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The K 2022 offered an immense range of innovations and application examples for – and with more – sustainable materials. Interestingly hereby was that bio-based versions were extremely popular.

Shoes made from waste gas: genetically modified bacteria produce ethanol from waste gas, which is then used to create plastic, e.g. for the Cloudprime shoes from On.

16:9

Thermoplastische Elastomere

Silikone

Messe K-Kunststoffmesse

Masterbatches

Polyethylen

Streifinger, Florian

Polylactid

Polyamide

Biokunststoffe

Kunststoff Werkstoffe

Effektpigmente

Polypropylen

Faserverbundwerkstoffe

Kunststoff-Rezyklat

Additive

Silikonkautschuk

Is Bio the New Standard?

Asahi Kasei, Kitakyushu College and Tokyo University of Science have developed a new technology for recycling carbon fiber plastic compounds.

Kohlenstofffasern / -matten

Kunststoff-Recycling

Kreislaufwirtschaft

Closed-Loop Recycling System for Carbon Fiber

Polyamide fibers need to be sufficiently flame-retardant for the use in textile applications. Flame-retardants containing halogens and coating fibers with those is a common practice, although it has some severe disadvantages. Inherently flame-retardant polymers, which are processed along with polyamide to form blends and subsequently spun into fibers, provide an attractive alternative.

Inherently flame-retardant polymers are processed along with polyamide to form blends and subsequently spun into fibers.

Flame Retardance of Plastic Fibers

Fasern

Blend

Flammschutzmittel

Kunststofffasern

Intrinsically Flame-Retardant Polyamide

At the Institute of Polymer Materials and Plastics Technology at the Technical University of Clausthal the requirements of the process were investigated, especially with regard to the necessary preparations and conditions of the plant periphery.

Extrusion of Carbon Fiber-Reinforced Polyetheretherketone (PEEK)

Extrusion of Carbon Fiber-Reinforced Polyetheretherketone

Faser- und Filamentextrusion

Filamente für additive Verfahren

Werkstoffe für additive Verfahren

Manufacture of FFF-Filaments

The FiberXpert fiber feeder is an example of how Kubota Brabender Technologie has developed new, pioneering processes and feeders from innovative ideas.

FiberXpert FX225 is ideal for feeding long, irregular fibers. 

Faserverarbeitung

Materialhandling

Feeding of Long, Recycled Fibers

Under the motto “It‘s all Wittmann”, Wittmann Battenfeld is presenting its machines and systems in the new Wittmann design for the first time.

Automation cell with SmartPlus 90 for manufacturing a spirit level.

Spritzgießen

Schaumspritzgießen

Spritzprägen

Energieeffizienz

Industrie 4.0 für die Kunststoffverarbeitung

Spritzgießmaschinen

Naturmaterialien

Green DC Current for the Injection Molding Machine

In the conception of functionally integrated and injection molding-appropriate designs, SimpaTec supports the company with up-to-date simulation expertise.

Flooded with water: the new generation of e-bike frames is manufactured by the WAIM process.

Holistic Product Development of a Carbon Fiber-Reinforced Bicycle Frame

Verbundwerkstoffe / Werkstoffverbunde

Nachhaltigkeit

Spritzgießsimulation

Analysetools, FEM

Drop by Drop

Due to the aspect of sustainability, natural fibers are interesting as reinforcements for plastics. To keep their ecological footprint as low as possible, it is advisable to use fibers from regionally grown plants.

The “perennial cup plant” is cultivated in Germany for biogas production. The fibers of the plant can be extracted from the resulting fermentation residues and subsequently used for composites.

Fermentation Residues from Biogas Production Are Turned into Fibers for Composites

Lightweight Construction with  Regional Plant Fiber

The battery system is one of the heaviest components in the powertrain of an electric vehicle. The use of lightweight materials and high-volume production processes according to requirements and functionality offers significant potential to reduce weight without compromising on safety or performance. A new technology concept shows the particular advantages of using a modified direct process with a tailored material selection.

Lightweight battery module with lithium-ion battery cells in pouch cell format and SMC module end plates.

Lightweight Traction Battery System for Electromobility

Composite-Halbzeuge

Elektromobilität

Leichtbau

Harzsysteme für Composite-Herstellung

Polyurethan

Energiespeichersysteme

Lightweight Construction  for Heavyweights

Until now, only metal has been used for the tailgates of VW cars. In its top of the line electric model, the ID.3, Volkswagen is now using a plastic-metal composite for the first time. One of the materials used for its production is a long glass fiber-reinforced polypropylene from Celanese. The material was required to not only satisfy the mechanical demands, but also enable an attractive appearance.

The ID.3 is Volkswagen’s first car with a tailgate made partly of plastic.

