Automated post processing of 3D printed metal and plastic components

Post processing solutions that meet the requirements for volume production

Companies across many industries have come to the conclusion that additive manufacturing will make them less dependent on traditional supply chains. However, an essential pre-condition for this approach is that the post processing operations must comply with the requirements for volume production. AM Solutions – 3D post processing technology is eeting these challenges with new solutions for the automated post processing and efinement of 3D printed metal and plastic components. In parallel, the division AM Solutions – Manufacturing service partner supports the development and production of AM components with comprehensive services.

Additive manufacturing offers companies the potential to become less dependent on traditional supply chains and, at the same time, make their production operations more flexible and faster. However, the post-processing of 3D printed components is frequently a stumbling block against achieving these goals. On the one hand many post processing steps still require costly manual work, and on the other hand the post processing operations are limited to handling single components or extremely small production ots.
This does not allow compliance with the established standards for volume production, namely consistent and repeatable product quality, process control, cost-efficiency and sustainability. AM Solutions – 3D post processing technology, a division of the Rösler group that specializes in the automated post processing of 3D printed components produced in large volumes, now offers new equipment that allows a way out of this dilemma.

Safe and stable post processing of plastic components in 24/7

operation With the new S2 system AM Solutions – 3D post processing echnology offers the so far only continuous flow shot blast machine for post processing of 3D printed plastic components produced with powder-bed printing systems. The ATEX compliant plug-and-play machine was designed for round-the-clock three-shift operation and is equipped with interfaces llowing its integration into interlinked manufacturing lines. The work pieces are loaded into the machine as complete print jobs. The loading takes place either by hand or automatically. Once in the machine, the plastic components are gently passing through a special feed loop belt in single piece flow. The tumbling action of the components ensures that they are equally blasted from all sides so that any residual powder is consistently and completely removed from the component surface. Depending on the utilized blast media, the work piece surface can also be homogenized and/or peened. The machine can be equipped with up to four blast nozzles. The number of blast nozzles, the blast pressure and the transport speed can be individually adapted to the respective work pieces. These process parameters can then be stored in the control panel as individual processing recipes. On average, a print job requires cycle times of 15 to 20 minutes. Depending on the condition of the raw work pieces, the Ra surface roughness readings can be reduced by up to 13 µm.

To ensure that the blast media remains at a consistently high quality, the compact shot blast machine is equipped with an effective blast media cleaning and recycling system. This, in combination with the integrated electronic reporting tool, guarantees repeatability of the blasting results, complete process control and a high cost-efficiency of the post processing operation. A patent application covering the machine and the process is pending.

Eco-friendly chemical surface smoothing and application of a color dye – at low costs

The C2, presented as a concept solution, illustrates that AM Solutions – 3D post processing technology has its origins in the development and production of machinery and consumables for volume production. This patent-pending innovation enables fully automatic chemical surface smoothing of 3D printed components made of common polymers and elastomers (including TPU) in series. Thus, the costly single piece handling of the work pieces is completely eliminated for this post processing operation. The bounding box allows the processing of work piece dimensions ranging from 10 x 10 x 10 to 300 x 300 x 300 mm and a wall thickness of at least two millimeters. In addition, the process includes a newly developed, non-hazardous processing media that was specially developed by AM Solutions – 3D post processing technology. This ensures that the surface smoothing operation is not only eco-friendly but that the subsequent waste disposal is not subject to any environmental restrictions and is cost-effective.

The innovative C2 chemical surface smoothing system, for which a patent application is pending, can be retrofitted for applying a color dye on plastic components. The C2 will be commercial available in the first quarter of 2022.

Overcoming adversity with Sidel: high-speed PET water line installed for Iraqi National for Food

Sidel has successfully installed its first high-speed PET packaging line for water in Baghdad as part of the greenfield project of Iraqi National Company for industrial food (Iraqi National for Food). With a speed of 48,000 bottles per hour (bph), the outstanding line efficiency of 96% corresponds closely with the high sustainability standards and right-weighting expertise in packaging design provided by Sidel. The new Dinar bottle produced for Iraqi National for Food comes in three sizes and is manufactured with the lightest preform on the market, based on Sidel’s StarLite™ design.

Iraqi National for Food belongs to the Iraqi National Group of Companies, which is one of the country’s leading companies in manufacturing, trade and transportation. Founded in 2019, Iraqi National for Food is recognised for its high-quality nutritional products. The company has many self-owned brands – ncluding “Hindrin” carbonated soft drinks, “Dinar” healthy water and “Ra’eege” pasteurised juice.

Iraqi National for Food initiated the new greenfield project to meet a growing demand for bottled water. After witnessing and experiencing first-hand Sidel’s solutions at two customer sites in Turkey, Iraqi National for Food chose Sidel as their partner to install the complete PET water packaging line.

