DSM Engineering Plastics extends Diablo family for further
weight reduction in automotive under-the-bonnet applications

Following the successful introduction in 2007 of Stanyl Diablo OCD2100, a high performance grade of Stanyl for under-the-bonnet (UTB) applications, DSM will showcase two new Diablo high heat resins at K 2010: Stanyl Diablo OCD2300 and Akulon Diablo. Both new products are a direct response to some of the main trends in the automotive industry, including weight reduction. The new materials also facilitate system cost optimizations and productivity gains, long term sustainability and reduced environmental impact.

Stanyl Diablo OCD2300
Stanyl Diablo OCD2300 is a unique high heat PA46 material, developed specifically to meet the need for long term temperature resistance at elevated temperatures. Stanyl Diablo OCD2300 joins the family of Stanyl PA46 grades that offer a revolutionary improvement in long term thermal stability. This technology, developed and patented by DSM, extends the functional life of components well beyond the limits of other high temperature polyamides. By limiting thermal oxidative breakdown, Stanyl Diablo withstands more than 3,000 hours at aging temperatures of 230°C before its tensile strength is less than half of its initial value.

Requirements for Under the Bonnet (UTB) applications are changing constantly. Environmental requirements, EURO V and VI legislation and the call for reduced fuel consumption have resulted in significant changes, e.g. the use of smaller engines with higher turbo pressures and EGR (Exhaust Gas Recirculation). As a consequence, automobile UTB components such as air ducts, air intake manifolds and charge air cooler end-caps are exposed to continuously rising operating temperatures. With increasingly critical temperature and tougher life time requirements, long term service life of components made from current thermoplastics can be at risk. Stanyl Diablo OCD2300 is currently the only high performance PA that can withstand these temperatures whilst offering better mechanical properties than other high performance polymers for these types of applications.

Stanyl Diablo OCD2300 was recently tested, validated and released by a German OEM for use in application up to 230°C CUT, where key applications include resonators, hot charge airducts and charge air cooler end-caps.

Christian Kilgus, Business Development Manager for DSM Engineering Plastics says: "Stanyl Diablo OCD2100 and OCD2300 outperform current high heat resins on high temperature stability, but also on weldability, weld strength and the weld's long term heat stability. Part design and function can be reached more easily and, more importantly, UTB part reliability can be guaranteed for the lifetime required." Stanyl materials are easy to process. During injection molding, tool temperatures of 80°C and melt temperatures around 300°C are normally used. Short cycle times can be achieved to reduce system costs.

Akulon Diablo
To complete its Diablo portfolio, DSM will also be introducing Akulon Diablo, a high heat PA6 material. This high performance grade of Akulon was developed specifically for use in air\fuel systems, which may be subject to temperatures of up to 210°C continuous use, even 230°C over shorter periods. Akulon Diablo is currently being sampled and will be commercially available later this year.

Ralph Ramaekers, Global Manager, Powertrain Engine/Transmission & Turbo for DSM Engineering Plastics, says: "The addition of both Stanyl Diablo OCD2300 and Akulon Diablo significantly increases metal replacement options for UTB applications. Our Diablo portfolio now allows us to meet all the needs of the supply chain for air ducts. In addition, we also offer our standard Akulon PA6 solutions, Akulon Flex PA6 specifically tailored for flexible ducts and Arnitel TPE for clean air ducts. So we can now offer single-source solutions for all ducts, end caps and resonators. And we have extensive application knowledge to support customers with CAE, design and design optimization so they can meet OEM requirements."

DSM has an established reputation for delivering eco-efficient automotive solutions, offering CO₂/emission/fuel consumption reduction via metal-to-plastic conversion in applications such as air inlet manifolds and air ducts. For further information, view website: www.dsm.com

speedigus - Rapid prototyping just got faster

Polymer specialist igus has developed a new tooling method for injection moulding which can get custom designed parts delivered in less than 24hrs. As there are no minimum order quantities, speedigus is suitable for one offs, prototyping, low volumes and bridge tooling.

