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Focus on drastically reduced cycle times: KraussMaffei delivers HP-RTM system to British university

- Unique research landscape for fiber-reinforced lightweight construction- First-time use of multiple mixing heads provides clear advantages in precision and cost-efficiency- Great opportunities for the automotive and aviation industry Drastically reduced cycle times and processes ready for large-scale production – Developing new technologies and applications for the fiber-reinforced lightweight construction of tomorrow is front and center at the Composite Centre of the University of Sheffield Advanced Manufacturing Research Centre (AMRC) in the United Kingdom. The institute is expanding its expertise especially in the field of highly reactive and fast-reacting resin and hardener systems using the new KraussMaffei RimStar Compact for the HP-RTM process (high pressure resin transfer molding). Unique research landscapeThe new KraussMaffei RimStar Compact at the AMRC ranks among the world's largest, most state-of-the-art and flexible of its kind for the HP-RTM process. "The specific selection of two dosing units and the corresponding mixing heads allows for a particularly precise mixing of the resin system. This makes the system the first of its kind in which multiple mixing heads are used in the full scope of functions in order to enable a perfect cavity fill. Even materials that are highly reactive and fast-reacting at the same time—which are increasingly in demand for the HP-RTM process—can be reliably processed," explains Sebastian Schmidhuber, Head of Development for Reaction Process Machinery at KraussMaffei.Processing such highly reactive matrix materials opens up entirely new development opportunities for composite materials and components with more intricate geometric structures. "The curing times are critical here. Using highly reactive systems, they can be reduced down to three minutes. With such short times, they offer great opportunities for the manufacturing industry," adds Darren Wells, Research Engineer at AMRC.Another advantage of KraussMaffei's new RimStar Compact, from both a process technology and cost-effectiveness standpoint, is its compact design. Matrix material injection and curing take place in one and the same mold. This results in a consistently high quality of the components and in high process reproducibility.High flexibility proves its valueAbove all, Darren Wells appreciates the great flexibility of the KraussMaffei RimStar Compact. "Thanks to its modular design, we are able to quickly and individually meet our customers' specific needs. In this way, we provide them with a unique research and development landscape to test and verify the cycle time and cost savings advantages of the HP-RTM process live." Stephen Lambert, RPM Business Manager at the KraussMaffei Group UK, also sees great opportunities for the HP-RTM process in the UK. "We are looking forward to further future collaboration and development projects at the AMRC. Particularly in the area of vehicle manufacturing and aviation, we see great potential. As an outcome of the collaboration, we have recently received the first series production order of a premium British automaker."

Aeyoung Park 2018-06-26

3D Printing LSR

Yes, you read that right: Liquid silicone rubber (LSR) is now 3D printable.▲ Liquid Additive Manufacturing (LAM) is a new process for 3D printing LSR.This part was printed of Dow LSR on a German RepRap LAM machine.Resilient honeycomb structures are being explored for custom orthotic soles of footwear.At NPE2018 in Orlando, Fla., Distributor RDAbbott, Cerritos, Calif., showed off a system for 3D printing with LSR, developed by Dow Silicones (previously Dow Corning), Midland, Mich., and German RepRap, a maker of 3D printing equipment.Called Liquid Additive Manufacturing (LAM), the system injects liquid A and B components from two pressurized tubes into a pump that maintains a 1:1 ratio. The pump feeds a head under x-y motion control, which and lays down a continuous bead, similar to FDM or FFF-style 3D printers. The system deposits layers as thin as 0.2 to 0. 35 mm thick, which are fully cured by a heat lamp, a whole layer at a time. The system uses Dow’s Evolv3D LC 3335 LSR material, which produces a 44 Shore A hardness without post-cure and 46A with post-cure. The LAM 3D printer reportedly produces parts with 100% of the tear strength of injection molded samples, 90% of their tensile strength and hardness, and 85% of their elongation. Applications in development include honeycomb custom orthotic shoe soles.▲ A prototype of the German RepRap liquid additive manufacturing (LAM) machinefor 3D printing LSR was demonstrated at NPE.The patent-pending printer was introduced earlier this year; it can print at 10 to 150 mm/sec. Dow is developing additional LSR grades, expected later in the year, that will offer other Shore A hardnesses.Source: Plastics Technology

