Combined Trexel and 3M Technologies Revolutionize Lightweighting of Plastics

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1 Combined Trexel and 3M Technologies Revolutionize Lightweighting of Plastics 20 Percent Density Reduction Proven With Molded Auto Parts To address demanding lightweighting needs in the plastics industry, 3M and Trexel have demonstrated a breakthrough that enables manufacturers to realize 20 percent density reduction of finished plastic parts with mechanical properties comparable to standard formulations. Manufacturers can also reap improvements in dimensional stability, process throughput and sustainability. The achievement signifies one of the world s largest advancement in the lightweighting of plastics. The breakthrough is especially significant for the transportation industry and namely, automakers, as reducing overall vehicle weight is a key initiative as they face increasingly stringent fuel economy standards, and carbon emission reduction targets. 3M, a manufacturer of high-strength glass bubbles, and Trexel Inc., the exclusive provider of MuCell Microcellular Foam injection molding technology demonstrated the revolutionary results by combining a variety of optimized polymer resin systems using 3M Glass Bubbles im16k with Trexel s unique MuCell foaming technology. This marketing collaboration between Trexel and 3M is a game changer for the plastics industry especially in the automotive sector. It s challenging to take weight out of plastic parts without sacrificing strength, durability or function. Through this innovative approach, customers can speed up the process and significantly reduce weight, while maintaining the part integrity. Steve Braig, President and CEO of Trexel, Inc. According to Trexel and 3M the new process can be replicated at any facility around the world for plastic parts, such as automotive under the hood, interior and exterior and other molded parts. Braig went on to explain that significant weight savings can be achieved in a variety of resin systems including both filled nylon and filled polypropylene, especially significant to automakers as even a small weight reduction can make a difference as incremental design and parts adjustments can add up quickly. As a result, automakers consider every aspect of a vehicle from the smallest bracket to the engine that powers it for potential weight savings. Used alone, 3M Glass Bubbles or Trexel s MuCell foaming technology can realize from eight to 10 percent reduction in weight while maintaining mechanical and physical properties, said Doug Rowen, global business director for 3M Glass Bubbles. But combined, the technologies complement each other resulting in significantly increased weight

2 reduction, cycle time reductions and improved dimensional stability of finished parts. The combined 3M and Trexel technology also offers several additional benefits including lower cavity pressure resulting in reduced clamping tonnage, no sink marks, and increased sustainability resulting from the use of less petrochemical feedstock. As part of 3M s line of high-strength glass bubbles, the company s latest product in the family, im16k, is especially relevant for automotive applications. im16k is a highstrength injection molding grade glass bubble for polypropylene, polyamide and other polymer systems and features crush strength of >16,000 psi making it uniquely suited to survive injection molding and compounding processes. Incorporating glass bubbles, like im16k, into the process improves dimensional stability, resulting in less shrinkage and warpage thereby reducing reject parts and reprocessing. Manufacturers can also increase process throughput when using resin systems filled with im16k as there is less finished part mass to cool, reducing cycle times by 15 to 25 percent. Alternatively, MuCell foaming technology uses the controlled use of gas to create a foamed part, resulting in high quality precision and engineered plastic components, while greatly reducing production costs associated with lower material consumption, shorter molding cycle times, and reduced machine clamping tonnage requirements. The MuCell process enables automotive component manufacturers to lightweight plastic parts for overall vehicle weight reduction and improved fuel economy. The process also leads to predictable and repeatable part geometry, allowing for the use of lower cost polyolefin resins without warpage or distortion. Bubbles im16k and Trexel MuCell processes to the design freedom of plastic parts results in reduced material density which will lead to a new dimension of weight savings in plastics. Both 3M Technical Service and Trexel processing engineers globally are ready to assist customers with their demanding lightweighting objectives Braig said. While both 3M and Trexel technologies have proven unique benefits that help the industry achieve weight reduction objectives in many applications, the combined technologies have demonstrated even better weight reduction performance, without sacrificing critical performance requirements. said Rowen. For more information regarding 3M Glass Bubbles, visit For more information about the Trexel process, visit The combined technologies result in unprecedented mass reduction in injection molded parts adds Braig. Adding 3M Glass

3 Joint Venture by Trexel Inc. and Matsui Manufacturing Co. Ltd. Forms Trexel Japan Co. Ltd. Allows further penetration of the Trexel MuCell injection molding technology into the Japanese marketplace Trexel Inc., the exclusive provider of MuCell Microcellular Foam injection molding technology has significantly increased its presence in the Japanese market by creating Trexel Japan Co. Ltd. from a joint venture with Matsui Manufacturing Co Ltd. The operation, based in Tokyo, started September 1, 2013, and is led by president Mr. Hisashi Tsugawa. Mr. Tsugawa has over 20 years of progressive management experience in the Japanese injection molding industry, most recently serving as General Manager of Sato Light Industrial Co. and previously in progressive management responsibilities at GE Plastics Japan. Japan is a very promising market for our technology, adds Braig. The growing demand for reduced costs and sustainability allow the advantages of our MuCell process to stand apart. We see great opportunity with the Japanese automotive sector specifically as they can benefit greatly from our lightweighting process technology. We are very excited to work with Matsui in this important market. As a global leader of auxiliary equipment for the plastics industry and with extensive expertise in the Japanese marketplace, Matsui makes an ideal partner for this venture. Steve Braig, President and CEO of Trexel, Inc To better service the existing and growing customer base in Japan, local process engineers and technological resources support the Trexel Japan Co. Ltd. sales organization. The newly created subsidiary allows Trexel, who has a majority stake in the venture, further penetration into the Japanese market, specifically with the automotive OEMs and Tier one suppliers who can reap the same lightweighting benefits as those in North America and Europe. Trexel Inc and Matsui Mfg. Co. Ltd. have fostered a relationship over the past few years. Trexel has participated in Matsui s The Association of Green Molding Solutions, a global alliance of sustainable injection molding suppliers that was formed in This association holds annual conferences

