Lanxess Launches Hollow-Profile Hybrid Technology

• First customer projects at the prototype stage
• Innovative tolerance management for profiles with varying dimensions
• No internal support required for the hollow profiles in the production process
• Manufacturing process and component properties can be simulated precisely

Lanxess is currently in the process of launching its hollow-profile hybrid technology on the market. With this new lightweight design technology, metallic hollow profiles can be functionalized on conventional injection molding machines with plastic compounds. The result is plastic-metal composite components that boast far greater torsional stiffness and strength than could previously be achieved with other technologies for functionalizing hollow profiles. “Hollow-profile hybrid technology has now progressed to such an advanced level that we have embarked on a variety of development projects with customers and have already reached the prototype stage with some of them,” says Dr. Matthias Theunissen, an expert in lightweight design at Lanxess. The potential applications in the automotive industry include cross car beams, coupling rods, stabilizers and seat elements. In addition, the new lightweight technology could be used to produce skiing and hiking poles and components for furniture and the construction industry, for example.

The hollow-profile hybrid technology is a further development of the “traditional” plastic-metal composite technology (hybrid technology) using sheet metal. The general strength of the new technology is that processors can manufacture with short cycle times, as is typical for injection molding in high-volume production. As a result, the manufacturing process is efficient and economical. There is no need for auxiliary units or tooling technology, which keeps investment costs low. The fact that reasonably priced hollow profiles with relatively large dimensional variations can be used helps to make the process cost-effective, too. As Theunissen explains, “With the aid of innovative tolerance management, we can prevent profiles of that type from damaging the mold or stop leaks occurring in the injection molding cavity.” When the thin-walled hollow profiles are overmolded with the molten plastic, high pressures often exceeding 400 to 500 bar occur in the cavity. As a result, there is a high risk of the profiles deforming or collapsing. “We have optimized the process such that the profiles withstand the pressures that occur and do not need to be supported from inside,” says Theunissen.

For the hollow-profile hybrid technology, Lanxess offers highly reinforced polyamide 6 types such as the easy-flowing Durethan BKV60H2.0EF DUS060, which has a short glass fiber content of 60 percent by weight. With their high strength and stiffness, these compounds further enhance the performance of the corresponding components. In a simulation study, Lanxess examined how using the compounds pays off in the design of an automotive cross car beam. “The component can be designed with around 30 percent less weight than an all-steel structure while offering better mechanical performance in some respects,” says Theunissen. Typical load cases and component properties were calculated, such as vibration behavior and the stiffness of the steering wheel in the direction of gravitational forces. “The component also underlines the huge potential of the technology in implementing cost-saving functional integration. For example, connections for the A-pillar as well as mountings for the steering column, dashboard, climate control units and airbags were directly injected.

Lanxess has developed new calculation models for the hollow-profile hybrid technology based on simulation tools that have proven successful for years in conjunction with the “traditional” hybrid technology. These allow precise prediction of the production process and the quality of the connection between the metal and plastic. “With these tools, we can, for example, accurately predict the maximum stresses hollow-profile hybrids will withstand and at what point they will fail. We apply this expertise in working with our customers,” explains Theunissen. A newly developed test specimen was used to validate the simulation. Extensive component testing for static and dynamic load cases underpinning the simulation results was carried out on real components.

For more details: www.lightweight.lanxess.com

Xsys And Nilpeter Collaboration Confirms No Compromise In Print Quality When Using Latest Thermal Plate Technology

Following the completion of a comprehensive new print trial, Xsys has revealed the results of detailed tests comparing flexo printing with thermal plates and those processed with solvents. Working together with press manufacturer Nilpeter, the company set out to find a more sustainable solution that would not compromise print quality.

The sample job was printed, in turn, with the solvent nyloflex  FTS plate and the thermal nyloflex XVH plate from Xsys. The thermal plate was processed with a nyloflex  Xpress Thermal Processor, which offers considerable sustainability benefits compared to standard solvent processing systems in use.

“Our main aim with this print trial is to confirm that there is no compromise in print quality when switching from Xsys solvent plates to thermal,” said Friedrich von Rechteren, Global Commercial VP at Xsys. “In fact, what we found is that besides producing excellent print quality and improving flexo’s green credentials, the versatile nyloflex XVH thermal plate – like the solvent nyloflex  FTS – also reduces complexity, inventory and waste to provide a higher Overall Equipment Efficiency (OEE).”