Aeyoung Park 2018-06-07

New 3D-Printed Airless Bicycle Tire

Berlin-based 3D printing manufacturer BigRep says it printed the “world’s first” airless bicycle tire using its Pro FLEX material, a TPU-based filament. ▲ BigRep printed what it calls the “world’s first” airless bicycle tire usingits Pro FLEX material, a TPU-based filament.A new 3D-printed airless bicycle tire promises to make flat tires a thing of the past. Berlin-based 3D printing manufacturer BigRep says it printed the “world’s first” airless bicycle tire using its Pro FLEX material, a TPU-based filament.BigRep says it successfully tested functionality on the streets of the German capital. The airless tire was a successful prototype to demonstrate the ease and speed at which flexible spare parts can be 3D printed. BigRep believes this world-first application showcases the potential of 3D printing to develop new complex geometries that cannot be achieved using traditional production methods.Marco Mattia Cristofori, BigRep product designer says the company replaced the ‘air’ in the tire by customizing the build pattern to be a three-layered honeycomb structure. Requiring no post-processing or gluing work, it was printed to scale as a large 1:1 object on the BigRep ONE 3D printer, which has a build volume of one cubic meter. Designed to match the dimensions of Cristofori’s own bicycle wheel, the Pro FLEX-printed tire has high-strength properties to withstand the conditions of city cycling.Printing thermoplastic elastomers is a challenge in the FFF additive manufacturing industry, however, BigRep engineered Pro FLEX following intensive testing to ensure ease of use. Strong print bed adhesion from this high-performance filament allows BigRep and its Pro FLEX customers to 3D print large flexible parts without detachment issues.“We have expanded our technical portfolio with a high-impact, high-temperature-resistant material in Pro FLEX, which has higher interlayer-bonding than we have ever seen before, and robust chemical resistance for a range of technical applications,” says Stephan Beyer, Big Rep CEO. “There is a clear use case for flexible parts that can be customized and printed on a needs basis, across med-tech, aerospace, automotive and other industries.”This is not BigRep’s first venture into the transportation world. The company has worked on automotive, aerospace and other transportation projects for such clients such as Aerobus, BMW, Deutsche Bahn, Etihad and Nissan.Source: Plastics Technology

Aeyoung Park 2018-06-05

Latest technologies boost productivity of extrusion process

The demand for high efficient machinery is rapidly growing with the technology advancement nowadays. To remain competitive in this ever-changing global market, the extrusion machinery manufacturers are making every effort to provide cutting-edge solutions and to offer the promise of better extruding with high productivity, high output and low cost.More productive with new automated solutionThe Maag Group rolled out the new maax 400S automated solution for improving extrusion productivity. The automated expac system comprises an extrex gear pump, screen changer, maax automation solution, and drive unit.In order to close the gap of its two existing controllers, the maax 100S and maax 600S, a 12” monitor variant is now available following the introduction of the enhanced extrusion controller maax 400S.The new maax 400S can control up to four variable-speed drives, and can be upgraded up to a maximum of 32 heating/cooling zones (in the basic software configuration). It retains the intuitive user control, screen page layout and color concept of the existing controllers, which enables customer-specific requirements, such as page layout, additional pages or special component control, to be met within certain bounds.The maax 100S features a 7” monitor, with a maximum of two drives and maximum 16 heating/cooling zones. The maax 600S has a 15” monitor, with a maximum of four drives and 48 heating/cooling zones (in the basic software configuration).New screen changer with lower downtime and costAn advanced melt filtration system from Nordson Corporation has enabled Cyklop, an international supplier of industrial packaging systems for load securement, to increase productivity, reduce downtime, and cut material waste in the production of strapping tape from PET bottle flake.At its facility in Cologne, Cyklop replaced an older-model hydraulically powered backflush screen changer with the recently introduced BKG HiCon V-Type 3G system. Cyklop reports that the new screen changer reduces operating costs because it needs 30% fewer backflushes and requires screen changes 40% less frequently. Employed in a production line at throughput rates of 450 to 550 kg/hr, the new system maintains flow and melt pressure at constant levels, ensuring uniform product quality.As introduced, the BKG HiCon V-Type 3G screen changer requires less maintenance and operator supervision than either the older Nordson system or a backflush system from a competing supplier. The system is particularly good in dealing with contamination surges, since the filtration area is regenerated very effectively in a short amount of time.In the BKG HiCon V-Type 3G screen changer, melt flow from the extruder is split at the entry side and guided to four screen cavities on two screen-bearing pistons with screens in each cavity. Each pair of cavities is positioned so that they can filter their respective melt streams, until the piston removes one of the cavities from the process to remove contaminant buildup by means of backflushing.In normal operation, polymer is flowing through all four cavities. While one of the screens in the cavities is changed or flushed, the other three or 75% remain in the process so that throughput remains uninterrupted.Advanced extruders offering highest output with small footprintProcessing Technologies International, LLC (PTi), a leading global manufacturer of high-performance sheet extrusion machinery, has significantly reduced the footprint of its Super-G HighSPEED Extruders. According to the company, the result is the highest extrusion output per square foot in the industry.The superior manufacturing output is made possible by the introduction of a tuck under motor which creates a smaller footprint for both Super-G HighSPEED models which are used for the processing of polypropylene (PP) and high-impact polystyrene (HIPS) for the packaging market.PTi’s Super-G SGHS3000-36D model features a vertical U-configuration and tuck under motor which reduces the machine’s footprint by more than 33% to 12-ft 8-in, compared to 17-ft 7-in for the original model.The Super-G SGHS3000-36D is equipped with a 500 hp motor and runs at a maximum speed of 1000 rpm while the Super-G SGHS3000-42D has a 600 hp motor and runs at a maximum speed of 1200 rpm. For processing of PP, the Super-G SGHS3000-36D has a production output of approximately 3,000 lb/hr.In 2017, PTi entered the high-speed extruder segment with the launch of its Super-G High-Speed Extruders which deliver significant performance advantages and overcome the limitations of competitive products.Reducing stagnation with new hybrid extrusion toolThe new 800 Series Hybrid is a result of incorporating the next generation multi-layer die technology into Guill’s popular 800 Series. According to Guill, the challenge was to create a hybrid design that incorporates the benefits of layer overlapping, while reducing unnecessary complexity and making operation easier.This was achieved by overlapping layers in each semi-deflector, using a single cone. The inherent benefits of the 800 Series are retained, including compact design, low residence time and a common deflector bore that eliminates tolerance stack up. The highly efficient design reduces cost and size, as opposed to other methods of overlapping layers.The 800 Series Hybrid extrusion tool greatly reduces stagnation because overlapping layers are more inherently balanced than single layers and also because each semi-deflector is “tuned to flush.” Conventional deflectors must simultaneously achieve a balance between flushing, balancing and eliminating the weld line. There is less difference between the slowest moving material and the fastest moving material in the deflector channels, thus making the viscosity more consistent in the deflector. Source: China Plastic & Rubber Journal

