Engineers are looking for ways to boost value and gain business. One example comes from Mazda, which is leveraging a plastic foaming process developed at MIT. Mazda’s injection molding process cuts part weight 20 to 30 percent by mixing supercritical fluid with plastic resin, such as nylon, in the injection barrel. The SCF causes the melt to expand rapidly when injected into a mold, requiring less resin. After initial injection, the mold core is precisely retracted, creating an outer layer with microscopic bubbles that ensure each part has the necessary strength and rigidity. The size of the bubbles in the core layer are adjusted to reduce density as desired, thus allowing control of the resin savings. Mazda says the technique can be used on most plastic car parts, and will be introduced on 2011 models.Mazda’s initial announcement called the technology proprietary, and Mazda has in fact been awarded patents for the development. Mazda, however, neglected to mention that the microcellular foam technology was developed at MIT and licensed to a Massachusetts company called Trexel. More than 300 molding machines use the SCF technology. Eighty-five discrete components have already been developed for use in cars, Trexel President David Bernstein told me in a recent meeting in Woburn, MA. MuCell works best with semi-crystalline engineering resins.
Mazda apparently did develop the concept of using core-back or “expansion” molding with the process, a brilliant idea. Trexel and Engel will be showing their approach to core-back molding at the National Plastics Exposition in Chicago June 22-26.
I’ll be posting more ideas on microcellular foam here at www.designnews.com, and writing articles for the print edition as well. One big issue I’ll explore is how the microcellular foam process can improve component properties.
A recent report sponsored by the American Chemistry Council (ACC) focuses on emerging gasification technologies for converting waste into energy and fuel on a large scale and saving it from the landfill. Some of that waste includes non-recycled plastic.
Capping a 30-year quest, GE Aviation has broken ground on the first high-volume factory for producing commercial jet engine components from ceramic matrix composites. The plant will produce high-pressure turbine shrouds for the LEAP Turbofan engine.
Seismic shifts in 3D printing materials include an optimization method that reduces the material needed to print an object by 85 percent, research designed to create new, stronger materials, and a new ASTM standard for their mechanical properties.
A recent study finds that 3D printing is both cheaper and greener than traditional factory-based mass manufacturing and distribution. At least, it's true for making consumer plastic products on open-source, low-cost RepRap printers.
For industrial control applications, or even a simple assembly line, that machine can go almost 24/7 without a break. But what happens when the task is a little more complex? That’s where the “smart” machine would come in. The smart machine is one that has some simple (or complex in some cases) processing capability to be able to adapt to changing conditions. Such machines are suited for a host of applications, including automotive, aerospace, defense, medical, computers and electronics, telecommunications, consumer goods, and so on. This discussion will examine what’s possible with smart machines, and what tradeoffs need to be made to implement such a solution.