dsm engineering plastics (advanced thermoplastic composites) … · (advanced thermoplastic...
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DSM Engineering Plastics(Advanced Thermoplastic Composites)
ALV Composites NLBrightlands Materials CenterNovember 27, 2019
Dr. Raj MathurGlobal Manager, ATC
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About Royal DSMBright Science. Brighter Living.
2
DSM is a globalpurpose-led,
science-basedcompany
specializing inNutrition, Health &Sustainable Living.
Our purpose is:to create
brighter livesfor all.
DSM was founded in 1902 and is listed on Euronext Amsterdam
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DSM Engineering Plastics and DSM overall
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Quick facts and figures
DSMoverall
DSMEngineering
Plastics
Safety
21,000excludingaffiliates
0.33frequency index
of recordableinjuries
€ 8.85 bnFigures for 2018
Planet
For thirdconsecutive yearDSM named on Fortune Magazine’s
‘Change the World’ List 2018
#1globally in
sustainabilityby Sustainalytics
~1,900Workforce Net sales
~€ 1.5 bnFigures for 2018
Production
8production
facilities
R&T Investment
~4.5%of revenue
reinvested in R&T
Technology
~90%of all new cars and electronicsdevises use DSM technology
Workforce Net sales
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Industries we serve
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Building andconstruction
Industrialequipment
Transportation Medical
Automotive Electronics Electrical
Renewableenergy
Consumergoods
Bright Science in advanced materials
Food packaging
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Global footprint to support customers across the globe
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Quick facts and figures
Production locationsR&D locationsOffices
Tokyo - Japan
Incheon – South Korea
Bangkok - Thailand
Taipei - Taiwan
Kaohsiung - Taiwan
Jiangyin - China
Shanghai-China
Shenzen-China
Pune - India
Togliatti - RussiaEmmen -
Netherlands
Genk - BelgiumSittard - Netherlands
Geleen - Netherlands
Detroit - USA
Evansville - USA
Silicon Valley - USA
São Paulo - Brazil
Singapore
Querétaro - Mexico
Ho Chi Minh City - Vietnam
DSM Engineering Plastics
Chennai- India
Gurgaon - India
Pantnagar - India
Düsseldorf - Germany
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Rapid shift to New Mobility, Connectivity & Artificial IntelligenceIndustry Mega Trend: New Technology (1/2)
Autonomous Car
Virtual /Augmented Reality HolographicDisplay
InternetCloud
5GNetwork
Edge vs.Cloud Computing
SpeechRecognition
ConnectedHome
Digital
2000 - 2007 2007 - 2017
Mobile
Since 2017
New Mobility
ArtificialIntelligence
Connectivity
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ICE Optimization &Lightweighting
Electrification
Connectivity & SafetyADAS & Autonomous
Shared Mobility
• Increasing demand for higher-performance materials:– Increased innovation challenge– Increased complexity
• Demand for new applicationsincluding radically new designs(thinnovation, miniaturization,simplification)
• Demand for functional materials
High-performance plastics for automotiveand E&E components as Connectors,Sensors, Power Distribution
Strong application and technologysupport for OEMs and Tiers
Application-specific CAE simulations formold flow, mechanics, thermal and EMIshielding characteristics
DSM Engineering Plasticssupports with:
Technology shift asks for new and innovative high-performance materials
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Industry Mega Trend: New Technology (2/2)
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Co-developing throughout the value chain
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Bright Science in advanced materials
Compound ConvertorMonomer Polymer SystemSupplier OEM End
User
High-Performance Materials
• Review applicationrequirements
• Analyze datasets• CAE support
• Temperature• Mechanical• Chemical resistance• UL and other global
safety standards
• Quality control• Identify
productionefficiencies
• Documentation• Data sheets• Regulatory affairs
statements• Life cycle analysis
Design MeasurePerformance
ProductionSupport Compliance
Science, Expertise & Support
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Advanced Thermoplastic Composites
Continuous Fiber Reinforced Thermoplastic (CFRT) composites
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DSM isa leading innovatorin high-performance
materials
A broad Advanced Material Solutions Portfolio
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Bright Science in advanced materials
PEI
PSU
PES
PCmPPO Blends
PEEK
PPALCP
POM
PA4T
PA4T
PA46
PA410PPSTPC
PET
PA6 PA66 PA6/66
PBT
ABSPS PVC
PMMAPE PP
Amorphous Semi-crystalline
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CFRT(GF)
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Glass transition temperature (ºC)
DSM TECHNOLOGIES
• First Aliphatic PA with the highest melting point
• Inventor of Diablo technology
• First halogen-free PPA that is blister resistant
• PPA with highest Tg (160°C) in the world
*ENABLING• 160°C Tg
• Optimal chemical resistance
• High peak temperatures
• High tensile modulus
120 140 16060 80 100
360
320
280
240
200
Mel
tte
mpe
ratu
re(°
C)
PA410
PA6, PA66
PPS
UD Tapes
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Applicable DSM Materials
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Why ATC?
