Contemporary healthcare would stand unbearable lacking the countless plastic-based medical products we misappropriate. Plastics are all over, from examination gloves to sterilized needles and adhesive dressing strips from blood bags to IV tubes or heart valves. Plastics packaging is predominantly apt for medicinal applications. Appreciations to its excellent barrier assets, it securely watches infections. Inventions in plastics are manufacturing novel measures. Artificial plastic heart, of bacteria-resistant plastics or of body parts tailored to the needs of the patient and printed in the 3D printer will be possible.
Conventionally, metals, glass and ceramics were used for remedial implantations, devices and cares. Though, polymers are well matched to these applications as they bid light weight, improved biocompatibility and lesser cost. Fibres and resins used in medical applications contain polyvinyl chloride (PVC), polypropylene (PP), polyethylene (PE), polystyrene (PS), polyethylene terephthalate (PET), polyimide (PA), polycarbonate (PC), acrylonitrile butadiene (ABS), polyetheretherketone (PEEK) and polyurethane (PU). The utmost used plastics material is PVC trailed by PE, PP, PS and PET. PVC extensively used in pre-sterilized single use medical applications. It is a multipurpose plastic used in medical applications for ages.
There are several uses of plastics, For the newest heart surgery, like in slim tubes to unblock blood vessels. The deposit hindering the vessels can be shattered by a small spiral-shaped implant, a vessel support. The vessel support is finished with plastics established explicitly for the medical field and charged by means of active constituents.
Plastics are being used as orthopaedic devices. They bring into line, support or right malformations. They even advance the purpose of portable parts of the body or substitute a body part, captivating its key function. Synthetic material on the other hand plays a dynamic part for contaminated arteries that cannot be aided by vessel support. An affected unit of the aorta is detached and the opening is linked by a flexible plastic prosthesis, making the body’s sustenance entirely functional again.
3D printing is presently bein
g used by the medical industry to produce prosthetic hands that are inexpensive than conventional prosthetics. This may be particularly valuable for children who might require different prosthetics as they grow. Engineers can print 3D imitations of certain body parts via scans of an MRI machine. It will allow surgeons to prepare for complicated surgeries.
Damages incurred to the eye or chronic irritations, like corneal erosion, can impair vision, and if a transplantation has less chance of victory, a prosthesis is the solitary option. Artificial corneas made from unique silicone are accessible for treatment. It is 0.3 to 0.5 millimetres thick, very translucent, flexible and made of bio-mechanics like that of a natural cornea, it can return clear sight.
Those with severe impaired hearing can have a plastics implant to bring sound back to their ears. It comprises of many components – a microphone, a transmission device connected to a micro-computer worn on the body, a stimulator and an electrode carrier with 16 electrodes for 16 different frequency ranges. It converts audio impulses into electric ones. It bypasses the dented cells and stimulates the acoustic nerve.
Plastics pill capsules release the correct amount of its active constituents at the right time. The tartaric acid-based polymer progressively pauses, gradually releasing the active constituents over an extended period. These ideal treatments avoid having to regularly take huge amounts of pills essential for a patient in order to get the required dose.
There is a collection of plastics single-use medical products that include bed pans, insulin pens, IV tubes, tube fittings, plastic cups and pitchers, eye patches, surgical and examination gloves, inflatable splints, inhalation masks, tubing for dialysis, disposable gowns, wipes and droppers, urine continence and ostomy products. The usage of plastics materials in hospitals is almost endless and continues to grow each day. Plastics continues to look out for those in need of healthcare via the advancements that the medical industries have achieved.
The Accused Plastics Aids in Healthcare
Plastics with Technology Create Futuristic Vehicles that Meet Consumer Demands
The advantages of plastics in the automotive industry has increased consumer demand much more than before. A wide scope of technology is used in order to fulfill these demands.
All through our lives we have witnessed numerous transitions one of which is utilization of steel to lightweight alternatives by the automotive industry. An automotive of the 1950s contained almost no plastic but today they contain 100-150 kilograms of plastics. These automotive vehicles are high in performance, safety, construction and functionality.
Automotive industries are the third most plastic consuming sectors. The plastics industry hand in hand with the automotive industry poised to play a role in the revolution of the automotive industry in the usage of thermoplastics, ABS, polyamide, polyacetal and polycarbonate with alloys and blends of different polymers which will be discussed in detail further.
Plastics in an automotive eases manufacturing, the sourcing comes from renewable raw materials, and its design can be improved by development and research i.e. it increases design freedom and innovate potential. Additionally, it helps reduce corrosion, extends vehicle life, provides versatility in integrating components, safety and comfort. The major role of plastics in automobiles is that they become affordable, lightweight and fuel-efficient thereby increasing consumer demand.
In order to have an accurate understanding of the benefits plastics, it is necessary to know the different types and functions as well. The plastics that are commonly used in automotive vehicles are Polypropylene (PP), Polyurethane (PUR), Poly-vinyl Chloride (PVC) but there are an additional 10 different polymers used (66% just the 3 mentioned previously).
First, PP, a saturated addition of polymer produced from propylene which is durable, resistant to numerous chemical solvents, and is imperious to water. This kind of plastic is prevalent in an automotive and is found in car bumpers, cable insulations, carpet fibers, etc.
The characteristic qualities of PUR are its toughness, flexibility, abrasion resistance, and high resiliency. It takes on very soft or hard forms and is well-suited for everything from tires to suspension brushing to seating.
PVC is a type of plastic that comprises of 16 percent of all plastic in a typical automotive. It is resistant to chemical and solvent attack, has flexibility, is flame retardant, has thermal stability and high gloss with little or no led content. PVC works extremely well in a huge range of auto parts to create instruments like panels, electrical cable sheathing and door parts. The PVC is stiff or flexible depending on the amount and type of plasticizers used.
