There have been major moves under way to improve bottle design. Triggered by huge price hikes for plastics last year, the first trend features thin-walling, which is also a green improvement. A process refinement enabled a 19 percent weight reduction, saving over three million pounds of plastic annually in a Kraft salad dressing bottle. The optimized bottle design increased shipping efficiencies by 18 percent by allowing a greater number of bottles shipped per truckload. There has been an explosion in bottle thin walling in the past 18 months.
There has also been a huge improvement in the use of recycled PET in bottles. One of the leaders is Coca-Cola, which is developing a joint venture plant in South Carolina to produce food-grade recyclate. Capacity of the plant will be one billion pounds/yr, with half of the capacity being used by Coke and other half sold to external blow molders. Virtually all of the raw materials will be coming from municipal recycling programs. Coca-Cola Co. said it will boost recycled content of its PET bottles to 10 percent by the end of 2010 and 25 percent by 2015. Coke had reached 10 percent recycled content in North America in 2004 and 2005, but the level slipped to 3 percent or less. Coke’s wants to keep recycled material cost neutral with virgin PET. There is so much demand now for recycled PET that there actually is a shortage of supply.
BMW has already incorporated more than 10,000 3D-printed parts in the Rolls-Royce Phantom and intends to expand the use of 3D printing in its cars even more in the future. Meanwhile, Daimler has started using additive manufacturing for producing spare parts in Mercedes-Benz Trucks.
SABIC's lightweighting polycarbonate glazing materials have appeared for the first time in a production car: the rear quarter window of Toyota's special edition 86 GRMN sports car, where they're saving 50% of its weight compared to conventional glass.
Design engineers play a big role in selecting both suppliers and materials for their designs. Our most recent Design News Materials Survey says they continue to be highly involved, in some ways even more than the last time we asked to peek inside their cubicles.
Daihatsu is one of the first carmakers to customize car exteriors using 3D printing's mass customization capabilities. Effect Skins -- small exterior bumper and fender panels in different colors and textures -- can be ordered for its Copen convertible.
Several new products in this group of new adhesives, coatings, and sealants are formulated to protect sensitive electronic components, or to seal components of commercial and military aircraft. Others are designed to operate in tough, messy, dirty oil & gas operations, or for rotary applications and motors.
Focus on Fundamentals consists of 45-minute on-line classes that cover a host of technologies.
You learn without leaving the comfort of your desk. All classes are taught by subject-matter experts and all are archived.
So if you can't attend live, attend at your convenience.