March 4-7, 2019 in Charlotte, North Carolina
Plastics in Motion is a unique opportunity to:
If you are interested in presenting at Plastics In Motion 2019, send an abstract to Amos Golovoy. Speakers attend the event gratis and may bring two co-workers for the price of one.
Plastics in Motion Organizing Committee:
Marco Barbolini, Röchling Automotive
Clare Goldsberry, Senior Editor, Plastics Today
Amos Golovoy, President, AG Research
Ken Kerouac, President, Source Tek
September 21, 2018: abstracts due.
January 31, 2019: last day for discounted registration and to reserve hotel rooms at conference rate.
March 4, 2019: Plastics In Motion 2019 begins
The conference will be held at the Sheraton Charlotte Hotel in Charlotte, North Carolina.
Sheraton Charlotte Hotel
555 S. McDowell Street
Charlotte, NC 28204
A block of rooms has been reserved at the special conference rate of $189/night. The Plastics in Motion group rate is available until January 31, 2019.
Reserve a room online
Attendees can click here to book their room online at the group rate.
Reserve a room by phone
Call (866) 625-4988 or (704) 372-4100 and request the Plastics In Motion group rate.
Monday, March 4 2019
Tuesday, March 5 2019
Where will the future of mobility take your business? The convergence of electrification, autonomous capabilities, connectivity, and ride sharing will drive OEMs and suppliers to rethink their business models and adopt new strategies to compete in tomorrow’s automotive market. This keynote presentation will explain the impact of disruptive vehicle technologies on the industry, identify how these technologies will change manufacturing strategies, and offer a general framework to address these challenges and compete in the evolving industry.
At present, automotive industry players are designing their innovation strategies to cope with a time of disruptive changes which are driven by aspects of a different nature:
– Socio-economic aspects related to more stringent environmental regulations and the development of new urban mobility models.
– Technological aspects related to powertrain electrification and advanced connectivity and driving assistance technologies.
– Industrial aspects that require the application of advanced manufacturing technologies in order to respond with flexibility and efficiency to an increasingly variable demand of components.
These changes have a special impact on the interior of the car, where parts and components with advanced functionalities must be incorporated in order to respond to new global trends. This presentation shows how the manufacture of these components requires the development ofplastic materials and their transformation processesto meet new technical and environmental requirements and new demands on connectivity, safety and comfort on board the vehicle.
A new generation of high-heat ABSs with significantlylower emissions than previous types are reported. These ABSs meeting numerous automotive standards and requirements of VIAQ (Vehicle Interior Air Quality) are becoming the norm for European models and now available in NAFTA. Unique PC-modification and additives have enabled the ABSs to be used in many high impact applications previously dominated by PC/ABS.
Vehicle autonomy and electrification has enabled the development of new and advanced materials/plastics, especially for automotive interior applications. These new categories of vehicles demand lightweighting, high end surface finish and functionality from the materials used in interior applications. Cpk Interior Products has developed new graphene based thermoplastic polyurethane (TPU) to address the aforementioned needs. This new material will be used for instrumentation panel and door trim applications.
This paper will discuss the product development, processing aspects and performance of TPU-Graphene and compare with current materials used in automotive interiors. The work that Dr. Farrar is presenting was carried out with Murali Reddy, Ph.D., also of Cpk Interior Products.
Driven by the increasing number of electronics, electronic components and sensors in modern vehicles, the demand for surface resistivity to repel dust on instrument panels and consoles has been a challenge for the automotive industry. We will discuss how inherently static dissipative polymers (IDP) differ from traditional antistat and conductive particle/fiber technology, allowing for a permanent solution for dust repellency on sensitive TPO components. These permanent antistats will enable charge mobility and control of static without controlled dissipation of charge imbalance to ensure optimal ESD safety and maintain static dissipative properties throughout the life cycle of plastic automotive interiors.
Microban® International, Ltd. is the global leader in antimicrobial, odor control, and surface modification technologies. Our proactive systems keep products cleaner and control odors by preventing damaging microbial growth before it starts. In this presentation, we’ll discuss how our technologies can enhance the performance of polymeric materials and provide tangible benefits solutions for manufacturers and peace of mind for consumers.
