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WELDING
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Computer simulation of laser welding.
As laser welding of plastics becomes more widely used it becomes correspondingly important to know just what is happening - or what should be happening - in the weld. DuPont Engineering Polymers and TWI (formerly The Welding Institute) have got together to devise a computer model of the laser welding process. S D Rostami, I A Jones (TWI) and C Norrey (DuPont Engineering Polymers) describe the work.
PIPE & PROFILE EXTRUSION
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Nylon 12 takes the pressure in gas pipe.
Nylon 12 gas pipes have been in use commercially for the past 20 years in countries including Australia, New Zealand, Poland and Chile. And as the gas industry moves towards higher delivery pressures, nylon 12 is seen to have increasing advantages over polyethylene and PVC.
Rewinding offline takes the brakes off extrusion.
Pipe Coil Technology has introduced equipment which separates the coiling process from extrusion. The company says that small diameter pipe, tube and hose is traditionally wound at the end of an extrusion line but automatic coiling equipment for each line is expensive and output is often limited by the coiling process.
European approval for Dowlex-based pipe system.
Underfloor heating systems and radiator connections made in Dowlex 2344 PE-RT Type 1 pipes have been awarded a European Technical Approval. Dow Europe says that this is the first time any pipe system has been given an ETA.
Flexible calibration and line control change pipe diameter and class on-the-fly.
Changing pipe diameter or pressure class is a time-consuming operation which reduces the effective production time of an extrusion line. In recent years a few devices have been brought to market which can change pipe specification without stopping the line. The most recent was introduced towards the end of last year by iNOEX of Germany.
Pump handles multiple cooling requirements for clean room extrusion.
A pump has been developed by FT Refrigeration for medical plastics extrusion operations where a single cooling system is required to cool several processes at different temperatures in a clean room environment.
New developments expected to drive WPC extrusion to greater heights.
Filling thermoplastics to high levels with wood flour has created a class of plastics - wood plastic composites - with unique properties and applications. They have been taken up enthusiastically in the USA, but the forecast growth in Europe is yet to come. Brian Hackwell reviews developments in the technology and suggests that the latest generation, which gives improved end products, could trigger the promised European growth.
Battenfeld builds quieter calibration tables.
To pre-empt EU guideline 2003/10/EU Battenfeld Extrusionstechnik has adapted its calibration tables to reduce noise and energy consumption. The guideline, which becomes effective in 2006, stipulates minimum requirements for employees' health and safety against hazards such as noise.
Add transverse patterns without post processing.
A device to produce transverse relief patterns on extruded profiles without post-processing has been developed by a Swedish company.
Standard profile downstream for Cincinnati Alpha.
A packaged line for small rigid profiles is now available from Cincinnati Extrusion to work with its Alpha extruder series. The new downstream has been named Alpha Profline and is available from Eur 46,000.
REACTION PROCESSING
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Silicone and PU gaskets from the same mixing head.
In-situ gasketing normally uses polyurethane, but there are applications where the operating temperature is too high for conventional polyurethane. The answer is to use foamed silicone systems, and Cannon has developed a cost-saving machine which can handle both materials.
FILM & SHEET CONVERSION
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Glove machine is faster and more efficient.
A faster machine for making disposable wrist-length gloves has been introduced by Cibra of Italy.
Lenticular sheet creates 3D signs.
A new type of acrylic sheet known as Perspex Lenticular has been developed by Lucite for the production of Solid Vision 3D signs. These are said to be set to 'revolutionise' street furniture and outdoor advertising.
Infra red pre-heating improves control of hot embossing.
Heraeus Noblelight carbon medium wave infra red equipment has enabled API Foils to achieve higher line speeds and better heating control in the hot embossing of holographic foils.
Polycarbonate replaces steel in nuclear plant safety guards.
Guards for nuclear equipment used by British Nuclear Fuels have traditionally been made of steel but Barkston has been commissioned to design and manufacture a prototype for a plastics guard for a rotating component used in UK plants.
Syntactic foam plugs reduce forming cycle times.
Hytac syntactic foam has been launched by D4R-CGP Europe for the production of plug assisted in-line thermoforming packaging such as yogurt pots, beakers, containers, flower pots and blister packs for food or pharmaceuticals.
Single station formers from Thermoforming Solutions.
ADTS single station thermoforming machines are new from Thermoforming Solutions.
New TFT former selling in the UK.
Henry Lenox Industrial has taken a number of orders for the TFT FC 600 E form, cut and stack thermoforming machine which was introduced last year. British Falcon Plastics of Paignton has installed one for medium length runs.
