IKV.impulses The online event series on current plastics technology topics

Short-fiber-reinforced thermoplastics play a central role in the development of high-performance yet lightweight plastic components. However, their mechanical properties are strongly determined by the fiber orientation, the local microstructure and process-related influences. The reliable prediction of the stiffness of such materials therefore represents a central challenge for component design and structural simulation.
This IKV-Impulse will present current approaches to data-driven modeling of short-fiber-reinforced thermoplastics. The aim is to use data-based methods to improve the prediction of mechanical properties, in particular stiffness, and thus create a sound basis for material models in simulation. Current developments and results from research will be presented and it will be discussed how data-driven approaches can contribute to further improving the modeling and evaluation of fiber-reinforced plastics.

Main topics:

• Data-based modeling for the prediction of stiffness in short-fiber-reinforced thermoplastics
• Use of experimental and simulative data to improve material models

Moderation:

• Nicolas Rozo Lopez, Institute for Plastics Processing (IKV) at RWTH Aachen University

Lectures:

• Multi-fidelity approach with machine learning for short-fiber-reinforced thermoplastics
  Luiz Lise, Institute for Plastics Processing (IKV) at RWTH Aachen University
• Machine learning approach for predicting effective properties of short fiber-reinforced thermoplastics
  Florian Rückert, TU Chemnitz, Chair of Solid Mechanics

Registration

The use of recycled plastics is coming under increasing pressure as a result of the European Packaging Ordinance (PPWR) and the growing requirements for sustainable material cycles. Manufacturers and in-market suppliers are faced with the task of using recyclates in such a way that they are both ecologically beneficial and safe and legally compliant, especially in applications with food contact or in sensitive product areas
As part of the impulse event “Safe use of plastic recyclates – [analytics, evaluation and application potentials]”, we are working with partners from industry and research to shed light on key issues relating to the quality, safety and approval of recyclates. Current regulatory developments, analytical methods for assessing pollutants and innovative technological approaches to functional coatings will be presented.
A particular focus is on the practical implementation of valuation strategies and their relevance in the context of the PPWR. The aim is to show ways in which the quality and usability of recyclates can be improved through targeted analysis, functional barriers and process optimization and how this opens up opportunities for new applications in the packaging and consumer goods industry.
Take advantage of the event to gain insights into current research results, exchange ideas with experts and receive impulses for the safe and sustainable use of plastic recyclates.

Main topics:

• Regulatory framework and requirements from the EU packaging regulation (PPWR)
• Focus on analytical methods for the identification and quantification of contaminants in recycled materials
• Evaluation concepts and toxicological risk assessments
• Technological approach alongside decontamination by developing functional barriers for the use of recyclates

Moderation:

Dr. Orkun Kaymakci | Beiersdorf AG

Lectures:

• From analysis to application and safe integration of recyclates into the material cycle
  Ali Cetin, IKV
• Driving Circularity in Skin-Care Packaging: Challenges and Opportunities in PCR Plastics, Dr. Orkun Kaymakci, Beiersdorf AG

Capture, Utilization and Storage (CCUS) is considered an indispensable technology for significantly reducing CO₂ emissions from industrial processes and energy generation. Various materials are used along the entire process chain, from separation and transportation to storage/utilization. Plastics in particular, with their special properties such as chemical resistance, resistance to environmental influences and high production and installation efficiency, play a key role in making CCUS technologies technically feasible and economically viable.

There are many fields of application: polymer membranes for CO₂ separation, corrosion-resistant plastic linings for pipelines or fiber-reinforced composite materials for tanks. CO₂ also opens up new perspectives in terms of its use, for example as a raw material in plastics production or in the synthesis of chemicals. Hydrogen serves here as an example of how CCUS processes can be embedded in existing and future energy systems.

The event will provide a practical demonstration of where plastics are indispensable in CCUS technologies today and give an outlook on the potential that this class of materials offers for a climate-neutral industry and circular economy.

• Key technologies for CO₂ separation and the role of polymer membranes & coatings
• Plastics in CO₂ transport and safe storage
• Use of CO₂ as a raw material for new plastics and chemical products
• CCUS in the context of other future technologies, e.g. hydrogen

Moderation:

Jonathan Alms, M.Sc. | IKV

Lectures:

• Carbon Capture, Utilization & Storage: How plastics enable key technologies
  Marie Hadenfeldt, M.Sc. | IKV
• Accelerating direct air capture materials development with high-throughput testing | Salar Asoobar, Avantium

The lectures and discussions will be held in English.