We have Acrylonitrile Butadiene Styrene (ABS), a durable thermoplastic resistant to weather and chemicals, created by polymerizing styrene and acrylonitrile in the presence of polyuridine. The styrene provides the copolymer with a shiny, tough exterior. The rubbery butadiene creates resilience to very low temperatures. With correct adjustments it can enhance impact and heat resistance , and durability. ABS can be used to produce dashboards and wheel covers.
Following ABS, we have Polystyrene (PS) which is easy to manufacture, has chemical and electrical resistance with an availability in high-gloss and high-impact varieties and is commonly used in housings and displays.
Polyamide (PA), also known as Nylon 6/6, is a general-use nylon that possess mechanical qualities and wear resistance. PA is used where there is a need of a strong low-cost rigid and stable material. It also has low friction characteristics and can absorb water easily. It is found in cams and weather-proof coating.
Next is Polyethylene (PE) that has good resistance to chemicals, high impact resilience, low density and solid durability. It is useful where moisture resistance and low-costs are necessary like in glass-reinforced car bodies and electrical insulation.
Polyoxymethylene (POM), the next in line, is rigid, contains massive yield strength, high stability in cold or low temperatures, highly chemical and fuel resistant. It is used to fabricate the interiors and exteriors of automobiles, fuel system parts and small gears.
Polycarbonate (PC) is a distinctive combined with rigidity, hardness and durability alongside weathering impact, optical, electrical and thermal qualities. PC has a remarkable impact strength and is a fine go-to material for car buyers that also provides UV resistance.
Poly-methyl-methacrylate (PMMA) is a type of acrylic that has reasonable tensile strength, UV and weather resistance. It is more transparent than glass and has a high optical quality and surface finish. With a huge color range, PMMA is used in windows, displays and screens.
Polybutylene Terephthalate (PBT) is a type of resin that has good chemical resistance and electrical properties. PBT is a hard and tough material with water absorption, resistance to dynamic stress, thermal and dimension stability. It is easy to manufacture and is used in sun-roofs, front parts, locking systems, housings, door handles, bumpers, and carburetor components.
Polyethylene Terephthalate (PET) is similar to PBT, has low water absorption and surface properties and is used in wiper arms and gears, headlamp retainers, engine covers, etc.
Lastly, Acrylonitrile Styrene Acrylate is known for its toughness and rigidity. It has chemical resistance and thermal stability. ASA has an outstanding resistance to weather, aging and yellowing and provides high gloss to housings, profiles, interior parts and outdoor applications.
The development and advanced performance in an automotive that induces these polymers in their productions increase usage and demand. Plastics offer mechanical properties, appearance, reduce weight, energy efficiency and high performance at low costs. On an average, one automotive contains about 150kg plastics and plastics composites. Engineered polymer composites and plastics are the second class of automotive materials after metals and alloys.
Commercial vehicles contain 50% plastic contents, the interior component including safety subsystems, door and seat assemblies. The mounting costs are lowered by replacement of plastic components that are also easier in assembling. The exteriors and interiors that include plastics are bumpers, doors, safety and windows, headlight, and sideview mirrors, housing, trunk lids, grilles and wheel covers.
One of the main advantages of plastics in an automotive industry is the lightweight factor brought by installation of innovative products of high rigidity with low weight. Lightweight production of automobiles involve certain environment imperatives and safety requirements that result to weight reduction and fuel abbreviation that lower car manufacturing costs compared to the rising prices of steel and iron for productions of fuel tanks. Advanced cars contain 50% plastics resulting into just 10% weight, making it light, cost-effective in the fuel economy thus reducing greenhouse gas emissions as well.
Rising problems of fuel hike and stricter environment regulations have driven focus towards fuel efficiency. There are 30,000 parts in a vehicle where 1/3 is made of 39 different types of plastics and polymers. 70% polymers are from the 4, PP, PUR, polyamides and PVC. The decision to choose plastics over other materials is due its high absorption property that then provides stricter safety standards, and more designs, that comes with Paint Protection Film (PPF), thermoplastic methane film, high gloss paint, etc., compared to metals.
High performance plastics that meet higher requirements than standard plastics, have better mechanical properties, lighter chemical and/or heat stability re used by automotive industries to manufacture automobiles. The applications of PP, PV, PVC, ABS and PC polymers are seen in the exterior furnishings, power strain, chassis, electrical components, and under the hood parts and in the interior, dashboards, fuel systems, interior trim, under-bonnet components, lighting, exterior trim, liquid reservoirs, and upholstery.
For the purpose of safety, PC, PP, AS, PVR, PA polymers are used. High strength polyamides are used in seat belts, airbags, child restraint seats, shatter resistant wind shields that use a thin layer of plastic, improved sound alternation and filter out most infrared rays. Bumpers to body panels, managements technologies, safety performance from external forces are all provided with the use of plastics.
A study by Research and Markets claim, “There has been a rise in demand of power train, interior and exterior furnishing application and by 2025 there will be an 8.8% growth.” Powertrains are the highest growing applications due to its decreased weight quality that boots performance, hikes productivity and saves costs. Advancements in durable automotive plastics will amplify use of plastic in cars.
The interiors of automotive plastics are durable, comfortable and pleasing. A study by Grand View Research on Interior leading application stated, “A 50 percent increase of volume was seen in 2016 in making seat bases, load floors, headliners, rare package shelves that were made of high performance plastics of GMT and ABS composites resulted to weight savings.” Digitalization on car dashboards, highly advanced futuristic technology and features, safety concerns and high electrical insulation are some additional elements provided by plastics that increase demand.
