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An air-free concept for bicycle tires

Bridgestone Corporation announces that, together with Bridgestone Cycle Co., the company has developed a next-generation bicycle tire as an effort to realize practical application of the “Air Free Concept,” a technology for creating tires that do not need to be inflated with air. The companies will advance feasibility studies seeking to make this new tire available in market by 2019. The “Air Free Concept” is a technology that eliminates the need for tires to be inflated with air to support the weight, using a unique structure of spokes stretching along the inner sides of tires. In addition, the resins that are used in the spokes and rubbers help realize more efficient use of resources. Bridgestone Corporation and Bridgestone Cycle adapted the “Air Free Concept” to develop bicycle tires without punctures. The high flexibility for design granted by resin has also enabled proposals of next-generation bicycles which have never been seen before. The Bridgestone Group aims to propose new ways of cycling utilizing the “Air Free Concept” while also adapting this technology to be used in various other types of tires. The Bridgestone Group is committed to continuously working toward a sustainable with the universal and eco-friendly mobility for supporting people’s lives. The next-generation wheel is a practical application of the company’s ‘air-free concept,’ which eliminates the need for tires to be inflated with air. instead, the tires support the rider’s weight by using a unique structure of spokes made from thermoplastic resin, which stretch along the inner sides of the wheel. the futuristic looking tires are made from entirely recyclable materials, and bridgewater are working to maximize the cyclical use of warn tires right back into new ones. Bridgestone first disrupted the (air) flow back in 2011, when an idea for an airless car tire was patented. the ‘air-free’ concept was designed not only to prevent riders and drivers alike pulling up on the hard shoulder to change their tires, but also in a bid to reduce c02 emissions and make transport more sustainable. come 2017, the company have finally adapted their technology for bikes. By simplifying the structure of the classic tire, bridgestone has reduced the resistance caused by wheels continuously changing shape as they roll. This in turn maximizes efficiency and reduces wasted energy—whether that comes from gas or man-power. By using thermoplastic resin—a synthetic resin that becomes flexible when heated and hardens when cooled, allowing it to be processed into a variety of shapes —bridgestone has unveiled design possibilites for next-generation bicycles that have never been seen before. The company set out to make the bicycle tire available in 2019, just in time for the Tokyo Olympics in 2020. In the future, the japanese tire-makers aim to continue working on their mantra to fuse convenience with sustainability, proposing even more ways of cycling using the ‘air-free concept,’ while adapting the technology to be used in various other types of tires. http://www.jeccomposites.com/knowledge/international-composites-news/air-free-concept-bicycle-tires?utm_campaign=1964145&utm_content=9883467598&utm_medium=email&utm_source=SmartFocus

Ms. Kang 2017-05-15

4 Reasons 2 Shot Molding is Better than Part Assembly

▲ 2-shot-molding When plastic parts require two components — especially if those components need to be different colors or made from different plastic polymers or resins — then you will benefit from working with a plastic injection molding company that has 2 shot molding capabilities. 2 shot molding creates one, integrated part from two different resins using a single machine and mold, rather than creating parts separately and assembling them. Here are four reasons why using 2 shot injection molding can be the key to a successful product. 1. Lower Costs Creating a complex part on a single machine has several cost advantages. Cutting down on the number of machines and processes involved (molding piece #1, molding piece #2, and then assembling them) can streamline and speed up production of the finished parts. Using only one machine cycle instead of two saves both energy and production costs. You also save labor costs by eliminating the need for separate assembly. 2. Product Quality When components need to be moved to a different machine for integration with other components, the risk of misalignment and other handling errors is increased. 2 shot molding, with the complete process done on a single machine, reduces the potential for defects and elevates product quality. The process also allows you to combine different plastic materials, such as nylon or silicone and thermoplastics, for more advanced designs. So you could have, for example, a tool with a hard nylon core and a soft plastic grip. You can also create parts with more than one color or texture, making them more visually appealing. 3. Performance 2 shot molding can also enhance a part’s performance. With this process, the two components are molded and bonded together without any need for glues, screws, or other adhesives used in separate assembly. The finished product is therefore more durable. The ability to combine hard and soft materials can also create better, stronger seals for parts such as gaskets. For example, a tubing connector with an o-ring that is built in through 2 shot molding instead of inserted separately will form a more reliable seal. Ergonomics are also improved by combining different materials, as with the hard tool and soft, comfortable grip. 4. Efficiency 2 shot molding eliminates waste in a variety of ways. A single machine cycle takes less time and energy, and the process results in fewer defects and wasted materials, all of which add up to cost-savings for you. Are you working with an efficient plastics manufacturer? At Viking Plastics, we are on a lean journey: we actively dedicate ourselves to eliminating all forms of waste, simplifying our processes, and improving efficiencies on a daily basis. Utilizing the 2 shot injection molding process is one way to accomplish all of these goals. http://www.vikingplastics.com/4-reasons-2-shot-molding-is-better-than-part-assembly/

