Automotive: DSM, Chromatic & RepRap to develop 3D PU parts; Eastman/NB to create new solutions with bioplastic

Chemical firm DSM has entered into a new partnership with Chromatic 3D Materials and German RepRap (GRR) to produce flexible parts using Chromatic's line of polyurethane (PU) materials.

Despite the advantages of using flexible materials for a diverse range of parts, 3D printing with PU and similar materials can be complex. DSM collaborates with partners across the 3D printing value chain to remove such barriers. Together, DSM, Chromatic and GRR aim to pave the way for the widespread, industrial adoption of flexible materials across the additive manufacturing industry. GRR will make its printing equipment and expertise accessible to manufacturers keen to use Chromatic's FlexTune line of PU elastomer materials, which are flexible, durable and reliable.

Drawing on Chromatic's experience and DSM's comprehensive knowledge of additive manufacturing materials, markets and applications, the complete solution offered by the three partners will enable manufacturers in many industries to benefit from the advantages of flexible, 3D printed materials.

Examples of specific applications that benefit from flexible parts include noise-reducing buffers and mechanical clutches for power transmissions in cars, and gaskets used in train braking systems. Chromatic's materials have also proven highly successful in the footwear industry for personalized insoles.

DSM and Chromatic originally teamed up to introduce and explore thermoset materials for 3D printed parts, a broad class of materials offering a level of adaptability, durability and resilience not possible with thermoplastics used in 3D printing. Together with GRR, the companies will go on to expand their collaboration to market Chromatic's line of FlexTune materials, which will be available globally.

Cora Leibig, CEO at Chromatic 3D Materials, says: “The introduction of FlexTune 3D printable polyurethanes elastomers is a vital step for additive manufacturing to becoming the industrial process for manufacturing flexible parts.”

Meanwhile, in other news, specialty plastics provider Eastman is collaborating with NB Coatings, a specialist in paint on plastics for both domestic and transplant original equipment manufacturers (OEMs), to create a new solution for interior Class A painted surfaces with Trēva engineering bioplastic. Trēva offers a viable option for companies interested in creating sustainable, cost-effective products. With the recent commercialisation of its carbon renewal technology, Eastman produces Trēva with biobased and recycled content. When painted with NB Coatings paint systems, Trēva can meet the demanding Class A surface requirements as specified by OEMs.

"Trēva provides a biobased, sustainable alternative to polycarbonate, ABS and PC-ABS for interior automotive applications at a cost-neutral position," said Chris Scarazzo, Eastman automotive market segment leader. "Eastman's material innovations match what OEMs need to develop lasting parts with sustainable materials and help them achieve their goals for sustainable content and replacement of petroleum-based plastic."

Sourced from sustainably managed forests, Trēva has biobased content of 42-46%, certified by the USDA's BioPreferred program. To continue reducing waste and maximising resources, Trēva benefits from carbon renewal technology, Eastman's proprietary recycling process that recycles waste plastic typically sent to landfills or found as litter in waterways.

Carbon renewal technology is a chemical recycling technology that diverts mixed waste plastics from the landfill and converts them to simple molecular components that are then reintroduced in the production of a variety of Eastman products, including Trēva without performance compromise.

In automotive applications, cellulose-based Trēva exhibits high performance and reduced environmental impact. With optical and birefringence properties, it provides high clarity and strength and is suitable for applications such as human machine interface (HMI) lenses. Trēva also withstands the challenges of automotive interiors, including high temperatures, humidity, UV, scratch/mar and general durability requirements. Trēva has low VOC emissions, which is critical for interior parts. Its processing ease and flow enable good dimensional stability and thin-wall designs for less material usage and lower weight.

"As an environmentally conscious coating provider, NB Coatings is excited to announce this paintability breakthrough in collaboration with Eastman," said Jesse Fritcher, NB Coatings vice president of technical. "Our trials with Trēva found adhesion of our coating technologies to be comparable, if not easier, than traditional grades of PC-ABS that are currently in use, providing new sustainable options for automotive design engineers."

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