The new future of the automotive industry evolved with the brining of electric, hybrid and hydrogen powered vehicles that worked on new battery technology that used renewable resources. Electric Vehicles (EVS) are not were different from other automotive vehicles, though they were devoid of fuel systems, pumps, tanks, connecting cables, etc.
The introduction of EVS increased demand of PC that is used in sensors and LEDs. Applications of polymer components in battery packs created opportunities for lightweight engineered polymers and composites. Soon, there will be an increase in demand for PP as well in the new application in the exterior and interior of the car and under the hood replacing metal parts. High priced ABS will be replaced by low priced PP. PC growth will be seen in the emerging application of car sensors (lenses).
The overall consumption of polymers is expected to continue to grow depending on the plastics types, application in automotive, interpolymer substitution as well as recycling efforts in different regions. The growth rates of plastics like PP, PA, PC and PE will be due to EVS.
Plastics provide sustainable mobility to an automotive with the use of engineered plastics which will soon create a future for chemical and automotive industry to collaborate for better recyclability and sustainability. There will be developments in the automotive plastic productions and recycling system.
Influence of these propelled industry growth economically in Asia-Pacific locations like China, India, Thailand, Vietnam and Indonesia. The new future of automobiles involves expansion of manufacturing and increase in investments.
Plasticulture, the Pseudonym for Plastics and Agriculture Combined!
The ultimate couple, plastics and agriculture, Plasticulture, have been supportive for each other’s growth since long known in history. Now, they are upgraded and have even better versions of themselves than before, all with the help of technology.
There was always an existent staple use of plastics in modern farming. In the 1940s, E. M Emmert, a horticulturist at the University of Kentucky, discovered plastics film to protect crops and produce higher yields. They were used in agriculture as durable, cost-effective replacements for glass in greenhouses and tunnel sliding. Further research and development made it possible to create more efficient greenhouses and tunnels.
Plastics in agriculture helped farmers across the world to upgrade their farming while reducing ecological footprints of their activity. It allowed farmers to grow vegetables and fruits in all seasons and of even better quality than those in the open field.
Polyolefins (polyethylene) (PE), Polypropylene (PP), Ethylene-Vinyl Acetate Copolymer (EVA), and less frequently, Poly-vinyl chloride (PVC), Polycarbonate (PC) and Poly-methyl-methacrylate (PMMA) are some plastics used in agriculture. These plastics provide innovative and sustainable solutions for farming that help save water which is the most essential need of crops, maintain a temperature suitable for the growth of plants that otherwise farmers struggle with, improve flower productions, and allow crops to be planted in deserted areas.
The application of razor-thin sheets of polyethylene film on farmland has been going on since the 1950s. The employment of these plastics sheets provides successful moderation of soil temperature, limit weed growth, and prevent moisture loss. This increases the yields by 30% at low costs. Countries across the world with agricultural sectors as one of their chief suppliers of food, feed, and fiber, incorporated their interests towards the consumption of plastics for cultivation.
When we talk of plastics in agriculture, we are introduced to the term Plasticulture. Plasticulture in India came as a helping hand to farmers to help double their farm income by 2022 with a 14% contribution to the national economy. The mitigation measures of it would solve problems caused by erratic nature, reduce water usage, prevent contamination from external agents, and soil erosion.
To elaborate, Plasticulture helps distribute water to farmlands judiciously, thereby conserving a natural resource. It also reduces harvesting losses caused by unfavorable weather conditions, infiltration of weeds, pests, and others that inflict harm to the crops and increases the output value of the produce with sustainable agricultural practices.
The extensive variety of plastics prove beneficial on farms for operations and economic efficiency. For instance, Greenhouses, also known as intensive-care units, make use of protected cultivation films i.e. they are covered with firm nets of plastics through a frame. A closed large structure that lasts 6 to 45 months depending on photo stabilizers, geographic location, weather, and use of pesticides provides plants with correct sunlight exposure and conditions with physiological properties. They also create appropriate environmental conditions to avoid extreme and harmful temperatures therefore, extends growing season and protects crops from pests, the crops grow in a controlled environment.
High tunnels, on the other hand, have functions similar to a greenhouse. But, high tunnels have an open structure and therefore cannot control the environment like that of a greenhouse. They are not permanent and its pipe or framework is covered by a single layer of greenhouse – grade 4 to 6 mil plastic. High tunnels and greenhouses help extend the growing season by creating a favorable regional environment. Due to their beneficial features, maximum utilization of greenhouses and high tunnels are seen in China, with ongoing development in South Europe and annual growth in Africa and the Middle East.
Another area that uses plastics is mulching. Mulch is a layer of material(s) that covers soil-surface with plastics film that helps maintain humidity and reduces evaporation, improves thermal conditions, prevents weed from overtaking water, and the nutrients of the plants. It is a water conservation technique that manipulates an increase in crop yields and improves product quality by controlling soil temperature, retaining moisture, and reducing evaporation. It makes use of protective cultivated films like plastics covers that reduce weed and pest pressure while lessening stabilizer and fertilizer use. Plastics mulches make use of Low Density and Linear Low Density Polyethylene (LDP and LLDP) which can later be retrieved and disposed after usage. Greenhouses and high tunnels also make use of it for the ground.
Another use of protected cultivation films is for low tunnels. Low tunnels provide same effects as greenhouses but have different complexity and height. Their structure is built high enough to cover the canopy of plants. The films used are thinner than those of high tunnels and the plastics have a shorter lifespan, about 6 to 8 months i.e. less than one agricultural campaign. The polymers used are EVA or EBA copolymers that have transparency, clarity, and thermal insulating effects.
Silages are proof of the value of plastics in agriculture. Silage piles are covered with plastics to protect the product and keep it safe and fresh. The plastics film is resistant to dust, rain, moisture, and other external elements and have airtight seals that prevent rotting. They are cost effective and can be easily transported. The silages can impart long periods of storage capacity that help in the output of farmlands that increases income.
