3M Unveils Weight Reducing 3M™ Glass Bubbles iM16K Grades Applicable for PP & PA Systems

3M is introducing the newest member of its high-strength hollow glass bubbles product line that will change the way the industry uses lightweight fillers. This new product will enable customers to do more with their resin systems. 3M™ Glass Bubbles iM16K are a high-strength injection molding grade for polypropylene and polyamide systems. They enable manufacturers to produce optimized resin formulations for lower-density filled plastics - without compromising strength or other physical properties.

Now, manufacturers can do more beyond reducing weight. With a density of just 0.46 g/cc, resin systems optimized with iM16K can reduce weight by 15 percent or more in polypropylene-filled systems, and 18 percent or more in nylon glass fiber systems, while maintaining optimized physical properties. Manufacturers can see productivity gains when using resin systems filled with high strength glass bubbles, such as iM16K. Because iM16K is hollow, like all 3M glass bubbles, there is less finished part mass to cool, which may reduce cycle times by 15 to 25 percent, depending on the resin system. iM16K is specially engineered to survive injection molding and compounding processes and features crush strength of >16,000 psi. Incorporating glass bubbles into processes improves dimensional stability, which translates to less shrinkage and warpage - thereby reducing reject parts and reprocessing.

Today, businesses in every industrial sector understand the need to "do more" to reduce their carbon footprint and improve the sustainability of their products throughout their life cycles. For industrial consumers of plastic parts - particularly those in the transportation market - the benefits of lightweighting have an obvious impact.

Case in point: REHAU, a global polymer processing firm, has been developing a low density PPSU material called "RAU-Flight," made with 3M glass bubbles for use in a variety of interior aircraft cabin components. According to Bernd Kupferer, business unit manager, Industrial Solutions at REHAU, this new material could contribute to significant fuel savings for aircraft operators.

"We have determined that a single handrail system for an Airbus A320, made with these new RAU-Flight materials, would reduce weight by more than 5kg per aircraft, resulting in a savings of about 1000 liters of fuel per year," states Kupferer. "If you extend this to a fleet of 150 aircraft, over a 15-year operating life, the total fuel savings would be about 2.25 million liters of jet fuel. That not only saves money for the airline, but is also a significant reduction in carbon emissions."

3M glass bubbles build on 3M's legacy of innovation and are based on 3M's Ceramics, Coatings and Advanced Materials Technology Platforms.

SABIC Premiers State of the Art Higher Performance & Lighter Weight Materials at JEC 2012

At JEC Europe, Booth #U17, SABIC's Innovative Plastics business is spotlighting a variety of lightweight, high-performance composites and other advanced materials that are making important contributions to its customers' sustainability initiatives across major global industries. In particular, the outstanding weight-out and non-halogenated flame retardance provided by SABIC's high-performance Ultem™ polyetherimide (PEI) materials are increasing their appeal as environmentally responsible solutions. Customers are choosing Ultem materials for a broad range of applications - not just in aerospace, where they have achieved notable successes, but also in automotive, rail, oil & gas and building & construction.

Ultem carbon-fiber-filled resin, structural foam, and textile fiber can slash part weight by up to 50 percent to reduce fuel consumption and carbon emissions. These innovative materials also provide exceptional, inherent flame-smoke-toxicity (FST) performance for which Ultem PEI technology is famous. The company is also displaying Ultem powders that enhance FST performance of thermoset composite systems and polyphenylene ether(PPO™) resin additives that increase heat and toughness of epoxy systems. SABIC's global technology resources and deep industry expertise enable the company to deliver sustainable solutions for the evolving needs of their customers in a variety of market segments worldwide.

"SABIC's advanced materials and additives can resolve a dilemma facing a number of industries - how to achieve greater sustainability without sacrificing performance," said Ilknur Gur, general manager Europe, engineering resins, Innovative Plastics. "Our Ultem technologies - already widely used for demanding interior aircraft components - also provide an outstanding combination of light weight and high performance properties for many other critical applications as a replacement for metals and thermosets. The success of Ultem resin is just one example of how SABIC's engineering thermoplastics and composites are helping customers pursue successful environmental strategies and competitive differentiation."

Carbon-fiber-filled Ultem Resin

Offering high modulus and mechanical strength, this unique compound is based on Ultem resin and aerospace carbon fiber technology. When used to replace heavier airline-grade aluminum in interior components, carbon-fiber-filled Ultem resin can cut weight by up to 50 percent while improving strength by 40 percent vs. die-cast aluminum. The compound complies with the U.S. Federal Aviation Administration's (FAA) Federal Aviation Regulation (FAR) 25.853 requirements for flammability, Ohio State University (OSU) 55/55 heat release standard and smoke density and key OEM specifications for FST. Potential injection molding applications include tray table arms, armrests, footrests and galley items. Components can be powder coated, painted or plated.