Two firsts in Baghdad: Sidel’s high-speed PET water line and the lightest preform

Following an analysis of the market and the customer’s requirements, Sidel proposed a complete PET packaging line for water featuring a Sidel Combi as a turnkey solution, covering the entire process from packaging design to equipment supply. It thus became Sidel’s first and fastest high-speed line in Baghdad. The 48,000 bph line has a line efficiency of 96%. The complete line solution not only ensures high efficiency and quality, but also high sustainability standards which are of utmost importance to Iraqi National for Food. For example, at the beginning of the line, Sidel’s EvoBLOW blower fitted with the AirEco2 double air-recovery option.

reduces the required volume of compressed air by 35%. Furthermore, the Sidel Matrix Filler SF100 reduced filler enclosure provides a smaller filling environment with fewer chemicals and less water used during external cleaning. The air filtration system used in the filling process keeps the environment safe while ensuring high product quality.

In terms of packaging design, the bottle is designed and manufactured in three sizes (330 ml, 500 ml, 1500 ml) with one of the lightest preforms on the market (StarLITE base), further enhancing the roduct’s sustainability.

Close cooperation overcomes lockdown obstacles

To complete the installation on time, Sidel and Iraqi National for Food cooperated closely during this period, overcoming numerous logistic challenges posed by the lockdown further to the COVID-19 pandemic. “The situation made the process of dispatching our installation team as well as arranging spare parts more difficult. Although the line arrived at the site before the lockdown, the project execution was still hindered by the restrictions, especially because no one was allowed to travel to Iraq at the time. By tackling the dilemma together with the customer, Iraqi National for Food managed to arrange an exceptional flight for our team a few months after the lockdown,” explained Vedat Guler, Sales Director – Middle East at Sidel.

The installation and start-up only took six weeks and the first sellable bottle was produced and launched on the market by the middle of June 2020. “We are very happy that we chose Sidel for our complete water line project, in particular during the pandemic. The Sidel team provided great onsultancy and conducted efficient execution so that our product could be launched in a short period of time,” said Mohammed Jasim, Executive Manager at Iraqi National for Food.

LANXESS’ High Performance Materials business unit to become legally independent

New structure for best possible growth opportunities in the high-performance plastics business

Mumbai, November 16, 2021 – Specialty chemicals company LANXESS will transfer its High Performance Materials (HPM) business unit to an independent legal corporate structure. HPM is one of the leading suppliers of high-performance plastics. The materials are used primarily in the automotive, electrical and electronics industries. Electromobility in particular is a promising field of application for the LANXESS plastics, which are used predominantly for car bodies, battery housings and charging infrastructure.

“The global market for new forms of mobility is developing very dynamically and is strategically rearranging itself – creating many innovative alliances and partnerships. In order to get the most out of the growth opportunities in this market and to be able to act flexibly, we will create a separate legal structure for the business unit,” said Hubert Fink, member of the Board of Management of LANXESS AG. LANXESS will begin implementation in the first half of 2022.

The portfolio of the HPM business unit includes the engineering plastics polyamide and polybutylene terephthalate, as well as thermoplastic fiber composites. The business unit is characterized by the high backward integration of its production processes.

The business unit employs around 1,900 people at 14 sites worldwide. Sales are in the low single-digit billion euro range.

LANXESS again with leading positions in Dow Jones Sustainability Indices

• First rank in Dow Jones Sustainability Index (DJSI) Europe; second rank in DJSI World
• Outstanding results in the areas of product stewardship, management of water related risks, and human rights

Mumbai, November 17, 2021 – LANXESS once again convinces in terms of sustainability: The specialty chemicals company placed first in the Dow Jones Sustainability Index (DJSI) Europe in the “Chemicals” category, scoring 87 out of 100 points. In the DJSI World, LANXESS came in second place. The Group achieved particularly good results in the areas of product stewardship, management of water-related risks, and human rights.

“We want to play an active role in the transformation of the economy and global value chains towards a more sustainable world,” said Hubert Fink, member of the Board of management of LANXESS AG. “We consider the renewed very good ranking in the Dow Jones Sustainability Index as proof of the success of our efforts.”

The Dow Jones Sustainability Indices evaluate economically relevant ESG factors once a year. ESG stands for the sustainability dimensions Environment, Social and Governance. The DJSI World lists the best 10 percent of the global companies evaluated per sector, while the DJSI Europe lists the best 20 percent of companies headquartered in Europe.

Sustainable use of water and chemicals

Two years ago, LANXESS published its plan on how to become climate-neutral by 2040. In 2020, the specialty chemicals company also committed to reducing water withdrawals at sites in areas with particularly high water stress by 15 percent by 2023.

