Covestro also has introduced glass-filled polycarbonates that deliver maximum strength and durability in surgical instruments and drug-delivery devices. They are suited for the load-bearing interior parts of self-medication devices, particularly those with viscous or high-volume medicines. Single-use sterile instruments are a current trend in surgery for reducing the risk of infection. In addition, a solid thermoplastic polymer can be more efficient than a metal material, said Covestro.

New low-friction and glass-filled polycarbonates from Covestro are suited for applications in which plastic parts slide against one another. They notably enable smooth, reliable, and durable movement without lubricants in drug-delivery devices. Covestro will showcase the new products during a customer webinar on March 30, 2021.

Two series with different strength levels are available. The high-performance series includes the polycarbonates Makrolon M810 GF, Makrolon M820 GF, and Makrolon M830 GF. The high-flow series includes the polycarbonates Makrolon M410 GF, Makrolon M420 GF, and Makrolon M430 GF. The latter are used for filling larger or thinner parts with improved productivity. All types are dimensionally stable and biocompatible according to ISO 10993-1.

The IntElect S mid-size range caters specifically to high performance applications with the shortest cycles, high material throughput, which typically consumes more energy affirms Gladigau. “Given the rapid rise in energy prices, counteracting the impact on rising manufacturing costs through higher productivity, processing repeatability and reduced waste is increasingly imperative with regard to competitiveness. For this very reason, market interest in our IntElect S series remains very high,” reports the product manager.

Compared with glass-fiber-reinforced polyamide, glass-fiber filled polycarbonates exhibit a better combination of different properties when used for drug-delivery devices and surgical instruments, according to Covestro. This improves their resistance to humidity and temperature fluctuations as well as their mechanical properties. Aided by a special process called Rapid Heat Cycle Molding, parts that require particularly glossy or smooth surfaces can be produced from the Makrolon GF types.

By expanding the IntElect S series, Sumitomo (SHI) Demag is resolute in its ambition to open up the all-electric moulding machine market and the associated benefits to even more product applications, including low part weights and narrow tolerance components. Positioned squarely between the conventional IntElect all-electric series and the new high-speed packaging injection moulding machine PAC-E, the IntElect S is geared specifically towards plastic processors mass-manufacturing narrow tolerance and thin-walled components at the fastest speeds.

Engineered specifically for high volume packaging and medical applications requiring the highest processing precision in the fastest cycle time, Sumitomo (SHI) Demag is growing its global expansion of the IntElect platform.

“Cycle times of between three and 12 seconds and injection speeds of up to 350 mm/s are the typical range of this machine," reports Gladigau. He draws special attention to the resilient, high performance drives, shorter clamp spindles and longer service life. Culminating in faster acceleration of the injection speed to achieve on average a one second cycle time saving when compared to a standard IntElect model.

Indicative of the current energy challenges, for packaging applications, the IntElect S can lower energy consumption to between 0.25 to 0.32 kilowatt hours per kilogram, states Gladigau. Citing it as the epitome of mass production efficiency, compared to hybrid machines this increased production capacity combined with saving tens of thousands of euros per year on energy, can result in one of the fastest machine paybacks.

Benchmarking dry cycle times on thin wall packaging products with equivalent electric systems on the market, IntElect S remains at the forefront of innovation and energy efficiency, assures Gladigau.

Covestro’s new low-friction and glass-filled polycarbonates are suited for medical applications in which plastic parts slide against one another.

Featuring optimised tool movement, nozzle position, injection and ejector movements and metering speed, the IntElect S model outperforms previous generations of IntElect machines. Increasing the capacity of the IntElect’s braking energy recovery system not only improves energy efficiency but also extends the lifespan of electrical components and capacitators. Verified by extensive machine and part lifecycle durability tests, notes Gladigau. Clamp spindles tested under the hardest conditions showed no evidence of visible wear after millions of cycles. Guaranteeing safe operation of the machine, even in the fastest-cycle applications.

The new low-friction, wear-resistant polycarbonates Makrolon M204 LF, Makrolon M402 LF, and Makrolon M404 LF ensure that injections proceed smoothly and reliably. The low-friction plastics also feature high dimensional stability and are superior in this respect to the competing material polyoxymethylene (POM), according to Covestro. The materials comply with the ISO 10993-1 biocompatibility standard and withstand most sterilization methods.

Filling an important gap in the mass-manufacturing market, notably thin-wall packaging, the company is releasing new sizes within its IntElect S all-electric high-performance injection moulding machine range, including medium clamping force (mid-size) machines between 220 and 450 tons. Product manager of the IntElect series Peter Gladigau, emphasises that with this latest release moulders requiring cycle time speeds of between three to 12 seconds now no longer need to compromise on any aspect of productivity, energy efficiency and processing speed and stability.