeneous fiber-matrix interaction.This material is already being used by aircraft overhaul and maintenance firm Hong Kong Aircraft Engineering for interior seating in the Airbus A350 aircraft.Meanwhile, application of pure boron fibers for polymer reinforcement is at a much earlier stage. This fiber can potentially replace carbon fiber in much the same way that carbon fiber has displaced aluminum over the very long term. The fibers are synthesized via a laser chemical vapor deposition route. However, there are still many technical and economic obstacles to overcome.New hybrid prepreg used for sports and leisure applicationsToho Tenax Co., Ltd., the core company of the Teijin Group’s carbon fibers and composites business, has developed a new high-tensile, highly shock-resistant prepreg that incorporates carbon fiber developed by Toho Tenax for aerospace applications and specialized carbon nanotubes.The new hybrid prepreg has been adopted by Mizuno Corporation in a new golf club shaft that weighs nearly 30% less than conventional shafts of the same thickness.A prepreg is a carbon fiber sheet pre-impregnated with matrix resin and used as an intermediate material for CFRP.The high-tensile prepreg enables the shaft to bend suitably as the ball is impacted and then cuts the shock of impact by more than 10% to reduce club movement on the follow-through swing.The hybrid combination of carbon fiber and carbon nanotubes realizes superior CFRP that offers improved tensile strength and shock resistance, according to the company. The CFRP also is extra durable because the carbon fiber and matrix resin do not peel away from each other thanks to the carbon nanotube’s balanced dispersion.Since CFRP is used in different fields, its prescribed properties must differ widely depending on the application. Teijin is developing technology for various combinations of carbon fiber and matrix resin and for specific processing needs.Competitiveness increased thanks to natural fiber reinforced plasticsIn their published study “Inventory of Lightweight Construction in Germany”, the experts from the VDI Centre for Resource Efficiency also described the role of fiber and natural fiber reinforced plastics in the scope of lightweight materials.There is great potential for further weight reduction through the use of FRP, according to the study. As mentioned, FRP such as CFRP and glass fiber reinforced plastic (GFRP) have been posting very high growth rates and would very likely to gain in importance in the long term (after 2020).The experts said the use of natural fibers would increase the competitiveness of FRP as using renewable resources has been an emerging trend.Flexible plastic and corrugated paperboard packaging supplier Rengo Co., Ltd. has leveraged its cellulose production technology to develop a cellulose nanofiber via an intermediate material. The target applications include composite materials for automotive.Typically made by “microfiberizing” the cellulose contained in wood cellulose fiber to the nanometer level using chemical or mechanical processes, the cellulose nanofiber is said to have one fifth the weight of steel but five times its strength.As the production costs remain high, Rengo hopes to work with companies and universities on product development in order to achieve commercialized production.On the other hand, Mitsubishi Paper Mills believes that the adoption of lower cost cellulose microfibers will be a good alternative. It says that cellulose microfibers are adequate enough for reinforced thermoplastics for many applications, and they can be incorporated into the polymer matrix much more easily.The Japanese company already offers cellulose fiber reinforced PP compounds on a commercial basis. Its high purity cellulose fiber PCV30-F PP compound offers reinforcement levels of 10%, 20% and 30% with better tensile strengths when compared to neat PP resin. In addition, heat distortion temperatures are substantially improved.Looking forward, the research and developments of FRP will definitely continue to be a trend in the plastics industry. While innovative and improved formulation plays a crucial role in the process, enhancing automation of composite fabrication and extending into 3D printing of composites could also be the key facilitators to give the materials greater design freedom and cost efficiency.Source: CPRJ International
Aeyoung Park 2018-11-01
기사제목

First Coffee Capsule Composable at Home

- Organically based synthetic material with sunflower seed shells protects fossil resourcesOn 15 October 2018, in cooperation with Golden Compound, the internationally active packaging manufacturer ALPLA is bringing a world first onto the market: a biodegradable coffee capsule that consumers can dispose of in their home compost.▲ World first: a biodegradable coffee capsuleTogether with materials manufacturer Golden Compound, ALPLA has developed a market-ready coffee capsule that environmentally aware consumers can use with a clear conscience. The capsule is made from the material Golden Compound green. This comprises an organically based material and ground natural fibres from sunflower seed shells. The capsule and filter fleece are completely biodegradable in the garden compost within a maximum of six months, and are free from aluminium and genetically modified organisms. ALPLA provides its customers with the capsule and the garden-compostable lid.The first user in the world is Amann Kaffee from Vorarlberg, Austria. The coffee roaster is presenting the new product as part of the ‘Gustav – fair for consumer culture’ trade fair in the Dornbirn trade fair district from 19 to 21 October. Golden Compound will also be represented at the industry trade fair Fakuma in Friedrichshafen (Hall B4, Booth 4114) from 16 October.BY-PRODUCT OF SUNFLOWER PROCESSINGGolden Compound uses sunflower seed shells as a reinforcing material. They are a by-product of the food industry and not in competition with food production. In this way, Golden Compound green protects fossil resources and reduces the carbon footprint. Composting the capsule generates humus, and the coffee grounds contain valuable plant nutrients such as potassium, phosphorus and nitrogen.EXCELLENT CHARACTERISTICSThe material also has excellent characteristics, as confirmed by numerous certificates: the oxygen barrier is very much comparable with conventional plastics such as PP-EVOH-PP. The monolayer coffee capsule is thus aroma-proof without outer packaging. Furthermore, Golden Compound green is certified in line with the standards ‘OK compost HOME’ and ‘OK biodegradable SOIL’ from TÜV.More information about the company: www.alpla.com, sustainability.alpla.com and www.golden-compound.com
Aeyoung Park 2018-10-16