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Technical Updates - February - March 2016 issue

1. CFRP CHASSIS FOR HYUNDAI'S HYDROGEN CAR
A super-lightweight, carbon-fiber-reinforced plastic (CFRP) chassis designed and built for the new Hyundai Intrado hydrogen-powered crossover concept car has been recognized at this year's UK Composites Industry Awards. The chassis design is made up entirely of molded parts fabricated using Axon Automotive's patented Axontex structural beam composite technology. Crestapol 1250LV acrylic thermoset from Scott Bader (Northamptonshire) is the specified infusion resin, that is vacuum assisted resin transfer molded (VARTM) around the 3D beam design, which combines woven carbon fiber braided tubing around low density polyethylene (LDPE) preforms that foam and expand during infusion.
Source: Plastics Today Newsletter, November 16, 2015.

2. POWERTRAIN INNOVATION AWARD FOR HONDA, DELPHI, DUPONT
A heated tip port fuel injector used on the Honda Fit and Honda City vehicles sold in Brazil captured the most innovative use of plastics award in the powertrain category at the 45th SPE Automotive Innovation Awards Competition & Gala. The Delphi Multec 3.5 Heated Tip Port Fuel Injector has an integrated heating device that rapidly heats ethanol fuel so it can evaporate and be ignited more efficiently in cold weather. The integrated component, overmolded with DuPont Zytel HTN polyphthalamide (PPA), eliminates a secondary gasoline tank, commonly used to improve cold start. Zytel HTN PPA was selected to overmold the component because it offers lower melt viscosity than competing PPAs, which helps protect the sub-assembly during molding.
Source: Plastics Today Newsletter, November 12, 2015.

3. CONTINUOUS PHYSICAL FOAMING EXTRUSION HEAD
SPE's recent 31st Annual Blow Molding Conference in Pittsburgh October 12-14 (www.blowmoldingdivision.org), was home to a new interesting technology, W. Mueller GmbH’s continuous physical foaming extrusion head. The three-layer, continuous foam extrusion blow molding head has been under development for a year. It uses an injection and dynamic mixing module to inject and disperse nitrogen into the plastic melt flow inside the head, where a special mixing element combines the two into a foamed middle layer. The amount of nitrogen injected into HDPE ranges from 0.05 to 0.12 L/min, reducing part weight by up to 20%
Source: SPE Plastics Engineering Blog, November 23, 2015.

4. 100% POST-CONSUMER RECYCLATE PET FOR SPRAY BOTTLES
Migros and M-industrial company Mifa AG has developed a Sustainable packaging solution with its spray bottles which is innovative and eco-friendly packaging for cleaning agents. The spray bottles are being produced from 100% recycled, post-consumer polyethylene terephthalate in a closed loop (without down-cycling). By this development much of the petroleum can be saved. Far too often plastics are today indeed recycled, but used for low-grade products (downcycling). A challenge in the development was the achievement of the highly transparent appearance while using 100% recycled material. The spray bottles are not only environmentally friendly, they are also a genuine innovation as the bottle is made transparent without discoloration.
Source: Packaging Connections Newsletter, December 21, 2015

5. PASTEURISABLE, HOT - FILL PET JARS
New Thermalite jars offer various features such as sustaining hot-filling (to 95oC) & pasteurisable used to replace glass for food. They offer significant weight reduction (up to 85%) and carbon footprint savings, having advanced container design, unique manufacturing process with various filler benefits: reduced noise, eliminate stoppage and spoilage due to breakage, less secondary packaging, minimal changes to filling lines. It offers various retailer benefits: as they are used in areas inaccessible to glass – extends cross-selling opportunities; More jars fit on shelves – or more space for other product lines. ThermaLite® Helios is used for a burger relish/sauce by Helios to support a limited edition burger campaign by an international fast-food chain. This pack is the winner of World Star awards 2015.
Source: Packaging Connections Newsletter, January 15, 2016

