Today's KNOWLEDGE Share : Pros of 3D Printing

Today's KNOWLEDGE Share

What are the Pros of 3D Printing?

1. Flexible Design

3D printing allows for the design and print of more complex designs than traditional manufacturing processes. More traditional processes have design restrictions which no longer apply with the use of 3D printing.

2. Rapid Prototyping

3D printing can manufacture parts within hours, which speeds up the prototyping process.This allows for each stage to complete faster.When compared to machining prototypes,3D printing is inexpensive and quicker at creating parts as the part can be finished in hours,allowing for each design modification to be completed at a much more efficient rate.

3. Print on Demand

Print on demand is another advantage as it doesn’t need a lot of space to stock inventory, unlike traditional manufacturing processes.This saves space and costs as there is no need to print in bulk unless required.

3D design files are all stored in a virtual library as they are printed using a 3D model as either a CAD/STL file.

4. Strong and Lightweight Parts

The main 3D printing material used is plastic, although some metals can also be used for 3D printing.Plastics offer advantages as they are lighter than their metal equivalents.This is particularly important in industries such as automotive and aerospace.

5. Fast Design and Production

Depending on a part’s design and complexity,3D printing can print objects within hours, which is much faster than moulded or machined parts.It is not only the manufacture of the part that can offer time savings through 3D printing but also the design process can be very quick by creating STL or CAD files ready to be printed.

6. Minimising Waste

The production of parts only requires the materials needed for the part itself, with little or no wastage as compared to alternative methods which are cut from large chunks of non-recyclable materials.Not only does the process save on resources.

7. Cost Effective

As a single step manufacturing process,3D printing saves time and therefore costs associated with using different machines for manufacture. 3D printers can also be set up and left to get on with the job,meaning that there is no need for operators to be present the entire time.

8. Ease of Access

3D printers are becoming more and more accessible with more local service providers offering outsourcing services for manufacturing work.This saves time and doesn’t require expensive transport costs compared to more traditional manufacturing processes produced abroad in countries such as China.

9. Environmentally Friendly

As this technology reduces the amount of material wastage used this process is inherently environmentally friendly.The environmental benefits are extended when you consider factors such as improved fuel efficiency from using 3D printed parts.

10. Advanced Healthcare

3D printing is being used in the medical sector to help save lives by printing organs for the human body such as livers,kidneys and hearts.

source:twi-global.com/EOS M290

Today's KNOWLEDGE Share : Enhanced flexural properties of aramid fiber/epoxy composites by graphene oxide

Today's KNOWLEDGE Share

Enhanced flexural properties of aramid fiber/epoxy composites by graphene oxide:

The reinforcing effect of graphene oxide (GO) in enhancing the flexural strength and flex modulus of aramid fiber (AF)/epoxy composites were investigated with GO-AFs at a weight fraction of 0.1-0.7%. The flexural strength and flexural modulus of the composite reached 87.16 MPa and 1054.7 MPa,respectively, which were about 21.19% and 40.86% higher than those of the pure epoxy resin. In addition, the flexural properties and interfacial shear strength (IFSS) of composite reinforced by GO-AFs were much higher than the composites reinforced by AFs due to GO improved the interfacial bonding between the fiber& matrix.

Graphene possesses many remarkable properties, including high Young’s modulus (1100 GPa),superior fracture strength (125 GPa),large surface area (2630 m2/g).Due to these excellent properties, graphene and its derivatives, in particular grapheneoxide (GO) ,have found interesting applications in nanocomposites.GO has been demonstrated as an ideal reinforcement of the fiber-matrix.Research work on polymer nanocomposites.It showed that incorporation of nanoscale fillers graphene,with low content into polymers can obtain good enhancements in mechanical and physical properties. directly added GO into epoxy resin,the results showed that the mechanical properties of GO/epoxy composite were improved effectively. Among them,the maximum flexural modulus and flexural strength reached 2.94 GPa and 130.46 MPa,which are about 10.11% and 14.67% higher than those of the pure epoxy resin,found that GO utilization is an effective approach for improving the flex properties of carbon fiber reinforced polymer composites.The enhancement can be attributed to the existence of GO,providing fiber with increased roughness and polarity, resulting in strong mechanical interlocking between the fiber and matrix.

In this work,GO modified the AF surface firstly, then enhanced the epoxy matrix with GO-AFs. Based on the mechanical interlock mechanism mentioned above to systematically examine the role of GO in improving the flexural properties and IFSS of the AF/epoxy composite.

Although pure aramid fibers can be used to reinforce epoxy resin, significantly improved flex strength, flex modulus and IFSS can be obtained by introducing GO to modify aramid fibers.

1.The flexural strength and flexural modulus of the GO-AFs/epoxy composite containing 0.1 wt% GO-AFs are 87.16 MPa and 1054.7 MPa,which are about 21.19% and 40.86% higher than those of the pure epoxy resin.

2.The flexural strength and flexural modulus of the AFs/epoxy composite containing 0.7 wt% AFs are 81.59 MPa and 816.51 MPa, respectively, which are about 13.54% and 9.05% higher than pure epoxy resin.

