For optical applications such as mobile phone lenses, the process produces parts with reduced birefringence and anisotropic shrink. In automotive lighting applications, the X2F process can produce complex geometries, thicker lenses, and larger shapes. X2F puts the material into the mold cavity at high pressure “without abusing it,” Fitzpatrick explained. “We’re molding automotive headlamp lenses, virtual reality lenses using materials ranging from acrylic and PC to COC and COP, very complex lens polymers costing up to $100/lb. When you mold these materials, you need to mold them without birefringence, which is caused by stress as the molecules try to get back to their natural position. We’re molding these materials without stress and no sink.”

In the span of four months since the initiation of the conflict between Israel and Palestine in the Red Sea and Suez Canal region, a discernible shift has occurred in the supply dynamics of polyethylene (PE). European, Turkish, and North African buyers have reportedly shown an increasing preference for American PE. US traders and distributors are noting a surge in consumer demand originating from across the Atlantic Ocean in the early months of 2024. Export data sourced from the US International Trade Commission reveals a notable uptick in shipments of polyethylene to various North African countries since the conclusion of the fourth quarter of 2023.

X2F is also molding PEEK with 60% carbon fiber or 60% glass filler, resulting in more complex, stronger, and durable parts with enhanced performance. “We are doing what no other compounders are doing today,” said Fitzpatrick. “We’re able to add these fillers at the machine, and that brings our customers greater flexibility in their molding capabilities because these materials can’t be pelletized.”

The low-density polyethylene (LDPE) market also witnessed substantial activity. LDPE exports to Egypt reached their peak in November 2023. Additionally, LDPE outflows to Tunisia in December marked the second-highest volume in a year. The fourth quarter of 2023 saw continuous growth in LDPE exports to Tunisia, culminating in a noteworthy development where LDPE shipments from the United States to Egypt took place in December for the first time since August of the same year.

Materials typically needing 20,000 to 30,000 psi injection pressure can be run on a conventional machine with 1,000 to 5,000 psi in the mold cavity using X2F technology.

Examples include using X2F technology to help waterproof consumer electronics, such as watches and mobile phones, or to protect circuitry in industrial and automotive applications that need enhanced reliability. The X2F process also allows for fewer production steps, dramatically improved yields, shorter cycle times, and the processing of new materials with advanced properties.

Until she retired in September 2021, Clare Goldsberry reported on the plastics industry for more than 30 years. In addition to the 10,000+ articles she has written, by her own estimation, she is the author of several books, including The Business of Injection Molding: How to succeed as a custom molder and Purchasing Injection Molds: A buyers guide. Goldsberry is a member of the Plastics Pioneers Association. She reflected on her long career in "Time to Say Good-Bye."

The upheaval caused by the conflict in the Red Sea has disrupted polyethylene shipments from the Middle East. In response to this disruption, US exporters have seized the opportunity to capitalize on the altered market dynamics, enabling them to gain a more significant market share.

Polyethylene imports from the United States to Europe experienced a substantial uptick in the fourth quarter of 2023, registering an increase of approximately 24% when compared to the corresponding period in 2022. As 2023 drew to a close, the estimated consumption of polyethylene, excluding exports to Belarus and Kazakhstan, amounted to 3,109.15 thousand tons. This figure represents a substantial growth of 25% compared to the same period in the preceding year. Notably, there was an increase in supplies of both high-density polyethylene (HDPE) and low-density polyethylene (LDPE) from Russian producers.

The X2F system uses controlled viscosity (low pressure) and a patented pulse-packing approach to create high-value components.

X2F is commercializing a new category of molding technology that leverages controlled viscosity (low pressure) and a patented pulse-packing approach to create high-value components for a variety of industries. X2F has also announced the hiring of a key technical person, Ken Jacob, a plastics industry veteran and technology expert, as the company looks to expand its reach.

High Density Polyethylene (HDPE) Market Analysis: Plant Capacity, Production, Process, Technology, Operating Efficiency, Demand & Supply, End-Use, Grade, Foreign Trade, Sales Channel, Regional Demand, Company Share, Manufacturing Process, 2015-2035

This trend is anticipated to persist amid the ongoing conflict, creating a scenario where the availability of US exports is expected to decline in the short term. Consequently, European buyers express concerns about the security of their supply chains, a sentiment likely to persist until the culmination of the first half of 2024.

The new category of molding technology benefits, in particular, delicate electronics encapsulations and automotive lighting applications with complex geometries.

