Artificial intelligence, improved product development discussed at Antec

Denver — Artificial intelligence, 3D prototypes and reduced CO2 emissions were part of the discussions during the Society of Plastics Engineers 2023 Antec in Denver.

Artificial intelligence computing has helped solve challenges for materials maker Alterra Holdings LLC in Seymour, Ind.

Process engineer Saeed Arabi cited an example of a supplier shipping resin with higher moisture, causing an extrusion line not to run effectively. With AI, the problem can quickly be identified and addressed through use of cameras, scales and sensors.

"Once you see that the raw material is the problem, you can adjust blending speeds or do whatever else needs to be done," Arabi said. He added that AI can track production rates or scrap rates and can predict potential disruptions in the supply chain.

Alterra is using its proprietary SmartChronos AI at its compounding plant in Seymour. "We can learn based on data," Arabi said. "By connecting all production lines, we can capture all of that information and improve operating efficiency by 25 percent."

Multicomponent injection molding of ABS and liquid silicone rubber can save cycle time and eliminate assembly processes, according to researcher Ralf-Urs Giesen of the University of Kassel in Kassel, Germany.

On medical parts, ABS needs to be pre-treated for proper adhesion with LSR, Giesen said. The resulting parts have excellent adhesion properties. Giesen also pointed out that sterilization and aging can influence bonding in ABS/LSR parts.

Food and beverage giant PepsiCo Inc. has found a way to take plastics packaging from concept to manufacturing in five days.

PepsiCo of Purchase, N.Y., has done so with advanced rapid prototyping through 3D printing and with a virtual packaging lab for rapid analysis on physical performance, plastics engineer Thangthip Tekanil said.

3D models of packaging can be printed overnight, with molds then quickly assembled with patented modular set technology.

"Traditionally, it would take four weeks to get a mold," Tekanil said. "We can do it with 90 percent less time and money."

PepsiCo's research in this area is aimed at reducing the overall packaging development timeline from 12-18 months to six to nine months. "Additive manufacturing is an enabler to a fast-track process," Tekanil said. "From early design screening to pilot plant trials has gone from a few months to a few weeks."

Materials maker Covestro has found ways to leverage polycarbonate materials to achieve a lower carbon footprint.

Medical applications contribute to waste and CO2 emissions because many of them are single-use, design and processing engineer Joshua Wagner said. Higher rigidity can reduce material consumption for medical devices, he added.

Processors "can use less material without sacrificing performance" with PC, according to Wagner. PC also can yield lower energy consumption in medical device packaging.

Covestro's high-flow Makrolon-brand PC allows for increased cavitation, reduced pressure, lower temperatures and longer flow lengths in medical applications. The firm is based in Leverkusen, Germany, with U.S. headquarters in Pittsburgh.

Wagner cited a case study of a drug delivery device that showed the benefits of the material. He added that both Makrolon and Covestro's Bayblend-brand PC/ABS have shown good property retention after being recycled multiple times.