Ms. Kang 2017-05-15

Target Starts Featuring Clothes Made From Plastic Bottles

By Rachel Slavik MINNEAPOLIS (WCCO) — Concerns over global warming have many people doing their part to help the environment. Now the environmentally conscious can go green in the clothes they wear. Repreve, a company based in North Carolina, has found a way to convert plastic bottles into fabric. And one Minnesota company is incorporating the material into one of its clothing lines. Shopping for her kids’ clothing typically comes down to two factors for Stacy Gianino. “I’m looking for something that catches my eye because it’s cute, but also that’s durable because my kids play hard [laughs]!” Gianino said. Most of her purchases come from Target’s Cat and Jack line. “Cat and Jack has the knee guarantee, so we’re big fans,” she said. ▲ Jeans made with fibers from plastic bottles (credit: CBS) Known for durability, some of the clothing has another unique characteristic. Their swimsuits and denim are made of recycled material. “Our guest told us that sustainability and protecting the environment was really important,” said Julie Guggemos, Target’s senior vice president of product design and development. Target partnered two years ago with Repreve after hearing that guests wanted products that didn’t negatively impact the environment. “It’s our responsibility to create and manufacture products that have a positive impact on the environment,” Guggemos said. Repreve stood out because of its innovation in the recycling of plastic bottles. The company converts the plastic into yarn for clothing. According to Repreve, certain types of plastic bottles have the same chemistry make up as polyester. Repreve turns those bottles into flakes, which is then melted into a fiber. That fiber is then converted to yarn, which is reproduced into various types of fabrics. “When I first learned about the conversion of recyclable bottles to yarn, I was a little bit in disbelief,” Guggemos said. She says the collaboration between the two companies has had an impact in reducing plastic bottle waste. “Since July of 2016, we have recycled nearly 250 million bottles,” Guggemos said. “And so to put that in context, if you were to line those bottles up, you could wrap the Mall of America three times.” Style and function may be important factors in buying clothing, but sustainability can be just as appealing for some customers. “Definitely peaks my interest and I’d be more likely to buy it,” Gianino said. Repreve fabric is also found in dozens recognizable labels like Patagonia, Adidas and Quick Silver. Guggemos says Target plans to incorporate more of the fabric into its products in the future. http://minnesota.cbslocal.com/2017/04/15/target-plastic-bottle-clothes/