Screw Extrusion Additive Manufacturing (SEAM) technology enables large-volume, screw-based additive manufacturing and opens up completely new possibilities for fast and cost-efficient toolmaking.
Together with YIZUMI Germany, IKV is investigating the possibilities of tool design based on additively manufactured Screw Extrusion Additive Manufacturing (SEAM) components. The aim is to demonstrate the suitability and limits of large-volume, additively manufactured molds. The production of a longboard made of polyurethane (PUR) with an additively manufactured insert and a plasma-activated stainless steel sheet serves as a practical demonstrator.

Conventional molds for PUR components are time-consuming and cost-intensive to manufacture, especially for prototypes and small series. By using SEAM technology, Moulds can be realized significantly faster, more flexibly and more cost-efficiently. The project focuses on the central questions of tool design: How can temperature control, fatigue strength and mechanical stability be integrated into an additively manufactured mold, and what limits result from the design?

While IKV is responsible for the design, analysis and process evaluation, YIZUMI Germany is contributing its expertise to the design and production of the additive mold. Using the longboard as a demonstrator, the performance of the concept is clearly tested: Both the loads and quality requirements of a PUR component and the potential for industrial use become visible. The result is a proof of concept that shows how additively manufactured molds can be used for PUR components and what advantages they offer over conventional approaches – especially in terms of time, cost and flexibility.

Deposits on chill rollers are a well-known problem in flat film extrusion: they impair film quality, lead to rejects and reduce productivity. The formation of deposits occurs both with virgin material such as PET and especially with recycled material. IKV has therefore developed an optical inspection system that records the formation of deposits in-line and can be integrated cost-effectively into existing systems. A camera and intelligent image processing are used to analyze and objectively quantify gloss changes on the roller surface. This allows the formation of coatings to be tracked in time and space and correlated with process parameters and material properties.

In the webinar, IKV presents the system development and current research results. From an industry perspective, the impulses are supplemented by exciting insights into the cleaning of the acquired flooring.

Moderation:

Dr.-Ing. Lisa Leuchtenberger, Head of the Extrusion and Rubber Technology Department at IKV

Keynote speeches:

• “Detect before Defect – Development of a test environment for the inline detection of roller coating in flat film extrusion”
  Dr.-Ing. Lukas Seifert, Deputy Head of the Extrusion and Rubber Technology Department at IKV
• “Cleaning of smoothing rollers in flat film extrusion”
  Nora Subel, Product Manager Service & Modifications at Reifenhäuser Cast Sheet Coating GmbH & Co. KG

Thermoplastic elastomers (TPE) open up various possibilities in modern product development. By foaming the TPE used, the range of applications can be further extended and material can be saved at the same time. The possible applications are diverse and range from sealing technology to visual applications in automotive engineering. In addition, TPE can be remelted and also offers considerable advantages over established materials in terms of the circular economy.

Recyclable soft-touch components in automotive engineering thanks to foamed TPE

By combining a polypropylene carrier flooded with a highly foamed TPE, mechanically recyclable soft-touch components can be produced. The properties of the components can be precisely controlled via the process control and specifically adapted to the application. However, the process control differs considerably from other applications and high degrees of foaming can only be achieved with specially optimized materials. The component design also plays a special role due to the narrow process window

Lectures:

• Thermoplastic elastomers foam for a wider range of applications
  Alexander Heinze, ALLOD Werkstoff GmbH & Co. KG
• Recyclable soft-touch components thanks to the use of foamed thermoplastic elastomers
  Jan Wolters, IKV

In the production of polyurethane components in molds, release agents are conventionally used for non-destructive demolding. These are currently still an integral part of the process and pose various challenges. In addition to the extended cycle time due to the application into the cavity, the downstream cleaning of the mold and component also represents a time and financial expense. Precautions must also be taken for environmental and personal protection. In order to address this topic, the Impulse presentations will deal with dry demolding, i.e. the replacement of internal and external release agents with permanent, release-friendly tool coatings. The first lecture will present the concept of a measuring cell with which it will be possible to investigate the combination of material system and tool coating for a number of pieces in series production.

Long-term investigation of permanent interfaces

The possibility of release agent-free demolding of PUR systems has already been successfully demonstrated in previous IKV research projects. This means that it is already possible to produce suitable tool coatings for compact and foaming polyurethanes. However, the application of the coating is currently still a cost-intensive process that is only financially viable for large quantities. There are currently no reliable findings on the durability of the coating over several thousand demoldings. The first presentation will deal with the development of a measuring cell that will enable automated testing over the service life of the interface. Component production and demolding are to be automated. Meanwhile, measured values of the environment, the process and information about the demolding behavior are recorded over time. The collected values are stored in a database and make it possible to recognize changes in production and demoulding.