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Weight Loss is still the most effective emissions reduction technology
Transmission/gearbox
Stop-start
Auxillary consumption reduction
Rolling resistance
Aerodynamics
IC Engine Improvement
Hybrid
Traditional LW (HSS/Aluminum)
Extreme Light-weighting (max CRFP)
CO2 g/km improvement
3-4
1-5
3-5
2-6
6-15
10-30
4-12
12-35
3-4
Technology
Source: A.T. Kearney
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DSM is globally recognized forsustainability performance.
FOR THE 3RDYEAR, IN FORTUNE
MAGAZINE’SCHANGE THE WORLD LIST
(2018)
TOP RATINGIN ESG INDEX
IN OUR INDUSTRY(2018)
CHEMICALSINDUSTRYLEADER IN
ESG RANKING(2018)
CONSTITUENTOF FTSE4GOOD
INDEX(2018)
A- FOR CLIMATEB- FOR WATER
(2018)
Leading the way in integrating sustainabilityacross business and operations
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75%+PURCHASEDRENEWABLEELECTRICITY
0SAFETY
INCIDENTS
ENTIREPORTFOLIOOF BIO- AND/OR
RECYCLED-BASEDALTERNATIVES*
v Not exceeding < 0 . 2 5 Safety frequency index by 2021
Safety Frequency Index = number of accidents with leave x 1 000 /number of employees
Today
*At least 25% recycled and/or bio-based content by weight in thefinal product
DSM Engineering Plasticsis a business with ambition
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UDT Physical CharacteristicsTape
Specifications Typical Values Remarks
Thickness 0.10-0.25 mm STD: +/-0,02 mm
Width Up to 1000 mm(300 mm Nominal)
Slitting toachieve narrow
width
Length Any length possible 300 m (nominal)
Slitting ≥ 6 mm +/- 0,1 mm 1 mmincremental step
ü Very good spreading of fiber bundles within thepolymer matrix.
ü No voids observed
ü Fibers fully impregnated
ü Fibers are all aligned straight – no undulationobserved
Artifacts
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Standardization
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Market Approach
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Visual Presentation of A Supply Chain Gap
Fibers+Resin UD tape Tape lay up Consolidation Thermoforming
Not visible; not understood
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ATC Materials
• UD tapes can be woven and/orstacked into plates (0.2 mm to 5mm thick) and shaped bythermoforming/over-molding
• The UD tapes can be used asinserts in injection molding
• The UD tape can be wound(filament-winding) into pipes ofvarying cross-section profiles
• Metal-Composite Hybrids(Composite Patches)
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Applications
UDTape
Thermoforming(tailored blanks)
Insert molding
Winding
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Our Approach
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A product-development process that can drive the metal-composite conversion with a high degree of success
• Modest raw-materials to UD Tape conversion costs ($)• Cycle-times approx. 1 minute (like injection-molding $)• Extensive/Exotic retooling not required
Key technology-partnerships in the value chain:• Partnerships for UD Tape Winding, Tape-placement &
Thermoforming and CAE simulations of UD Tape basedcomposites behavior in customer applications
• Key OEM/TIER market-pull for PTO opportunities
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Applications (History 2012-2016)
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Composite door panel with sideimpact beam (JLR)
Patented composite hybridMaxFiberSteel™ wheel (Maxion)
Floor module (CRF)
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Applications
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Front Bumper BeamCover
Plate/Bracket
ATL + Thermo-form + Over-mold Winding
2m length
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Circularity
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Cradle to Cradle Use
• Grinded material sieved over 3 mm mesh• No issues with feeding regrind materials in
injection molding
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Circularity
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Comparison with Commercial Compounds
Consistent and reproducible test-data
Regrind Q-HG10* Retention (%)Modulus(GPa) 15 15 100
Tensilestrength(MPa)
200.2 215 93
Strain AtBreak (%) 2.4 2.9 83
* Average value calculated from >15 production batches
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Conclusions
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Trend Toward Multi-Material Design
Source: M.Goede, VW Group Research, SLC
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Summary
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Leveraging UD tapes
PARTDESIGN
MATL.SELECT
MANUF.PROCESS
1. An integrated approach to parts design, materialselection and manufacturing process is key tometal-to-composite conversion• Short Cycle Times• Low Conversion Costs• Low Re-Tooling Costs
2. Emphasis on light-weighting (multi-material approach)3. UD tapes are the building blocks of ATC4. External partnerships optimize time-to-market
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