A summary is presented of a market survey by the Nova-Institute of the current status and future market development of the use of natural fibres in composites for German automotive production in 2003. Statistics are presented on the consumption of natural fibre-reinforced composites in the German automotive industry for 1996 to 2003, on production processes used for natural fibre-reinforced composites and on consumption of natural fibres, wood fibres and reprocessed cotton fibres by this industry in 2003. The development of the injection moulding of natural fibre-reinforced PP for automotive applications is mentioned.

The use of nanoadditives to permit the manufacture of blends from previously incompatible polymers is discussed. An example of a PP/PS blend (Elan XP from Putsch Kunststoffe) is described, which features high stability during processing as a result of the addition of specially-processed nanoclay (montmorillonite). The density, melt flow index, mechanical and thermal properties of three grades of the blends are tabulated. The application of these blends in the manufacture of moulded parts for vehicle interior fittings and trim is discussed. 3 refs.

Husky Injection Molding Systems' Quadloc Tandem Index System injection moulding machine for large two-component automobile components is described. The QTI system combines tandem technology and the indexing system on a two-platen machine. The use of the machine by Lear Corp. for production of large multi-material automobile components for interior and exterior applications at its original equipment manufacture customers is described with particular attention to a door component made from talc-filled PP and a thermoplastic elastomer. 2 refs.

Nanocomposites based on isotactic PP and organically modified bentonite clay were prepared by melt intercalation. Thermooxidation of compression moulded films of the nanocomposites was carried out at 110C for up to 165 h. IR spectroscopy results showed that the PP compounds based on the modified clay had a higher thermal stability in the solid state than those with the natural clay which may have been due to a higher dispersion of clay particles reducing oxygen diffusion through the samples. However, the thermal degradation of PP with the modified clay was higher than the pure polymer. This may have resulted from the acidic nature of the clay, interaction between the clay and PP stabilisers and decomposition of the organic salt during processing. 36 refs.

The effects of filling rate and subsequent ageing at elevated temperature on the mechanical properties of injection moulded recovered polypropylene (PP) were investigated by stiffness, strength, elongation at break and Charpy impact resistance testing. The results are discussed in comparison with those for virgin PP processed under the same conditions. 31 refs.

The effects of filling rate, holding and cooling times, and subsequent ageing at elevated temperature on the surface properties such as gloss of test plaques of recovered and virgin polypropylene injection moulded using a mould with an embossed surface were investigated by surface gloss and roughness (profilometry) measurements. The results are discussed in terms of topographical matching between the polymer surface and mould topography. 20 refs.

Composite parts are decorated for a number of reasons. In most cases, the appearance of the part as it exits the mould lacks the desired surface smoothness, colour, texture and/or other desirable characteristics. While a post-mould coating can add value, improve aesthetics and extend the life of the part, it historically has added significant cost and an additional production step. Until recently, coating the part in the mould had significant limitations. In the past few years, however, several new options have emerged as practical alternatives to post-mould coating of composites, including for the first time, the possibility of giving a Class A surface to long fibre-reinforced thermoplastic materials. Other techniques include the co-moulding of thermoformed multilayer thermoplastic "skins", the application of paint to the mould surface prior to moulding and the application of a coating to a cured composite part while it is still in the mould.

When it comes to assessing the heat resistance of plastic materials, the only attempt that most data sheets make to capture this capability is heat deflection temperature. However, one of the flaws contained in the HDT test is its failure to capture the effect of time on the properties of a polymer. The focus of this article is the chemical effect of prolonged elevated temperature exposure on a product. Antioxidants or heat stabilisers, although representing only a fraction of 1% of most formulations, govern to a great extent the effective lifetime of the product.

Electric injection moulding machines have caught on at different rates around the world, but their abundance is undeniable. Roughly 30% of the injection machines sold in North America in 2004 were fully electric, while in Europe it was about 5%. This first article in a series looks at current electric injection machine penetration, applications, technology and how they impact moulding strategy.

Innovation is the key to growing the wood-plastic composite (WPC) market. WPC penetration in the decking/railing market is expected to grow from 15% in 2004 to 25% in 2009, an increase of only about 2%/year. The WPC segment of the decking industry is maturing and the industry faces challenges achieving higher growth. Keller Products, a manufacturer of furniture products, has launched a project to explore and develop new markets for extruded parts made of WPCs. Keller Products' top candidate feels like real wood, is sandable, paintable and accepts most stains. The material is 30-40% wood flour with an ABS base. The US Navy is investing in research to commercialise WPCs in marine applications. One application is pier chocking, coextrusions consisting of an inner foam web and an outer high-density flange. DuPont recently introduced a new coupling agent, Fusabond, which could significantly improve strength and reduce water absorption in wood-PE composites.

It is briefly reported that a new type of rotational moulding machine from Persico, the Leonardo, is set to revolutionise the industry. Savings in both energy and labour are provided by the machine, which does away with the traditional oven normally associated with rotomoulding technology. A further advantage is that a wider variety of polymers, including PP, can be rotationally moulded. The Leonardo applies heating and cooling directly to the mould in a temperature controlled closed-loop system, achieving dramatic reductions in energy consumption. Persico has fully automated the machine, including material loading, part loading and unloading, reducing operator input to simply the start-up stage.

Packaging materials and their properties, including PP, PETP, PVC, PS, nylon and polycarbonate, are discussed.