The thermal nyloflex XVH Digital plate brings similar benefits to the table as the solvent nyloflex  FTS Digital. Both are inherent flat top dot plates with a smooth surface that has a very fine grain making them able to hold customized surface screening patterns, such as Woodpecker. They also both feature good wettability and anti-ink fill-in (AIF) technology, which keep plates clean for longer print runs to allow increased press uptime.

The thermal nyloflex  XVH, however, offers additional benefits, most notably in sustainability by not requiring solvents for processing and thereby avoiding VOC emissions in the print room and further into the atmosphere. Productivity is also significantly increased as the nyloflex Xpress Thermal Processor delivers print-ready nyloflex thermal plates in less than one hour, which translates to 88% lower energy consumption. It also eliminates the long drying times experienced with solvent systems, which often cause a bottleneck in production and delay press restart when damaged plates have to be replaced. The print trials were conducted at the Nilpeter Technology Center in Denmark, where the sample jobs were produced on a flagship FA-17 Line narrow web flexo press running at 200 m/min. The same design was printed on three different substrates: a 38-micron White BOPP, a self-adhesive white PE and a 45- micron PET shrink material with a solvent nyloflex  FTS 114 Digital plate and a thermal nyloflex  XVH 114 Digital plate, using UV flexo inks from Flint Group Narrow Web. Jesper Jørgensen, Global Sales Manager at Nilpeter, said, “When we compared the results from the two different plates, there was no difference in quality or registration – it was just spot on. With most new jobs, there are always some start-up difficulties getting the plates, the inks and the material to mix and match together, but we found it surprisingly easy. It was a walk in the park.”

Friedrich von Rechteren concluded, “We can now fully recommend the nyloflex  XVH plate as an alternative solution to current market challenges, because it delivers print quality that equals solvent plates, offers reduced Total Cost of Ownership, and is more environmentally friendly.”

For more details: www.xsysglobal.com

Xeikon Expands Its Organization In Greater China

Xeikon has appointed Sean Wu General Manager for Greater China, signalling the company’s increasing presence in the region. In his new role, Wu is tasked with managing the significant growth in interest for Xeikon’s digital solutions in China, particularly from label and packaging printers and converters working with the high demands from brand owners and designers, creating unusual, unique and high-end products to meet ever-evolving consumer demand. Wu will also manage and coordinate Xeikon’s new warehousing facility at its Technical Innovation Center in Shanghai, where the company can now provide same day consumables and parts delivery and technical support.

Wu says: “I am pleased to be a part of Xeikon’s future plans in China. The Xeikon family is a great community of innovation and forward thinking. I have long admired Xeikon’s technology, and with the huge growth we are seeing in the labels and packaging sectors in China, it is exciting for me to present Xeikon’s innovative solutions to these markets. With the new warehousing facility now open in Shanghai, we are able to quickly respond with technical help and 24hr delivery service on parts and consumables. I have been working in the IT sector for almost 30 years – for Hitachi, EMC and IBM. I also worked for many years as General Manager at InfoPrint where I was in charge of selling Continuous Print solutions. My new role is a big opportunity and I now hope to bring my IT and management skills to support Xeikon.”

Xeikon’s Innovation Center in Shanghai is designed to house the latest Xeikon equipment to support the expanding Chinese markets. The hands-on centre of digital printing excellence is welcome places of interaction were visitors and customers can test a variety of applications and options for new revenue streams and business growth. With this new state-of-the-art warehousing facility, Xeikon is now able to deliver a same-day response to its customers across the whole of Greater China.

Xeikon designed its Innovation Center in Shanghai to be a benchmark of excellence. Printing and converting companies are invited to discuss their business strategies and compare results on Xeikon equipment. Wu continues: “We are also able to provide customers with the full suite of Xeikon services, including training and support as well as our online and comprehensive advisory service Transform with its hotline for advice and guidance on digital transformation. With the new warehouse in operation, we can also efficiently handle all our customers’ enquiries with a very fast response and a 24hr delivery”.

Klaus Nielsen, Director & General Manager APAC, concludes: “We are delighted that Sean Wu has joined Xeikon as General Manager for Greater China. He brings a wealth of expertise and proven management skills. The Chinese market continues to expand, and this appointment is the next step in our G2M strategy for this region. In his newly established role, Sean will further develop and strengthen Xeikon business in Greater China.”