The industry for the collection and harvesting of post-consumer resins (PCR) to yield specific streams of materials has expanded tremendously in the past several years. Buckeye Polymers now has several years of refining the olefinic portions of these materials to yield input feedstreams for the production of families of high impact polypropylene copolymers and TPO’s. The characterization of the physical and mechanical properties of the PCR has allowed us to employ this feedstream as the basic ingredient within these resin families compounded on our twin screw extruders. The resulting products meet the part performance requirements for use in various automotive applications ranging from functional black plastic parts to fascias and are currently used in these applications within the industry. This technical presentation will present the data of the PCR feedstream and some of the subsequent products, as well as the analytical path taken in the development of these materials as a lower cost alternative for functional black plastic parts and automotive fascias.
With the continued focus on the increased cost of energy there is an excellent opportunity to increase energy efficiency through weight reduction of injection molded components. ‘Light weighting’ of parts while maintaining, or even improving, their performance in their respective application fields, such as automotive and aerospace fuel efficiency, is now a focal point in the injection molding industry. Direct Fiber Compounding, MuCell or ProFoam are technologies that will be discussed.
The need for lightening and therefore the replacement of metals becomes an increasingly important factor even more with a view to the evolution of the car market towards hybrid and / or full electric vehicles.
In this context Radicigroup Performance Plastics proposes solutions with new materials, especially based on on polyamides polymers, with specialty grades designed to overcome the most severe standards in the presence of high temperatures, high mechanical stresses, aggressive chemical environment.
The introduction of hybrid and electric motors poses new challenges such as the demand for flame-retardant materials, electro-friendly grades able to guarantee the safety of electrical and electronic circuits, thermally conductive materials, etc.
The presentation will show, in the case of internal combustion engines, the most important characteristics of the new materials and some examples of application of metal substitution explaining the advantages in terms of weight reduction, lower CO2 emissions, economic advantages.
For hybrid and electric vehicles, some interesting solutions with special flame-retardant materials will be presented. Next to this will be illustrated the characteristics of polymers, some of which are still experimental, including the “electrical neutral” polyamides, the thermally conductive polyamides, high performance materials for the EV batteries thermal management.
Lower vehicle weight directly translates into number of consumer and environmental benefits. Plastics, especially polypropylene compounds, have enabled significant industry lightweighting over the past decades. As pure material performance improvements start reaching their limits, the next generation weight reduction is best coupled with the deployment of foaming technology. Non-visible structural carriers made in glass fiber reinforced PP deliver up to 30% weight loss, while visible foamed parts present new potential for taking pounds out of a vehicle. We performed a systematic investigation on how to best leverage foaming technology for various automotive components and present the latest update on material solutions on offer.
The use of Glass Fiber Reinforced PP in Automotive Components continues to increase due to their favorable strength/impact balance and lower specific cost compared to engineering thermoplastics. Traditionally higher mechanical properties were obtained for these material at the expense of melt flow rate or processability.
Asahi Kasei Plastics has recently developed Thermylene® P11 family of PP-GF materials. These offer higher tensile strength at room temperature and elevated temperatures along with improved creep and fatigue resistance and high flow. This novel property balance is expected to enable OEMs and Tier suppliers to fine tune the necessary performance without worrying about any compromise. These are targeted for glass fiber reinforced PA6 and PA66 as well as Long Glass PP replacement.
Plastics are now estimated to comprise anything between 100kg to 250kg of the total weight of a modern passenger car. Thus, any method of reducing the weight of individual plastic parts is worthy of investigation.
“Assisted Molding Technologies” refers to several injection molding processes which can be “bolted-on” to an injection molding machine to improve various aspects of injection molded articles and help with “Lightweighting”.
The presentation will concentrate on TWO specific technologies:
The basic physics of each process will be explained and numerous applications of each process shown.
The importance of computer-aided engineering to design parts and optimize tooling for each technology will be discussed and several landmark case studies presented.
Chemical foaming agents are additives that are used in the molding of automotive parts. Creating a cellular structure in TPO parts allows faster cycle times, part stability and density reduction. TPO has become the dominate thermoplastic used in auto part development. It is important to understand the synergies of formula components and potential effects on physical properties of finished parts. The speaker will have case studies demonstrating cost savings and foam processing tips.
Wednesday, March 6 2019
Mr. Herrmann held an executive position at Automotive Plastics from 1965 until 2007. He has intimate knowledge of the technical developments of thermoplastic and thermoset materials for automotive applications. He was involved in the development of interior plastic parts and systems from simple painted or metallized parts to systems and modules like front ends and cross beams and load floors as well as the development of exterior parts such as bumper systems and body parts such as fenders, hoods and tailgates.
Mr. Herrmann will discuss some of his vast experience in automotive plastics and suggest some future insights.
