Thursday, 16 October 2025

My Highlights from K Fair 2025 – The Global Hub for Plastics & Rubber Innovation

Hello and welcome to a new post! The K trade fair in Düsseldorf once again proved itself as the ultimate meeting place for the plastics world—international, innovative, and truly immense. This year, I had the opportunity to witness some  developments that are shaping the future of our industry, particularly in the areas of sustainability, digitalization, and advanced materials.

K Fair 2025: My highlights and discoveries

My Key Discoveries:

🔹 China’s Growing Leadership:

Chinese plastics and rubber companies are not only increasing in number—up nearly 50% from the last event, now making China the second-largest exhibiting nation after Germany—but are also leading in innovation, product development, and circular economy initiatives. Their presence and technological advancements were truly impressive.

🔹 AI in Daily Production:

Artificial intelligence is no longer a buzzword; it’s now an integral part of daily operations. Connected machines and real-time data analysis are accelerating both the speed of innovation and speed to value across the industry.

🔹 Industry Transformation:

While revenue growth remains a challenge, this period is being used as an opportunity to streamline internal structures and consolidate portfolios, preparing for a more resilient future.

🔹 Energy Costs & Plant Closures:

High energy costs in Europe continue to impact the sector, leading to the closure of several chemical plants—a trend that cannot be ignored.

🔹 Recycling as a Sustainability Driver:

Recycling has evolved from a cost-saving measure to a key driver of sustainability, especially when combined with product carbon footprint passports and digital material twins.

🔹 M&A Activity:

Mergers and acquisitions remain active, with notable deals such as Engel’s acquisition of Trexel, a specialist in foaming technology for injection molding.

Let us deeper dive into the latest innovations in circular economy and recycling, digitalization and smart manufacturing, new materials, and machinery enhancements:

Circular economy and recycling innovations

Next-level recycling technologies: Companies like Gneuss showcased melt filtration and extrusion technologies designed to significantly improve recycling processes. The VDMA's Circular Economy Forum provided live demonstrations of implementing circularity within plastics production.

High-quality recycled materials: BioPlastics & Recycling GmbH presented certified post-consumer recycled (PCR) regranulates, including rPP and rPE with FDA approval, setting new standards for quality and sustainability.

Upcycled materials: Researchers showcased new materials, such as the BAETA technology, which transforms recycled PET bottles into carbon capture material.

Sustainable product design: Prototypes and commercial products were presented that were designed for better recyclability, including mono-material solutions and reusable systems. For example, Covestro and VAUDE introduced a recyclable, mono-material backpack made from TPU. 

Innovative recycling technology: Syensqo showcased its innovative recycling technology for circular sulfone polymers. 

Digitalization and smart manufacturing

Artificial intelligence (AI), the Internet of Things (IoT), and automation were on display to showcase the future of smart manufacturing. 

AI for efficiency and sustainability: Exhibitors highlighted how AI-based process optimization can increase the throughput of blown film lines, automatically coordinating components for greater efficiency. Reifenhäuser also introduced "Reifenhäuser Next," a brand centered on an AI chatbot and digital learning platforms to combat skilled labor shortages and solve production challenges.

Digital twins: This technology was featured for creating virtual representations of production lines, allowing for the simulation and optimization of manufacturing processes before physical implementation.

Predictive maintenance: Advanced sensor technology and cloud applications enable the real-time monitoring of machinery, allowing for predictive maintenance that reduces unplanned downtime.

Digital Product Passports (DPP): In response to EU regulations, new technologies were presented to support the implementation of Digital Product Passports, which provide information on a product's raw materials, production processes, and recycling paths. 

New and advanced materials

Sustainable polycarbonates: Covestro showcased its Makrolon® RE and Makrolon® RP polycarbonates, which incorporate recycled content or are based on renewable raw materials. These were used in applications ranging from electronics to medical devices.

Bio-based alternatives: The Fraunhofer Institute presented a new helmet made from bio-based polylactide (PLA), offering comparable protection to conventional helmets with a two-thirds reduction in CO2 emissions. Expanded PLA (EPLA) was also shown as a sustainable alternative to EPS foam.

High-performance materials for e-mobility: Complex busbars: Syensqo collaborated with Clayens to present a 360-degree approach for developing complex busbars for electric vehicles. 

Recycled polyamide: RadiciGroup received an award for a battery module made from its recycled Renycle polyamide. 

New polymer distribution companies: Omya's polymer distribution business made its official debut as the newly formed Omya Performance Polymer Distribution at the K Fair 2025 in Düsseldorf. The company showcased its portfolio of specialty polymers, innovations, and solutions for the plastics industry.  

Machinery and equipment enhancements

Manufacturers introduced new and improved machinery that was faster, more efficient, and better integrated with digital systems. 

First all-electric, tie-bar-less injection molding machine: ENGEL unveiled the new victory electric, its first all-electric, tie-bar-less injection molding machine, which combines their electric drive technology with their tie-bar-less design for increased efficiency and precision. The new machine is a world premiere that focuses on design advancements to meet specific customer requirements for greater benefits.  

