Due to their high moisture absorption, bast fibers have only been used to a limited extent in plastics and durable applications. Therefore, one of the innovation goals of the DuroBast project is to reduce the moisture absorption of the fibers through modification and then process them into yarns, nonwovens, and fabrics. To this end, the fibers will undergo pre-treatment. Specifically, fiber cavities and inter-fiber spaces will be filled with a thermoplastic that prevents water absorption even in damaged areas and cut edges of the composites. With this objective in mind, the team is examining and comparing the properties of various bast fibers, different processes, and the mode of action of different hydrophobic agents.

Canadian auto parts molder Windsor Mold Group is marking its fifteenth year as an Engel customer and, as an early adopter of Engel’s iQ weight control software, now plans to upgrade all of the compatible Engel machines in its fleet with the software.

Germany’s government-funded DuroBast project is focused on the use of bast fibers for the production of composite structural components. The project aims to develop thermoformable thermoplastic composites employing renewable bast fibers as reinforcements for a range of applications in automotive and sports equipment. Initial research work has focused on composite components such as bus bellows, center consoles, and snowboards.

To achieve 100 % bio-based material combinations in the long term, the research team is also striving to use a bio-based polymer matrix. The process should subsequently enable improved bonding of the matrix to the natural fiber component. Here, the yarns, nonwovens, and fabrics obtained from the fibers must meet the requirements of the intended end applications. Identifying the optimal fiber length, denier, purity, and strength; spinning method; and degree of fiber roasting are proving to be a challenge in this context. All selected components also must fulfil the target criteria of processability, economic efficiency, availability, and sustainability.

In the meantime, Windsor Mold has ordered two new Engel combi M multi-shot injection molding machines – a 1,900 US ton and 1,000 US ton – both with the iQ weight control package. Installation of the machines is expected in early 2022.

Recently, Windsor Mold tested Engel’s iQ weight control software on their Engel machines. IQ melt control determines the optimum plasticizing time for each application. Instead of plasticizing at the maximum possible speed, the system takes advantage of the part’s in-mold cooling time to allow for plasticizing. The machine operator only has to enter the screw type and the material to be processed. The software was shown for the first time at K 2019, and became available worldwide in January.

From left to right: Ken Schad, regional sales, Canada for Engel and Mike Nicholls, planning and development manager for Windsor Mold. Photo Credit: Engel

Interdisciplinary research team seeks to develop thermoformable thermoplastic composites using renewable bast fibers as reinforcement.

“We conducted a trial at our test site in Ohio and were so pleased with the results that we installed the software on ten of our Engels,” said Mike Nicholls, Windsor Mold’s planning and development manager. “So far, we’ve seen 10 per cent in scrap reduction [and] our plans are to convert about 90 per cent of our Engel machines to the iQ weight control program over the next three to five years.”

In addition to flax, initial investigations have confirmed the advantages of the hemp plant. Its climatic requirements allow cultivation in Germany and, thus, offer supply security in times of an uncertain global logistics situation. Hemp’s price is also favorable versus flax fibers, and the entire plant can be utilized in medical and food applications, such as hemp seeds. Hemp is also environmentally advantageous with its ability to concentrate large quantities of CO2 during cultivation. In fiber-reinforced plastics, hemp can reduce the proportion of fossil plastic components by replacing them with renewable alternatives.

The project partners are Dräxlmaier GmbH & Co. KG, Gustav Gerster GmbH & Co. KG, Hübner GmbH & Co. KG, Institute for Textile Technology RWTH Aachen, Leibniz Institute for Composite Materials GmbH, nova-Institut für politische und ökologische Innovation GmbH, Rhenoflex GmbH, silbaerg GmbH, Wagenfelder Spinnereien GmbH and the Chair of Materials Test Engineering (WPT) of TU Dortmund University.

Engel’s global headquarters is in Schwertberg, Austria. The company has North American headquarters in York, Pa. Its Canadian subsidiary, Engel Canada Inc., is located in Waterloo, Ont.

A Tier 1 supplier to the majority of the top OEMs in the automotive industry, the Windsor, Ont.-based molder’s connection to Engel dates back to 2006, when it purchased its first two Engel injection molding machines, and since then Engel has been its exclusive supplier of large tonnage multi-shot machines. Windsor Mold currently has 45 Engel injection molding machines ranging from 310 to 3,000 US tons at its Windsor’s multiple locations in Canada, the U.S., and Mexico. The main focus of the Engel multi-shot machines is production of automotive leafscreens and pillar appliques.

Native bast plants such as flax, hemp, and nettle have been used for fiber production for centuries. Their fibers are characterized by an array of properties and are suitable for the manufacture of a variety of products. Besides clothing, these fibers historically were used for technical applications such as sacks, sails, ropes, and nets. Today, their lightweight construction potential makes bast fibers an interesting material alternative in the development of fuel-efficient cars and electro-mobile solutions. Another advantage of flax and hemp is their low tendency to splinter, a positive attribute especially in traffic accidents.

Under the leadership of the Fraunhofer Institute for Structural Durability and System Reliability LBF, an interdisciplinary research consortium with 11 partners from science and industry, is working on the development of innovative bio-based materials. Members of the consortium are linking their expertise in all areas of the value chain and aim to transfer project results to concrete applications such as automotive interiors (door panels), sports equipment (snowboards), and public transport (bus bellows) in the near future.

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.

Initial tests on the production of hemp-polypropylene organic sheets delivered promising results. These fiber-reinforced thermoplastics exhibit strength and low density and are just as easy to process as conventional sheet metal components. The research team intends to comprehensively test further material combinations and processes in the following months.