With all the innovations, new material usage, and advances in plastics, it is important for organizations to leverage future-focused strategy. In an age where new technologies emerge daily, how can leaders in the plastics industry ensure success? Learn about key actionable tools plastics organizations can leverage to plan and prepare for the future, today. This type of strategic foresight tests assumptions and challenges perspectives not simply for the next 3-7 years, but for the next 20-50 years.
In this interactive session, the founders of GadflyZone will provide an overview of how industrial companies can use data to improve the effectiveness of their strategic decision making process. Drawing on examples from Materials manufacturers, but applicable to all industrial companies, they will show how that sector is undergoing a familiar transition – from having been product centric for over a century to providing market-facing solutions.
Currently, both marketing and segmentation strategies at industrial enterprises rely on traditional methods such as customer feedback, sales calls and static market reports. However, innovative companies are mirroring technologies more prevalent in consumer space, such as the use of advanced data science and automated intelligence. This session will explain how industrial companies could pragmatically, and successfully, use these approaches including big data analysis and data mining techniques, to create a potent mix of result oriented & data-driven marketing strategies.
The presenters will split time between presenting the approach and demonstrating the solution via a web-based interactive app to give a flavor of how these problems are being solved, specifically applied to light weighting applications in the automotive segment.
The beauty cover is the most visible component in the engine compartment, so its surface finish is paramount. In addition, the engine cover is required to resist high dynamic loads and to absorb the noise deriving from engine vibrations. Sound absorbing materials, as polyurethane foams, are applied under engine cover polyamide skin for solving noise and vibration problems. In a conventional multistep manufacturing process, the two parts are produced with two processes and different machines and, subsequently, they are assembled with metal washers.
Sapa has developed a new One-Shot method to manufacture the engine beauty cover, where inside an injection molding machine both the molding of the component in thermoplastic material, in fiber-reinforced polyamide, and the foaming in expanded polyurethane, occur. The thermoplastic part and the sound absorbing foam are well adhered and the assembly step with metal washers is avoid. The one-shot Engine beauty cover process allows to reduce the number of production steps, the number of operators involved, the production costs, to improve the process productivity and the quality of the finished product.
Mr. Molaro is presenting on work carried out with his colleagues Innocenzo Macchiarolo, Sofia Lanzillo, and Giovanni Affinita, also of Sapa S.R.L.
Goals of this presentation include:
We developed together with Plasmatreat a unique process that bonds metal to plastic with 47MPa. The presentation will describe the process steps needed and the way the compounds are optimized to provide better adhesion. Finally we will show applications with metal inserts that use the PST technology to have sealed inserts with no leakage.
Ultrasonic Welding is a commonly used technology in the manufacturing of vehicles. The most prevalent area where ultrasonics is used is the interior components such as the individual pillars, door panels and other interior parts. Another great area that ultrasonic technology is being utilized in is fascia. With all the sensors included for safety on a bumper, we have seen an increase in the usage of ultrasonic technology here. Lastly when opening the hood there are many plastic parts such as filters, motors and other components that are welded together with ultrasonics. In our presentation, Herrmann will give an overview and an outlook on the trends and technology developments that help manufacturers meet the requirements of today and tomorrow.
Industry standard spoilers for SUV segment consist of a painted PC/ABS upper piece bonded to a PC/ASA lower piece or painted PC/ABS. Nissan, Branson and INEOS Styrolution partnered in determining the feasibility of using an ASA molded-in-color lower material for ultrasonic welded spoiler application. A DOE was conducted by varying the energy input into the ultrasonic weld for different material combinations. The ASA-PC/ABS combination had equivalent bond tensile strength to that of the current system at all 3 energy inputs.
Consumers continue to demand high quality surfaces both inside and outside of their vehicles. Consequently, Class-A surface is one of the carefully scrutinized quality requirements by automotive producers. Polypropylene compounds, used in ever-increasing number of applications, are key for achieving outstanding part aesthetics.
Over the years, Borealis has invested into developing new material solutions and technologies to support Tiers and OEMs in fulfilling consumer wishes for durable, scratch resistant, defect-free and high-quality painted parts. We will share update on some of the latest material developments and market success stories.
Experimenting with big data led Faurecia to a deep transformation of its industrial operations. Sources of productivities, not addressable until now, were uncovered during an exploratory phase. Demonstrating the capacity of big data to identify problems & help resolving them, as well as predict risk of coming nonproductive events. A pilot phase confirmed the value to industrialize the solution, and led Faurecia on the path of a complete digital transformation, from connectivity of machines to the one of operators. Going through the setup of a complete IT architecture including a Data Lake. To benefit fully of the use of Big Data to reach beyond Operational Excellence. And much more:
This presentation, a vivid demonstration with real examples, offers to go through the adventure of this development.