Aeyoung Park 2018-05-15

A thermoplastic composite tape

featuring high strength for pipe and pressure vessel reinforcementSabic introduces UDMAX GPE 46-70 tape, the last addition to its expanding portfolio of unidirectional fiber-reinforced thermoplastic composite tape products. Commercially available worldwide, the new glass-filled high-density polyethylene grade is designed for reinforcing industrial applications, such as pipes and pressure vessels, offering unmatched tensile strength.This novel product has one of the highest glass content available in the industry today combined with optimal thermoplastic resin impregnation, thanks to Sabic’s proprietary high-pressure fiber impregnation technology (HPFIT). By using UDMAX tape to reinforce oil, gas and water pipes, boilers and storage tanks, customers can significantly increase mechanical performance while reducing weight and help improve corrosion resistance in the most demanding environments.“As pipe and pressure vessel manufacturers face rising demand for higher performance, longer life and greater safety, advanced thermoplastic composite technologies from Sabic can offer a practical solution for various industrial applications,” said Hans Warmerdam, commercial director, Sabic Fibre Reinforced Thermoplastics (FRT). “Our new UDMAX GPE 46-70 tape delivers the exceptional strength needed to meet tough industry challenges, and promotes more efficient pipe and pressure vessel designs for transport and installation. This new product also illustrates how Sabic continues to invest in technological innovations that give our customers an ever-increasing selection of strong, lightweight thermoplastic composites in place of traditional materials.”Unique technology for maximum performanceThe UDMAX GPE 46-70 tape offers exceptionally lightweight and high strength and is a replacement for metal and other traditional materials. Featuring Sabic’s HPFIT that quickly and precisely enables the spread and combination of thousands of glass or carbon fibers with a thermoplastic matrix, the UDMAX GPE 46-70 tape has 70 percent fiber by weight content – one of the highest available today.“Maximizing fiber content can raise tensile strength up to 957 MPa, which in turn affects the burst pressure resistance of a pipe or vessel – a key performance indicator,” said Joris Wismans, technical director, Sabic FRT.HPFIT also enhances UDMAX tape in several other ways, by offering:Good fiber distribution for uniform performanceTwist-free fiber orientation (twisting reduces mechanical properties)A uniform and consistent tape thickness that helps optimize the conversion process and product designExpanded design freedomReinforcing pipes and pressure vessels with UDMAX tape offers designers new options for achieving desired performance. For example, the use of UDMAX GPE 46-70 tape can enable pipes to withstand higher loads, while reducing the number of tape layers for less-demanding environments, lowering overall weight for easier transport and installation.