In his presentation, Hendrik Beiersdorf (ACMOS Chemie) will provide in-depth insights into modern release agent technologies for various PU application areas. In a clear and practical manner, he demonstrates the special features of cold foam and integral foam applications and compares two different separation processes in terms of their respective advantages and disadvantages.
Further information and the exact title of the lecture will follow shortly.

Main topics:

• Polyurethane processing
• Digitalisation
• Interface layers

Moderation:

Jonathan Alms, IKV

Lectures:

• Development of a measuring cell for automated testing of the fatigue strength of permanent release coatings (Lucas Rau, IKV)
• Release agent-related influencing variables in cold flexible and integral foam production (Hendrik Beiersdorf, ACMOS CHEMIE KG)

We are expanding the originally announced session “Simulative process analysis in injection molding” thematically: On June 24, we will not only present the latest research approaches to simulation in injection molding, but also introduce the new technology network KI4KI – Artificial Intelligence for the Plastics Industry.

Why?
Because AI marks the next stage of digitalization – and can already be used today in the injection moulding process, in material development and in production.

🔍 What you can expect:

AI methods in material development
Lukas Seifert, M.Sc., IKV Aachen
How machine learning supports compounding and shortens development times.

Intelligent material card adaptation for precise deformation simulation of injection molded components
Sebastian Schwan, M.Sc., IKV Aachen
How material data is recorded under real conditions and simulatively optimized – for realistic results.

AI in application: Efficient injection molding in series production
Felix Müller, plus10 GmbH
How AI-supported assistance systems reduce waste and speed up set-up processes.

Valid material data, precise simulation, higher-level analyses
Michael Bosse, Simpatec
Practical impulses from industrial applications.

Introduction: KI4KI – Why now is the right time to invest in AI
Insights into the new IKV technology network

Moderation:

Dr.-Ing. Christoph Zimmermann, IKV
Dipl.-Ing. Mauritius Schmitz

Technical plastic components are usually exposed to high mechanical, thermal and chemical requirements. In the automotive industry, for example, these requirements include high temperature and media resistance. Thermosets are among the plastics that are able to meet these requirements due to their high cross-linking density. However, their high cross-linking density means that thermosets, unlike thermoplastics, cannot be joined by welding. Accordingly, the screw connection, in particular the direct screw connection, represents a promising possibility for realizing an economical and detachable connection of thermoset components. In contrast to thermoplastics, however, there are no guidelines for the design of a direct screw connection for thermosets. This knowledge gap is to be closed as part of the cooperation between the IKV and the KTP in the “Duroplast Direktverschraubung II” project. To this end, design guidelines for direct bolting are to be developed for both short and long-term stresses.

As part of the lecture, IKV will present the results already achieved in the field of short-term loading of thermoset direct screw connections. In addition, the intended investigations into the long-term dynamic loading of thermoset direct bolted joints are outlined and discussed.

Main topics:

• Thermoset injection molding
• Direct screwing of plastics
• Mechanical testing

Moderation:

Dr.-Ing. Christoph Zimmermann, IKV

Lectures:

• aiXtight – 100% detection of the head support for direct screw connections
  (Dr.-Ing. Rainer Peters, aiXtrusion GmbH)
• Derivation of design and application recommendations for the direct screwing of thermosets
  (Guilherme Labanca Bachiega, IKV)

Thermoplastic elastomers (TPE) open up a wide range of possibilities in modern product development – from flexible connecting elements to complex functional components. However, due to the special properties of TPE, developers are faced with new challenges when designing TPE components.

Special requirements for the design of TPE components

When designing TPE molded parts, designers are faced with a number of special requirements: Melt properties such as flowability and recovery behavior must be precisely taken into account. In addition, aging resistance or the often complex anisotropic mechanical properties play a decisive role in the simulative mapping of deformation behavior. Only those who understand these factors in depth and integrate them into the design process can successfully develop durable and functional components.

Key topics:

• Design rules for TPE components
• Anisotropic modeling of TPE

Moderation:

Noah Mentges, IKV

Lectures:

• First-hand practical design advice – from material selection and component design to optimization for series production and function (Lukas Kling, ALLOD Werkstoff GmbH & Co. KG)
• New simulation method for describing the direction-dependent mechanical properties of TPE – a perspective for use in product development (Noah Mentges, IKV):