To convince Big Data is key to increasing Industrial Performance.
This joint presentation from iD Additives and Sumitomo (SHI) Demag focuses on increasing production efficiency of injection molded automotive parts by light weighting resin, limiting warp, reducing cooling time, and reducing the overall cycle time through the use of foaming agents in high speed machinery. The faster you can inject a part, the more foaming agent you can use, which leads to greater weight savings, less molded-in stress, and better surface quality. A case study will be presented which shows how foaming agents can be used in high speed machinery to give customers better quality parts and greater savings without sacrificing physical properties that are often a result of thinning the walls.
Understanding how material properties change during the molding process is critical for simulations to address big molding challenges such as warpage. Incorporating phenomena such as cooling rate effect on P-V-T and viscoelasticity behavior change from melt to solid state allows simulation to get a higher level of accuracy in warpage predictions. In this study, the geometries of both plaque and hat-section beam are investigated. A Design of Experiments (DOE) is conducted on both these geometries using which effect of conditions such as packing pressure, cooling time are studied on warpage. The warpage prediction of all the cases is performed in Moldex3D and the results are compared to the real part shape obtained from Digital Image Correlation (DIC) analysis.
Mr. Yang’s presentation will cover his work with Xianjun Sun, Danielle Zeng, Lingxuan Su, and Patricia Tibbenham of Ford Motor Company, as well as his colleagues at Moldex, Alex Baker and Susan Lin.
Over the past 30 years, numerous items have been transformed from metal to plastic in the auto industry. There were certain targeted applications that could not move to plastic due to factors such as: fuel resistance, tight tolerances, vibration, and mechanical strength. In the last decade, Helvoet has successfully introduced applications moving from metal to plastic in the powertrain system including demanding applications in: fuel, air management, transmission, and brake systems. This presentation will discuss the road map to these achievements, and the end result of what is now tens of millions of components.
No matter how large or small of a molding operation, custom or captive, there is a great demand for automotive plastics processors to lower the cost of the molded parts, increase the productivity of their equipment and improve the quality of their parts, all the while maintaining healthy margins. This can be a balancing act between using the most effective technology while working within a shrinking budget.
This presentation discusses the advantages of dry ice cleaning solutions in a variety of automotive applications: 1) as a replacement for solvent and/or mechanical cleaning for the removal of contaminants from mold cavities and vents while the molds are at operating temperature and still in the machine, 2) deflashing plastic molded parts, 3) removing excess film from IMD parts, and 4) the surface preparation of molded parts prior to painting or coating, replacing traditional aqueous/chemical washing/drying. While the principles discussed in this presentation are applicable to multiple plastics processes (Blow Molding, Extrusion, Thermoforming, etc.), the focus of this presentation will be on injection molded parts being made on the various steel and aluminum mold substrates commonly used. Supporting research from several independent studies (Kettering University, Materials & Process Associates, etc.) will be presented along with industry case studies, pictures and video clips to demonstrate the various proven solutions.
The attendee will achieve an understanding of how utilizing dry ice solutions will reduce costs, improve quality, increase productivity, extend the asset life of the mold, and improve the environmental quality and worker safety in their molding operations. They will also obtain a benchmark understanding of the operating theory and principles behind the dry ice cleaning and surface preparation process. Prepare to believe in magic!
Thursday, March 7 2019
Automakers and their suppliers continue to seek light weight solutions for structural automotive components while also delivering component performance requirements. This paper examines the properties of hybrid composite blends using polypropylene reinforced with both long glass fiber and cellulose fiber. These blends offer a balance of stiffness and impact strength while also incorporating a natural fiber component weight and sustainability benefit. These blends have demonstrated unanticipated benefits of lowering both cycle time and injection molding energy consumption by 25% or more. While that benefit is not thoroughly understood, the result is consistent across many different parts and molding sites.
Recently, there has been an increasing interest in the use of carbon fiber reinforced plastic (CFRP), in the automotive industries, due higher strength to weight ratio compared with traditional metals. It is worth noting there is five-fold increase from the number of car models using CFRP compared to decade ago, which lends support to the assumption that carbon fiber demand by the automotive industry will rise sharply in coming years as light-weighting becomes increasingly important. CFRP market expect to grow 20% by 2020 for automotive applications. A key bottle-neck for CFRP growth is its pricing due to several expensive processing steps and materials (figure below)- including a very expensive UV coating (~ $500/lb) followed by clear coat (~ $ 5MM investment). These additional expenses make CFRP lees-affordable to automobile markets.