Tailgate of the Volkswagen ID.3: Fiber-Reinforced PP Enables the Use of Plastics

Kfz-Elektronik

Standardkunststoffe

Pultrusion

Long Fibers, Smart Look

Particularly two industries have shown considerable interest in FPP technology: aerospace industry in automating the lay-up processes of multi-material lightweight components with sandwich cores, as well as manufacturers of CFRP pressure vessels for hydrogen-powered vehicles (FCEVs), who can thus achieve savings in the double-digit percentage range. In both areas, FPP is the first technology to automate critical fiber lay-up processes in order to industrialize the production.

Laminate reinforcement of filament-wound pressure tanks. The shape of the patches and the gripper is adapted to the size and complexity  of the component.

New Applications for the Automated Production of Fiber Composite Components

Greifer

Inspektionssysteme

Industrieroboter

Automatisierungstechnik

Reinforcement on Approach

During the shredding of fiber-reinforced plastics, fiber fragments are released that settle on the skin and clothing, which can lead to itching and may possibly also be inhaled. In a project on the subject of fiber dusts, a study is being carried out on how toxic such fiber fragments are, and which shredding technology is most suitable for preventing – or at least reducing – the release of inhalable fibers.

Mechanical Recycling of Fiber-Reinforced Plastics

Fiber Dust Formation during the Recycling of FRP

Lanxess has expanded its composite range called Tepex flowcore. The product family is specially developed for various compression molding processes.

No additional injection-molded material was used to produce the ribbing on the demonstrator model. It is made entirely from compression-molded Tepex flowcore.

Ductile Composites for Compression Molding

Lightweight design with fiber-reinforced plastics saves energy resources in the use phase of automobiles and aircraft. However, the savings are often offset by higher consumption in production. Therefore, the focus is increasingly shifting to sustainability in manufacturing. The Research Institute Neue Materialien Bayreuth has conducted a corresponding sustainability analysis for the processing of thermoplastic UD tapes into functionally integrated components.

Fig. 4. The demonstrator component “2D-MultiMat” was manufactured with laminates of woven fabric organosheets and UD tapes (CF or GF/CF hybrid) based on PP and injection-molded functional integration (PP-GF) with the FORCE process chain.

Evaluate the Environmental Impact of the Production of FRP Components

UD-Tapes

Organobleche (gewebeverstärkte Thermoplast-Halbzeuge)

Schnüre, Bänder, Tapes

How Sustainable Is  Lightweight Design Really?

Short glass fiber-reinforced plastics are widely used in structural and housing components that are  permanently exposed to vibrations with frequencies up to around 103 Hz. In order to enable  appropriate dimensioning against high-frequency vibration loads, the influence of frequency on material  fatigue is investigated in this work.

Whether in kitchen appliances or in the automotive sector: thermoplastics are often exposed to heat and vibrations during their lifetime. 

Fatigue of Short Glass Fiber-Reinforced Technical Thermoplastics

Messtechnik

Alterungsprüfanlagen, Ermüdungsprüfanlagen

High Frequency Fatigue

Tapes must be stacked both with high accuracy and efficiency. In the ongoing development of its tape-stacking cell, Engel places a third focus on simplifying operation. CAD-based tape stacking, which Engel has implemented in a customer’s system for the first time, will play a role here. Further new features are the pyrolysis function for cleaning the welding elements, as well as the modular end-of-arm tooling for handling the semi-finished products.

The new modular end-of-arm tooling of the tape stacking cell increases both the cost effectiveness and the flexibility. The functional elements can be individually positioned thanks to a perforated grid.

CAD-Based Tape -Stacking

Anlagen zur Composite-Herstellung

Bildverarbeitungssysteme

Greifer für die Kunststofftechnik

Precise but Highly Efficient

Internal pressure loads are typical for fiber-reinforced plastic components. To increase the burst strength of components, the fiber orientation can be modified in a targeted way during injection molding by means of a rotating mold core. A newly developed simulation method allows this modified fiber orientation to be taken into account at the design stage.

Practical implementation of a mold system with rotating core.

Mold System with Rotating Core Improves Mechanical Properties

Werkstoffprüfung, mechanisch

Spritzgießwerkzeuge

Design Methodology for Parts Subject to Internal Pressure

Short fiber-reinforced plastics are used for many technically demanding applications. For efficient development processes and high product quality, their anisotropic material properties must be factored into the design cycle. A simple approach often taken is to reduce the material stiffness. However, a more accurate approach is to consider the effective fiber orientation. This article discusses the pros and cons of both approaches.

Water pump bFlow C as an example of a part manufactured with short glass fiber-reinforced plastic.

Universal-Prüfmaschinen für Zug, Druck und Biegung

Modellierung

Qualitätssicherung Kunststoff

Anisotropic Simulation of  Short Fiber-Reinforced Plastics

Lehvoss will be coming to Fakuma with compounds for lightweight construction applications, including those intended to serve as metal substitutes.

Lehvoss will be coming to Fakuma with compounds for lightweight construction applications

Compound

Messe Fakuma

Replacing Metals with PPA Compounds