Research and innovation is driving the plastics industry, finding new applications, replacing conventional materials in a win-win situation.

The use of plastics is growing exponentially in all spheres of life, not just in consumer products but also in the field of energy and transportation as the quest of better, cheaper and lighter materials continues unabated. Plastics play an important role in many forms of additive manufacturing (AM), now more commonly known generative manufacturing or 3D printing. Hardly any technology is currently attracting so much attention as additive manufacturing. Additive manufacturing processes are causing a stir among users in the design and packaging, aerospace and automotive industries as well as in the fields of dental and medical technology and machines and plant engineering. The processes promise great freedom of design and allow individual components to be manufactured with highly complex geometries and internal structures. While there is a growing awareness of the opportunities presented by the direct additive manufacturing of plastic parts with thermoplastics, these technologies have matured to such an extent that they are now sometimes being used to complement or even replace conventional production processes, particularly in view of increasingly fast-changing consumer tastes and trends as well as in view of the new challenges that the industry is facing in regard to the individualisation of plastic products.

Recently, EOS, the global technology and quality leader for high-end additive manufacturing solutions, presented an extensive range of AM solutions for all fields of application – from rapid prototyping to large-scale production – at K 2016 Fair in Dusseldorf.

In the area of plastics-based additive manufacturing, EOS presented the high productivity system EOS P 770 for the first time. The company held live demonstrations at its booth. Thanks to its new hardware and software features, the EOS P 770 is up to 20 per cent more productive and can achieve up to 10 per cent decreased costs per part than its predecessor. For the innovative production of mould inserts for large-volume production using injection moulding, EOS together with GF Machining Solutions (GFMS) also presented the metal system AM S 290 Tooling.

According to Mr Anand Prakasam, Country Manager, EOS India, "Highly productive systems for plastic-based additive manufacturing, such as the EOS P 770, enable the fast and reliable manufacturing of functional prototypes and serial production. For the production of large-scale series using injection moulding, DMLS solutions by EOS similarly offer distinct benefits in terms of productivity and part quality. "

Cost-effective production of large plastic parts

The EOS P 770 is a polymer system with two 70 W lasers used for the production of large parts and for industrial manufacturing with a high throughput. The system is based on the proven EOS technology of the successful system EOS P 760 and offers improved part quality with a production volume of over 150 litres. With the largest building volume available on the market, the EOS system permits the production of parts with lengths of up to one metre.

With 10 commercial polymer materials and 18 combinations of materials/layer thicknesses currently available, EOS is a benchmark in terms of material variety. In addition, the EOS ParameterEditor allows customised exposure parameters to be defined based on proven starting values.

The EOS P 770 system is ideal to manufacture large parts and high quantities of parts. Exemplary applications can be found in many areas. EOS itself, for instance, manufactures air ducts on the system, built in PA 2200 material. This serial part is installed into the EOS M 290 metal system. Up to four of these large, functionally integrated air ducts can be manufactured in one build job. Compared to the predecessor system, the build time is reduced by good 20 percent.

DSM’s Stanyl Diablo AIMs high

In another development, Royal DSM, the global Life Sciences and Materials Sciences company, has collaborated with Tier One automotive supplier Mahle GmbH to develop the world’s first high-volume use of high-heat plastic in an air intake manifold (AIM) that integrates a water-cooled charge air cooler (CAC). DSM is a market leader in the development of high-temperature-resistant thermoplastics for automotive engines.

Using DSM’s high temperature resistance polyamide 46, Stanyl® Diablo OCD 2100, Germany-based Mahle is producing the first high-volume application of high-heat plastic AIM/CAC combination for use in BMW’s B48 engine. BMW uses the B48 engine in several different car models.

Legislation aimed at lowering vehicles’ CO2 emissions is driving innovation. Car manufacturers want to deliver higher-performing engines while still meeting the new emission limits. One means of achieving this in turbo systems is to integrate the CAC into the AIM, using liquid to more effectively cool the air instead of air-to-air cooling. CAC integration also reduces the air duct length, thereby improving engine responsiveness and reducing turbo lag.

“Such a design can drive the AIM’s continuous operating temperature up to 220°C, which in turn boosts the mechanical demands on the materials used in those components. This new geometry also requires materials with robust weldability and weldline aging resistance in order to maintain the part’s integrity. The Stanyl Diablo fulfilled all customer requirements,” says Mr Valecka, project manager integrated manifold BMW B48 at Mahle.

DSM offers a complete portfolio of high-performance materials for air intake manifolds whether they have an air-to-air CAC or an integrated, liquid-cooled CAC. This includes Akulon® polyamide 6, Akulon Diablo polyamide 66, Stanyl and Stanyl Diablo polyamide 46. DSM engineered its Diablo technology specifically for continuous-use temperatures up to 230°C. The new Stanyl Diablo HDT2700 further offers a best-in-class heat deflection temperature (HDT) under load even beyond existing Stanyl Diablo grades.

The excellent mechanical properties of both the HDT2700 and OCD2100 grades provides superb weld strength and ensures part integrity under pressure pulsation loads. These materials outperform competitive materials in regards to thermal oxidative stability, maintaining high stiffness at elevated temperatures and pressure loads.

As under the hood performance requirements become more extreme, Stanyl Diablo materials deliver robust performance, function integration, and design flexibility while eliminating the need to return to metals. Stanyl provides up to 40% weight reduction versus aluminium, and its excellent processing characteristics reduce material and production costs.

DSM’s new Akulon Diablo HDT2500 withstands a 220°C continuous-use temperature and has a heat deflection temperature (HDT) of 240°C. Akulon Diablo fills the gap between Akulon PA6, Akulon PA66/6 and Stanyl Diablo by combining long-term heat-aging performance and mechanical properties.

PolyOne to begin specialty engineered materials production in India

PolyOne Corporation has announced that it expects to begin local production of specialty engineered materials at its existing facility in Pune, India in January 2017. Initial production will include specialty engineered polymer materials used in high performance applications that have the need for flame retardant properties, high strength and durability, stiffness, chemical resistance, or weatherability.

PolyOne opened a new facility in Pune in 2014 initially focused on the production of colorant and additives to serve end markets such as transportation, electronics & electrical, healthcare, wire & cable, and packaging. Specialty engineered materials manufacturing capability is currently being installed within the facility, and production trials begin later this year.

“PolyOne continues to build upon our strong reputation in India for collaborating and innovating with our local and multi-national customers,” said Craig Nikrant, president, Specialty Engineered Materials, PolyOne.

Vikas Vij, managing director, PolyOne in India, added: “India remains a region of growth for manufacturers and consumers, and by enhancing speed to market, it gives our customers a competitive advantage. We're proud to be their materials and service provider as we innovate and grow together for the future.”

PolyOne Corporation, with 2015 revenues of US $3.4 billion, is a premier provider of specialised polymer materials, services and solutions.