For more details: www.xeikon.com

Teknor Apex Completes Build of New European Manufacturing Facility with Center of Excellence in Germany

Teknor Apex Company is announcing the completion of their new state of the art 50,000 m 2  facility in Rothenburg ob der Tauber, which increases its manufacturing capacity of custom compounds and establishes a new European Center of Excellence for plastics research and development. The site employs more than 100 positions in manufacturing, business support and commercial operations. The new Teknor Apex facility extends its technical capabilities and accelerates the technology developments.

The Rothenburg facility produces thermoplastic elastomers (TPEs) and engineering thermoplastics (ETPs), ranging from general-purpose compounds to highly specialized formulations. An extensive laboratory will be used for developing new compounds and providing customers with design support, application development, as well as product and process training.

The new facility was built with a strong focus on environment sustainability and holds certification for ISO 14001– Environmental Management and ISO 50001– Energy Management. The plant utilizes LED lights, a closed loop water system, heat recovery systems with heat pumps to support it, and meets the highest requirement in heat insulation of the building.

“The team’s ability to complete the build and successful transfer of our manufacturing operations while in the midst of a pandemic is a true testament of their partnership and commitment to serving our customers in Europe.” said Suresh Swaminathan, president of Teknor Apex. “We are excited about our new laboratory which serves as a hub of innovation, serving the region as a source of customized formulations, application development expertise, and process optimization.”

Customers in Europe will also benefit from the global capabilities and broad experience of Teknor Apex, noted Jan Duyfjes, General Manager Europe. “Teknor Apex has long served major markets such as automotive, electrical and electronics, and regulated applications such as food-contact and medical, and it is a source of knowledge in matters such as regional and global regulatory compliance,” said Mr.Duyfjes. “With manufacturing operations in the USA, Europe, and Asia, we can provide global support and supply stability to European customers with plants in multiple countries.”

For more details: www.teknorapex.com.

Solvay Launches New Ajedium Build Sheets Portfolio For Additive Manufacturing

Solvay is introducing a new portfolio of additive manufacturing (AM) build sheets marketed under the umbrella of the company’s Ajedium brand products. Build sheets or plates are used in additive manufacturing processes as basic surfaces on which the extruded AM filament layers are built upon or 3D printed.

Solvay’s Ajedium Build Sheets are compatible with 3D printers for fused deposition modeling (FDM), including vacuum and non-vacuum technologies. They can be customized to any thickness and size to meet the specific dimensions of different 3D printers, and are also available with adhesive backing to protect the building surface and prevent defects during the printing process.

Solvay offers Ajedium Build Sheets in a range of options which can be produced from different high-performance polymers, such as Udel PSU, Radel PPSU, and KetaSpire PEEK. They deliver excellent stiffness and flatness, durability, thermal resistance and adhesion properties. The broad portfolio enables designers to select the build sheet that is most compatible with their printing material and printer temperature chamber, while providing them with the peace of mind that the sheet will neither warp nor crack during printing. Additionally, the surface can be treated to further enhance the adhesion of printed parts.

“Ajedium Build Sheets are a natural extension of our proven high-performance Ajedium solutions for critical applications in markets from Aerospace and Automotive to Energy, Electrical and Electronics, Healthcare and Industrial,” states Rodolfo Patricio, Aerospace & Defense Marketing Manager at Solvay. “At the same time, they complement our portfolio of Radel PPSU, KetaSpire PEEK, Solef PVDF filaments and new material solutions for additive manufacturing.”

Solvay’s new Ajedium Build Sheets underscore the company’s strategy to position itself as the industry’s leading supplier of customized AM solutions for applications with high-performance specialty polymers. The strategy rests on three pillars: materials, process and design. For materials, Solvay enables a growing choice of AM-ready filaments and powder materials. In regards to AM process development, Solvay has been working on the Solvay printer evaluation program (S-PEP) and partnerships with leading equipment suppliers. For design, Solvay partnered with Digimat by e-Xstream, a simulation software database enabling customers to predict and optimize their parts in order ‘to print right the first time’ as well as organizing the Solvay AM Cup competition for talented design and engineering students.

For more details: www.solvay.com/en