THIN WALL MOULDING | INNOVATION


Resources is again applying its trademark creativity and formulation capabilities to advance the state of the art, this time with a PP impact copolymer offering a unique combination of desirable proper- ties. During our decade of collaboration, we’ve witnessed first-hand the company’s leadership in resin development. With the introduction of this new AP5195-LV PP impact copolymer, the packag- ing industry stands to benefit in multiple ways.”


Composite materials To demonstrate thin-wall applications for its Tepex Dynalite continuous-fibre-reinforced thermoplastic composites, Lanxess has looked to an electric skateboard that uses Tepex Dynalite overmoulded with polyamide. Electric skateboards are, Lanxess contends, extremely challenging to design. The electric components of a skateboard, such


as the battery and the motors that drive the wheels, need to be housed in very confined spaces to keep the board light, compact and easy for the rider to handle. EMI is a family business based in France that manufactures the Okmos SL-01 electric skateboards. Conventional skateboards usually consist of a


relatively flat wooden board where the rider stands, also known as the deck. Under the deck of electric skateboards is a plastic box containing equipment including the battery. The EMI design, however, has a trough-shaped deck. With the exception of the motors – which are mounted on the back of the skateboard – the trough houses all the electric and electronic functions, including the battery. The trough is enclosed by a cover. Because of the strength of the Tepex reinforced composite, the trough can be manufac- tured with a wall thickness of just 3mm. “Tepex is extremely resilient thanks to its high torsional and bending strength, and very lightweight into the bargain. The deck weighs just 2.5 kg,” says Jean-Marie Olivé, Technical Manager Application Development at the High Performance Materials (HPM) business unit at Lanxess. “Despite the thin walls, the electric and electronic components in the deck are safely protected against impact as well as moisture.” The trough-shaped composite part is manufactured in a single hybrid mould- ing process step. First, a robot inserts the metal base plate used to attach the truck axles into an injection moulding tool. It then places a heated and plasticised Tepex section in the tool. In


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one operation, the section is then formed and the entire structure overmoulded with a short-glass- fibre-reinforced PA6 compound. “The process is very efficient and highly inte-


grated, meaning that not only can the base plate be fixed in place, but fastening elements, wire ducting and the battery holder can also be mounted in the same operation. That means that unlike many conventional electric skateboards, the latter does not have to be screwed in separately,” says Jules Staedelin, R&D Manager at EMI. The composite section is made from PA6-based


Tepex Dynalite 102-RG600(6), which is reinforced with six layers of continuous-glass-fibre rovings. The deck cover is also made from this material. Lanxess PA6 grade Durethan BKV30H2.0EF is used for overmoulding. This compound, which contains 30% short glass fibres by weight, is optimised for this purpose. Its melt flows easily, which ensures that even long flow paths can be implemented without problems when the injection mould- ing tool is being filled.


EMI has developed its new electric


skateboards entirely in France, and it manufactures them there as well, under the Okmos brand. The injection moulding tool for the hybrid moulding process is also based on in-house expertise.


CLICK ON THE LINKS FOR MORE INFORMATION: � www.arburg.com


� www.sumitomo-shi-demag.eu � https://socarpolymer.az � www.milliken.com � www.fhr.com � www.lanxess.com � www.okmos.fr


March 2022 | INJECTION WORLD 29


Above: The Okmos electric skateboard is manufactured by EMI in France


Left: The trough containing the battery and electronics for the Okmos skateboard has a wall thickness of just 3mm


IMAGE: LANXESS


IMAGE: AMI


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