6. NANO TUBE LAMINATE FROM DANAFLEX
Danaflex has developed nano tube laminate having limited elasticity and is not absorbed in air when squeezed (the so-called effect of permanent deformation)also winning the World Star Award. The new product is indispensable for packaging sauces, toothpastes and similar personal care products and household products. The material has high barrier properties, which prevents the penetration of water vapor, oxygen, and a variety of bacteria inside the package. High barrier properties inhibit release of active ingredients. High quality films contributes to high-quality printing and external presentable.
Source: Packaging Connections Newsletter, January 14, 2016

7. TPE'S BETTER SEALING CAPACITY FOR VACUUM CLEANERS
MöllerFlex relies on injection molding technologies that are particularly innovative using Kraiburg's THERMOLAST® K TPE. The complex component geometry of the vacuum cleaner shell is executed in two-component injection molding with cube technology. In the two sides of the cube mold that are usable for manufacturing, the injection molded parts are molded simultaneously. In this process the cube mold rotates 180° two times so that the production steps run simultaneously and a complete injection molded part is produced. In this manner the vacuum cleaner shell and the perimeter TPE bumper strip are formed in virtually one production step.
Source: Omnexus-SpecialChem Newsletter, November 26, 2015.

8. LOW HARDNESS TPE FOR WEATHER SEALS FROM POLYMAX
PolymaxTPE, has developed a low hardness TPE elastomer exhibiting better performance than that of thermoplastic vulcanizate (TPV) widely used in weather seals by providing higher tear strength, lower compression set and cost benefits. This new grade, D6940, is ideally suited for weather seal application that requires low deformation stress, rubberlike seal recovery, UV resistance, and paint stain resistance. With hardness reduced to 40 shore A, D6940 TPE still exhibits 12% higher tear strength than a weather seal grade TPV with 60 shore A while providing low compression set of 14% at 23°C and 36% at 70°C, respectively.
Source: Omnexus-SpecialChem Newsletter, November 24, 2015.

9. NEW HIGH HEAT ABS FOR ROOF HATCHES OF HEAVY DUTY TRUCKS
BOS Group, has selected new High Heat ABS HH3114 from ELIX Polymers for the production of roof hatches for heavy duty trucks of a German premium automobile manufacturer. The roof hatch is produced with sequential controlled hot runner valve gates. using ELIX ABS HH3114 to meet the high requirements of the application. In production, HH3114 offers a number of processing advantage including excellent processability and high flow, resulting in competitive cycle times. Less mold deposits means less mold cleaning and bring significant cost savings and higher productivity. The final part offers a weight reduction of 8% when compared to PC/ABS
Source: Omnexus-SpecialChem Newsletter, November 26, 2015.

10. LSR MOLDING BY ARBURG AT PLASTEC
Arburg GmbH (Lossburg, Germany) will showcase some of its signature equipment at PLASTEC West, which returns to Anaheim, CA, from February 9 to 11, 2016. The LSR-based magnifying glasses will be molded on an electric Allrounder 470 A with 1,000 kN of clamping force and a 290-sized injection unit. The machine from the high-performance Alldrive series manufactures four flexible LSR magnifying glasses in a cycle time of around 65 seconds, claims Arburg. The highly transparent material has a hardness of 70 Shore A, says the company, and the system uses a four-cavity mold from Shin Etsu with cold runner technology and an ejector system. The magnifying glasses, which weigh 8.4 grams, are positioned in the mold and gripped by a Multilift Select robotic system.
Source: Plastics Today Newsletter, December 3, 2015.

