For many years, the United States enjoyed a cost advantage for olefinic plastics because of lower prices for natural gas used to make feedstocks. It looks now like Brazil may become the country with a feedstock cost advantage because of its huge sugar cane crop. “We have needed more capacity in South America to meet growing demand for polyethylene,” says Diego Donoso, commercial director for basic and performance plastics in Latin America for Dow Chemical. “For the last two years we haven been studying alternative feedstocks.” Dow chose sugar cane as a feedstock for a projected plant for economic reasons. Sugar cane is “advantaged” any time the price of oil is over $40 a barrel, Donoso told me at the Dow Business Center at K 2007. Oil has been trading at record highs over $80 a barrel. Dow is teaming with Brazilian cane producer CrystalSev to build a 700 million lbs/yr polyethylene plant in Brazil—the biggest such plant ever contemplated. Construction is expected to begin next year and finish in 2011. The molecular structure of the finished plastic will be identical to the structure of plastics made from hydrocarbons. As such the material has no sacrifice in properties, and is fully recyclable in normal streams. The environmental argument is, of course, also compelling. Donoso told me that 4.4 pounds of carbon dioxide will be consumed for every pound of plastic created. Dow rejected any notion of making PE from corn-based ethanol because the carbon dioxide numbers did not work. Dow is the biggest producer of PE in the world. There’s another interesting note to this story. It fits into a Dow transformation process called “asset light” in which Dow reduces its equity footprint in basic plastics, whose price volatility has battered corporate profit predictability in the past. Dow and partner CrystalSev are each putting 50 percent equity in the new company that will make sugar-based PE in Brazil.
A new compression molding compound material combines the light weight, strength, and rigidity of carbon fibers with the flexibility and lower cost of glass materials in a composite compatible with automotive production.
Plastic bearings are real and millions of them are in use doing heavy-duty jobs we used to think only metals could do. Some of Germany-based igus's bearings are traveling around the world as functional parts in a car to demonstrate what they can do.
Baxter showed off his 2.0-derived moves at ATX West this year. The big red guy still looks pretty much the same, but has some new abilities, mostly due to software. The research robot version is now being used in corporate R&D departments as a design platform.
End-production using 3D printing, including objects made of multiple materials in one pass, is getting closer to reality as we saw on the exhibit floor at the recent Pacific Design & Manufacturing Show.