In order to store animal grains and straws, to protect bale production, silages were developed. It provides flexible harvest dates, less weather dependency, and greater flexibility in ration formulation. There are 2 types of silages, individual, in which each bale is wrapped as a solo unit, and second, where the bale is positioned end to end with a PE-film wrap applied around large-round bales. Its usage is strategically high in the northern parts of Europe.
A general supply of plastics is seen in the manufacturing of nets for harvesting and post-harvesting practices. Plastics nets made by twisting plastics threads in a knitted form allows fluids to flow through. Nets most widely make use of raw materials of High Density Polyethylene (HDPE) and PP, and possess anti-hail, anti-bird, and anti-wind features. They are also used for picking and aid to modify microenvironment around a crop. It protects plants against virus-vector insects and also provides shade for the interior of greenhouses. There is an approximate 17% calculated usage of it in Italy.
Furthermore, plastics irrigation pipes are used to prevent water and nutrients wastage. Plastics reservoirs and irrigation systems deliver rainwater retention facilities that contribute to water management. Water can be stored in dams covered with plastics material to avoid leakage and this water is then distributed to other systems via pipes. As a part of micro-irrigation, it also helps in drip irrigation in the form of sprinklers. The farm plastics used for piping in irrigation or draining is resistant to dust and corrosion. It is also helpful for water reservoirs, channel lining, irrigation tapes and pipes, drainage pipes, and drippers.
From storage of crops in closed spaces under a plastics film to reduction in emission of pesticides, as they remain fixed on plastics covers, plastics play a vital role in agriculture. Boxes, lightweight crates for crop collecting, handling and transporting or for displaying crops, tapes used for greenhouses, silage films, fumigation films, bale twines and wraps, nursery pots, strings and ropes, all prove to be highly functional plastics products.
On a side note, packaging of fertilizer sacks, agrochemical can containers, and tanks for liquid storage make use of plastics in the agricultural field as well as pond liners and artificial ponds that conserve water in monsoons.
Protected cultivated films are the largest group of plastics used in agriculture, 4.4 million tons, according to a study in 2012. The United States Department of Agriculture confirmed that there is, “… a use of plastics in crop production and cultivation protection, including plastics film mulches, row covers, tunnels, and greenhouses…”.
In conclusion, the real challenge in the consumption of plastics in agriculture is to ensure the maximum life-span of films and disposal with minimal damage to the environment. There are many recycling and recovery opportunities for agricultural plastics like greenhouse covers to be recycled. They are washed thoroughly on retrieval, before grinding and extruding into pellets, and may be used to make outdoor furniture. After recycling they add to the value chain, operation, technical and economic efficiency. Along with mechanical recycling and chemical recycling, energy recovery is also available, all with the use of plastics in agriculture. The National Collection Schemes (NCS) states that agri-plastics waste increases circular economy and avoids the negative impact on the environment by recycling it and incorporating recyclates into new products.
Plastics Paving Our Way to the Sky
Since 1970, plastics have been a major component in the aerospace industry. Though plastic materials were established in the late 1800s and set in use in the 1930s, it was not until World War II that it was installed in aircrafts. Owing to the lack of several manufacturing supplies in the war-time, engineers initially saw to plastics to substitute rubber components in airplanes. One of the first applications for aerospace plastic components was the lining for fuel tanks. Ultimately, high performance plastics were industrialized to be used in parts of planes and helicopters.
Various components and navigational functions, structural elements and interior components are all made out of plastic. Plastic has numerous advantages like lightweight properties, ten times lighter than their metal counterparts, and can be economic in nature. It is also prone to resist corrosive materials and do well in chemically severe surroundings. Transparent plastics on the other hand have more impact resistance than glass, which increases safety. These factors make plastics an ideal choice in comparison to the metal alloys usually employed in the aerospace industry
Some common plastics and their possible applications are conversed below.
Polyetheretherketone (PEEK), is a semi-crystalline organic polymer favoured in the aerospace industry. It is used in conditions where it may be bare to low temperatures and atmospheric elements. Its applications can originate in pump gears and valve seats. It can endure huge quantities of radioactivity and has excessive resistance to hydrolysis i.e. it can be exposed to high-pressures of water and vapor without degrading. Besides, it displays great thermal and mechanical properties of low flammability and creep resistance. PEEK’s functioning temperature goes up to 450 °F. Common applications consist of valve seats and pump gears.
Thermosetting Polyimide is used in countless physical applications in the aerospace industry. It has high resistance to chemicals and shows outstanding mechanical properties. The major benefit that it proposes is the ductileness, ceramics and less in weight than metals. Instances of probable applications include electric standoffs (spacers) and insulators for threaded nuts and other components.
Polyamide-imide (PAI) is favoured due to its resilience to most substances and radiation at room temperature. It is fire resistant and therefore does not let off fume when it burns. It has a high mechanical strength that holds up to 500 °F. Due to these assets, PAI is often used as a replacement for many metal components in the aerospace industry.
Polychlorotrifluoroethylene (PCTFE), a fluorochemical plastic, a material suitable to be used in or outside corrosive surroundings. It has an ideal combination of physical and mechanical properties, fire and chemical resistance, and very low moisture absorption. It can bear temperatures from -400 °F to +400 °F and displays countless electrical properties making it a fitting choice for aerospace applications.
Polytetrafluoroethylene (PTFE) is a fluorocarbon polymer and an electrical insulator. It has high tear resistance, low flammability and can retain its properties in aerospace conditions. PTFE is used for insulating the myriad wires and cables in an aircraft.