The paper describes a novel one-stepmethod of forming stacked CFRP in which thermoplastic polyurethane films (TPU), especially Estane®paint protection films (PPF) applied and/or impregnated to eliminate the use of UV coatings & clear coatings to impart properties such as weathering, scratch, abrasion, improve esthetics, water-proof, and corrosion resistance. Another method also includes use of colored TPU films to eliminate in-line defects when using uni-directional carbon composite. This novel method eliminated extra processing steps (putty and sand-paper). Several trials have been completed and auto OEMs viewed the invention as ‘disruptive’ and predicting an impact on the CFRP market growth.
High cost pressure within the automotive industry forces automobile manufacturers as well as their suppliers to lower production costs at both ends. However, at the same time vehicle weights are increasing due to electrification and the ever-growing comfort. To compensate the addressed, lightweight parts with a high degree of functional integration are needed and to be produced in short cycle times.
This paper will present several innovative injection molding applications for the serial production of endless fiber reinforced thermoplastic parts with KraussMaffei FiberForm technology. It’ll also present the automation and heating process of the organo sheets, which is being behind it, and important to reach cycle times under 60s. The individual production steps will be presented to the audience in detail to explain the technology, which leads to an economic advantage compared to conventional composites manufacturing processes.
This study focuses on the hybridization of Benzoyl Peroxide (BP) treated Banan-Sisal Fibre (BSF) combination and its subsequent reinforcement with PLA matrix to enhance mechanical properties of BSF-PLA composites that are ideally suited for automobile applications. The alkali treated fibre followed by BP treatment gave higher values tensile, flexural and impact strength for T-BSF/PLA composites than UT-BSF/PLA composites and virgin PLA matrix. The above chemical treatment enhanced fibre/matrix interaction significantly by eliminating hemicelluloses and allied impurities, which further improved the impregnation of BSF within the PLA matrix. The results of the study discovered that BP treated BSF improves the compatibility between the PLA matrix and BSF through cross linking. Furthermore, extrusion and injection molding of BSF reinforced PLA composite has been found to be an ideal route to fabricate BSF/PLA composites exhibiting better mechanical properties. The SEM micrographs of UT-BSF/PLA and T-BSF/PLA composites clearly indicate that the nature of bonding established between fiber and matrix was physico-chemical. Thus, we tend to conclude that the systematic and protracted analysis of this present study may pave an avenue to an increased scope and future for BSF reinforced PLA composite for automobile applications.
Mr. Kumar will be presenting on his work with B. Asaithambi, Department of Manufacturing Engineering, Annamalai University, Chidambaram, Tamil Nadu, India
Selection of vinyl ester or unsaturated polyester resin for the production of carbon fiber reinforced polymer (CFRP) composites can offer many benefits, including ease of processing and economy. The performance and mechanical strength of these composites is directly correlated to the adhesive strength between the resin matrix and the carbon reinforcement. In this paper, we present a new additive, BYK-C 8013, that has been developed as a coupling agent for these vinyl ester and unsaturated polyester systems. BYK-C 8013 enhances and strengthens the adhesion between matrix and reinforcement. We demonstrate how addition of BYK-C 8013 to a CFRP vinyl ester system increases the mechanical strength (flexural and transverse to the fiber) and describe how this allows greater design freedom and performance for such systems. Furthermore, we demonstrate how BYK-C 8013 may be added at different stages in the manufacture of such a composite, either being added to the resin before processing or applied directly to the dry carbon fabric as a new technology, “Second Sizing.”
It is desirable to use polymer composites to replace metal components for weight saving purpose in some automotive, aerospace, sport and building applications. Although this effort has been successful in many engineering components, there is a challenge to replace those parts which require high strength, stiffness and toughness in particular components. The current state-of-art technology of fibre and filler reinforced composites and nanocomposites has failed to achieve this, often enhancing one or two properties with sacrificing other properties. This presentation will introduce a new generation polymer composite which can achieve very high strength and stiffness without sacrificing toughness of the material.
Professor Gao will be presenting on his work with Isaiah Fasanya and Carl Brown, also of the School of Science and Technology, Nottingham Trent University.
Sponsors of Plastics in Motion receive many benefits, including two admissions to the congress, a tabletop at the exhibit, as well as their company logo displayed on the website and on screen during conference breaks. If you are interested in sponsoring Plastics In Motion 2019, please contact us.