K 2013: Trexel and 3M revolutionize lightweighting of plastics

At the recently concluded K 2013, the challenge of lightweighting was met by a range of innovative solutions. One of these innovations resulted from the team up of 3M and Trexel. The two companies 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.

“This revolutionary process has provided better dimensional stability even while mass reduction of 20 percent has been achieved. More important, this has been made possible with a 5-10% lower total part cost,” according to Mr. Stephan Braig, President & CEO of Trexel.

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  and would benefit especially the automotive sector,” said Mr. Braig. “Through this innovative approach, customers can speed up the process and significantly reduce weight, while maintaining the part integrity.”

Mr. Braig also explained that 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. 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 8 to 10 percent reduction in weight while maintaining mechanical and physical properties. But combined, the technologies complement each other resulting in significantly increased weight reduction, cycle time reductions and improved dimensional stability of finished parts.

The combined 3M and Trexel technology also offers several additional benefits including lower caviNike Air Max 98