11. TECHNOLOGY FOR LONG FIBER COMPOUNDS
Coperion GmbH (Stuttgart, Germany) in cooperation with ProTec Polymer Processing GmbH (Bensheim, Germany), Coperion now offers complete installations for the production of long fiber reinforced thermoplastics (LFTs), meeting the growing need for LFT pellets. Melting of the polymer and mixing with special additives takes place within the extruder. Production of long fiber reinforced thermoplastics employs the pultrusion process. Here glass, carbon, metal or natural fibers are mixed into a polymer matrix. Through the pultrusion process, the individual fibers of the strands are impregnated. Coperion uses the ZSK Mc18 twin screw extruder or the STS Mc11.
Source: Plastics Today Newsletter, November 29, 2015.

12. EXPAND TONNAGE OF ELECTRIC INJECTION MACHINES
That ball screws are potentially an Achilles heel for all-electric machines of medium size and upwards is somewhat of an open secret in the processing sector. NSK (Tokyo) has come up with a solution: a new method for grinding the nuts employed in its products to lengths of 800 mm (1.4-times the length of conventional nuts). This was not an easy task it hastens to add, involving the development of a dedicated nut grinding machine. Longer nuts make it possible to increase the number of load balls in the nut, thereby increasing the maximum allowable axial load by a factor of 1.3 and the service life of the ball screw 2.8-fold versus nuts fabricated using conventional cutting processes.
Source: Plastics Today Newsletter, December 2, 2015.

13. HAITIAN ABSOLUTE’S ZHAFIR ZERES SERIES
The strongest sales driver for the Zhafir brand continues to be the Venus Series. The Zeres Series, identical in construction to the Venus II Series, offers an integrated hydraulic system so that customers can select the solution that’s best for them, depending on their preferences and parameters. Benefits include: Servo-electric drives for high dynamics, energy efficiency, and precision – one cycle after another; Injection speeds up to 350 mm/s; Swivel-mounted injection unit for rapid screw exchange and simpler maintenance; Free programmable hydraulic core pull located directly at the moveable platen; Energy-efficient hydraulic system for core pulls, ejector and nozzle movement; Sigmatek control, including mold-protection function and RFID card.
Source: Plastics Today Newsletter Advertisement, December 22, 2015.

14. PERFORMANCE OF PP UPGRADED BY MILLIKEN ADDITIVES
Saudi Arabian polypropylene producer National Petrochemical Industrial Company (NATPET) is debuting a newly-enhanced PP impact copolymer grade for injection molding that employs Milliken's Hyperform HPN-20E nucleating agent in place of conventional sodium benzoate in order to achieve better shrinkage control and improved stiffness without affecting impact performance. Teldene B20ML targets market segments such as large pails and automotive. It can also be used in food and non-food packaging. Nucleated PP grade offers better balance of shrinkage control, improved stiffness without affecting impact performance.
Source: Plastics Today Newsletter, December 1, 2015.

15. BOOST TO THERMOPLASTIC PRESS-FORMING PROCESSES
Surface Generation (UK) is developing new press-forming mold faces incorporating its patented Production to Functional Specifications (PtFS) technology for the production of high-performance thermoplastic composite components. By integrating Surface Generation's new thermal management technologies into the mold face itself, WMG and AGC are able to continuously adapt heating and cooling levels for each mold area and process stage in real time, with the expectation of improving both the quality and throughput of compression molding applications.
Source: Plastics Today Newsletter, December 2, 2015.

16. PETAINER INNOPAC PACKAGING NOW IN MUMBAI
New Delhi-based Petainer Innopac Packaging, a joint venture between PET packaging company Petainer UK Holdings (London) and its local partner Innopac Containers (New Delhi, India), has opened its doors to its new manufacturing plant near Mumbai area in India offering customers high quality, high performance and sustainable PET/plastics packaging solutions using Petainer’s advanced polymer engineering technology. The plant houses state-of-the-art blowmolding equipment to manufacture the 20 liter bulk water cooler jar, petainerCooler, using preforms produced from Petainer’s manufacturing sites in Europe, as well as a fully-equipped onsite design studio, laboratory services and warehousing.
Source: Plastics Today Newsletter, December 8, 2015.

