PolyOne recently collaborated with a leading global automotive OEM and its injection molder to eliminate paint from a new vehicle’s interior.

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The low-viscosity grade Ultrason® P 2010 can be used in injection stretch blow molding to manufacture bottles which benefit from the customized properties of the high-temperature thermoplastic: It shows superior toughness, chemical resistance and long-term high-temperature stability. It is food contact compliant in the US, the EU and China and easy to process without scrap losses, using suitably configured hot runner systems. “Ultrason® is the ideal material not only for high-quality baby bottles with good transparency but for lightweight drinking bottles used by adults, too,” says Cheong Kim from BASF Sales for Ultrason® in Korea. “It shows no discoloration by contact with all kinds of juices and soft drinks as well as green or black tea. Ultrason® has proven its value for bottle manufacturers in Asia for many years: They can choose the most suitable material for their respective manufacturing method and trust in our on-site application support as well as BASF’s supply reliability of the different grades.”

The key to molding good parts is for OEMs to decide, very early on, that a part will be colored with molded-in color masterbatch; that decision will then support the development of a mold and part suitable for masterbatch.

The industry’s challenges, in light of COVID-19 and an uncertain economy, could open the door much wider to greater use of metallic-effect masterbatches, as these significantly lower cost per part. The challenge with masterbatch remains molding parts that do not have visual defects such as flow or weld lines.

The Korean baby products manufacturer UBMOM, Seoul, is now using BASF’s Ultrason® P to produce baby bottles. The polyphenylsulfone (PPSU) meets UBMOM’s high-quality needs for its smart feeding bottles that are safe, durable and easy to handle. Ultrason® P 2010 is approved for food contact (FDA and NSF) and features high chemical resistance, excellent strength and resistance to superheated steam up to 134°C. These properties ensure that the baby bottles are safe to use, while being lightweight and shatter-proof. They can be reused many times without loss of their mechanical and optical qualities because Ultrason® P 2010 easily withstands sterilization in microwave ovens or in boiling water. The transparent, slightly honey-colored BASF thermoplastic allows for designing colorful baby bottles in many designs and shapes.

And though the argument against masterbatch always is about these visual defects, little is said about scrap from paint lines, which can reportedly be more than 20%. Painting is not only more costly, and energy-intensive; it also generates very high levels of non-recyclable scrap.

PolyOne recently collaborated with a leading global automotive OEM and its injection molder to eliminate paint from a new vehicle’s interior. To support the transition to molded-in-color (MIC) parts, PolyOne provided metallic-effect Smartbatch FX masterbatch colorants for two PC/ABS side panels on the center console of a compact SUV now entering commercial production. The parts (two; one on each side of the center console) are C-shaped, 35-cm long, and at their widest point 11-cm wide.

“Typically, you do not want a bunch of holes or sharp curves in a part if you intend to use metallic-effect masterbatch. Too often, a mold is made for molding of parts that will be painted, and then — when it is time for a facelift — the OEM decides it wants to save some money and shift from paint to masterbatch. However, without investing in a new mold, the existing mold design often makes it very difficult for masterbatch to be successfully used.

“Our main focus is on the health of babies and we want to develop bottles that take mothers’ concerns seriously”, says Yong Woon Park, CEO at UBMOM. “So we are constantly trying to provide our customers with the highest quality products. With its light material color and high mechanical performance, BASF’s Ultrason® perfectly fits into this approach as it supports our commitment to material safety and flexibility in design. Especially the clear and light color of the PPSU helps us to design colorful feeding bottles that keep their visual quality over a long period of time.”

Paint adds a great surface finish to automobile parts, but painting always adds cost, time, and additional logistics requirements according to PolyOne. By using Smartbatch FX metallic masterbatches, the molder was able to produce parts ready for assembly with no secondary processing required. Suitable for standard injection molding machinery, Smartbatch FX reduces the cost per part by 30 percent or more compared to painted parts. Lowered energy requirements versus painting and the reduction of VOCs also make this masterbatch a more environmentally sustainable solution.

“Many car parts are painted, not just metal and thermoplastic exterior parts, but also thermoplastic parts in a vehicle’s interior,” notes Gary Fielding, vice president and general manager, Color and Additives EMEA at PolyOne. “We have successfully helped carmakers transition from paint to MIC for many exterior applications such as skid plates and trims. This recent project is a significant step forward in reducing the cost to manufacture highly visible interior applications.”

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and is a proud dachshund owner.

To provide customers with additional information on making the switch from paint to molded-in-color parts, PolyOne has created an eBook titled, “Trend Report: Efficient Manufacturing And Molded-In Color.”

Ultrason® is the trade name for BASF’s product range of polyethersulfone (Ultrason® E), polysulfone (Ultrason® S) and polyphenylsulfone (Ultrason® P). The high-performance thermoplastic is used to manufacture water filtration membranes, stylish, durable and safe household and catering applications as well as lightweight components for the automotive and aerospace industries. Ultrason® brands can substitute thermosets, metals and ceramics in many applications because of their extraordinary property profile.

BASF is accelerating its plastics journey towards a more sustainable future! At CHINAPLAS 2024, BASF will showcase its latest innovations, competencies, and developments – particularly in the areas of sustainability and co-creation. Join us at CHINAPLAS 2024 and let us walk you through the MAKE–USE–RECYCLE phases in our plastics journey.

Transitioning from paint to the use of MIC with Smartbatch FX helps manufacturers in the automotive, appliance, consumer goods and other industries create attractive, durable parts at reduced cost. PolyOne’s metallic-effect masterbatches can be incorporated into pre-colored compounds or dosed at a molding machine.

Transitioning from paint to masterbatch for metallic-effect parts is not new, but it is nowhere near as widespread as one would expect according to some auto industry observers. Inertia — We’ve always done it that way — and legacy investment in paint lines, supports the continued use of paint.