Aeyoung Park 2018-05-04

Full stereocomplex PLA technology now commercially available

Full stereocomplex PLA for commercial application by Total Corbion PLA▲ PLA is a biobased and biodegradable plastic produced from renewable raw materials (sugar or starch). (Image: Total Corbion PLA)Total Corbion PLA, a global technology leader in Poly Lactic Acid (PLA), announces the launch of a novel technology that can create full stereocomplex PLA in a broad range of industrial applications.The proprietary technology will enable PLA applications abe to withstand temperatures close to 200°C (HDT-A). Samples of glass fiber reinforced stereocomplex PLA will be made available to those wanting to test the new technology for their applications.According to the company, the new technology enables stereocomplex PLA, a material with long, regularly interlocking polymer chains, to have an even higher heat resistance than standard PLA.This breakthrough in PLA temperature resistance unlocks a range of new application possibilities, and provides a biobased replacement for PBT and PA glass fiber reinforced products.For example, injection molded applications for under-the-hood automotive components can now be made from glass fiber reinforced stereocomplex PLA, offering both a higher biobased content and a reduced carbon footprint.The technology can offer these same sustainability benefits to the wider automotive, aerospace, electronics, home appliance, marine and construction industries.“Over the past decades, the benefits of full stereocomplex PLA have been studied by universities and R&D departments on a laboratory scale”, says Stefan Barot, Senior Business Director Asia Pacific. “Now, Total Corbion PLA is the first company to scale up this technology and make it available for a broad range of industrial applications. The technology enables full stereocomplex morphology not only in the lab environment but also in commercial production facilities”.Commercial samples of full stereocomplex PLA will soon be made available for customer evaluation. Total Corbion PLA is looking for brand owners, converters and compounders that wish to validate and capitalize on this new technology.Total Corbion PLA will have a booth at the NPE 2018.

Aeyoung Park 2018-05-04

TPE fills role efficiently in both interior and exterior vehicle parts

The automotive industry is one of the largest and fastest-growing markets for thermoplastic elastomers (TPE). Used in both interior and exterior applications, these tiny TPE parts make the car“complete”, helping to fulfill the requirements of automakers with efficiency and cost-effectiveness.▲ Weather resistance and adhesion to extruded and foamed EPDM profiles are important criteria for window trim profiles.According to Smithers Rapra’s report, the global TPE market has grown at a compound annual growth rate (CAGR) of 5.4% since 2012 to reach 42.24 million tons in 2017. It is expected to continuing growing at a rate of 5.5% in the next five years, topping 5.5 million tons in 2022.“The automotive industry, being the most important consumer of TPEs, sets the pace here,” said the report author, Patrick Ellis.This segment grew at an above average rate of 5.9% for 2012-2017 and reached 1.84 million tons – or 43.4% of the total market in 2017. The prediction for 2022 is a consumption of 2.46 million tons, representing a market share of 44.4% and a CAGR of 6.0%.Ease of processing for door and window sealsDoor and window seals, which require dimensionally stable corner joints and end elements, are usually made with styrene butadiene compounds (SBC) and crosslinked thermoplastic vulcanized (TPV) rubber.The cost-effectiveness of TPV is limited, however, due to diverse factors in the manufacturing process, in particular the window trim. “The production of diverse sealing frames and window trims of EPDM profiles with molded corner and end elements requires new material solutions,” said Michael Pollmann of Kraiburg TPE.The core requirements for corner joints and end elements of window trim profiles include strong adhesion and weathering resistance, which are ensured by the long term process stability of the TPE/rubber connection. It is also necessary to minimize the injection temperature of the TPE solutions in order to reduce the cooling and cycle times of the two-component elements.Kraiburg TPE has developed a new series of compound under its THERMOLAST K family in two-component applications with ethylene propylene diene monomer rubber (EPDM), providing an alternative solution with added values.In addition to adhesion properties, its AD/EPDM/UV series offers long term resistance to UV radiation and thermal effects with a hardness of 70 Shore A. These compounds exhibit superior stability, so the EPDM profile is neither compressed, nor destroyed or deformed.This solution is being tested by several Kraiburg customers in the automotive industry. It feature uniform color fastness of EPDM and TPE and there is no tendency of stickiness or phase separation.“Our tests showed that the cleanliness of the EPDM contact surfaces to the TPE are crucial in these two-component elements and that freshly cut seal profiles result in optimal adhesion,” said Pollmann.Low VOC solution for interior partsFor automotive interior, minimizing emission of volatile organic compound (VOC) is of utmost importance for automakers. OnFlex LO is PolyOne Corporation’s latest innovation for the automotive industry, reducing VOC by up to 50% versus existing TPEs.OnFlex LO can be overmolded onto polyolefin substrates using a two-shot injection molding process.“Consumer concerns and industry regulations have made vehicle interior air quality a major focus for automotive manufacturers,” said Woonkeat Moh, General Manager, GLS Thermoplastic Elastomers Asia and Specialty Engineered Materials Asia for PolyOne.Suitable for numerous components, including HVAC seals, buttons, controls, coin trays and drink holder mats, OnFlex LO can be overmolded onto polyolefin substrates using a two-shot injection molding process.PolyOne tested OnFlex LO TPE against its existing TPEs according to VDA 278 standard for VOCs and fog, and VDA 270 standard for odor. Results showed OnFlex LO TPE cut VOC emissions by approximately 50% and fog emissions by 40%, while maintaining outstanding low odor performance.“Our new material will play an important role in minimizing further off-gassing of chemicals to help automakers create a healthier, more enjoyable vehicle environment,” stated Michelle Hearn, Director of Global Marketing, PolyOne.At Fakuma 2017, Hexpol TPE highlighted its expanded product portfolio for a number of applications. Among them is its Dryflex TPE for automotive interior applications such as floor mats, cup holder liners, fascia mats and HVAC components.The Dryflex TPEs display low fogging and low odor performance, including grades with results ≤3 in odor standards such as VDA 270. According to gravimetric fogging standard DIN 75201 they have condensate <2mg and in thermal desorption analysis VDA 278 they achieve VOC results <500µg/g and Fog <1,500µg/g.Source: China Plastic & Rubber Journal

