1:30 pm – 6:00 pm:
T16-Product Design and Development and Injection Molding Joint Session
(Moderators: Lynzie Nebel and Erik Foltz)-Room S320D
1:30 pm – 2:00 pm:
Preventing Plastic Failure
Paul Tres, ETS Inc.
Plastic product design involves actual part design, material selection, tool design, processing, testing and final product validation. This paper discusses all the above steps for a component which catastrophically failed while being used by the customer.
2:00 pm – 2:30 pm:
The Strategic Value of Designing for Cost
Laurel Bougie, Customer Success Manager , aPriori
Today, manufacturers are being pressured at every angle regarding cost. Customers are asking to pay less for a product, supply chains are asking to be paid more, and stakeholders are asking for a higher margin leading some manufacturers to scratch their heads and say, where do I start? Many of the challenges today stem from lack of visibility surrounding cost drivers when designing a product leading engineers to have little or no insight on the impact design changes have on overall product cost. This lack of visibility often causes late stage engineering churn as completed products exceed target costs and manufacturers are faced with a difficult decision, miss a product launch date or release a product with minimal (or no) margin. aPriori’s Design to Cost solution helps design teams identify and eliminate cost drivers early in the design process, preventing a cycle of churn throughout the organization, causing lost revenue and lost productivity. In this session, you will learn how early visibility to cost drivers will reduce churn and rework throughout your organization and how aPriori uses specific software features to provide design guidance based on cost, encouraging engineers to make cost effective decisions and removing cost related surprises at the conclusion of any project.
2:30 pm – 3:00 pm:
Optimizing Design and Processing for Long Fiber Thermoplastic Parts
Erik Foltz, Senior Managing Engineer, The Madison Group
Suhas Kulkarni, FimmTech Inc.
A robust process produces parts that are consistent in quality cavity to cavity, shot to shot and run to run despite the natural variations such as that of the machine, material, environment and the operator. A capable process produces parts that are consistent within the required quality requirements. Both these are a requirement for a successful molding operation. To reach to this success, the part design, the mold design, the mold build, the machine selection and the molding process need to be considered all at one time right at the start of the project. Unfortunately, in most cases, a designer designs the part, throws it over the wall to the mold maker who makes the mold and throws it over the wall to the molder who then ends up with a substandard process with several quality issues. The talk will focus on how and why to apply concurrent engineering principles for the success of a project.
4:00 pm – 5:00 pm:
How Poor Design Can Severely Limit Materials, Tooling and Processing Capabilities
Vikram Bhargava, Author, Trainer and Consultant
For a plastic part or assembly to perform as expected, proper consideration must be given to material selection, part design, tooling, and processing. In many instances, design errors are misclassified as tooling, processing or material issues. It is also not uncommon to attribute design related failures to customer abuse! As an example, a sharp transition in the wall thickness can cause: – Flow marks Misclassified as poor gate design or location, inadequate cooling, too little or too much holding pressure, high injection speed causing chain breakdown or pigment degradation, contamination, etc. – Poor chemical resistance and cracks Misclassified as the chemical resistance of the material – Failure in drop Misclassified as processing issues causing high molded stresses, material weakness, customer abuse, etc. – Warpage Misclassified as uneven packing pressures, poor cooling, etc. Numerous actual parts will be shown to illustrate the foregoing.
5:00 pm – 6:00 pm:
The Effect of Rapid Heating Cooling Molding on Polycarbonate Based Material Properties
Jessica Boyer, Covestro LLC
The plastic industry uses advance injection molding technologies to enhance part performance and surface appearance. Rapid heating cooling molding (RHCM) technology has been shown to enhance surface appearance and achieve high mold surface replication. In this article, we examined the physical properties of Polycarbonate and Polycarbonate/ABS to compare conventional injection molding (CIM) and RHCM. The comprehensive study investigated stress-strain properties, weld-line strength, impact performance, and flow length. The results demonstrated that RHCM did not affect the bulk material physical properties. In some cases, the study showed an increase in physical properties for weld-line strength and flow length.