"Standard tool manufacture can take 4-8 weeks and is normally only available for minimum orders of around 5,000 pieces," says Matt Aldridge of igus UK. " But, with speedigus you can get a single part in just one day. All we need is the required quantity and a 3D CAD file of the part."

igus currently manufacture speedigus parts in eight common iglidur materials (iglidur G, J, W300, X, M250, P, A180 and H2) as well as igumid G, the igus E-Chain material; the designer selects the material best suited to the application, using the simple online selection tool: www.igus.co.uk/speedigus

As iglidur materials are maintenance and lubricant free, long lasting and have a low coefficient of friction, the majority of speedigus parts manufactured to date are custom design components that have a bearing function:

iglidur G General purpose material.
iglidur J  Very low friction material with low moisture absorption, and excellent service life when used at low to medium loads.
iglidur W300  Similar mechanical properties to iglidur G, with longer service life and can run on almost any shaft material.
iglidur X Universal chemical resistance, runs at extremely high temperatures (up to 315°C) and can withstand pressures of up to 150 MPa.
iglidur M250  Flexible material, extremely tough and very well suited to parts with a large wall thickness. 
iglidur P  Similar mechanical properties to iglidur G, but waterproof.
iglidur A180  Conforms to FDA (Food and Drug Administration) requirements for contact with food, and resistant to most cleaning agents.
iglidur H2  Designed for mass production in automotive applications, suitable for automotive prototyping.

"Because speedigus uses standard igus materials, the igus useful service life calculation program is still valid," adds Aldridge. However, engineers can also draw upon other features and benefits of iglidur materials, such as the combination of light weight with electrical conductivity, chemical resistance or high temperatures. The igumid E-Chain material additionally offers design possibilities for structural parts, such as brackets, side plate or covers.  

Ideal for orders up to a few thousand parts, prototypes or one-offs speedigus can accommodate parts that fit into an envelope up to 475 x 750 x 200 mm, with wall thicknesses down to 0.5 mm. All that is required for a quotation is a 3D CAD file, preferably a STEP file, and the required quantity. 

Standard speedigus tooling lead time is fifteen days from placement of order, but parts can be produced in as little as 24h. Every speedigus quotation comes with full technical component information including lead time options. Tooling charges for the speedigus systems start from £1000 and unit costs are from just 10 pence. As part of this service speedigus custom tooling is kept for repeat orders as and when required. If production should move to high volumes, then igus manufacture a standard production tool, and unit costs then reduce considerably.

For further information about speedigus or to make an initial enquiry, view website: www.igus.co.uk/speedigus or email: speedigus@igus.co.uk  Refer to page 156

High performance thermoplastic copolyester (TPC) with a 20%-50% content derived from renewable resources, depending on the hardness of the grade

Following the successful introduction of EcoPaXX™, a bio-based, high performance engineering plastic, DSM Engineering Plastics launched Arnitel® Eco at K 2010. Arnitel Eco is a high performance thermoplastic copolyester (TPC) with a 20%-50% content derived from renewable resources, depending on the hardness of the grade. The new material, which is already being sampled to selected customers, is specifically suited for applications in Consumer Electronics, Sports & Leisure and Automotive Interior.

Francis Aussems, Project Manager Bio-Polyesters for DSM Engineering Plastics, says: "There is a clear customer need for bio-based engineering plastics which combine performance with a reduced carbon footprint. LCA calculations of Arnitel Eco show a reduction in greenhouse gas emissions, cradle to gate, of up to 50% versus oil based thermoplastic copolyesters. Using our long-standing experience in Arnitel product development and our flexible manufacturing base, we are pleased that we are able to introduce this new extension to the Arnitel family." 

Arnitel Eco is a first generation product, which is currently not yet suitable for high temperatures. However, future generations of the product are envisaged for the future. 

This innovation follows the successful launches of Arnitel XG for halogen-free flame retardant solution for wire & cables and Arnitel C, a breakthrough technology for wire and cable coating, delivering the best high-heat aging performance of any TPC. This underlines DSM's commitment to the introduction of new products with lower environmental impact. 

Fredric Petit, Sustainability Director DSM EP, adds: "After the successful launches of EcoPaXX and Palapreg Eco, Arnitel Eco is the next bio-performance material of DSM and this is fully in line with DSM's mission to 'create brighter lives for people today and generations to come'. This mission is supported by DSM's core value, which states that its activities should contribute to a more sustainable world."

For further information, view website: www.dsm.com