3.The IFSS value of GO-AFs/epoxy composite reaches 8.29 MPa, which is higher than that of untreated AF by 36.8%.

4. GO is an excellent potential modifier to modify AFs.

source: Yinqiu Wu ,Bolin Tang &team

Today's KNOWLEDGE Share : Acrylic (PMMA) vs. Polycarbonate (PC) :

Today's KNOWLEDGE Share 

Acrylic (PMMA) vs. Polycarbonate (PC) :

Acrylic offers greater tensile strength than polycarbonate, typically around 80 MPa, compared to polycarbonate at 60-70 MPa. That means it can stretch a bit more before breaking.

Similarly, acrylic wins the battle for flexural strength at 115 MPa vs. 90 MPa for polycarbonate, set a heavy object on unsupported sheets of each and PC will give way first (but not by much).

Both polymers are quite impact resistant, but where acrylic comes in around 17 times that of glass, polycarbonate boasts a whopping 250x increase.

However, polycarbonate is more prone to scratching than acrylic, but as many eyeglass wearers know, coatings are available to avoid this common problem.

There's little difference in transparency between acrylic and polycarbonate (92% light transmission for acrylic vs. 88% for PC). Glass straddles the two at 90% transparency.

Leave these two polymers outside for a few years, however, and you’ll have no problem determining which is polycarbonate, since it will have taken on a yellowish hue; acrylic is much more resistant to sun and UV-light. That said, stabilizers are available for its UV-challenged issues.

Put those same plastic parts in a hot oven and just the opposite will occur. Where acrylic has a maximum service temperature of 100 °C (212 °F), polycarbonate is good to 150 °C (300 °F).

Fire is a different matter. Polycarbonate has low flammability and tends to self-extinguish while acrylic burns slowly and releases carbon monoxide, so it is not recommended where flames may be present.

Chemical resistance is another important attribute. Polycarbonate is generally the winner here since it better withstands acids and alkalis and can be cleaned with ammonia-based products. Not so with acrylic. Both polymers, however, fare poorly around solvents (which are often used to join machined acrylic and polycarbonate parts)

source:www.protolabs.com

Today's KNOWLEDGE Share : High shear layers in Injection molding process

Today's KNOWLEDGE Share

A local temperature increase in excess of 100°C is absolutely a realistic number for the thin high shear layers in Injection Molding.

Because this high T will last often less than a second (filltimes are short, the cold steel mold is extremely close), such high melt T will not necessarily result in a very visible quality loss, like discoloration.

This high shear-heating also happens in your barrel if you push RPM and backpressure up. However, testing for melt T plunging a thermocouple on the purged melt will hardly measure a significant change in average temperature, because the very hot layer is extremely thin (small overall volume fraction).

Despite the small volume involved in possible degradation, significant issues may arise, like VOC (volatile organic compounds) degassing, which will mess with your process and parts.

The message is : be aware that due to the low thermal conducivity of plastics, heating will be very localized (adiabatic) and will be difficult to evidence with typical observation/testing, while already creating issues.

Vito leo

Today's KNOWLEDGE Share : New Project to Develop 100% Recyclable Flexible Skinpack Packaging Using rPET

Today's KNOWLEDGE Share

The BOTTLE4FLEX project: developing 100% recyclable food packaging:

The European Union’s Circular Economy Strategy stipulates that all plastic packaging in the European Union must be 100% recyclable by 2030. This is a particular challenge for food-contact packaging.

Recycling flexible PET packaging is tricky because it is made up of layers but in Spain, recycled polyethylene terephthalate (rPET) is the only type authorised for post-consumer recycled content for food packaging.

AIMPLAS, the Plastics Technology Centre, Covinil and Eroski took up this challenge by launching the BOTTLE4FLEX project which aims to develop 100% recyclable flexible skinpack packaging using rPET. 'Skinpack' is the type of clear packaging which clings closely to the product, so that consumers can actually see what they are thinking of buying while producers and distributers get the benefit of cost-effectiveness and flexibility. Unfortunately, these advantages are offset by a major drawback: since it is made up of layers, it is very difficult to recycle.

Through innovations in chemical recycling and polymerization technologies, the project consortium aims to overcome this drawback. The key will be to develop a single-material film based on rPET. The BOTTLE4FLEX project is focusing on promoting solvolysis processes for recycling and modifying the properties of PET through partial depolymerization. It will also harness innovative technologies such as reactive extrusion, as well as monomers and additives to increase the flexibility of recycled PET.

The research project is funded by Spain's Ministry of Science, Innovation and Universities and the EU under the Recovery, Transformation and Resilience Plan.

source:www.circulareconomy.europe.eu

 

ENVALIOR AND FORD WIN SPE AUTOMOTIVE AWARD FOR MOST INNOVATIVE USE OF PLASTICS

Envalior and Ford Motor Company received the "Most Innovative Use of Plastics" award in the "Materials" category at the 53rd SPE Automotive Innovation Awards.

