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NPE2018 Show Daily - Thursday

NPE is truly ‘Breaking the Mold’ as a multifaceted experience, with activities, discoveries and opportunities to satisfy the needs of anyone who works in the plastics industry or has a need to know about plastics

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THURSDAY NPE 2018 : THE PLASTICS SHOW SHOW DAILY EXTRUSION | PRINTING | CONVERTING Booth W6663 WINDMOELLER & HOELSCHER P A S S I O N   F O R   I N N O V A T I O N If you extrude, print on or convert film, we manufacture the machinery you need. Technology you can count on. Come see what's new: TURBOCLEAN automated resin purging for fast job changes Film Performance Monitor (FPM) for FILMEX II cast film lines www.whcorp.com Funcঞonal Products 3D Printed with Carbon's Digital Light Synthesis Carbon's Digital Light Synthesis (DLS) technology creates high-quality, isometric parts suitable for consumer applicaঞons such as the midsole for the Adidas Futurecra[ 4D. By Stephanie Hendrixson Addive Manufacturing Digital Light Synthesis (DLS), a proprietary 3D prinঞng technology developed by Carbon, is said to eliminate the need for tradiঞonal proto- typing and injecঞon mold tooling to bring products to market. The technology is an alter- naঞve to injecঞon molding for manufacturing end-use parts across industry verঞcals, includ- ing consumer goods, industrial parts, dental and life sciences. Examples of 3D-printed products made with DLS from Adidas and Vita- mix are on display in Carbon's Booth S24160. Digital Light Synthesis depends on Conঞnu- ous Liquid Interface Producঞon (CLIP), a pho- tochemical process that projects light through an oxygen-permeable window into a reservoir of UV-curable resin. As a sequence of UV im- ages are projected, the part solidifies and the build plaorm rises. A thin liquid interface of uncured resin between the window and print- ing part forms a dead zone where resin can flow beneath the curing part as the print pro- gresses. A[er prinঞng parts are baked in a forced-circulaঞon oven, seমng off a chemical reacঞon that strengthens the material. Accord- ing to Carbon, parts made this way are isotro- pic and have consistent, predictable mechani- cal properঞes as well as smooth surfaces. Adidas is using the speed and design com- plexity enabled by DLS in its development of the Futurecra[ 4D line of high-performance footwear. The "athlete-data driven" shoe in- cludes 3D-printed elastomer laমces, creaঞng midsoles made with DLS. The midsoles' laমce design is a "previously impossible" geometry made possible with DLS that offers good ener- gy return for athletes. Material selecঞon proved to be criঞcal for the Futurecra[ 4D applicaঞon, as Adidas re- quired a producঞon-grade elastomer to achieve a sঞff but resilient midsole. Carbon iterated more than 150 different formulaঞons for the elastomer material used in the Future- cra[ 4D midsoles. Now, the company is un- veiling another material in this family that of- fers even higher resilience: EPU 41. The new material premieres here at NPE2018 along with EPX 82, a high-strength engineering ma- terial with good long-term durability. In another case, Carbon partnered with Vi- tamix and The Technology House (TTH) to re- design and manufacture a durable microfluidic nozzle used for rinsing and cleaning Vitamix blenders in commercial seমngs. These nozzles must withstand high water pressures and ex- posure to bleach, detergent and saniঞzers. The exisঞng nozzle was made as an assem- bly of six injecঞon-molded pieces. TTH copied the exisঞng design and 3D printed these piec- es using its Carbon SpeedCell equipment and Rigid Polyurethane (RPU) material. Making these parts with DLS helped to eliminate tool- ing costs and reduce part lead ঞme. But, the team then went farther, redesigning the noz- zle to be 3D-printed in one piece, removing assembly and secondary operaঞons costs. The new nozzles are lighter, cost less and offer 10 ঞmes improved durability over the previous design, Carbon says. Trend Watch: Versaঞlity on Display An example of eye-catching molding displays at NPE: This Arburg automated cell molds watchstraps in two colors and durometers of LSR and assembles complete watches. By Mahew H. Naitove Plascs Technology This year, expect to see mulঞ-material mold- ing and integrated mulঞ-process cells taking center stage. Also, desires to eliminate costs of assembly or secondary operaঞons has led to trends such as molding parts with mulঞple colors, hard and so[-touch components, and combinaঞons of thermoplasঞc and thermo- set—liquid silicone rubber (LSR) or liquid ure- thane coaঞngs. Also look for displays dedicat- ed to in-mold decoraঞng or labeling, as well as rotaঞng "cube" stack molds for integraঞng the process of combining materials and in-mold assembly operaঞons. A popular replacement for a mulঞ-barrel injecঞon machine is a standard machine con- verted with auxiliary add-on injecঞon units that sit on the floor beside the clamp or mount verঞcally on a platen. Advancements in these units are conঞnuing, now including all-electric versions and the ability to add LSR capability to a standard machine. New developments in foam injecঞon mold- ing focus on adding versaঞlity by allowing for physical foam molding on a standard machine with lile or no modificaঞon. Another way machine builders are display- ing versaঞlity is simply through the strategy of their basic machine design. Look for presses based on the concept of modularity to enable a range of customizaঞon while sঞll remaining affordable, as well as more efficient clamp designs that do more with a smaller footprint. Two-platen presses for saving space can now be found at all size ranges, and innovaঞons in the specs of toggle clamps are expected to be forthcoming. 22

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