1:30 pm – 6:00 pm:
T17-Technical Marketing: Applications
(Moderator: Donna Davis)-Room S320C
1:30 pm – 2:00 pm:
Improve the Performance of Your Retort Flexible Film
Sergi Salva Saez, UBE America Inc.
In this presentation UBE will talk about the challenges of using flexible barrier films replacing traditional retort packaging and the research done to develop the right structuctures and Nylon materials to overcome these challenges.
2:00 pm – 2:30 pm:
Thermally Purified Carbons for Food Contact Applications – a Case Study on EU Compliance
Rijo Jacob Robin, Superior Graphite
Polymers are finding more and more application in the food handling and processing equipment in industries and households. Be it for metal replacement or lower cost or corrosion resistant purposes. Modified polymers using graphite are particularly suitable for demanding applications require the materials to be of conductive or lubricious. Graphite modified polymers are the best solution for self-lubricating parts in environments that can’t accommodate liquid lubricants. To ensure carbonaceous material be of technical quality and purity as stipulated in Plastics Regulation (EU) No 10/2011, Superior Graphite uses its proprietary electro-thermal purification technology, which exposes carbon and graphite materials to temperatures above to 2400°C. Result is a high carbon content and virtually free of impurities. Removing volatile gases and select heavy materials creates a highly ordered crystalline structure with exceptional purity, consistent quality, and increased resiliency, lubrication, and thermal and electrical conductivity.
2:30 pm – 3:00 pm:
Biopolymer Compounds for Applications Requiring Marine Degradation
Stanley Dudek, Polymer Processing Tech, LLC
The development of a biopolymer netting for the establishment of new oyster beds in intercoastal waterways is described. The netting secures the growing oysters for 18 months before biodegrading to allow the oyster bed to grow. The establishment of multiple beds will improve the water clarity and promote the growth of seagrass.
3:00 pm – 3:30 pm:
Novel Applications of Beta Nucleated Polypropylene in Film, Thermoforming, and Injection Molding Applications
Philip Jacoby, Jacoby Polymer Consulting
Polypropylene can exist in three different crystal forms known as the alpha, beta, and gamma forms, and the alpha form is the most common. The beta crystalline form can be produced in molded and extruded PP parts via the addition of certain nucleating agents. The beta crystal phase can be used to produce some very unique PP products, as well as improve the properties and lower the cost in a wide range of applications. Mayzo has developed a very high activity beta nucleant that is offered in the form of a masterbatch. The converter can add this masterbatch at the extruder hopper in order to create products that exploit these benefits. In this presentation we will examine the ways in which beta nucleation is used today to produce microporous breathable films used in electronics, protective apparel, and construction applications. We will also discuss some new novel applications of breathable PP films. The use of beta nucleation to improve the thermoformability of PP leading to lighter weight and less expensive containers will also be discussed. Finally we will examine how beta nucleation is used to improve the toughness of molded PP parts, and also see how the heat seal strength of PP can be improved without the use of low-melting random copolymers.
3:30 pm – 4:00 pm:
Copolyester based WPC (Wood Plastic Composites)
Tae Young Kim, SK Chemicals
Wood-plastic composites (WPC) are composite materials made of wood fiber/wood flour and thermoplastics. Since a polyolefin-based resin, generally used in WPC, exhibits hydrophobicity, it shows low interfacial adhesion when mixed with hydrophilic wood flour, which causes a problem in that flexural strength of WPC is lowered. In case of a polyvinyl chloride (PVC) resin, a phthalate-based plasticizer and stabilizers containing heavy metals can be used in order to enhance processability during the process to make WPC, which are easily extracted out from WPC, causing an environmental pollution problem. Both PP and PVC based WPC are vulnerable to climate changes due to its low dimensional stability according to temperatures, causing many defects and problems. In case of polyester (PET) resin, polyester base resins compatibilizes well with wood, but due to high processing temperature, the wood flour are burned during the process, which makes it impossible to use PET for WPC. Accordingly, in order to solve the above-described problems, ECOZEN® based WPC has been developed. ECOZEN® based WPC has improved physical properties which show superior flexural property (higher than 2 times compared to PP based WPC), impact strength, and lower thermal expansion (or shrinkage). Also it can be easily processed even without help of additional coupling agents, since ECOZEN® shows excellent interfacial adhesion with wood flour. This allows of WPC with higher content of wood flour, which benefits in terms of cost competitiveness and environmental friendliness.
