Today's KNOWLEDGE Share:Prosthetic made by Filament Winding Process

Today's KNOWLEDGE Share

Steptics brings automation to the prosthetic world via the filament winding process. “We first build a mandrel which has the inner geometry of the prostheses,” says Kun. “The fiber is pulled through epoxy resin and then wound onto the rotating mandrel. The resin is typically used for vacuum infusion processes in the aircraft industry, and we use T700 type carbon fiber from Toray [Tokyo, Japan], although we could also use glass fiber or basalt or other fibers. T700 has good properties that are very well known, and it is well proven in filament winding.”

“We filament wind a long, shaped tube that we then cure in an oven,” he continues. “It’s pretty much the same curing process as with filament-wound pressure vessels. We then we cut the long tube into slices, and cut the slices into halves to get semi-finished parts. These are then individually machined to tailor the geometry and performance to the individual amputee.”

AI-assisted customization

One reason prostheses have been challenging to industrialize is the need to customize each product for the individual amputee. “That’s true,” says Kun. “We need to know the amputee’s weight and whether a left or right foot prosthesis is needed. We also want to know what they want to do with the prosthesis. Are they a walker or a jogger? And that defines the spring characteristics needed in the final prosthesis.”

For the first process, says Kun, “we have the first production line, and have made a proof-of-concept prosthesis and tested it according to ISO 10328. It performed well and withstood 2 million cycles of loading without any degradation. This first product will be a CFRP blade or sole that is a sports prosthesis, amputation level 270.”

“Our first steps were to reduce costs through automated production and development of AI for individual customization,” says Kun. “Now, we want to tackle the issue of sustainable materials. Unfortunately, carbon or glass fiber do not have the best CO2 footprint. However, many natural fibers don’t have the strength and stiffness to withstand the predominant loads. Thus, by themselves, they aren’t yet suitable for running blades or even everyday prostheses. We are still researching what reinforcements could work.”

source:steptics/compositesworld.com

Today's KNOWLEDGE Share:POM vs Nylon

Today's KNOWLEDGE Share

Comparative Analysis of POM with Other Plastics:

Some of the key advantages and limitations of POM compared to other plastics are highlighted below:

POM vs Nylon:

POM has lower moisture absorption and better dimensional stability than nylon

It has higher tensile strength, hardness and modulus than nylon

Nylon offers higher toughness, ductility and impact strength compared to POM

Nylon has better chemical resistance than POM, especially to bases, oils and greases

POM provides lower coefficient of friction than nylon

POM vs Polycarbonate:

POM has much higher strength, hardness and stiffness than polycarbonate

PC offers very high impact resistance compared to brittle

POMPolycarbonate has superior temperature resistance up to 140°C vs 90°C for POM

POM has lower moisture absorption and better dimensional stability

PC has higher ductility and fracture toughness compared to POM

POM vs Polyimide:

Polyimide can withstand much higher temperatures than POM

It has excellent strength retention at high temperatures vs POM

POM offers better impact strength and machinability

Polyimide has superior wear resistance and chemical resistance

POM has lower density and moisture absorption compared to polyimide

source:beeplastic.com

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Today's KNOWLEDGE Share:Hypetex wins government backing for coloured flax fibre

Today's KNOWLEDGE Share

British technology company Hypetex has been awarded a significant grant from Innovate UK to develop the world’s first technical coloured flax fibre, which will have applications in the sustainable manufacturing of cars, boats and other products that are usually made with carbon fibre.

Called FlaxTex the material is strong, lightweight and 100 per cent biodegradable, having a net positive carbon footprint at point of manufacturing. It can be colourised whilst enhancing its performance properties, with the process adding some important manufacturing attributes compared to standard flax fibre.

As such, FlaxTex’s mechanical properties represent the closest sustainable substitute for robust and lightweight materials like glass fibre and carbon fibre in composite structures.

The performance of standard flax fibre is often hindered by its high moisture absorption, resulting in reduced structural integrity when used in composite construction. In addition, the natural brown colour of flax has been deemed unappealing for product use.

Flaxtex solves these issues by removing moisture through the colouring process and sealing the fibres, which waterproofs them and enabling their core mechanical properties. Hypetex’s patented nano-pigment technology changes the colour adding an aesthetic quality to the material.

This colouring process is set to transform industrial design possibilities of Flax natural fibres by enhancing the strength and performance while simultaneously reducing post-processing requirements and total energy usage. This also aligns with Hypetex’s commitment to supporting the green transition and helping manufacturers meet government expectations on the path to UK Net Zero targets and the European Green Deal.

Over the course of a 12-month industrial research project, Hypetex will further optimize its resin systems and processes, expanding the use of FlaxTex across various markets.

FlaxTex has a range of industry uses, including on construction, automotive, sports equipment and furniture products. Hypetex’s receipt of the Innovate UK Smart Grant marks another significant milestone in the company’s trajectory, cementing its position in the sustainable advanced materials market.

source: Hypetex/jeccomposites.com

Today's KNOWLEDGE Share: Lubrizol Launches Bio-based Thermoplastic Polyurethane

Today's KNOWLEDGE Share

Lubrizol Launches Bio-based Thermoplastic Polyurethane for HMAs

Lubrizol announces the expansion of its bio-based thermoplastic polyurethane (TPU) portfolio for adhesives with the addition of Pearlbond™ ECO 590 HMS TPU for hot-melt adhesives (HMAs).

