bioplastics | Innovation Right:
Prototype chainsaw
component in PHA from Bio-On
ment and production of opti- mized PHB formulations for injection moulded parts. In addition, formulations and processes to produce multilayer structures were successfully produced by co-injection, in order to obtain multifunctional mate- rial properties to improve the final performance of plastic parts in the selected sectors. “Starting with easy, generic shapes, by the end of the
project, complex multilayer parts, such as spinning tops, were successfully developed, produced and tested at Fraunhofer ICT,” says Bergmann. “Multifunctional parts based on tailored material properties can be created, which are suitable to replace engineering materials and decrease weight, by more than 10%, without reduction of the mechanical and thermal properties.”
Foamed cores Bergmann says the BioCrystalSurf project aims to answer performance challenges of biomaterials, such as scratch resistance, cleanability, bacterial and media tightness, heat resistance, dishwasher suitability and colour fidelity. The project, coordinated by Tecnaro, is being funded by the German Federal Ministry of Education and Research and runs until 2018. Fraunhofer ICT and Tecnaro are developing new, bio-based PLA material formulations tailored for implementation in multifunctional PLA core-shell structures. Bergmann cites integral foams, reducing part weight, material usage and material costs, combined with a highly crystalline compact surface. “Functionality and feasibility of the material for the
production is investigated at demonstrator level using a variotherm-controlled mould in combination with thermoplastic foam injection moulding (TSG),” he says. “Besides generating optimum conditions, the parameters of the TSG process are controlled in such a way that both a high surface crystallinity and foamed core structures are achieved within economically viable cycle times.” To achieve this, an inline measurement system is
Fraunhofer ICT spinning top test parts: (left) core in PLA (blue) and skin in PHBV plus cellulose; (right) core in PHBV plus cellulose and skin in PLA (orange)
24 INJECTION WORLD | March/April 2017
www.injectionworld.com
integrated into the process for process monitoring and control. The surface crystallinity is measured in-line in the mould using near-infrared spectroscopy detection
techniques, so that ultimately the overall process is also controlled via
these parameters. “The targeted development of surface-crystalline,
and UV-stable, readily-cleanable, scratch-resistant PLA materials can only be achieved if suitable formulations are developed which enable good processing,” says Bergmann. “Based on the extensive experience of Fraunhofer ICT and Tecnaro in both areas, formulation and injection moulding process, all partners are confident of being able to deliver a substantial contribu- tion in order to broaden use and application areas of thermoplastic biopolymers based on PLA using injection moulding processes.” At Natureplast in France, Thomas Lefèvre, CEO says
the company develops new compounds for injection moulding by blending various biopolymers, including PLA and PHA, as well as polyolefins derived from sugar, with natural fillers obtained as waste from other processes. The company mostly uses waste from agricultural industries, such as fruits and vegetables, seeds, seashells, algae, but also textile waste and materials from the construction industry. The additives are dried, ground and sieved by the company before compounding. Until now, pre-treatment and compound- ing has been on an R&D scale, with production being subcontracted. Next year, the company will begin industrial production in-house, with an initial capacity of around 2,500 tonnes/year for production of custom- developed compounds. Green Dot in the USA is also working with waste
materials. It is moving ahead with the introduction of various Terratek biocomposites that can be processed by various routes, including injection moulding. The company uses biodegradable and non-biodegradable polymers for the matrix. Terratek BD2114, for example, is a new biodegradable compound for horticultural
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