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Plastics Engineering February 2016 00 Cover NEW_Layout 1 1/20/16 10:53 AM Page cvr1 Plastics Engineering February 2016 Plastics in Electronics: Lighter & Brighter • “Wraparound” Electronics • Polymers in Li-Ion Batteries • Molding Polycarbonates • The Word on Plastics Recycling • 3-D Printing & AM: New Options 00 Cover NEW_Layout 1 1/20/16 8:02 AM Page cvr2 01-03 contents NEW LAYOUT_editorial 1/20/16 8:02 AM Page 1 FROM SPE SPE Member Benefits: What Can They Do For You? received a call the other day from Teri Chouinard, new Paulson Training, Pennsylvania College of Technology, and membership chair for the SPE Automotive Division. She UL partnerships. told me that she would be attending an upcoming event “SPE is partnering even more now,” I said, “because we Ifor new members and wanted to review the SPE member realize this really benefits our members.” benefits. SPE and SPI are partnering to offer free membership for I logged into 4spe.org so I could use our homepage to all U.S. students. This allows students to package their SPE help navigate our conversation. We talked about the membership with an SPI electronic membership. This way, launch of THE CHAIN, SPE’s very own community forum, plastics students are networking with professionals before and how members were really finding it a benefit to they even hit the workforce, making for a smoother transi- exchange information on all technology aspects of our tion at the start of their careers. industry. They like being able to ask trusted sources for SPE has also partnered with Credible, an organization help on a technical problem or new innovations. that refinances student loans, which gives SPE members For people seeking more extensive support, they can and their families a simple, free service that can help them find a specialist in various plastics fields on SPE’s save money by comparing their options. Consultant Circle. Or if they’re simply looking for the Teri especially liked it when I told her about SPE selling newest detailed technology information, all SPE members HOP™ (Hands on Plastics™) science education kits now. can access SPE’s Online Technical Library, which contains We talked about how the kits contain everything needed to over 25,000 research and technical papers on materials, introduce K-8 students to the chemistry and characteristics processes, applications, etc., in polymer and plastics tech- of plastics in a classroom setting. I told her about the nology. I told her the library grows each year with over grandfather who purchased a kit because he volunteered 1,000+ new papers! to go into his grandchild’s class and teach. He called me the We spoke about how everyone in this day and age is so day after to tell me the class was a success. He said it was busy, and they have very little time to filter the right infor- quite easy to do because everything he needed, including mation about what’s going on in their specific part of our the experiment instructions and the teaching tips, were in industry. Several members had vocalized that they the kit. received way too many general newsletters and it would We also spoke a bit about the Industry-Academia be a real benefit to them to get only the current industry Collaboration committee, which connects the industry happenings related to their technical area. I told her that’s with the academic-research world for specific projects. how PLASTICS INSIGHT, SPE’s weekly fully customizable Teri’s daughter goes to one of the schools that received an online report of current plastics industry happenings, equipment donation from a manufacturer. She comment- came to be. You can customize the report, so you only ed on how important it is to her daughter’s and other stu- receive the information that’s relevant for you or your dents’ education for companies and universities to work company. together in other areas as well, like project collaboration We talked about SPE’s publications PLASTICS ENGINEER- and mentoring. ING magazine and SPE Technical Journals both having a At the end of the call, I told her that if anyone had any new look and feel. She commented that she noticed the questions or needed any more information on any of these magazine had more content as well. benefits, to contact SPE staff. They would be happy to help! Meanwhile, SPE members receive discounts on all of SPE’s conferences around the world—about 40 events per year—and on other education and training programs Sue Wojnicki through the SPE, such as weekly Webinars, and on our Manager, SPE MarComm www.plasticsengineering.org | www.4spe.org | FEBRUARY 2016 | PLASTICS ENGINEERING | 1 01-03 contents NEW LAYOUT_editorial 1/20/16 8:02 AM Page 2 I I CONTENTS VOLUME 72 NUMBER 2 FEBRUARY 2016 FROM SPE SPE Member Benefits: What Can They Do For You? There’s a lot that can be said about all the new initiatives and 1 changes SPE’s HQ has introduced over the last year or so RESIN MARKET FOCUS Polyamide Global Dynamics By IHS