Huntsman’s automotive team has ensured there are no associated processing disadvantages. The Acoustiflex VEF BIO system can still be used to quickly create components that have complex geometric shapes and sharp angles, with high productivity rates and demold times as low as 80 seconds, depending on part design.

Huntsman has launched Acoustiflex VEF BIO — a visco-elastic foam containing up to 20% bio-based content derived from vegetable oils for molded acoustic applications in the automotive industry. This new solution can lower the carbon footprint of automotive carpet back-foaming by up to 25% compared with existing Huntsman systems for this application. The technology can also be used for dash and wheel arch insulation.

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.

The process involves the manufacture of injection moulding tooling cavity inserts from mould grade aluminium to fit the company’s existing mould tool bases. Plastic Parts Direct says production quantities can be as low as 10 or facilitate upwards of 10,000+ parts with a tool life expectancy running into years in many cases.

The Acoustiflex VEF BIO system addresses rising demand for material technologies that can help automotive manufacturers lower their carbon footprint without sacrificing performance. The bio-based content in its Acoustiflex VEF BIO system has zero impact on any of the acoustic or mechanical characteristics required by makers of parts or automotive OEMs, said Huntsman.

Acoustic performance analysis experiments show that Huntsman’s original VEF systems can outclass standard high-resilient (HR) foams at lower frequencies (<500 Hz). Acoustiflex VEF BIO system achieves the same magnitude of sound-reducing capability.

Irina Bolshakova, Global Marketing Lead for Automotive Polyurethanes at Huntsman, explains more: “Previously, there was a frustration that incorporating bio-based content into a polyurethane (PU) foam system would have a detrimental impact on performance, specifically on emission and odor levels. The development of our Acoustiflex VEF BIO system proves that doesn’t need to be the case.”

Now, with Plastic Part 3D’s additive manufacturing facility, the company is offering a more economical solution for projects requiring smaller quantities of 10-500 injection moulded parts or for the prototyping of designs before committing to traditional tooling.

UK manufacturer Plastic Parts Direct has launched a new 3D printing service for injection mould tools following a 50,000 GBP investment.

Visco-elastic foam containing up to 20% bio-based content lowers automotive carbon footprint without sacrificing performance.

“Polyurethanes are very hard to beat when it comes to pure acoustic performance,” continued Irina. “They are incredibly effective at muffling sound, reducing vibrations, and dampening down any harshness caused by the movement of a vehicle. Our Acoustiflex VEF BIO system takes that to the next level. Incorporating bio-based content into the mix to deliver a lower carbon acoustic solution, that does not compromise emission or odor requirements, is far better for vehicle brands and their partners and customers – but also the planet.”

The company, which specialises in precision plastic injection moulding, tool making and model-making, has expanded its rapid prototyping, machine tooling and 3D printing capabilities to launch Plastic Parts 3D. First announced towards the end of last year, the new venture was introduced in response to a growing number of customers seeking small match mouldings who had previously been put off by high tooling costs associated with a small amount of product.

For parts where 3D printing may not be the most suitable option, the company has also introduced a new Rapid Aluminium Tooling service for the production of rapid prototypes and end-use parts with a turnaround time of 10 working days.

In developing the Acoustiflex VEF BIO system, Huntsman has continued its work in the development of zero-amine, zero-plasticizer, and extremely low aldehyde-emitting PU foams. As a result, the system is ranked low in emissions and odor.