A demonstrator by Kurz to show off their wood-effect polyester foil hot stamped onto acrylic sheet, which is backlit with integrated tough sensor. A black mask is printed on the reverse side of the semi-transparent foil, which helps control the lighting effect. This kind of technology is used in appliances as well as automotive applications. In car interior applications, where head impact is a risk, polycarbonate (PC) is preferred over acrylic (PMMA).
Relevant materials
Polymethyl methacrylate (PMMA), PMMA, Engineering plastic, General purpose Thermoplastic polyester, BOPET, Film, Biaxially oriented polyethylene terephthalate
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"Polyethylene terephthalate (PET), Appliance, Automotive, Electronics product, Foil, Hot stamping, In-mould electronics (IME), In-mould label (IML), Kitchen, Laminated, Lighting, Polymethyl methacrylate (PMMA), acrylic
Cross-section through the detachable roof modules of the Ford Bronco. This part is made with a thermoformed thermoplastic outer layer, which is back-moulded with glass fibre and polyurethane resin (PUR), plus a Nomex honeycomb core for increased thickness (stiffness with minimal additional weight). It is manufactured by compression moulding, whereby the thermoformed polycarbonate (PC) is placed into the mould, onto which glass fibre and honeycomb are laid. A precise dose of PUR is applied by spraying on the layers and then the whole assembly is compressed in a mould and heated to cure.
Relevant materials
Polyurethane resin (PUR), PUR, Plastic Aramid fibre (AF), PMIA, M-aramid, Nomex, Polymetaphenylene isophthalamide Polycarbonate (PC), PC, Engineering plastic, General purpose
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Aramid, Automotive, Composite, Compression moulded, Honeycomb, Laminated, Nomex, Plastic, Polycarbonate (PC), Polyurethane resin (PUR), Thermoformed
Dry moulded paper packaging, produced from multiple layers of paper pressed and bonded together with heat. While the raw materials are more expensive than moulded pulp, the production rate is much faster and energy costs are lower. The raw material prices are decreasing as the paper is becoming available from more mills. The challenge is finding paper webs (rolls) with crosswise grain, to ensure high strength and stable packaging when laminated together with the conventional lengthwise grain stock. These examples were produced on an OMG Thermoforming machine.
Relevant materials
Paper, PAP, General purpose, Kraft, 60-300 g/m2
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Compression moulded, Food contact, Kraft, Laminated, Moulded pulp, Packaging, Paper
A Fraunhofer ICT concept for expanded polylactic acid (EPLA) foam safety helmet. EPLA is roughly equivalent to the price of expanded polypropylene (EPP), but more expensive than expanded polystyrene (EPS).
Relevant materials
Biodegradable polyester, EPLA, Bio-based foam, Expanded polylactic acid
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Bio-based composite, Bio-based plastic, Biodegradable plastic, Biodegradable polyester, Composite, Expanded polylactic acid (EPLA), Foam, Laminated, Polylactic acid (PLA), Safety, Sports, Transport
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