Technology Transfer
Powder Pre-Heating System
reSource, Inc. of Ohio have developed some interesting technologies for
handling of powders as they are dispensed into the mold. One system includes
pre-warming of the powder to reduce cycle times.
You can see more details at www.resourceinc.us.
Supavent
Rory Jones of Plastecnica in New Zealand has developed an interesting
flexible vent concept that has received good reports from molders who have
used it in service. Using a silicone rubber sleeve with a 'reed-valve-like'
slot in one side to allow pressure to dissipate during molding, the Supavent
can be reused from part to part.
It can also be used for pressurizing molds
See http://www.laplastecnica.co.nz/
for details.
Cyclic Resins
Cyclics Corporation has been working on GE developed materials that begin as
a powder or pellet, turn into a liquid during molding and reform to create
durable products based on PBT chemistry. They have conducted preliminary molding trials that show good
initial results in rotational molding and are now moving to commercial scale
applications. The materials offer high temperature
resistance and excellent stiffness along with excellent surface characteristics
and permeation levels capable of handling fuel tank requirements. Their plan is to bring materials to market
in a staged process aimed at demonstrating the material's capabilities and then
ramping production to produce it at a competitive cost point. Contact yi-feng.wang@cyclics.com
for more information or see www.cyclics.com.
Mold and Flange Coating System
Maus Coatings continue to develop their coating options for mo(u)lds in the
UK. The photographs above show a new ceramic coating on the flanges aimed at
improving wear during demolding and cleaning. The mold on the right has their
Black Maus Coating (BMC) on the body of the mold as well as new low profile
alignment pins.
For more information contact John Barker at Maus Mold Services - john@mausmouldservices.co.uk
Flexible Insert Holders
Yogesh Vakharia of Iowa City, Iowa is working on a new concept for flexible
insert holders. These rubber components allow inserts to move during the
cooling stage of the process, thus helping to reduce stress on the parts:
Initial trials have looked promising. Contact Yogesh at ymvakharia@mchsi.com
for more details.
He is also working on a microwave heating system for
polyethylene parts based on the use of his composite molds. These are currently
being used as a rapid prototyping method for short run parts but with
development may be suitable for larger volumes of parts:
New Graphics Systems
Bob Kistler of 220-221, Inc. has launched a range of new graphics including:
- Solution Applied Decals
- Water Based Decals
- 'Peel-and-Stick' Graphics
For more information take a look at www.220-221.com
New Machine Concept
Edy Vega of Advanced Rotomolding Technologies has developed some new
concepts for machines including infrared ovens without the need for doors and
track systems that allow for by-passing of molds during transfer between
operating stations.
See www.rotomolding.ca for details.
Cooperative Projects
Powder Production Technology
A major US university has some interesting technology for producing powders
directly from an extruder without the need for grinding. We have been looking
at projects that would test it's potential for rotomolding. There is a need
for funding to pursue the idea - if anyone is interested in finding out more,
drop me a line at email@paulnugent.com
and I'll put you in touch with the researchers.
RotoSchedule Software
I
have had a plan to take the RotoCycle software to the next level and develop
it into a scheduling program for rotomolding machines of different
configurations based on cycle settings, quantities, changeover times and
delivery dates. My timetable is too hectic to devote time to it. If anyone is
interested in a blueprint for the program complete with the RotoCycle engine
and software, let me know (email@paulnugent.com). I'd prefer to see it come to fruition than sit on
my desk forever.
Color Technology for Rotational
Molding
I'm working with an expert on color for rotational
molding to develop a report on guidelines for producing colors for rotomolding
- which pigments work and which don't, etc. Targeted at material suppliers
interested in improving their technology or shortening their learning curve,
the report is an invaluable tool. If interested, drop me a line at email@paulnugent.com
for more details.
Tech Topics - Roto and Non-Roto
These are some items from the world of plastics and technology that might be
worth keeping an eye on.....
Low Cost Jet Aircraft
A number of developments are paving the way for low(er)-cost jets for private
use.
The Eclipse is under test as an $850,000 platform for private use or for
fractional ownership. It is much cheaper and faster to produce due to the use of
'friction stir welding' for construction instead of rivets. I saw this last week
at BYU in Utah during a visit to meet Dr. Brent Strong - interesting
process.
A second aircraft is being produced by Moeller Corporation in California that
aims to be almost a replacement for luxury cars. With a target price tag in
volume production of $80,000 it has vertical take-off and landing, seats four,
reaches 400mph and produces mileage similar to a large car. Some see it as the
ultimate replacement for a luxury car with greater flexibility and speed.
PVC and PUR Powders for Slush Molding
Adams Renosol (www.adams-renosol.com),
Teknor Apex (www.teknorapex.com) have
produced a range of PVC slush molding powders. Some of these grades can be used
directly in rotomolding. Bayer Corp has developed polyurethane slush molding
powders that are currently being used for automotive applications but may have
broader appeal.
LEDs Replacing Standard Bulbs
High performance LED systems are being used to replace standard lights as
long-life and energy efficient substitutes. They are being used for traffic
lights in Denver, Colorado replacing 13,000 150W halogen bulbs (that need to be
replaced every 6 months) with 12W LED units (that need replaced once every ten
years). They estimate savings in the order of $5 million. The method is also
being considered for car brake lights with faster activation times (0.25s
faster) that could translate into a safety improvement.
Carbon-Carbon Composites
Reduced cost carbon-carbon composites for use in high performance
applications such as brake systems may be available soon at much reduced costs
over their current counterparts. Parts produced using automated spray technology
have been made a pre-pregs that are then formed using RTM. Work is on-going at
Purdue University in Indiana - maybe something in the future for mold
constructions that could withstand high oven temperatures.
Rapid Prototyping
Stratsys Inc. of Minnesota has introduced a rapid prototyping unit for under
$30,000 called a 3-D Printer. Using ABS material, the system can produce solid
models for fit and function testing by 'printing' them. The models can be up to
8" x 8" x 12" (200 x 200 x 300mm). The system can be linked into
a network. Remember when color printers or copiers cost this for 2-D printing! I
saw this at the recent Plastech show in New York City - fascinating potential. Coming soon to every engineering department near you.....
See www.stratasys.com for more
details.
Plastic E-Paper
New printable electronic plastic 'paper' with circuits and ink built in to
produce readable text have taken a step closer to being a commercial reality. E
Ink Corporation and Lucent Technology have combined to produce thin flexible
displays and Gyricon LLC. has produced 'SmartPaper' for e-newspaper
applications. The potential for roll up screens and wirelessly transmitted
newspapers now exists.
See www.eink.com and www.gyricon.com
for more details.
Nanocomposite Materials
Foster Corp. of Connecticut have introduced nanocomposite compounds for
injection molding with increased rigidity and stiffness over natural polymers.
The olefin elastomers and nylons use nano-scale particles at very low addition
levels to improve properties. Keep watching for this to migrate into
rotomolding.....
See www.fostercomp.com for more
details.