ADDITIVES
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Colour Tone enters liquid colour masterbatch market.
Colour Tone Masterbatch is spending £125,000 to move into liquid colour masterbatch. The company has set up a new division called Colouring Solutions and the money will be invested over the next year in plant and technical resources at its plant in Bedwas.
All-PVC colour masterbatch for window profiles.
PVC masterbatch specialist Astropol has developed a new colouring concept for uPVC extrusions, particularly window profiles.
Colour and additive masterbatches for biodegradables.
PolyOne has introduced a new European range of colour and additive masterbatches for biodegradable resins. They include anti-block, slip, denesting agents, laser-marking additives and optical brighteners.
Process aid improves PC moulding.
The efficacy of MoldWiz processing aids in polycarbonate injection moulding has been demonstrated by UK distributor Genie Kenraw in trials over the past six months with several of its customers.
Injection process aid for nylons and ABS.
Sasol has developed a new process aid that improves the injection moulding processability of ABS and polyamides, both filled and unfilled, enabling lower temperature profiles, faster plasticising, easier mould filling and shorter cooling times.
Masterbatches for agricultural films and monofilaments.
Italian masterbatch producer Viba has introduced new light stabilizers for agricultural products which last for three to five seasons depending on location and climate.
Polymeric plasticiser replaces phthalates.
Hyperlast has developed a new polymeric PVC plasticiser to replace phthalates or enhance conventional plasticisers.
Spherical boron nitride fillers keep chips cool.
GE Advanced Materials has introduced PolarTherm XLR boron nitride fillers to dissipate the increasing heat generated by smaller and faster semiconductors.
Higher output for latest gravimetric blender.
The latest Multi Weigh blender from Colormax incorporates the Posimax B300 solid phase pumping feeder and is designed to blend and feed screwlessly up to four materials simultaneously at significantly higher rates than the standard Multi Weigh.
Enclosed weighing and mixing keeps dust contained.
The new Conair TrueBlend gravimetric blender has a completely enclosed weighing and mixing section to prevent the escape of fines and dust.
Free software minimises ingredient cost.
K-Tron Feeder Group says that processors can minimise total ingredient cost by using its new FeedSmart recipe optimiser tool. Recipe proportions for each ingredient are entered with cost per ingredient and feeder setpoint tolerance range and the tool replaces expensive ingredients with components of lower cost where permissible.
MATERIALS HANDLING
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Braby expands its materials handling interests.
Silo manufacturer Braby has been expanding its operations, taking on distributorships. It now represents a German big bag unloading system and is in partnership with a Belfast-based plastic silo builder.
Energy adapted to drying demand.
Koch Technik equips its new KKT driers with a control which allows energy consumed to be adapted to actual material throughput and the characteristics of the granulate.
Angled body improves access to hopper loader.
The latest Conair Access self-contained hopper loaders have an angled body making it easier for maintenance personnel to see and reach inside for cleaning.
INJECTION MOULDING
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Milacron delivers its first Chinese-built injection machine.
Milacron's Chinese joint venture with Jiangnan Mould & Plastic Technology Co has delivered its first Chinese-built injection moulding machine - the first of a number ordered by Jiangnan for delivery this year.
Screw and barrel cleaner purges high temperature materials.
Polyklene R is a new granular cleaning material from CRC to remove residues from barrels, screws and hot runner systems.
Rapid insert change without damaging the pressure sensor.
Kistler has introduced the Type 6155AE mould pressure sensor based on an adaptor to allow tools to be disassembled and inserts changed rapidly without risk of damage to the sensor or its cable.
Nissei hybridises its FN series.
Nissei has introduced electric screw drive for its FN series of eight machines from 80 to 460 tonnes. The recently introduced TACT control system is also now used and the design's hydraulic circuits have been improved.
No need to replace interlocks.
Interchangeable wear surfaces of new DME IN2 interlocks eliminate the need to replace the entire side interlock.
AUTOMATION
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Up to six-axis articulation for heavy tooling.
New Wittmann 7-Series linear robots are intended for injection moulding machines up to 2,000 tonnes and can handle large automotive or appliance components or insert moulding with heavy end of arm tooling.
Tool change target for steelmaking support company.
Corus Northern Engineering Services has linked with Tool Change Systems to offer tool change equipment, services and consultancy to injection and blow moulders, particularly those engaged in the automotive and aerospace industries.
ENGINEERING MATERIALS
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Innovative TPUs from Distrupol and PTS.