Ms. Kang 2017-05-15

Romeo RIM transforms mature technology into innovative process

By: Clare Goldsberry in Injection MoldingRomeo RIM, a processor based in Romeo, MI, that specializes in reaction injection molding (RIM), has built its business on innovative cutting edge technology since its founding in 1982. Today, Romeo RIM is putting a modern spin on what used to be thought of as a mature technology—a closed-mold method—into an innovative process that reduces cycle time and costs. That’s how Matt Getty, Vice President of Business and Product Development, explained the company’s initiative to PlasticsToday. Developed in collaboration with KraussMaffei, the rotary carrier press will reduce cycle times from about 10 to 12 minutes to 60 to 120 seconds. ▲ Developed in collaboration with KraussMaffei, the rotary carrier press will reduce cycle times from about 10 to 12 minutes to 60 to 120 seconds. Romeo RIM specializes in RIM, structural RIM (S-RIM), and long-fiber injection (LFI), which is another version of the RIM process. RIM uses two liquid components that are injected into a closed mold. The chemical reaction between the two liquid materials produces a solid plastic part. Typically the material is polyurethane (PU) or dicyclopentadiene (DCPD). Getty adds that Romeo RIM is “modernizing RIM and making it very competitive in the industry in ways in which people are not aware.” The company can produce parts ranging in size from 3 x 3 to 11.5 x 11.5 feet in a single piece, such as tractor roofs. “All of our processes—both open and closed mold—are low pressure, requiring less force to mold, meaning you can utilize lower-cost materials such as aluminum and nickel shell for tooling, as well as epoxy for lower volume production and prototypes.” RIM processing can produce parts with a variety of benefits including class-A surfaces, wall thickness changes, impact resistance, encapsulated inserts and in-mold coating. DCPD provides exceptional impact resistance and a good class-A appearance; it is ideal for molding very large parts, Getty explained. As an example, Getty cited an 8-x-5-foot component the company molds as one piece—consolidating the part in one molding cycle—that previously had been molded in several pieces. “DCPD is excellent for heavy truck, agriculture and construction applications,” he added. In the LFI process, PU is mixed with chopped fiberglass. “We have the ability to engineer a composite part with different mechanical performance levels to meet customer requirements,” explained Getty. He adds that LFI is 70% lighter than steel, 20% lighter than aluminum and 40% lighter than sheet molding compound, and it is 50% lighter than fiberglass-reinforced plastic in density. For the LFI process, Romeo RIM uses robots to spray the slurry into the open mold; the PU resin is simultaneously poured with the chopped fiberglass in varying lengths, typically 1 inch. The process involves low-compression molding to form parts, such as roofs for tractors and other heavy equipment, and body panels. The benefits of this process are low tooling costs and dimensional stability, as well as optimized weight and strength. In addition, the ability to in-mold paint (IMP) is a game changer. S-RIM is a composite molding process that also uses a PU resin. This allows Romeo RIM to achieve higher mechanical properties with aligned fibers in the process. Getty said that companies in the markets they serve are mostly interested in the LFI technology. “A lot of that is because it’s taking the same lightweight aspects—same weight as DCPD resin—and introducing rovings into it, leading to a much stiffer component than the DCPD. The rovings are positioned randomly in LFI, but provide a uniform property throughout the product. We mix PU resin and chop the fiberglass within the mix head, then spray that mixture into the mold and mold the part. It’s very cost competitive that way,” he explained. One of the company’s specialties is IMP, which was commercialized in the 1980s. The process involves painting the cavity of the tool immediately prior to injecting the PU with or without chopped glass. During the molding process, the paint chemically bonds to the PU material, becoming an integral part of the substrate. “This provides superior paint adhesion compared with traditional post-mold painting processes,” said Getty. “It’s also more cost effective than post-mold painting as a secondary operation because there’s no cleaning, prepping, sanding or priming. And we get a Class-A surface finish right out of the mold. “We are seeing demand for products using these processes in trucks and heavy equipment for the agricultural and construction industries,” said Getty. “They use the LFI process for different benefits such as the lightweight aspect, as well as the paint finish quality, particularly in construction equipment that gets a lot of abuse. The cost savings of molding components like hoods in one piece is also a big factor.” The next big thing for Romeo RIM, in collaboration with machine supplier KraussMaffei, is a 100% robotically controlled 9-x-4.5-foot rotary carrier press that will reduce cycle times from about 10 to 12 minutes to 60 to 120 seconds with in-mold painting robotically applied. “We’re going through de-bugging now and plan to start production in the next couple of weeks on what we believe is the fastest LFI molding machine in North America and maybe the world,” Getty stated. “It’s one of the most innovative things KraussMaffei has done; together we really pushed the limits of this technology.” The rotary operation of the new press has seven different mold carriers on a track and three different primary cells. In one cell, the robot sprays the paint; the second cell sprays another PU layer; and a third cell applies the LFI material. “This machine is fast, efficient and can mold seven different parts in six different colors with redundant systems so that all is done at the same time without having to shut the press down. It’s definitely more competitive from a price standpoint.” https://www.plasticstoday.com/injection-molding/romeo-rim-transforms-mature-technology-innovative-process/203234334056592?cid=flyout

Ms. Kang 2017-05-12

StackTeck showcases first-ever use of ultra-thin TRIM technology for single-serve cups in Mexico