In rail applications, carbon-fiber-filled Ultem resin is an excellent choice for replacing aluminum in seating and other semi-structural components. Further, its high heat performance makes it a great alternative for under-hood automotive parts. Finally, it can be used for heating, ventilation and air conditioning (HVAC) applications that demand high-temperature resistance and flame retardance.

Ultem Structural Foam

Ultem foam enables aircraft designers to leverage the best-in-class FST performance of PEI resin in a form that is 10 to 20 times lighter than traditional plastic components. It is an outstanding thermoformable core material choice for aircraft interior composite structures such as luggage bins, galleys and lower wall panels (dado panels). Ultem foam meets OSU heat release levels below 50/50, and offers low moisture absorption, excellent energy absorption and low dielectric loss. It is also transparent to radar making it a prime material for insulation of radomes. The Ultem foam product family comprises grades with three different densities.

Similarly, Ultem foam is an excellent candidate material for railcar side walls, ceiling panels and partitions. Its insulating properties make it a good choice for insulation of HVAC systems in high-end structures such as hospitals.

Ultem Fiber

Featuring the signature FST performance of Ultem resin, Ultem fiber provides light weight and excellent aesthetics for many applications in aerospace and rail - including carpets, kick panels, seating and wall coverings and safety and protective apparel. Woven fabrics incorporating Ultem fiber can be colored using conventional exhaust dyeing techniques, resulting in exceptional colorfastness and resistance to ultraviolet (UV) light.

Ultem Powders for Thermoset Composites

To extend the benefits of Ultem resin's exceptional FST performance, good metal adhesion and high heat resistance into thermoset composite systems, SABIC developed two powder technologies that efficiently disperse into thermosets and dissolve into solutions faster than coarse powders or pellets.

• Type I PEI powders, which are produced via processing chemistry, achieve particle sizes less than 45 microns. The powder is uniformly spherical to enable more-efficient dispersion and dissolution compared to mechanically ground powders. Applications include tougheners for epoxy resins and direct impregnation of fabrics or unidirectional tapes to create thermoplastic shape-able composites for use in industries like aerospace, automotive and oil & gas.
• Type II PEI powders, created by using patented process technology, have a particle structure that is fluffy and porous with a high surface area. Although particle size is greater than 100 microns, this structure enables the powder to disperse and dissolve very quickly into organic solutions and epoxies. Applications include solvent-based industrial coatings and adhesives, and thermoset resins for composites which can be used in aerospace, automotive, chemical process and oil & gas industries.

PPO Oligomer Resin Additives

PPO resin has a low dielectric constant and loss factor (Dk/Df) that enables better signal integrity at high frequencies when used in printed circuit board (PCB) laminates. SABIC has developed two oligomer additives that easily fit with common PCB fabrication methods. Noryl™ SA90 resin provides enhanced electrical properties, increased glass transition temperature (Tg) and toughness, and improvements in non-halogenated flame retardance for epoxy-based PCB applications. Noryl SA9000 resin provides many of these benefits for non-epoxy PCB applications. Applications include industrial and aerospace composites, adhesives and elastomers.

Sustainmetrics Carries out LCA on Cereplast Hybrid 101 Bioplastic to Assess its Environmental Effects

Cereplast, Inc. ,a leading manufacturer of proprietary biobased, sustainable bioplastics, completed a third party Life Cycle Assessment (LCA) report that assessed the environmental impacts of a number of conventional and renewable plastics from cradle to factory gate (from raw material extraction to the production of the plastic product), and determined that Cereplast Hybrid 101 is superior to all conventional plastics evaluated in terms of overall environmental impact.

The study was performed by Sustainmetrics and compared Cereplast Hybrid 101 bioplastic to four different conventional plastics includingLow Density Polyethylene (LDPE), Polyethylene Terephthalate (PET), High Impact Polystyrene (HIPS) and Polypropylene (PP). The LCA is currently undergoing third party peer review, which will be completed within the next two weeks.

The goal of the study was to assess the environmental impacts from cradle to factory gate through an LCA method that quantifies the environmental impact of the energy and materials used, wastes generated, and emissions released. The LCA provided a rating for each product's cumulative environmental impact including climate change, ozone layer depletion, and ecotoxicity, all of which were turned into a single ReCiPe eco-points score.

Impact assessments were conducted for Carbon Footprint (Global Warming Potential) using the official Intergovernmental Panel on Climate Change (IPCC) methodology, Abiotic Resource Depletion using the widely used CML methodology regarding the use of non-renewable materials such as oil and metals, and Overall Environmental Impact using the most recent ReCiPe single score methodology, which is the standard for creating an overall score.