4:00 pm – 4:30 pm:
Schulamid High Performance Nylon for Fuel System Applications
Ying Shi, A. Schulman Inc.
Schulamid 612 compounds have low moisture absorption, good chemical resistance, and no oligomers extractions comparing nylon 12. They are suitable for fuel system applications and are good alternatives to nylon 12 compounds. This presentation describes Schulamid 612 compounds portfolio and application examples.
4:30 pm – 5:00 pm:
Extending the Use and Properties of PVDF Polymer
Jason Pomante, Arkema
The World of PVDF Resin continues to evolve and change. PVDF is an excellent melt processible engineering resin with substantial chemical resistance, heat resistance, low permeation and many other wonderful properties. By using reinforcement additives in the neat resin, some basic properties can be enhanced such as heat deflection temperature, flame resistance properties, flexural strength amongst others while maintaining traditional PVDF properties such as UV resistance, chemical resistance and impact properties. This subject will be explored in detail to show advancements in PVDF technology along with some applications in the market. Also, PVDF is an excellent product for many stringent applications in wire and cable, aerospace and transportation due to the long lasting properties, however, some industries encourage weight reduction and cost savings. In an effort to deliver new technology to various market spaces, PVDF foaming technology is available to make very light weight articles in sensitive applications. Although past technology allowed for density reduction of around 20%, new technology has been developed allows PVDF to be continuously extrudable and obtain +60% weight reduction. Weight reduction can be obtain now that allows for PVDF to float! The advantages of this technology will be explored and described in order to not only show property enhancement but open new market space opportunities for PVDF. Both reinforced PVDF and low dentistry PVDF open up new opportunities that may allow cost savings to the end user.
Michel Ponting, PolymerPlus LLC
Micro- and nanolayer processing, is a technique which combines conventional cast film coextrusion equipment with a multi-layered feedblock, or a series of layer multiplier dies, to enable continuous polymer film fabrication on industrially relevant processing scales. Films processed in this manner can readily be created with hundreds or thousands of layers resulting in individual alternating layered polymer domains with thicknesses ranging from several microns down to less than ten nanometers. Though initially patented in the 1960s, fabrication of micro- and nanolayered polymer films via coextrusion has only recently gained broader acceptance in the commercial products arena.1 Building on the strong fifty year academic and commercial layer multiplication technology advances in processing have enabled modern day production of highly uniform intra-film layers, graded thickness film layers, and construction of 2D ordered structures. Nanolayered films are of interest both as both a developmental research area and as a scalable, cost effective commercial production technique toward high value added materials systems from conventional polymer materials. A review highlighting historical nanolayered coextrusion energy storage film development toward commercial film production and low rate device manufacturing is presented. Technical and commercial product development activities, target markets, and layering enabled enhanced electrical material storage properties will be discussed for nanolayered film capacitor devices. The nanolayering development case study will address layered film scale-up requirements and challenges, uniformity, and additional manufacturing challenges presented when integrating the micro- or nanolayered film into product supply chains with a special focus on quality assurance challenges and procedures.
5:30 pm – 6:00 pm:
Advances in Wear and Friction Solutions
Edward Williams, SABIC
This presentation reviews some of the basic approaches to improving wear and friction performance in thermoplastic compounds and introduces some newer ideas in non-halogenated wear compounds.