4 throughout Asia. The conference agenda is organized by a volunteer committee of all branches of the industry molders, machinery and materials suppliers with the specific goal of helping molders become more efficient and use fewer resources. This goal aligns perfectly with the benefits of Trexel MuCell Foaming technology. The Trexel MuCell foaming technology involves the introduction of precisely metered quantities of atmospheric gases (nitrogen or carbon dioxide) to create a foamed part, resulting in high quality precision and engineered plastic components, while greatly reducing production costs associated with lower material consumption, shorter molding cycle times, and reduced machine clamping tonnage requirements. For the automotive sector, the MuCell process enables component manufacturers to light weight plastic parts for overall vehicle weight reduction and improved fuel economy. The process also leads to predictable and repeatable part geometry, allowing for the use of lower cost polyolefin resins without warpage or distortion.

5 Trexel, Inc. Introduces New, State-of-the-art MuCell Super Critical Fluid (SCF) Dosing and Delivery System New T-Series MuCell system reduces operating costs and provides for simplified set up and operation Trexel, Inc is pleased to make the premier global introduction of their newly developed TSeries at the K Show. The Trexel T-Series SCF (Super Critical Fluid) Delivery System is a state-of-the-art gas delivery and dosing system based on Trexel s patented technology, and built to the most stringent industrial standards. The system is designed to convert gaseous CO2 or Nitrogen into a super critical fluid and precisely doses and injects the super critical fluid into the plastizicing unit of the injection molding machine, creating a lower density microcellular material structure in the molded plastic part. to changes in molding parameters to consistently deliver the exact required dose of SCF. The new system includes a 15 PC based graphical touch screen user interface with graphical diagnostic screens, historical data collection and output via a USB port. The standard T-Series version is configured for Nitrogen based super critical fluid but an available option allows molders to process either Nitrogen or CO2. There is also an option available for inline detection of Nitrogen purity in the gas supply line, assuring Nitrogen purity requirements are met especially in developing markets. Within the T-Series the T-200 is This new unit replaces the current Series II system that has provided MuCell users with reliable supercritical fluid (Nitrogen or CO2) injection for 10 years. The Series II technology originated with the need for continuous flow for extrusion and injection molding applications. The New T-Series systems designed specifically for injection molding applications produce SCF on demand only. This eliminates any need for hardware mounted on the injection unit (so no interface kit required), and significantly extends the seal life on the booster pumps while reducing energy consumption. The optimized booster performance allows for maximum booster life. The new controls on the T-Series are greatly simplified, and only require shot weight and percentage of SCF content - that is it! The system calculates everything else and optimizes SCF delivery during screw recovery. While the old system control was static, the new system control is dynamic and automatically responds available for shot sizes gr and the T300 for shot sizes gr. The introduction of the new T-100 for very small shot sizes and T-400 for large part applications (shot sizes >3Kg) will come in mid 2014.

6 Newly developed MuCell blow molding process for automotive plastic parts offers significant weight savings Achieved 32% weight savings and improved thermal and acoustic insulation characteristics with automotive air duct application As a leader in providing lightweighting solutions to the plastics injection molding industry, Trexel, Inc. has extended its MuCell processing solution to blow molded automotive components. In working closely with their OEM and Tier I customers, the company has recognized the need for lightweighting plastic parts beyond the traditional and proven injection molded interior, exterior and under the hood applications. To develop this robust MuCell blow molding process Trexel worked with ABC Group in Toronto Canada, one of the leading providers of blow molded products to the North American automotive industry. Over the last year, engineers from Trexel and ABC Group have been diligently working together on the development of MuCell blow molding. As a result of these efforts the first Mucell blow molding process was achieved with an automotive application. The part is a reinforced Polyethylene air duct with 1.5 2mm wall thickness. As a result of the Mucell process the density reduction is 41% of the foamed material, resulting in a 32% net weight saving of the finished part compared to solid. We are very excited about the results we have achieved so far. Commercial development of additional MuCell foamed blow molded parts including design and material optimization should result in higher than 40% weight reduction compared to the solid molded part. These results will be very attractive to OEM and Tier suppliers, and ultimately to car buyers who will enjoy improved fuel efficiency of their vehicles. Steve Braig, President and CEO of Trexel, Inc Besides weight savings, there are several highly desirable attributes of foamed versus solid blow molded parts: the microcellular material structure improves thermal insulation and also provides for improved acoustical properties. The MuCell technology, a physical foaming process, also has several advantages over the use of chemical foaming agents: no chemical reaction at narrow processing window, no chemical additive residue in final parts, and most importantly, MuCell foamed parts can be recycled in their original polymer designation; the process does not alter the chemistry of the polymer.