The reduction in Global Warming Potential for Hybrid 101 compared to conventional PP is 32% when you factor in biogenic carbon. When you replace 1,000,000 pounds of conventional PP with Hybrid 101, the environmental impact reduction is 800,000 pounds of CO2 eq., which is equivalent to driving 732,800 miles in an average passenger vehicle, or driving around the world more than twenty-nine times. If 0.1% of the global demand for PP was replaced with Hybrid 101, that's the same as removing 5,100 cars from America's roads or planting 1,200,000 trees, which would save millions of pounds of carbon dioxide a year.

"This is a very significant step forward in our quest for a safer planet," said Chairman and CEO of Cereplast, Mr. Frederic Scheer. "Cereplast created the concept of hybrid resins a few years ago, believing in the advantages of and seeing the need for this type of resin. This third party LCA report confirms the environmental benefits of the Cereplast Hybrid 101," added Scheer. "Companies that use the Cereplast Hybrid Resins® product line for consumer products, household goods, furniture and even automotive applications, will contribute to a cleaner planet without compromising the quality of their products. With Hybrid 101 at a similar price to standard polypropylene, we are expecting a surge in demand."

Intermestic to Use SABIC's Lightweight Ultem™ PEI Resin for Replacing Metal in Zoff SMART Eyeglasses

SABIC's Innovative Plastics business' world-class expertise and technology were further evidenced with the company's announcement that Intermestic Inc., a specialty retailer of eyewear and accessories, has chosen tough, lightweight Ultem™polyetherimide (PEI) resin for the frames of its new line of Zoff SMART eyeglasses. The tailored, aerospace-grade Ultem resin material solution helps meet Japanese consumer demands for fresh, new eyewear styles with exceptional long-term performance and feather-light comfort; by allowing Intermestic to eliminate titanium and aluminum from the material selection process.


The Ultem resin also provides exceptional flexibility, flame retardance, and resistance to chemicals, heat and ultraviolet (UV) light, as well as greatly expanded design freedom, which enabled Intermestic to create stylish, eye-catching frames for sophisticated consumer appeal. The success of the new Zoff SMART eyeglass line showcases how SABIC is continuously improving technology, applications and solutions to help its customers succeed.

"We are delighted with the capabilities of SABIC's Ultem resin, which represents a new chapter in the evolution of eyewear," said Mr.Takeshi Ueno, president, Zoff. "This one material provides a complete solution for creating superior frames - from extremely light weight for wearability, to exceptional elasticity that allows you to bend the earpieces freely. The high quality and performance of this SABIC technology continues to help us achieve competitive advantages in our market space."

"Our Ultem resin has proven its quality and performance in a range of extremely demanding applications in key markets such as aerospace and healthcare, and its versatility gives this material great potential to add value in consumer goods," said Takeshi Maruyama, Japan country manager, Innovative Plastics. "At SABIC, we take the time to understand the diverse industries where our customers compete, whether it's aerospace or eyewear, and create customer-centric solutions to meet the standards of those segments.

The Zoff SMART frames help validate Ultem resin's continued success in replacing traditional materials to reduce weight and improve design freedom. We believe that by taking the lead in using Ultem resin, Intermestic will be in a stronger position to capture a larger share of the rapidly growing eyeglass market in Japan." The Japanese eyewear sector is expected to grow from 450 billion Japanese Yen (JPY) (USD$ 5.54 billion) in 2011 to 1 trillion JPY (USD$ 12.32 billion) in 2015.

The Eyes Have It:

Ultem resin delivers a broad range of desirable performance properties for eyeglass frames. The material offers elasticity coupled with resistance to deformation, allowing the frame to be bent easily yet returned to its original shape. Zoff SMART frames made with Ultem resin meet the Japan Standard Association JIS B 7285 standard, whose testing includes 20,000 bending repetitions (opening and closing the frame). The SABIC resin's dimensional stability ensures that the lenses are retained in the frame, while heat deflection at high temperatures protects the frames even when left on a car dashboard in hot sun.

In addition to its intrinsic light weight of up to 50 percent vs. metal, Ultem resin is suitable for precision thin-wall molding down to 1.2 mm, cutting weight even more. The weight of the Zoff SMART frame is 9.4 g without the lens, which compares very favorably to metal frames typically weighing around 20 g. The material can be custom colored to provide a wide range of aesthetic effects. Other potential eyewear applications for Ultem resin include entertainment eyewear (such as 3D glasses) and safety glasses.

"SABIC is very proactive in its approach to understanding changing customer needs and acts quickly and effectively to help our customers succeed," added Maruyama. "Our successful collaboration with Intermestic to help develop the Zoff SMART eyeglasses is a clear example of how we do this."