Distrupol has added two new ranges of plasticiser-free super-soft thermoplastic polyurethanes to its product portfolio while Plastic Technologie Service in Germany has been working with Bayer on soft TPEs incorporating Bayer's TPUs.
Long-fibre glass-reinforced PBTs.
GE Advanced Materials has introduced two new grades of glass-reinforced LNP Verton polybutylene terephthalate intended as alternatives to competitive short-fibre glass filled PBTs, polypropylenes and nylons.
High glass content masterbatch cuts the cost of long fibre PP.
Arkema has developed a new Pryltex long-fibre glass-reinforced high content range with 50 and 65 per cent glass fibre contents which is used as a masterbatch to create glass fibre reinforced PP at varying concentrations.
Nano technology blends PP and PS.
Using a modified nano additive, German companies Sud-Chemie and Putsch Kunststoffe have succeeded in manufacturing the first completely compatible blends of polypropylene and polystyrene.
PACKAGING MATERIALS
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A secure future for polymer pricing?
The London Metal Exchange is about to begin a system of futures trading for commodity plastics. Futures trading smacks of big business, but the LME's Director of Exchange Development Neil Banks explains how smaller businesses can also benefit from plastics futures contracts.
Ticona COC forms films practically free of gels.
A second generation cyclic olefin copolymer (COC) material from Ticona produces highly transparent blown films that are practically free of gels.
Corn-based co-monomer promises stronger bottles.
A collaboration in the USA between the Iowa Corn Promotion Board and the Department of Energy's Pacific Northwest National Laboratory has opened the way for the production of isosorbide from corn-derived glucose which can be copolymerised with plastics such as PET.
RECLAMATION & RECYCLING
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Welsh plant aims to become a major centre for agricultural recycling.
A group of companies in South Wales is developing a recycling centre with an emphasis on reclaiming the agricultural plastics waste that farmers are about to be banned from burning or burying.
COMPOSITES
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Cage System may be the way to Class A composite surfaces.
The Cage tooling system developed by RocTool Company has attracted the attention of Azdel which is evaluating the system for the production of thermoplastic composites with a Class A surface finish.
TESTING & INSPECTION
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World class imaging technologies for Midlands SMEs.
Small and medium sized business in the West Midlands can now benefit from some of the most advanced imaging and visualisation technologies in the world thanks to a new initiative launched by the University of Birmingham. These include technologies that can visualise and interact with 2D and 3D data in life-size active stereo, or accurately capture data in 2D and 3D from the microscopic to a landscape scale.
New tensile and compression test frames from Mecmesin.
A range of motorised test stands for tensile and compression testing has been introduced by Mecmesin.
Instron adds thermal test chambers.
Instron SFL has introduced the first of a planned range of affordable thermal environmental chambers for testing materials under extremes of temperature - up to 350 degC, with optional cooling down to -70 degC.
TEMPERATURE CONTROL
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Improved control options for low cost temperature control unit.
Regloplas now offers its 90smart low cost mould temperature controller with an integrated RT60 controller at slight extra cost.
PROTOTYPING
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Stratasys introduces PC-ABS prototyping blend.
Stratasys is claiming a first for a PC-ABS blend material it has produced for use with its fused deposition modelling rapid prototyping and rapid production machines.
Now you can have coloured prototypes without painting.
The Manufacturing Engineering Centre at Cardiff University has become one of the first organisations in the UK to offer rapid prototypes in colour commercially.
Direct metal laser sintering for moulds.
The University of Wolverhampton's Innovative Product Development Centre has set up a rapid metal tooling and components service, using the direct metal laser sintering technique.
TOOLING
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Delcam's PS-Moldmaker brings 'intelligent' 3D mould design.
The latest version of Delcam's PS-Moldmaker 3D mould design software combines in-built 'intelligence' to ensure the most appropriate mould components are used with automation to speed the design process and flexibility to manage design changes efficiently.
Fast and easy positioning for laser welder.
Repairing tools with a laser welder has been made easier by Rofin-Baasel which has developed a laser welding system that speeds up operations on larger moulds and workpieces by using a weight-compensated cantilever arm for positioning the welding head.
SOFTWARE
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3D meets what-if.
Clive Maier tries a pure 3D mould filling simulation program that has found its way round long processing time that prevents what-ifs in conventional 3D simulation.
Moldflow-ANSYS interface brings realistic structural analysis.
The highlight of release 5.1 of Moldflow's Plastics Insight is an interface to ANSYS structural analysis software which enables users to export thermo-mechanical properties, fibre orientation and either process-induced residual stress or volumetric shrinkage data from MPI 5.1 to ANSYS software for more in-depth structural analysis.
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