17. PEEK, POLYAMIDE FOR 3D-PRINTED FUEL INTAKE RUNNER
Polyetheretherketone (PEEK) resin has been adopted to fabricate a 3D-printed fuel intake runner for use in the Polimotor 2 project. The fiber reinforced KetaSpire grade from Solvay Specialty Polymers (Alpharetta, GA) replaces the aluminum that was used in the original Polimotor. Additive manufacturing company Arevo Labs produced the part using its innovative Reinforced Filament Fusion technology. The Polimotor 2 all-plastic engine will feature a 3D printed plenum chamber fabricated with PA6 powders. The Polimotor 2 engine will also feature a 3D printed plenum chamber fabricated through selective laser sintering using a polyamide PA6 powder grade reinforced with a 40 percent loading of glass beads to enhance dimensional stability.
Source: Plastics Today Newsletter, December 7, 2015.

18. STEEERING ANGLE SENSOR’S GEAR DRIVE USES PA12
Valeo Schalter und Sensoren GmbH (Germany) have opted for VESTAMID® L1930 PA12 from the Resource Efficiency Segment of Evonik, Essen, as the material for the gear drive of the steering angle sensor. The steering angle sensor measures the steering angle of the steering wheel and continuously indicates to the dynamic stability control system—also known as the electronic stability control, or ESC—the direction in which the driver wants to go. VESTAMID® L1930 offers exactly these properties: As PA12 is temperature-stable over a wide range, from -40°C to 125°C. Its properties change only very slightly with variations in ambient humidity; molded parts show almost no dimensional changes.
Source: Omnexus-SpecialChem Newsletter, December 24, 2015.

19. USDA CERTIFICATION FOR LAUREL BIOCOMPOSITE’S PLA & PE
Laurel BioComposite, LLC has earned the USDA Certified Biobased Product Label for its Bio-Res PLA with 97 percent biobased content; Bio-Res PE with 62 percent biobased content and Bio-Res powder with 100 percent biobased content. Introduced in 2011 as a cost-effective, green replacement with improved performance properties for traditional petroleum-based resins in a variety of plastics manufacturing processes, Laurel BioComposite’s biomaterials offer a robust option without sacrificing required physical properties. Bio-Res powder for example, replaces calcium carbonate in sheet-molded or bulk-molded thermoset composites while reducing part weight by up to 25 percent. Bio-Res formulas are especially suited to automotive and truck panel applications.
Source: Omnexus-SpecialChem Newsletter, December 15, 2015.

20. LOW-COST HFFR TPE COMPOUND FOR FIBER OPTIC CABLE
Teknor Apex’s new halogen-free flame retardant (HFFR) compound for fiber optic cable provides excellent flame retardance while exhibiting significantly lower post-extrusion shrinkage than similar compounds with comparable flame properties. Halguard® 58625 compound has a UL-94 flammability rating of V-0 and an oxygen index of 50%, while exhibiting post-extrusion linear shrinkage of only 2%. Teknor Apex recommends Halguard 58625 compound for cable used in mass transit, data centers, cell towers, and other infrastructure applications. For outdoor uses, the new product exhibits good sunlight resistance when tested per UL-1581.
Source: Omnexus-SpecialChem Newsletter, January 5, 2016.

21. ABS-BASED 3D PRINTED ACOUSTIC GUITAR PROTOTYPE
Following hot on the heels of their 3D printed Car Jack, prototype one and two; Fouche 3D Printing has released pictures and video of the Cheetahs latest creation, prototype 1 of a 3D Printed Acoustic Guitar. There are lots of 3D printed electric guitars on the internet, but only a few acoustic ones. The neck has been printed in solid ABS, and the soundbox, was printed with two 3mm layers, to make for a 6 mm wallthickness. This means that the guitar weigh in at 3.5 kg, vs the 2.2 kg of the wooden guitar.
Source: Omnexus-SpecialChem Newsletter, December 14, 2015.

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