Smaller, faster machines: KraussMaffei introduced a process that compounds glass fiber rovings directly in the injection molding unit to reduce material costs. Netstal showcased its new-generation Elion MED series for medical technology, known for its speed and precision.

Simplified tool changeovers: Guill Tool & Engineering introduced its Cam-Lock system, designed to simplify tool changeovers on its extrusion heads.

Upgraded extrusion lines: Brückner presented its Greenline concept for film stretching lines, a new system for high-performance films, featuring a digital standard interface. 

And of course, one of the true highlights: reconnecting with old friends and colleagues from across the plastics industry—the K Fair always feels like a family reunion!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature: 

[1] https://en.kunststoffe.de/k-fair#:~:text=Increase%20in%20Exhibitors%20at%20K,Fast%2C%20Precise%20and%20Reliable

[2] https://solutions.covestro.com/en/digital-event-space/kfair

[3] https://www.specialchem.com/plastics/news/syensqo-to-showcase-high-performance-polymers-portfolio-at-k-2025#:~:text=Syensqo%20will%20make%20its%20first,15th%20in%20D%C3%BCsseldorf%2C%20Germany.

[4] https://www.plastech.biz/en/news/Syensqo-to-debut-at-K-2025-with-specialty-polymers-portfolio-21142#:~:text=Partnerships%20and%20live%20program%20at,for%20single%2Duse%20surgical%20instruments

[5] https://www.k-online.com/#:~:text=K%202025%20focuses%20on%20key,be%20returned%20directly%20on%20site.

[6] https://www.omya.com/en/industries/polymers/events/omya-at-k-show-2025#:~:text=Recently%20founded%20Omya%20Performance%20Polymers,the%20regional%20leadership%20team%20(bios)

Wednesday, 1 October 2025

Say Goodbye to PTFE? Discover the UHMW-PE Advantage in Plastics

Hello and welcome to a new post in which we are looking for a smarter way to reduce friction and wear in engineering plastics—without relying on PTFE.

Replacement of PTFE with UHMW-PE - How much should I add?

Ultra-High-Molecular-Wheigt-Polyethelyne (UHMW-PE) stands out as a highly effective alternative to PTFE and molybdenum disulfide, especially when high temperatures are not a concern for your final application. Discover how this innovative approach can boost performance and open new possibilities for your polymer selection and engineering plastics projects.

Table 1 shows how adding just 5 wt% of UHMW-PE to materials like PA 6 can dramatically lower the kinetic friction coefficient from 0.6 to 0.23. Similar improvements are possible with PBT (from 0.51 to 0.2) and PPS (from 0.38 to 0.14)!


Check out this post too 👉Polymer Material Selection: What are PTFE free alternatives for friction and wear compounds?

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature: 

[1] https://plasticker.de/news/shownews.php?nr=45528&nlid=64581.d.h.2024-10-30

[2] https://www.findoutaboutplastics.com/2022/07/polymer-material-selection-what-are.html

Wednesday, 17 September 2025

Designers & Engineers: Tired of Warped Polyamide Parts? Meet PolyArylAmide (PA MXD6)!

Hallo and welcome to a new blog post on one of my favorite high performance Polyamides: PA-MXD6 (also known as Nylon MXD6, or simple PARA). 

When designing with glass fiber-reinforced polymers, warpage is a common challenge—especially as fiber content increases. But what if you could achieve both high strength and dimensional stability?

Warpage Comparison: PA 6.6-GF30 vs PA MXD6-GF50

Figure 1 compares the warpage behaviour of a plate moulded in PA 6.6-GF30 and PA-MXD6-GF50. The graps shows that: 

🔹 PA-MXD6-GF50 (50 wt% glass fiber) shows dramatically lower warpage and anisotropy than standard PA 6.6 GF30 (30 wt% GF)—even with a 20 wt% higher glass content!

🔹 Lower anisotropy means your parts stay true to design, reducing costly rejects and post-processing.

🔹PARA’s unique structure minimizes the difference between parallel and transverse shrinkage, delivering precision and reliability for your most demanding applications.

Figure 1: Warpage comparison of PA 6.6-GF30 vs PA MXD6-GF30 and PA MXD6-GF50 [3].

Why compromise? Choose PARA for your next polymer selection project to achieve:

  • Tighter tolerances
  • Superior aesthetics
  • Consistent, high-quality parts

More on PA-MXD6 / PARA here: 

Polyarylamide vs Polyamide (PARA vs PA): What are the Major Differences Between PARA and PA (Polymer Material Selection Tip)?