Queen's University & Bombardier Join Hands to Develop Reinforced Polymer Bars for Monorail Project

Building and evaluating a section of new monorail test track in Kingston is providing a unique learning opportunity for Queen's civil engineering students through collaborative research with Bombardier Transportation's System Division in Kingston.

"This project represents a significant step forward," says structural engineering professor and Canada Research Chair Amir Fam. "It provides a unique opportunity for testing Queen's technologies and designs in collaboration with a major industry leader."

Dr. Fam, Mark Green and graduate student Nik Wootton are part of a team using cutting edge structural engineering technologies on two of the support beams for the 1.5 kilometre long test track. They are using glass-fiber-reinforced polymer bars to reinforce one concrete beam. The beam is 11 meters long and weighs 30 tons.

"This initiative is symbolic of the opportunities for Queen's and Bombardier to work together toward building a long term relationship," says Steven Liss, Vice-Principal (Research). The unique project represents one of the largest ever applications of this technology in transportation infrastructure, using polymer bars up to 25 millimeters in diameter.

"We recognize the research at Queen's to be leading in the field," says Ziad Rizk, Engineering Director and Site Manager (Bombardier Systems Division). Other companies and organizations involved in the project include Anchor Concrete, McCormick Rankin, a member of MMM Group Limited, Trancels Pultrall and St. Lawrence College.

Solvay & JSP Create Fully Moldable Unique Solef® PVDF Foam for the Aircraft Industry

Solvay Specialty Polymers announced recently that a second generation of Solef® PVDF Foam is now available for the Aircraft market. New Solef® 82050 is the only fully moldable PVDF foam able to pass the key Aircraft Fire, Smoke and Toxicity Tests (FAR and AITM), which certify complete resistance to flame, total heat release, low toxicity on combustion products and reduced optical smoke density.

Thanks to the development of the base polymer matrix, new Solef® PVDF Bead Foam displays increased mechanical properties and higher temperature rating compared to the first generation of Solef® 80 000 Series e-PVDF. In addition to this, the innovative material allows a significant weight reduction, up to a 50% density decrease over the existing product, which is already sixteen times lighter than Solef® PVDF resin.

The new product is offered as foamed molded items, which will be simultaneously introduced at the upcoming Aircraft Interiors Show in Hamburg, Germany and the JEC in Paris, France that will both take place from March 27 to 29. Parts made of Solef® 80 000 e-PVDF are manufactured by JSP in partnership with Solvay Specialty Polymers.

BASF's Ultramid® Finds Application in Creation of Lightweight Auto Seat Pan in Opel Astra OPC

The new Opel Astra OPC, a sport coupe, which was introduced at the Geneva Auto Show at the beginning of March 2012, has a seat panmade from a thermoplastic laminate with continuous fiber reinforcement (organo sheet). This is the world's first auto seat pan based on this technology manufactured for a production vehicle. The plastics used are polyamide specialties from BASF's Ultramid® product range. The seat pan is 45% lighter than its predecessor.

Thermoplastic laminates with continuous fiber reinforcement, also called composites, are plastic-impregnated fabrics that are processed into laminates. They serve as the reinforcement in plastic parts that must be especially lightweight yet still exhibit exceptional performance. BASF developed two special Ultramid grades for the Opel Astra OPC seat pan: an unreinforced grade acts as the material in which the glass fiberfabric is embedded, an impact-modified, short glass fiber-reinforced Ultramid is used as over molding material to achieve the necessary ribs and edges of the part by means of classical injection molding. Thanks to the high strength of the laminate, the wall thicknesses can be reduced considerably, allowing the weight of the seat pan to be lowered distinctly.

Simulation for composite parts with continuous fiber reinforcement:

After the seat pan in the Opel Insignia OPC was made from Ultramid in 2008, albeit still without laminate reinforcement, technological cooperation between the two companies went a step further. To design and build the seat pan for the Astra OPC, BASF engineers further provided material descriptions for the virtual design of both the continuous fiber-reinforced laminate and the over molded ribbed areas of the part. The knowledge gained from this experience will be incorporated into an extension of BASF's Ultrasim® universal simulation tool, making it possible to predict the behavior of thermoplastic composite parts with continuous fiber reinforcement.

The composite seat pan is produced by means of in-mold forming: this involves placing the heated and formable, thermoplastic laminate in the injection mold, turning it into the necessary shape, fixing it cleverly and immediately over molding it. BASF was able to support its customer with its own expertise in this innovative manufacturing process.

The seat back, the transverse support and the handle on the back are also made from Ultramid. The seat has 18 adjustment options, allowing optimal adaptation to the body of the driver or passenger. Following numerous other vehicle seats at Opel, the seat for the new Astra OPC also received an award from Aktion Gesunder Rücken e.V. (AGR), the Campaign for Healthy Backs.