In addition, LANXESS has pledged to further improve the sustainability performance of its product portfolio, eliminate critical substances in products, and to develop safe alternatives. The company has also committed not to market any new chemical end products that contain critical substances in a concentration of more than 0.1 percent.

Board remuneration linked to sustainability targets

In addition to voluntary commitments, the specialty chemicals company is focusing on incentive systems for greater sustainability: a new compensation system for the Board of Management has been in place since the beginning of the year. Roughly one-third of the variable compensation is linked to the company’s sustainability performance. Specifically, the company's performance in climate protection and occupational safety will be actored into the system for 2021.

TPEs gain ground in coffee-making equipment

KRAIBURG TPE, a global TPE manufacturer of a diverse range of thermoplastic elastomer products and custom solutions for a variety of industries, brews a perfect blend of design and functionality for coffee makers with its THERMOLAST® K FC/AD/PA and FC/CS series of compounds.

For many societies, drinking coffee has become a way of life. Coffee completes a morning ritual and caps an after-dinner habit as part of a daily routine.

Having become a generational obsession that shows no signs of waning, the coffee drinking culture is, thus, here to stay. As tastes have changed, so have coffee brewing methods, which have progressed from the simple boiling of ground coffee in pots and drip or filtered brewing to more mechanical methods such as espresso machines, siphons, French resses, and more
current methods.

Today’s coffee making equipment comes in a range of sizes, colors, and mechanisms to suit both personal and commercial needs, with preferences influenced by design and unctionality.

To meet these preferences, advanced materials such as thermoplastic elastomers are commonly used in coffee-making equipment.

Full-bodied material advantages
KRAIBURG TPE, a global TPE manufacturer of a wide range of thermoplastic elastomer products and custom solutions for multiple industries, offers the THERMOLAST® K FC/AD/PA nd FC/CS series of compounds for applications in coffee making equipment.

To ensure safety of use, the TPE compounds adhere to international food laws such as the EU No. 10/2011 and US FDA CFR Title 21. Plus, all the TPE series compounds can be colored in a variety of ways to achieve different color effects to allow for versatility in coffee making equipment.

KRAIBURG TPE’s compounds also contribute to the design and functionality of coffee brewing equipment in a number of ways, including simplifying product design via component eduction and combining their part functionalities.

Furthermore, the TPE compound’s soft-touch feature gives a distinctive soft and dry surface with great haptic and anti-slip properties, making it appropriate for use on handles, push buttons, and coffee cup banderoles, to improve hand grips.

KRAIBURG TPE’s compounds can also be used to produce the base of a coffee machine, to help reduce noise and squeaking during the brewing process.

Better characteristics with THERMOLAST® K series
For coffee makers that require PA adhesion, the THERMOLAST® K FC/AD/PA series is the answer. The compounds have excellent adhesion to PA6, PA6.6 (up to 50% glass fiber ontent), and PA12.

Other features of the THERMOLAST® K FC/AD/PA series are the hardness range from 40 to 80 Shore A and excellent abrasion resistance. The series is appropriate for use on handles and grips, as well as flexible connectors for coffee makers.

Meanwhile, KRAIBURG TPE’s THERMOLAST® K FC/CS series provides outstanding PP adhesion and short-term steam resistance.

The FC/CS series is designed to meet the material requirements of higher compression sets. It can be used as seals on coffee cups and tumblers, flexible connections, closures, and lids.

“Theoretically, we could do without fossil fuels altogether if the cycle was fully closed”

Interview with Peter von Hoffmann, General Manager Business Unit Engineering Plastics Applications at Coperion

Mr. von Hoffmann, the circular economy for plastics is a declared goal of the EU, so, from an economic point of view, is it more of an opportunity or a challenge for a machine manufacturer such as Coperion?
It is clearly an opportunity for us. With circular economy, the importance of recycling is increasing. As a manufacturer of extruders, we see many new business opportunities in that regard. We have invested enormously in the recycling business in recent years, which has already paid off, and we are witnessing a steady increase in incoming orders in this area. For five years now, we have had our own team and our own product management focusing on this topic. We always learn something new, because not all recycling is the same. You have to differentiate. There is now a whole range of different and also new processes. 

Could you give us an example?
Let’s look at mechanical film recycling. This is challenging because films, especially those used in the packaging industry, consist of several layers of different plastics. These different layers can be used to improve barrier properties and extend the shelf life of food. From a recycling point of view, however, films are problematic, partly because the plastics have different melting points. There is a process whereby the edge trim of the films is collected and processed and then reintroduced into one of the layers when new films are produced. That’s a mechanical way to recycle even at least partially a high-tech product like film. And with regard to post-industrial waste, this is a concept that produces no waste and is therefore a zero-waste solution, so to speak. We have already supplied our extruders to the first reference installations in Germany. The process is on the rise, also due to its energy advantage.