Aeyoung Park 2018-03-13

Plastic Leaf Springs for Series Application

Reliable Failure Prediction Fiber-reinforced plastics (FRP) are particularly suitable for structural lightweight construction as they have outstanding weight-specific properties such as high stiffness and strength, they are corrosion-resistant and also have superior fatigue behaviour. At the same time, they offer good damping characteristics and are thus predestined for use as spring elements. Because of the possibility of orienting the fibers in a spring in the load direction, enormous weight savings of up to 80 % can be achieved compared with classic steel springs. Nevertheless, a considerable amount of uncertainty in predicting the life expectancy of glass-fiber-reinforced plastic springs has until now been hindering their use in series application. A wide variety of fracture modes and the broad scattering of the test results under cyclical load that is typical of this material make it virtually impossible to obtain a quick and reliable estimate of the life expectancy.For this reason, a research team from the Ford research center in Aachen, Germany, and the Institute of Plastics Processing (IKV) in Industry and the Skilled Crafts at RWTH Aachen University is examining in a joint project called "Composite materials for chassis components" the fatigue and failure behavior of glass-fiber-reinforced plastic springs. The aim of the Ford-RWTH alliance is to develop a reliable prediction model that allows the series application of these leaf springs in the automotive industry.▲ Cyclical 3-point flexural test on a representative specimen to determine the fatigue properties of glass-fiber-reinforced plastics (© IKV) Cyclical 3-point flexural test on a representative specimen to determine the fatigue properties of glass-fiber-reinforced plastics (© IKV) zoomCyclical 3-point flexural test on a representative specimen to determine the fatigue properties of glass-fiber-reinforced plastics (© IKV)In a variety of tests, the material was subjected to a 3-point flexural load and tested under all sorts of different boundary conditions. With the help of the results, the team is implementing advanced analytical and numerical methods for calculating the life expectancy. The focus is always on the economic efficiency of the calculation, which is nowadays reflected in the calculation time needed for numerical models.Through the implementation and further development of phenomenological models for use in FE methods, it is possible to transfer the data from the material to the part without the need to calculate every load cycle individually. From the analytical and numerical descriptions of the damage and failure profile, new possibilities are derived for shortening the time needed for real tests. At Ford, a load spectrum is to be specified that produces the same damage development as a real load pattern but requires only a minimum of the testing time.Source: Kunststoffe

Aeyoung Park 2018-03-13