There is a diversity in the usage of plastics in aerospace applications as it weighs less, doesn’t erode, manufactures easily, is flame, fume, toxicity and heat release acquiescent. It offer a comprehensive flexibility in terms of design, colour, and texture. Plastic parts last longer and need not as much of maintenance than other materials. One of the prime motives for using plastics is eradicate weight from the plane thus reduces fuel consumption and cost. Therefore, plastics are used both inside and outside the aircraft, including cargo containers, dashboard enclosures, cockpit visors, dashboard enclosures, nose cones, beverage carts, counter backsplashes, mirrors, toilets, ceiling and wall panels and partitions, flooring, light lenses, signage, video bezels, various seating parts, window reveals, shades and dust panes.
For the economy of now, the hiked fuel cost and the appeal to lower ticket prices stimulates airline companies to buy minimum weighted aircrafts. With its light weight and resistance to high temperatures and corrosive materials, plastics can substitute metal or rubber components. The next decades will soon see aircrafts with plastic wings and tails.
LANXESS increases black pigment capacity
Debottlenecking at the world’s largest plant for synthetic iron oxide pigments
Specialty chemicals company LANXESS has expanded its capacity for black synthetic iron oxide pigments at its Krefeld-Uerdingen site by more than 5,000 metric tons per year. “The increased demand from the construction industry, in particular for our unique black pigments to color concrete, can be even better met with the debottlenecking measures that have now been completed,” says Holger Hüppeler, head of the Inorganic Pigments business unit at LANXESS. The company is thus continuing the systematic expansion of its production capacities for synthetic iron oxide pigments. LANXESS is the only supplier worldwide to produce these pigments using the Laux process.
Black is trending
In architecture and landscaping, the black coloration of concrete has been a trend for some time now. Concrete is a creative material, which provides a multitude of possibilities to building material producers, architects, and building contractors. With the use of suitable pigments, this applies not only to the architectural design of concrete, but especially to its coloration. “Thanks to their up to 15 percent higher tinting strength and reliable color consistency, our Bayferrox 330 and Bayferrox 340 black pigments are the preferred choice for coloring high-quality cement-based building materials – for example not only in manufacturing concrete paving stones and roof tiles, but also in architecture,” explains Hüppeler.
In addition, these special iron oxides from LANXESS offer further clear benefits. The pigments produced using the Laux process are the only synthetic iron oxides that are specially certified by an independent testing institute for safe use in ultra-high-strength concretes (UHPC). UHPC is used in construction projects where, for example, high load capacities and very lightweight, customized structures are required. And these high-quality pigments are also impressive when it comes to their sustainability credentials. They are certified for their high content of recycled raw materials by SCS Global Services, one of the leading companies for audits and independent certifications worldwide.
On the way to being more environmentally friendly
In Krefeld, LANXESS operates the world’s largest plant for manufacturing synthetic iron oxide pigments. The global importance of this site is confirmed every year by its extensive investment in capacity expansion and process optimization, as well as the continuous expansion of environmentally friendly production technologies.
Thanks to the unique Laux process, the production facility at the Krefeld-Uerdingen site already has an excellent carbon footprint. This is because this special chemical process uses the heat generated during the reaction to create steam, which is in turn used in the subsequent process steps. “Our goal is to use targeted measures to continuously reduce the CO2 footprint of our pigments. In the future the energetic use of hydrogen, which is produced during the production process of our pigments and can be used as a substitute for fossil fuels, will also play an important role,” says Hüppeler. Specialty chemicals group LANXESS has set itself an ambitious climate protection target. By 2040, the group aims to become climate-neutral and reduce its greenhouse gas emissions from the current level of around 3.2 million metric tons of CO2. By 2030, LANXESS aims to cut its emissions by 50 percent to around 1.6 million metric tons of CO2 compared with today.
lanxess.com
Heart Valves Made by Silicone Additive Manufacturing
In an additive manufacturing process, virtual heart valve models are created with the aid of a CT scan and a preeflow eco-PEN300 one-component dispenser: Fergal Coulter from the “Complex Materials Group” of ETH Zurich undertook research for medical technology – more precisely for the additive manufacturing of artificial heart valves. They were manufactured using custom medical-grade polysiloxanes, together with chemicals which resulted in stiff, medium, or soft silicones following UV-triggered polymerization. These materials conform to biocompatibility standards for cytotoxicity, as well as irritation and skin sensitization.
A customized 3D printed mandrel is produced, derived from a patient’s C/T scan. As one of several production steps, a part of the artificial heart valve is applied by using the eco-PEN dispenser. The dispenser is also used to print silicone reinforcing fibers onto the leaflets and then strengthen the edges. The non-leaflet areas of the valve (the “intraaortic triangles”) are constructed according to the scan of the patient’s aortic root. Then the silicone is cross-linked with UV light. In the second step, a silicone mold of the aortic root is created. An alginate is used to temporarily encapsulate the valve. The cap protects the valve leaflets and allows an over-hanging artificial vasculature and integrated stent to be applied. For this purpose, the assembly is scanned with a 1-dimensional laser. The surface is virtually recreated by computer. And the tool paths for an auxetic stent geometry are calculated. Afterwards, the eco-PEN300 is used again for printing: The printed struts are about 0.3 mm thick. Now the valve mandrel can be removed. The alginate cap is removed by oven dehydration. Depending on whether a coating was sprayed on as an intermediate step or not, the final result is a patient-specific artificial heart valve with a covered or windowed aortic stent.
The design of the completed heart valves is inspired by human biology (3-leaflet valves). Depending on the requirements, an individual geometry is implemented to obtain a tailor-made synthetic product. Through digital fabrication, an artificial valve is created as a functional implant. In contrast to the existing mechanical heart valves and tissue valves, this method is seen as promising for future applications.
The reasons for promising future applications:
- Completely individual heart valves are possible (based on a CT scan of the patient’s own heart valve).