Design Properties for Engineers: The ABCs of Polyarylamide (PARA; MXD6)

PA6.6 vs. PARA - Reducing the Wall Thickness of Injection Moulded Parts (Geometry Optimization Example)

Design Data for PolyArylAmide (PARA; PA MXD6) Selection: Mechanical Properties as Function of Temperature and Humidity

Mastering Injection Molding Tools for High Performance PolyArylAmide (PARA; PA MXD6): 6 Key Steps to Success

Design Properties for Engineers: Superior Gas Barrier Properties of PolyArylAmide (PARA; MXD6)

Check out my Micro Training below too:


And my dedicated Polyarylamide Hub here.

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] https://www.carbonele.com/news/pa-mxd6-material-properties-and-applications/

[2] https://onlinelibrary.wiley.com/doi/10.1002/app.56089

[3] https://www.syensqo.com/en/chemical-categories/specialty-polymers/technical-literature

[4] www.polyarylamide.com

[5] https://www.researchgate.net/publication/334669698_Effect_of_Fillers_and_Processing_Parameters_on_the_Shrinkage_of_Injected_Molding_Polyamide_66/link/5d39300292851cd04684421d/download?_tp=eyJjb250ZXh0Ijp7ImZpcnN0UGFnZSI6InB1YmxpY2F0aW9uIiwicGFnZSI6InB1YmxpY2F0aW9uIn19

[6] https://www.materialdatacenter.com/ms/de/Reny/Mitsubishi+Engineering-Plastics+Corporation/Reny+1002H/7617eb67/1617

Wednesday, 10 September 2025

Mastering Injection Molding Tools for High Performance PolyArylAmide (PARA; PA MXD6): 6 Key Steps to Success

Hello and welcome to a new blog post. Today we dive into the optimal tool making for Polyarylamide parts. 

Designing and producing injection molding tools for Polyarylamide (PARA; PA-MXD6) is both an art and a science. This high-performance polymer offers outstanding mechanical properties and surface aesthetics—but only if your tooling is up to the challenge! 

Here’s a deep dive into the six essential steps for success (Figure 1):

Figure 1: Overview of the six steps of tool making for molding Polyarylamide (PARA; MXD6). 

1️⃣ Part Design: Build on Solid Foundations

  • Use generous radii (≥0.6 mm) to reduce stress and ease ejection.
  • Apply draft angles: at least 1° for polished, up to 3° for textured surfaces.
  • Optimize gate placement and size—locate at the thickest section, with land lengths of 0.8–1.6 mm.
  • Take advantage of PARA’s low shrinkage (0.20–0.25%) for tight tolerances and minimal sink marks.
  • Simulate your design (Moldflow®, Flow-3D®) to predict flow, weld lines, and optimize geometry.

2️⃣ Mold Definition: Specify for Performance

  • Select abrasion-resistant steel (≥54 HRc) like Stavax ESR or Orvar Supreme to withstand glass fiber wear.
  • Design for “steel safe” dimensions—easier to remove than add steel!
  • Ensure robust venting (max 0.01 mm) and cooling (10 mm channels, 15–20 mm spacing).
  • Use hot runners for efficiency and consistent quality.
  • Calculate clamping force: 1 ton/cm² of projected area.
  • Add cavity pressure sensors for processing optimization, especially with multi-cavity tools.

3️⃣ Detailed Drawings & Production: Precision Matters

  • Prepare comprehensive technical drawings with all tolerances and features.
  • Plan for heat treatment and machining—every detail counts for tool longevity and part quality.

4️⃣ Cutting Steel: Prepare for the Long Haul

  • Mill, heat treat, and quench your steel to achieve optimal hardness.
  • Allow for deformation during heat treatment (“steel safe” approach).
  • After treatment, remove any brittle, oxidized layers by sandblasting to prevent future tool issues.

5️⃣ Assembly & Testing: Fine-Tune for Perfection

  • Assemble and adjust all tool components, ensuring smooth operation.
  • “Blueprint” the tool at low clamping force to check split lines and prevent flash (PARA has good flow properties, similar to PPS).
  • Design for easy maintenance: include features like mold centering adjusters, ejector return pins, and replaceable components.

6️⃣ Polishing & Surface Treatments: Finish Strong

  • Polish all surfaces to ensure easy part ejection and premium aesthetics.
  • Apply specialized surface treatments to extend tool life—especially important with glass-filled PARA.

Pro Tip:
PARA’s high flow and low shrinkage enable thin, complex parts with exceptional surface quality. But to fully leverage these benefits, every step of your tooling process must be meticulously planned and executed.

Are you working with PARA or considering it for your next project? Let’s connect and share best practices for robust, reliable, and beautiful injection-molded parts!

More on PA-MXD6 / PARA here: 

Polyarylamide vs Polyamide (PARA vs PA): What are the Major Differences Between PARA and PA (Polymer Material Selection Tip)?

Design Properties for Engineers: The ABCs of Polyarylamide (PARA; MXD6)

Design Data for PolyArylAmide (PARA; PA MXD6) Selection: Mechanical Properties as Function of Temperature and Humidity

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

Literature:

[1] Syensqo - Ixef PARA Design Guide