Renewable Sourced High-performing Resin:

The high-performing resin from a renewable source can be applied by adhesive formulators or designers in furniture, edge banding, electronics, hot-melt film, textile lamination, seam tape, footwear, and transportation.

Pearlbond™ ECO 590 HMS TPU is a fast-setting solution with good adhesion properties for applications that require a toluene-free and more environmentally friendly alternative, as well as high temperature and hydrolysis resistance. In addition, it is designed for improved processability (versus previous existing solutions in HMAs) and has wide wettability.

“The high thermoplasticity of this new grade and the fact that it can be processed by extrusion, makes all the difference from previous bio-based HMA polymers available in the market,” said MariaJosep Riba, global sustainability manager for Lubrizol Engineered Polymers. “In addition, it is a bio-based resin with high bio content, up to 59%, which makes it the ideal choice going forward if you are looking for performance and carbon footprint reduction.”

The expansion of our Bio TPU solutions, commercialized as Estane® and Pearlbond™ ECO TPU, supports the acceleration of Lubrizol’s global sustainability journey. This journey is based on three strong pillars, including Bio TPU, biomass balanced, and post-industrial recycled TPUs.

source:Lubrizol/adhesives.specialchem.com

Today's KNOWLEDGE Share:Researchers Develop Green Composite Using Japanese Washi Paper.

Today's KNOWLEDGE Share

Washi: the traditional Japanese paper, known for its beauty and strength, has been used in bookbinding, art, furniture, and architecture for hundreds of years. But more recently, washi's usage is on the decline, as people opt for more western style housing designs.

In a bid to revive interest in this traditional craft, a group of Tohoku University researchers has developed an environmentally friendly material from washi that boasts improved strength and biodegradability.

Details of the research were published in the journal Composites Part A: Applied Science and Manufacturing on May, 9, 2024.

Layered and Hot Pressed Sheets of Washi with Polybutylene Succinate:

Bio-based and biodegradable materials are increasingly sought after as the world seeks to move away from fossil based-plastic materials and build a more sustainable society. Green composites combine plastics with natural fibers, producing materials with higher strength, improved biodegradability, and a lower environmental footprint.

"We created a green composite from washi, which itself stems from plant fibers, improving its properties further whilst still maintaining its classical beauty," points out Hiroki Kurita, co-author of the paper and an associate professor at Tohoku University's Graduate School of Environmental Studies.

To produce the material, Kurita and his colleagues layered and hot pressed sheets of Washi with polybutylene succinate (PBS). To source the Washi, they worked with an artisan from a Miyagi-based washi-workshop. The material's ultimate tensile strength, i.e., the amount of stress the paper could withstand, stood at 59.85 MPa, representing an improvement of over 60%.

82% Biodegradation within 35 Days:

Washi has a lot of space between its entangled fibers. When combined with PBS, the plastic filled these spaces, thereby locking the fibers in place and preventing the fibers from moving.

PBS is also notable for its biodegradability, and the resultant composite material degraded much faster than pure plastic. After 35 days, it had biodegraded by 82%.The biodegradation was calculated by measuring the amount of CO2 released from the material when it was buried in compost. At the same time, researchers measured weight loss and loss of strength during degradation.

Not only was the team successful in producing a new material, but Kurita believes they were able to raise the standard of biodegradation testing and provide blueprints for future research into biodegradable composite materials. "We utilized both standardized and non-standardized methods for measuring biodegradability. The differing methods used will help researchers compare biodegradability between different materials moving forward."

Source: Tohoku University/omnexus.specialchem.com

Covestro and Arcesso's Arfinio® Technology is “Winner” in "German Innovation Award 2024"

The Innovation Award honors products, projects, and pioneering achievements that sustainably improve life

Arfinio® earns “Winner”-prize in the category "Excellence in B2B: Materials and Surfaces"

This technological breakthrough enables the rapid production of lightweight, repairable, and recyclable solid surface materials.

Covestro, one of the world's leading manufacturers of polymer materials and components, has been awarded “Winner” of the "German Innovation Award 2024" for outstanding innovation achievements in the category "Excellence in B2B: Materials and Surfaces" for its Arfinio® technology.

The award is presented by the "German Design Council." Candidates submit projects that have been launched on the market no longer than five years ago, but they can also be nominated by the council. The evaluation is carried out by an independent, interdisciplinary expert jury. The award ceremony took place on May 14 in front of around 300 invited guests at the Futurium in Berlin.

"We are very pleased that the German Design Council has honored us with this award," said Joan Miquel García Martínez, Senior Project Manager Arfinio® at Covestro. "Arfinio® is a real breakthrough for design, surfaces, and sustainability. This award shows the relevance of combining design, manufacturing technology, and materials for the development of new products and confirms that we are on the right track."

The Arfinio® technology, which Covestro has developed together with its partner Arcesso, a manufacturer of custom polyurethane parts, combines liquid high-performance polymers and unique minerals with the RIM process (reaction injection molding). This combination enables seamless shapes and surfaces – and was long considered impossible. The resulting products are durable, repairable, and lightweight, can be produced quickly, and allow for free designs. The material also contributes to sustainability as it can be produced with partially bio-based raw materials, can be mechanically recycled at the end of its life cycle, and reused for the production of new products.

source: Covestro