By: Clare Goldsberry in Packaging, Injection Molding StackTechStackTeck (Brampton, ON, Canada), a manufacturer of a range of injection molds used to produce plastic caps, closures, medical parts and thin-wall packaging, showcased one of its precision molds and its enhanced Thin Recess Injection Molding (TRIP) technology for ultra-lightweight packaging for single-serve applications at Expo Plasticos in Guadalajara, Mexico. Introduced in 2014, the company’s TRIM technology for molding thin-wall parts has since found numerous packaging applications. Ultra-thin evenly spaced panels covering 90% of the overall surface area of the part allow lightweighting while retaining structural integrity. Conventional thin-wall part designs molded in high-cavitation systems are typically limited to a length of flow to average thickness (L/T) ratio of 300 or less. By using TRIM, however, the ultra-thin panels can be molded at a thickness corresponding to an L/T of 600. Pushed to the limit, TRIM technology has been demonstrated to lightweight conventional thin-wall designs by 30 to 40% of part weight. TRIM technology applied to single-serve applications allows downstream printing in an area that can cover 75% of the part’s side walls, which translates into the lowest-possible-cost injection molding option. A four-cavity TRIM mold for a 200-ml round cup was running in a high-performance Arburg molding machine at Expo Plasticos. “We were excited to introduce this enhanced ultra-thin technology in Mexico for the first time,” said Christopher Day, Business Manager for Mexico and Latin America. “Visitors at Expo Plasticos saw firsthand how to mold a cup that has 0.008-inch-thick panels, offering the lowest possible cost with printable capabilities, while keeping IML as an option for this type of application. “We supported early IML systems in Mexico and continue to see significant growth,” added Day. “At the NPE shows in 2003 and 2006, we integrated turnkey IML systems at StackTeck, took them to the shows and from there shipped them to Mexico for production startups.” https://www.plasticstoday.com/packaging/stackteck-showcases-first-ever-use-ultra-thin-trim-technology-single-serve-cups-mexico/153881455956591

Ms. Kang 2017-05-12

Adidas to Mass-Produce 3D Printed Shoes in Vats of Warm Liquid Goo

Adidas just announced they’re partnering with 3D printing company Carbon to mass-produce a line of shoes with 3D printed mid-soles (the spongy bit that cushions your foot). Called Futurecraft 4D, they aim to make 5,000 pairs by the end of the year, ramping up production to 100,000 pairs next year. While 3D printing is often touted for its ability to customize products, Adidas will start with a single design to test the tech. Their ultimate goal, however, is to customize each shoe to fit the unique contours of a person’s foot. This isn’t the company’s first foray into the world of 3D printing—an earlier model of the Futurecraft shoe, made with Materialise, previously sold for $333—nor are they the only shoe company pursuing the technology. What’s interesting about this project is the challenges Adidas says Carbon’s technology can solve. And whereas 3D printed shoes have mostly arrived in small numbers, Adidas commitment to ramp up production is notable. The idea of printing objects on demand is exciting, but the reality is more nuanced. 3D printing is slow and costly. Traditional manufacturing processes like injection molding still reign supreme for mass manufacturing at cost. Adidas and Carbon are optimistic this may be changing for some products. Of the 3D printers we’ve covered over the years, Carbon's is a personal favorite. Instead of stacking layers to make an object, Carbon uses light and heat to selectively harden liquid resin. The result is very sci-fi. A digital design made manifest is hoisted from a vat of high-tech goo in a single finished piece. But Carbon's process has practical advantages too. For one, it’s relatively fast. Printing soles used to take Adidas 10 hours. Now it takes 90 minutes. And they aim to further reduce print time to 20 minutes. Also, each sole is printed continuously in one piece, which eliminates weak spots where layers meet. And the sole’s honeycomb geometry—the properties of which vary over the sole's length—wouldn’t be possible with injection molding. “Mechanical engineers have been taunting the world with the properties of these structures for years,” according to Carbon cofounder, Joseph DeSimone. “You can’t injection-mold something like that, because each strut is an individual piece.” The technology also allows for faster, more complete prototyping. Adidas ran through some 50 designs before landing on their final choice. A typical process, which would require copious retooling, would try out a handful of designs before moving on. By 3D printing both the design and the final product, Adidas can skip tooling on both ends. And unlike prior prototypes, the design and the final product are made of the same material—limiting the likelihood the final product will perform differently. In addition to Adidas, Nike, Under Armour, and New Balance have their own 3D printed shoe projects, but these have mostly been produced in small batches. While 100,000 pairs of shoes is a drop in the ocean relative to the hundreds of millions of pairs Adidas sells each year, it's a lot more than a few hundred pairs. Whether the shoe itself catches on? We'll have to wait and see. https://singularityhub.com/2017/04/07/adidas-to-mass-produce-3d-printed-soles-in-vats-of-warm-liquid-goo/