- The products are inexpensive to manufacture.
- Due to the materials used, immunosuppressors (blood thinners) may not be necessary in the future.
- Not only the design and geometry of the printed heart valve is similar to its biological counterpart, but also its functionality, which has been tested in detail on physiological blood pressure in Coulter’s experiments.
- The printed fiber-reinforced heart valve has lower mechanical stress and outstanding hemodynamics (= science of the movement of blood in the vascular system).
The task of the eco-PEN dispenser is to ensure the stability of the heart valve and atrioventricular valves. So that the system does not collapse when used under physiological conditions. As described above, the eco-PEN300 prints a part of the heart valve as well as a stent (= medical implant to keep vessels or hollow organs open) or a stent like structure for stability. The eco-PEN therefore also constructs the framework for the heart valve.
For implementation in this sensitive area, perfectly consistent precision in the area of micro dispensing is important: Repeatability must be guaranteed in dispensing such small quantities. Here the lightweight preeflow dispensers were able to convince. As the needle must always point perpendicularly to the precisely manufactured mandrel, its dispensing technology is complemented by an agile robot system.
Fergal Coulter about working with the preeflow dispenser: “The eco-PEN is an excellent extruder when printing with multiple different materials that have different viscosities and rheological properties. The precise volumetric dispensing of the pen removes variation in flow of the extrudate during long prints and reduces time spent in tailoring pressure profiles to achieve a constant material flow.”
An overview of the advantages of the high precision preeflow dispensers:
- Simple and flexibly adaptable to individual geometries
- Easy integration (the eco-PEN300 is used with a spacing of 300 µm and perpendicular to the curvature of the surface to be covered)
- Smallest dispensing quantities with absolute repeatability of > 99 %
To meet the requirements of the 3D printing market, ViscoTec has established its own Business Development Additive Manufacturing in 2016. The portfolio has been expanded: In the meantime, various 3D print heads have been developed, which can print both one- and two-component fluids and pastes and are even better suited for additive manufacturing.
https://www.preeflow.com/
A New Take on Metal–Plastic Hybrid 3D Printing
Scientists develop a novel and surprisingly simple method to print 3D structures made of metal and plastic, paving the way for 3D electronics
Current 3D printers employ either plastic or metal only, and the conventional method to coat 3D plastic structures with metal is not environment-friendly and yields poor results. Now, scientists from Waseda University, Japan, have developed a metal–plastic hybrid 3D printing technique that produces plastic structures with a highly adhesive metal coating on desired areas. This approach extends the use of 3D printers to 3D electronics for future robotics and Internet-of-Things applications.
Three-dimensional (3D) printing technology has evolved tremendously over the last decade to the point where it is now viable for mass production in industrial settings. Also known as “additive manufacturing,” 3D printing allows one to create arbitrarily complex 3D objects directly from their raw materials. In fused filament fabrication, the most popular 3D printing process, a plastic or metal is melted and extruded through a small nozzle by a printer head and then immediately solidifies and fuses with the rest of the piece. However, because the melting points of plastics and metals are very different, this technology has been limited to creating objects of either metal or plastic only—until now.
In a recent study published in Additive Manufacturing, scientists from Waseda University, Japan, developed a new hybrid technique that can produce 3D objects made of both metal and plastic. Professor Shinjiro Umezu, who led the study, explains their motivation: “Even though 3D printers let us create 3D structures from metal and plastic, most of the objects we see around us are a combination of both, including electronic devices. Thus, we thought we’d be able to expand the applications of conventional 3D printers if we managed to use them to create 3D objects made of both metal and plastic.”
Their method is actually a major improvement over the conventional metallization process used to coat 3D plastic structures with metal. In the conventional approach, the plastic object is 3D-printed and then submerged in a solution containing palladium (Pd), which adheres to the object’s surface. Afterwards, the piece is submerged in an electroless plating bath that, using the deposited Pd as a catalyst, causes dissolved metal ions to stick to the object. While technically sound, the conventional approach produces a metallic coating that is non-uniform and adheres poorly to the plastic structure.
In contrast, in the new hybrid method, a printer with a dual nozzle is used; one nozzle extrudes standard melted plastic (acrylonitrile butadiene styrene, or ABS) whereas the other extrudes ABS loaded with PdCl2. By selectively printing layers using one nozzle or the other, specific areas of the 3D object are loaded with Pd. Then, through electroless plating, one finally obtains a plastic structure with a metallic coating over selected areas only.
The scientists found the adhesion of the metal coating to be much higher when using their approach. What’s more, because Pd is loaded in the raw material, their technique does not require any type of roughening or etching of the ABS structure to promote the deposition of the catalyst, unlike the conventional method. This is especially important when considering that these extra steps cause damage not only to the 3D object itself, but to the environment as well, owing to the use of toxic chemicals like chromic acid. Lastly, their approach is entirely compatible with existing fused filament fabrication 3D printers.
Umezu believes that metal–plastic hybrid 3D printing could become very relevant in the near future considering its potential use in 3D electronics, which is the focus of upcoming Internet-of-Things and artificial intelligence applications. In this regard, he adds: “Our hybrid 3D printing method has opened up the possibility of fabricating 3D electronics so that devices and robots used in healthcare and nursing care could become significantly better than what we have today.”
This study hopefully paves the way for hybrid 3D printing technology that will enable us to get the best of both worlds—metal and plastic combined.
https://www.waseda.jp
Higher efficiency and cleaner work pieces for automatic de-powdering and cleaning of 3D components
The next generation of the S1 post processing system from AM Solutions – 3D post processing technology
With its numerous technical features, the latest generation of the S1 post processing system from AM Solutions – 3D post processing technology is setting new standards for de-powdering and cleaning of 3D printed components. These include the swivel-mounted rotary basket for ergonomic loading/unloading and prevention of contaminating the machine environment, swivel-mounted blast nozzles preventing re-contamination of treated parts and a design that is in complete compliance with ATEX standards. Of course, the gentle and, at the same time, intensive processing, the easy and safe change of blast media and the easy switch from automatic to manual operation ensure efficient and consistent high-quality processing results.
