DESIGN | SUSTAINABILITY
Injection moulding combines with 3D printing
Canadian 3D printing technol- ogy company Structur3d has launched the Inj3ctor Platform, a desktop injection moulding system that could appeal to designers and manufacturers in the footwear industry. The system is intended for produc- tion with elastomeric materials including polyurethanes and liquid silicone rubber.
Inj3ctor combines 3D-printed moulds with material cartridges to mix and inject two-component flexible materials for small-batch manufactur- ing. The platform is said to overcome difficulties in 3D printing rubber
materials with the desired properties. It is also hoped it can help with progress towards mass customised products in footwear and other sectors. Structur3d says: “Product develop-
foaming can deliver performance benefits. From the sustainability standpoint, there is the attraction of moving away from chemical foaming agents. Nonetheless, higher investment is needed for physi- cal foaming, and Leong expects the industry to make a phased transition from chemical foaming. There is still a lot of development potential in the
higher-volume footwear market for TPU. In his presentation, Kyle Posselt, R&D Chemist at Emerald Kalama Chemical, showed the global market for sole materials is growing by 5.4% to 28.757bn lbs in the 2018-2023 period (source: Lucintel Global Footwear Materials 2020). He said TPU has been replacing EVA in premium midsole applications due to its superior durability, higher abrasion resistance and its recyclability. Posselt discussed the benefits of using Modulast performance modifiers for urethanes produced by Emerald Kalama Chemical (which is being acquired by Lanxess, as announced in February). Major urethanes producer Huntsman is address- ing sustainability needs with the development of bio-based versions of feedstocks, said Carlos Faraon, PU Application Development Manager - Americas. The group’s bio-based roadmap has three phases: to have 50-55% bio-based content in polyols by the end of 2021; then to produce a pre-polymer with 70-75% bio-content; and by 2030 to produce MDI with 80-85% bio-content. Huntsman is also working on PU recycling, both mechanical and chemical. One of the chemical recycling options is a depolymerisation process developed for PET recycling, which might be suitable for use with PU. The increased interest shown by shoe brand
18 INJECTION WORLD | March 2021
Left: Structur3d’s Inj3ctor Platform uses 3D printed moulds and a desktop injection moulding system
ers can design a hyper-detailed mould using standard CAD software and 3D print the part with standard, durable or dissolvable plastic. Then users choose from tens of thousands of liquid rubber materials, customis- ing it based on desired durability, flexibility, and cure time. After program- ming the mixing ratio and injection volume, the Inj3ctor fills in the mould, creating a fully customised product.”
designers in plastics and their sustainability is reflected in moves announced by materials companies to specifically cater for their needs. In February, carbon and glass reinforced polymer compound maker Xenia Materials announced the creation of a new division called Xenia Footwear Materials Lab dedicated entirely to developing and supplying high-performance thermoplastic composites for the footwear industry. The division is based at Xenia’s site in Mussolente in Italy and will focus on injection moulded sports applications, including shells, midsoles, sole inserts and cleats. Xenia says: “Xenia Footwear Materials Lab is born with respect for the environment that sur- rounds us. We combine the client’s specific requests to the knowledge of our qualified technicians, supporting him in every single phase of his projects, with the aim to create innovative materials and new solution mainly for the worlds of winter sports, outdoor and bike.” In 2020, BASF opened its first global Footwear
Innovation Center at its strategic partner Longterm Concept’s facility in Changhua, Taiwan, adding to local Footwear Development Centers that BASF has in the US, Italy and Thailand. The Taiwanese centre has interactive zones for brands and injection moulders to select footwear materials and improve manufacturing processes. “The Footwear Innovation Center offers footwear customers an immersive and collaborative experi- ence to co-create innovative components, process- ing, and solutions together,” says Andy Postleth- waite, Senior Vice President, Asia Pacific, Performance Materials, BASF.
www.injectionworld.com
IMAGE: STRUCTUR3D
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