Ms. Kang 2017-05-12

Dutchfiets: a bicycle made from recyclable plastic

In the Netherlands, people love to cycle. In fact, there are more bicycles than people around. Most bicycles are made of steel, though we have shown examples of bikes made from aluminium, wood, paper, and even a 3D printed e-bike. The Dutch start-up Dutchfiets has taken another approach: they created a bicycle made from recyclable plastic. The plastic (PE) used for the bicycle is easily recyclable and energy efficient to produce. In addition, it is a very cheap and light material, and it doesn’t rust, unlike steel. The bike, which is available in several colours, is a bit bulky, as the frame has to be thick enough to hold a person’s weight. The frame of the bike consists of one piece, which is poured into a mould. Instead of a chain protected by a chain guard, the bike is actuated by a belt. This is because one of the aims of the bike is to make it easy for anyone to do their own maintenance, without going to a bicycle mechanic. Both the frame and the wheels are made of plastic, was extensively tested, even for colour changes because of the sun. The bike is equipped with puncture resistant tires, and the lights are integrated into the frame. It does not have derailleur gears. The bike is TÜV tested, and currently, there are 120 bikes in use. To make sure people bring the bicycle back at the end of its lifespan, a deposit of 100 euros is made when the bike is purchased. In the video below, you can see the bike in action. The aim is use bioplastics in the future, to make the bicycle more sustainable. The bike is the brainchild of Johannes Alderse Baas, a student mechanical engineering at Windesheim University of Applied Sciences in the Netherlands. When a friend asked to help find her an affordable and reliable bike, they came up with naught, which prompted him to design one himself, marketed for students. Dutchfiets won the ‘Start-up of the year’ award in 2015. Photos: Dutchfiets.nl https://materia.nl/article/dutchfiets-bicycle-recyclable-plastic/

Ms. Kang 2017-05-12

Hexion Inc. Introduces New Ultra-Low Emitting Bakelite® Phenolic Resin for Coatings

April 4, 2017Hexion Inc. (“Hexion” or the “Company”) is introducing a new Bakelite phenolic resin for the production of coatings with an ultra-low free formaldehyde (ULEF) content of less than 0.1%, at the European Coatings Show 2017 in Nuremberg, Germany.The new, low volatile organic compound (VOC) Bakelite® PF 7835 LB Resin maintains the superior adhesion and substrate protection of industry benchmark Bakelite® PF 6535 LB Resin, when used as a crosslinking agent for polyester and acrylic based container coatings. Crosslinkers bind polymer chains together, and are used to produce particularly tough and resilient coatings that can resist mechanical deformation, aggressive chemicals and sterilization processes. These coatings are used as protective liners in food cans, aerosol cans, tubes, and other metal containers.“Our new Bakelite ULEF phenolic resin will enable customers to formulate higher performance coatings, since they will be able to include a higher phenolic content without exceeding the preferred 0.1% limit of free formaldehyde for these applications,” said JP Aucoin, Vice President and General Manager, Global Phenolic Specialty Resins. “The extremely low level of free formaldehyde in this resin system is significantly less than that of any other phenolic resin available in the market and provides manufacturers with a variety of formulation advantages, such as anticorrosion properties and a long shelf life.”Beyond reduced free formaldehyde, the new Bakelite resin features free phenol levels below 0.5%, resulting in lower overall free VOCs. Hexion also offers Bakelite ULEF resins specifically designed for use in anticorrosive and powder coatings.For more information, consult with Hexion - Hall 7A, Stand 525 - during ECS 2017 in Nuremberg, April 4-6, or visit http://hexion.com/am/bakelitephenolicresins/ or www.hexion.com/contacts.http://finance.yahoo.com/news/hexion-inc-introduces-ultra-low-051500985.html

Ms. Kang 2017-04-07