Plastic components printed with powder-based 3D printing systems require complete removal of residual powder and an excellent surface preparation. This is essential for the success of subsequent manufacturing operations like painting or coating. AM Solutions – 3D post processing technology, a division of the Rösler group and specialized in post processing, has completely re-designed its S1 surface treatment system. This cost-efficient plug-and-play unit is ideal for the automatic de-powdering and cleaning of small to mid-size work piece volumes.
The new machine design allows the easy switch from automatic to manual operation without time consuming re-tooling. This can be highly advantageous for processing of somewhat larger single components. All the operator has to do is to unlock the rotary basket and move it to the rear of the blast cabinet. This provides work space for the manual handling and blasting of somewhat larger components. The clever design ensures that the operator is not exposed to any moving parts so that no additional safety features are necessary.
Automated de-powdering – fast, reliable and consistent
The integrated rotary basket allows the fully automatic processing of batches up to 25 liters and a maximum batch weight of 50 kg. The special basket design ensures optimal distribution and mixing of the components during the blast operation. This, in combination with the pivoting blast nozzles, guarantees the effective and gentle blast treatment of the components in short cycle times. Depending on the finishing task, the shot blast operation can be run with either glass beads or a suitable plastic media. Once the blast cycle is complete, contrary to conventional cabinets, where the blast nozzles are tilted upwards, in the S1 the blast nozzles are automatically swiveled out of the basket. This prevents any powder accumulated on the blast nozzle holder to fall back into the basket and re-contaminate the cleaned components during the subsequent shakeout.
For loading and unloading the basket swivels to the large opening in the cabin front but remains completely within the blast chamber. This allows the ergonomic loading and unloading of work pieces without the risk of contaminating the immediate machine environment with powder.
The PLC of the S1 allows the storing of multiple blast programs with work piece specific parameters like blast pressure and basket RPM. These parameters are continuously monitored during the complete process. They can be stored in the machine controls or transmitted to a higher level computer system. In case of deviations from the specified parameters the PLC provides an acoustic or visual warning.
Integrated health, work and component protection
Another significant feature of the S1 is that the inside of the cabinet and the rotary basket are lined with an antistatic polyurethane coating. The precisely defined shore hardness of the basket lining prevents any color contamination of the work pieces. The powder swirling around during the blast process is explosive. Equipment suppliers are frequently passing this potential problem on to the equipment operators by demanding that the amount of powder carried into the machine cannot exceed a certain limit. AM Solutions – 3D post processing technology has an resolved this issue by utilizing components like motors and valves that are in compliance with ATEX standards.
Because of the relatively low noise emission of <=80 dB(A) – when blasting with 3 bar – and the air-tight machine doors the S1 can be operated without safety glasses and noise protection.
Effective media classification for consistently good process results
Besides control panel, PLC, dust collector and easily exchangeable media bin the compact S 1 post processing system has also an integrated media classification system. This consists of a cyclone and a screen vibrator for discharging dust and broken down media. Only a consistently high media quality ensures high quality shot blast results.
Finally, the machine is equipped with two viewing windows (for automatic and manual blasting). An “air curtain” prevents the blast media from hitting the window panes.
With its well thought out technical design the new S1 meets not only the highest standards for process safety and efficiency but also for protection of the work place and the health of the employees.
www.solutions-for-am.com / www.rosler.com
New 3D printing solutions with more than ten medical-grade polymers
Expanded portfolio of polymers and further developed open filament system allows 3D printing medical devices for surgery and other applications
Kumovis, developer of the world’s first FLM 3D printer built for medical production, is presenting new high-performance polymers at the leading trade fairs in medical technology and additive manufacturing. At virtual.COMPAMED and Formnext Connect, visitors will also learn all about Kumovis R1 and the medical applications for which the industry-specific 3D printer is suited. Talk and discussion formats as well as the virtual Kumovis booth will provide opportunities for personal exchange.
Since its foundation in 2017, Kumovis has been developing 3D printing solutions for highly regulated infrastructures, healthcare in particular. To enable medical technology companies and hospitals to manufacture products in a resource-efficient way and ensure outstanding patient care, the Munich start-up has once more expanded its range of polymers that fit in with medical requirements. Implantable examples include PEEK, PEKK and PPSU. Their biocompatibility and resistance to common sterilization methods are the most important features for being usable in medtech, as well as their chemical and mechanical properties.
“Properties similar to injection molding”
Kumovis technologies and workflows are more cost-efficient and time-saving than using conventional processes such as milling or injection molding, particularly when it comes to manufacturing patient-specific medical devices and small series. The company also offers a variety of resorbable and other polymers in addition to the well-known PEEK for fused layer manufacturing in medicine. The expanded portfolio now includes PEEK reinforced with carbon fiber (PEEK CF), as well as a PPSU material that is mixed with barium sulfate (PPSU + BaSO4) for improved X-ray visibility. PEI and the resorbable polymers PLLA, PLGA, PCL and PDO are also part of the range that is processable by the Kumovis R1 3D printer.
“The positive response from the industry has been steadily growing since the introduction of the Kumovis R1 series in summer 2019,” said Stefan Leonhardt, Co-CEO and co-founder. “With this dedicated production system, the medical technology industry can process materials such as PEKK and PPSU in addition to the well-known PEEK in a reproducible way. And what is more, we achieve mechanical properties that are currently unique in 3D printing with polymers and can be compared to those of injection molding.”