Will chemical recycling also pick up pace?
Absolutely. The idea is to break down any plastic into its original components by pyrolytically cracking the hydrocarbons. From this original form, you can then go back to the plastic via the refinery process. This is a trend that major plastics manufacturers in particular are pursuing. The process is also interesting if you don’t want to or can’t recycle a single-variety product. If you managed to close this loop one hundred percent, then you could theoretically do without fossil base materials altogether.

All this is already technically possible?
Yes, it is possible. There are already reference plants in place, as well as various institutes that optimize this technology. We have already sold facilities for this purpose. A large-scale production plant with twin-screw extruders, which are more efficient in this field of application at higher throughputs than other machines on the market, is already underway.

Mechanical recycling is complex and expensive. Chemical recycling is even more expensive. The whole operation is only worthwhile when oil prices are high. Who will invest in such plants, if it isn’t clear whether they can be operated economically? 
Plastics manufacturers want to show that they are leading the way and increasing their share in the cycle. That’s why they invest in chemical recycling; even if it may not make sense from a purely economic point of view today, it certainly conserves resources and reduces the carbon footprint. However, they also want to be prepared in case there are future political requirements for a higher recycled content in plastic products, and there is a lot to be said for that at present.   

At the moment, it is still Europe that is driving the circular economy forward. Will the spark eventually catch on in the rest of the world?
If it’s only the EU focusing on circular economy, it is unlikely to be pushed through at a major pace. I am encouraged by the fact that the US has recently taken up the issue. The Biden administration has clearly set a focus here, and we can see that recycling is becoming increasingly important in the US, which wasn’t the case there a few years ago. In addition, many of the reactor manufacturers for chemical recycling are located in the US, as are many of the pilot plants. American companies together with European companies provide a much bigger momentum. Environmental protection measures are also growing strongly in China. We are absolutely confident that the issues that are currently being prioritised in Europe will very soon arrive in North America and then increasingly in Asia as well.

Video statement by Peter von Hoffmann: https://vimeo.com/639874437

Successful realization of CMF concepts in product design and production

Covestro receives the German Design Award for its CMF Aesthetics Toolkit

The goal is to inspire designers through the aesthetics and functionality of polycarbonate

Covestro will be honored with the German Design Award for its "CMF Aesthetics Toolkit". Developed in collaboration with designer Chris Lefteri, its purpose is to inspire designers to explore the aesthetic and functional possibilities of using polycarbonate. © Covestro

As announced by the German Design Council, Covestro’s CMF Aesthetics Toolkit will receive the German Design Award 2022 in the category “Excellent Product Design – Material and Surfaces.” The toolkit is designed to inspire designers to explore the many aesthetic and functional possibilities of polycarbonate in the field of color, material and finish (CMF). Developed in collaboration with renowned designer Chris Lefteri and Chris Lefteri Design Ltd, it is designed to pave the way for inspiring dialogue and creative collaboration between Covestro and its Color & Design (CMF) team with designers and CMF experts.

“For designers, samples are key to understanding a material’s potential, but they are products that rarely get the attention they deserve from material suppliers,” says Chris Lefteri. “Polycarbonate has some outstanding aesthetic properties that are showcased in the aesthetic toolkit we designed for Covestro. The shape, form and outline draw attention to its inherent transparency, color and surface effects that highlight its glass-like qualities. Through the interplay of the two parts, which can be overlaid in color, it is intended to inspire new applications and facilitate dialogue between designers and Covestro.”

The Aesthetics Toolkit shows CMF trends on different polycarbonate substrates – depending on the industry, application, color, texture and functionality. 24 trending colors and textures help designers understand the properties of polycarbonates while capturing the visual effects of different combinations in novel 3D form factors.

“We are very honored and excited to receive this prestigious award. It is a confirmation of Covestro’s expertise and activities in CMF. We are a leading materials supplier, and our ambition goes well beyond just providing materials,” says Dr. Christopher Stillings, Vice President, Global Head of Color & Design (CMF) in Covestro’s Engineering Plastics segment. “By working with Chris Lefteri, we look forward to inspiring more designers and CMF experts to create and realize aesthetic, efficient design and inspiring products with polycarbonate.”

He adds, “We see designers and CMF experts as key partners for innovation and want to work more closely with them by offering our capabilities from front-end trend research to back-end design applications. Covestro offers sustainable material solutions that deliver both high aesthetic value and high performance.”

The German Design Awards, which are among the most prestigious design prizes in the world, enjoy an excellent reputation far beyond specialist circles and are presented annually by the German Design Council.

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