Chemical 4 A number of factors are creating opportunities for buyers of nylon resins DESIGN NOTES 8 Additive Manufacturing Faces Challenges as it Grows By Robert Grace 8 But new technologies may open up options for designers for producing 3-D-printed parts better & faster Plastics in Electronics COVER STORY Plastics Get Flexible for Electronics By Geoff Giordano 14 Integrated circuitry, “wraparound” electronics, and other conductive applications are being made possible using plastics Plugging Into the Power of Polymers 22 By Jon Evans 14 Lithium-ion and other battery technologies will increasingly be getting more solid support and energy density from polymers Putting a Charge into Conductive Plastics By Doug Bathauer 26 Demanding electronics require new conductive materials Innovations in Hybrid Structural Instant Adhesive Technologies By Nicole Lavoie 28 Optimal properties are found in an adhesive that combines cyanoacrylate and epoxy chemistries About the cover: This reference design uses integrated printed circuitry enabled by DuPont ME series in-mold electronic inks. (Image courtesy of TactoTek and cover designed 22 by SPE MarComm Team; see the original photo and our cover story on p. 14.) 2 | PLASTICS ENGINEERING | FEBRUARY 2016 | www.4spe.org | www.plasticsengineering.org 01-03 contents NEW LAYOUT_editorial 1/20/16 8:02 AM Page 3 CONSULTANT’S CORNER Cold Runner Design: Sizing Up Your Runner System By David A. Hoffman 36 Designing runners for multi-cavity injection molds is no straightforward process Process Innovations Modern Molding for Polycarbonates By Mark Matsco 40 Emerging techniques optimize the appearance and production of PC-based parts 40 ACCE 2015 Highlighted Interesting Shifts in the Composites Industry: Part II 44 By Peggy Malnati More innovations are presented from last year’s SPE event, in this continuation of the review in the November/December issue of Plastics Engineering. The Word on Plastics Recycling: Momentum By American Chemistry Council 48 Plastics recycling is growing: steadily, broadly, and expansively INSIDE SPI Less is Less: The Battle to Wrap It Up in Plastic 52 News about the state of the plastics industry from SPI: The Plastics Industry Trade Association 44 DEPARTMENTS Energy-Saving Tip Market Place 50 By Dr. Robin Kent 68 Industry News Editorial Index 54 70 Industry Patents Advertisers Index 60 By Dr. Roger Corneliussen 72 Upcoming Industry 64 Events 48 www.plasticsengineering.org | www.4spe.org | FEBRUARY 2016 | PLASTICS ENGINEERING | 3 04-07 Resin Market Focus_046854 IndustryNews.QXD 1/20/16 8:01 AM Page 4 RESIN MARKET FOCUS Polyamide Global Dynamics s we begin 2016, a number of factors, including low Production Capacity Exceeds Demand crude prices, a strong U.S. dollar, and bearish mar- Requirements ket sentiment in China, are creating opportunities forA buyers of engineering resins to find new leverage points. Global nylon 6 resin capacity will increase over 30% in 2016, Nylon is certainly not immune to these global influences, paced by Northeast Asia, where several new lines are being but underlying demand is strong, particularly in the auto- constructed by several producers. In addition to a new nylon motive segment, and leading producers continue to benefit 6 capacity addition in Western Europe in 2014, new nylon 6 from innovations that create value and increase demand. and nylon 66 capacity is being added in North America, aimed at markets for engineering compounds and film. As a result, global nylon 6 production operating rates are fore- Innovations Drive Market Demand cast to be suppressed for several years until demand absorbs Global nylon consumption is growing almost 3% per year, as that new capacity. new applications—often improving upon conventional met- Global production capacity for nylon 66 is about one-third al designs—are brought to market. This is especially evident the size of nylon 6 capacity. While 40% of nylon 66 capacity in the automotive market, where nylon continues to pro- currently resides in North America, the most significant vide solutions for improved fuel efficiency, safety increases are underway in Northeast Asia, where the capac- performance, styling, and durability. ity is forecast to rise 50% over the 2015/2016 time period. Nylon is most often the polymer of choice for automotive applica- tions requiring heat endurance, fuel and oil resistance, and mechanical durability. Underhood and struc- tural applications such as engine oil pans, transmission oil pans, engine mounts, and strut mounts—until recently in the realm of metal—are notable examples of parts now being made of nylon compounds. The combined goals of weight and cost reduction, often coupled with performance advantages, drive material selection and prompt col- laboration by leading nylon producers, Tier 1 suppliers, and OEMs—and this frequently yields parts consolidation and reduction of secondary operations, compared with conventional approaches.
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