Ford redesigned an Exhaust Gas Recirculation (EGR) Cold Tube and diffuser, incorporating Xytron™ PPS thermoplastic material, to enhance fuel efficiency, reduce emissions, and improve durability.

The award celebrates the partnership between Envalior, Ford, Sogefi, and Viking Plastics, with each contributing to the development, molding, and supply chain of the innovative EGR assembly.

Livonia, MI, DECEMBER 5, 2024 – Envalior, in collaboration with Ford Motor Company, has been honored with the Most Innovative Use of Plastics award in the "Materials" category at the 53rd Annual SPE Automotive Innovation Awards Competition & Gala. This highly regarded event, held at Laurel Manor in Livonia, Michigan, celebrates groundbreaking achievements in automotive plastics.

The award recognizes the development of a re-engineered Exhaust Gas Recirculation (EGR) Cold Tube and diffuser, a critical component designed by Ford. By replacing Stainless Steel, with Envalior's advanced Xytron™ PPS thermoplastic material, the application realized a 28% part weight reduction and achieved superior chemical resistance to withstand extreme environments for long-lasting performance.

With Xytron™, the EGR Cold Tube and diffuser can now withstand a highly acidic environment with pH levels of 2.2 and temperatures up to 200°C. Furthermore, the new design eliminates the need for multiple components, including a gasket, O-ring and fasteners, resulting in a greatly simplified part that directly integrates into the air intake assembly. This sets a new standard for EGR system efficiency, greatly simplified manufacturing and assembly processes, and significant cost savings.

“This award validates Envalior's commitment to material innovation and the collaborative expertise of our team,” said Russ Bloomfield, Application Development Engineer at Envalior. “It highlights the power of partnerships between Envalior, Ford Motor Company, Sogefi, and Viking Plastics.”

Envalior also extends its congratulations to its partners, Sogefi and Viking Plastics, for their vital roles in this achievement. Sogefi serves as the Tier 1 supplier for the EGR assembly, while Viking Plastics molds the Xytron EGR Tube supplied to Sogefi.

“This recognition underscores Envalior's dedication to pushing the boundaries of innovation and fostering successful collaborations,” added Grace Showalter, Regional Commercial Director – Americas at Envalior. “We are incredibly proud of our team and partners for achieving this milestone.”

source : Envalior

Today's KNOWLEDGE Share:Jiangsu Suoteng Offers Dicumene as a Non-toxic, Synergistic Flame Retardant

Today's KNOWLEDGE Share

Jiangsu Suoteng Offers Dicumene as a Non-toxic, Synergistic Flame Retardant

Jiangsu Suoteng offers Dicumene (DMDBP), a non-hazardous, carbon-based initiator with excellent performance. It is mainly used for polymer cross-linking or grafting reactions at higher temperatures. 

Solution for Halogen-antimony Systems and Halogen-free Alternatives:

In recent years, the flame retardant industry has seen growing demand for dicumene. It is known for its high stability, safe use, and good environmental performance.

Dicumene is primarily used as an initiator, grafting agent, and flame retardant synergist in engineering plastics, flame retardant polyolefins, and other applications.

As environmental regulations become stricter, traditional flame retardants are facing restrictions due to low efficiency, large dosages, and environmental concerns. This has led to a shift toward greener, more efficient, and low-toxicity flame retardants.

Dicumene, as one of the earliest free radical initiators used as a flame retardant synergist, fits well with this trend. Its non-toxic, smoke-suppressing, and cost-effective properties are attracting increasing market interest.

It is widely used in flame retardant polystyrene, polypropylene, brominated and phosphorus flame retardants, bromine-phosphorus composite flame retardants, and engineering plastics. In the halogen-antimony flame retardant system, dicumene reduces the amount of halogen flame retardants and antimony trioxide, which lowers costs, enhances polymer performance, suppresses smoke, reduces toxicity, and improves flame retardancy and mechanical properties of plastics.

Dicumene also serves as a synergist in flame retardancy for polyolefin plastics, replacing antimony trioxide in bromine systems to boost flame retardancy and improve plastic properties. It is used as a grafting catalyst for polystyrene and polypropylene and as a polymer cross-linking initiator.

2,3-Dimethyl-2,3-Diphenylbutane (DMDPB) is versatile in plastic applications and works as a synergistic flame retardant in both bromine-antimony and halogen-free systems. Its high heat resistance makes it suitable for engineering plastics requiring higher processing temperatures. Dicumene is a popular, low-cost, non-toxic, and smoke-suppressing flame retardant.

Product Applications

Flame Retardant Enhancement: Used in polymers like PP, EPS, HIPS, XPS, ABS, etc. In halogen-antimony systems, it reduces halogen flame retardant and antimony trioxide usage, suppresses smoke, cuts toxicity, lowers costs, and improves polymer properties. It also enhances flame retardancy in halogen-free systems.

Minimal Impact on Tensile Strength: Adding 0.1%-0.2% to the system has minimal impact on tensile strength while enhancing flame retardant properties. This reduces the overall flame retardant usage by 15%-30%, offering a cost-effective solution.

Source: Jiangsu Suoteng/www.polymer-additives.specialchem.com