This process can be used in “very delicate” electronics encapsulation applications due to the tight control of temperature and pressure in the mold cavity, said Fitzpatrick, explaining that in encapsulated electronics the X2F process offers superior performance against moisture, temperature, and environmental conditions as compared to conformal coating, potting, or other low-pressure approaches.

With X2F’s process, materials typically needing 20,000 to 30,000 psi injection pressure can be run on a conventional machine with 1,000 to 5,000 psi in the mold cavity. “We get there from an entirely different direction,” explained Fitzpatrick. “We begin flowing and gradually build pressure, while not abusing the polymer in the process.”

For example, X2F can mold a 35-gram shot size of 75%-filled PEEK in a 4-ton clamp molding machine, competing against 200- to 250-ton machines, doing it at 10% of the power typically used. When a conventional molder processes filled or unfilled PEEK using 5 to 6 tons of clamp per square inch, X2F can achieve the same result at about 15% of that. “We need 1,000 pounds of clamp per square inch compared to the 12,000 lbs per square inch most people use for heavily filled materials,” Fitzpatrick said.

Rick Fitzpatrick, X2F founder and Chief Technology Officer, told PlasticsToday that the company’s goal is to perform complex molding using difficult-to-mold materials. “We didn’t start this company to attack the problem of viscosity but to get better control over injection pressure by bringing the material to a low and flowable viscosity,” explained Fitzpatrick. “Our extrusion screw is designed for this process that we’ve developed over the past 15 years.”

In the span of four months since the initiation of the conflict between Israel and Palestine in the Red Sea and Suez Canal region, a discernible shift has occurred in the supply dynamics of polyethylene (PE). European, Turkish, and North African buyers have reportedly shown an increasing preference for American PE. US traders and distributors are noting a surge in consumer demand originating from across the Atlantic Ocean in the early months of 2024. Export data sourced from the US International Trade Commission reveals a notable uptick in shipments of polyethylene to various North African countries since the conclusion of the fourth quarter of 2023. The upheaval caused by the conflict in the Red Sea has disrupted polyethylene shipments from the Middle East. In response to this disruption, US exporters have seized the opportunity to capitalize on the altered market dynamics, enabling them to gain a more significant market share. This trend is anticipated to persist amid the ongoing conflict, creating a scenario where the availability of US exports is expected to decline in the short term. Consequently, European buyers express concerns about the security of their supply chains, a sentiment likely to persist until the culmination of the first half of 2024. Sources in the industry point out that prices in the United States are particularly competitive within the region, especially for linear grades of low-density polyethylene and injection molded high-density polyethylene (HDPE). Noteworthy statistics indicate that monthly HDPE export volumes reached their highest point in 2023 for countries such as Nigeria, Algeria, and Poland in December. Tunisia, during the same month, experienced the second-highest HDPE export volumes in a year. Furthermore, Egypt received HDPE cargoes from the United States in December, marking the first occurrence since April. The low-density polyethylene (LDPE) market also witnessed substantial activity. LDPE exports to Egypt reached their peak in November 2023. Additionally, LDPE outflows to Tunisia in December marked the second-highest volume in a year. The fourth quarter of 2023 saw continuous growth in LDPE exports to Tunisia, culminating in a noteworthy development where LDPE shipments from the United States to Egypt took place in December for the first time since August of the same year. Polyethylene imports from the United States to Europe experienced a substantial uptick in the fourth quarter of 2023, registering an increase of approximately 24% when compared to the corresponding period in 2022. As 2023 drew to a close, the estimated consumption of polyethylene, excluding exports to Belarus and Kazakhstan, amounted to 3,109.15 thousand tons. This figure represents a substantial growth of 25% compared to the same period in the preceding year. Notably, there was an increase in supplies of both high-density polyethylene (HDPE) and low-density polyethylene (LDPE) from Russian producers.

“We’re quietly working along, defining what can and can’t be done with plastics and what is injection moldable. We’re defining where the plastic industry is going, rather than where it is,” Fitzpatrick said. “We’ve not come across a single material that we can’t mold.”

Sources in the industry point out that prices in the United States are particularly competitive within the region, especially for linear grades of low-density polyethylene and injection molded high-density polyethylene (HDPE). Noteworthy statistics indicate that monthly HDPE export volumes reached their highest point in 2023 for countries such as Nigeria, Algeria, and Poland in December. Tunisia, during the same month, experienced the second-highest HDPE export volumes in a year. Furthermore, Egypt received HDPE cargoes from the United States in December, marking the first occurrence since April.