Kumovis R1: From build chamber to integrated clean room
This is, among other things, due to the laminar air flow that allows for creating a homogeneous build chamber temperature of up to 482 degrees Fahrenheit (250 degrees Celsius). The patent-pending local cooling system helps to cool the molten polymer in a targeted manner, as well as adapted for each strand and layer. In this way, Kumovis takes processing high-performance polymers to an industrial level regarding mechanical properties, aesthetics, reproducibility and usability.
With the built-in filter system, users can turn the R1’s build chamber into a clean room environment that corresponds to ISO Class 7 based on the measured particle count. Kumovis R1 is also suitable for use in existing clean room environments. The start-up moreover reduces the risk of filament or build part contamination with the materials used for building the 3D printer. Kumovis also offers documentation and monitoring software solutions to help companies demonstrate compliance with parameter ranges in process validation.
Application tests successfully completed
The company supports both medical device manufacturers and hospitals in developing products and qualifying plants (IQ, OQ, PQ), as well as validating processes. To do this, Kumovis draws on interdisciplinary expert knowledge in mechanical engineering, medtech and polymers technology, as well as experiences with regard to funding programs. Applications implemented using the Kumovis R1 3D printer have already passed first ASTM testing. An example is the successful completion of worst-case load tests for spinal cages according to ASTM F2077. Another possible application of Kumovis technologies is the additive manufacturing of individualized implants for maxillofacial surgery and neurosurgery.
To further improve the competence of staff, Kumovis keeps expanding its team. From now on, the start-up publishes short explanatory videos called “Kumovis Insights” to offer, among other things, further first-hand insights into the advantages of special materials. At Formnext Connect from November 10 to 12, 2020, and virtual.COMPAMED from November 16 to 19, 2020, visitors to the virtual Kumovis booth will get a comprehensive overview of the new 3D printing ecosystem for medicine and the chance to reach the team directly.
DSM, SABIC, Cepsa, Fibrant, and Viscofan co-develop novel meat packaging material made from mixed post-consumer plastics
Geleen (NL), 1 December 2020 – Driven by a shared vision of sustainability and strong collaboration, DSM, SABIC, Cepsa, Fibrant, and Viscofan have together created a multi-barrier casing for meat products made via advanced recycling of post-consumer plastics. The transition towards recycled-based multi-layer films enables the packaging industry to adopt a more sustainable solution without compromising on functional performance. The development of this packaging material underlines a strong commitment to enabling a circular economy by working together with partners throughout the value chain, and addresses the increasing consumer, societal and regulatory demand for more sustainable multi-layer barrier casing solutions.
Produced by Viscofan, the newly developed sustainable casing consists of several layers of different polymers. DSM Engineering Materials supplies the high-performance certified circular polyamide (PA) Akulon® CRC-MB, and SABIC supplies the high-performance certified circular polyethylene (PE)* from its TRUCIRCLE™ portfolio of circular solutions. Both products are based on used and post-consumer plastics which would otherwise be discarded as landfill or lost to incineration. Using advanced recycling, the used plastic is converted into new feedstock, which then enters the production chain to deliver new virgin-quality materials.
Jason Zhang, VP Business Lines Performance Polymers at DSM Engineering Materials: “By introducing Akulon® CRC-MB, DSM is taking an exciting next step in its sustainability journey. The co-development of a recycled-based film for packaging applications underlines DSM’s commitment to working closely with partners, customers and suppliers to realize a more sustainable value chain and economy.”
Mark Vester, Global Circular Economy Leader at SABIC: “We’re committed to finding innovative solutions that help to capture value from used plastic which would otherwise have been discarded. This includes collaborating with players across the entire value chain to provide access to more sustainable materials, made using our TRUCIRCLE™ portfolio of circular solutions, and to work towards a circular economy for plastics. We are delighted to work with partners including Cepsa, Fibrant, DSM and Viscofan to help make this vision a reality.”
The high-performance certified circular polyamide Akulon® CRC-MB is produced through a strong value chain collaboration involving a range of partners applying a mass-balancing approach**. Firstly, SABIC produces certified circular benzene, based on materials produced via feedstock recycling of mixed-used plastics, which is used by Cepsa to make certified circular phenol. Fibrant then uses the phenol to produce certified circular caprolactam EcoLactam®, which is provided to DSM to produce its certified circular polyamide. Finally, Viscofan combines the certified circular polyethylene and polyamide to produce the multi-barrier film used to create casings for a variety of meat products.
Paul Habets, Director Marketing & Sales at Fibrant: “We’re proud that our EcoLactam® Circular is used in Viscofan’s newly developed product. This is an important milestone for us and our value chain partners supporting the development of sustainable and circular products. EcoLactam® means high-quality caprolactam with a lower environmental footprint. Together, we’re making important steps toward a carbon-neutral society.”
All of the advanced recycled materials within the value chain will have the globally recognized ISCC Plus certification and will not require re-qualification.
Multi-layer barrier films inherently offer strong sustainability advantages by helping to reduce preventable food waste – which accounts for 8% of total global greenhouse gas emissions – and extending the shelf-life of food products. What’s more, using post-consumer plastics as a feedstock mitigates the depletion of natural resources, reduces the accumulation of plastic waste and improves the environmental footprint.
Óscar Ponz, Chief Plastic Business Officer at Viscofan: “By combining our capacity for innovation and the latest available technology, we have today reached a unique solution in the market using post-consumer recycled plastics. In our sustainable casings program, next to today’s achievement, we’re also in a position to offer bio-based alternatives to our customers. Today’s announcement is a result of the shared commitment to make food systems fair, healthy and environmentally friendly for a more sustainable future. This important project is being developed with the collaboration of important Viscofan customers like ElPozo.”
www.dsm.com