Compound development
We have been developing plastic compounds based on construction and high-performance polymers since 1972.
Our core competence are modifications to optimise the tribological properties.
We carry out all customary and unusual modifications to high-performance polymers. This task is also supported by our excellently equipped development laboratory.
Some advantages for our customers:
- independent sources of raw materials
- all common reinforcing materials and additives
- reactive compounding
- high filling levels, good dispersion, linking and compatibility
- short development times
- melt filtration
- solutions up to the finished part from a single source
- no minimum quantities
- diverse product shapes (granules, semi-finished products, 3D filament, finished parts)
- Exclusive agreements for special compounds possible
From molecule to application*
chemically bonded PTFE / high-performance polymers
available on the basis of PPS, PAEK, PES, PEI, LCP.
We understand the properties of friction and wear not as a material property, but as a system property. This means that the counterpart and the transfer layer that will be formed are also taken into account when developing the compound. Also, the type of technical components, such gears, track rollers, sliding bearings, seals, spindle nuts and general wear parts, for which the compound has been developed for and the processing methods, such extrusion, injection moulding, machining and 3D printing, chosen to process the compound are taken into consideration in the formulation development.
Through our experience we understand how technical components work and which reactions and processes inside the plastic materials take place during the use and which modifications are necessary to reduce negative reactions.
To optimise the performance of technical components, it is not “only” enough to improve the tribological properties, but also others, since these also interact with the tribological properties.
These are essentially thermal and electrical conductivity, adhesion, hardness, toughness, rigidity, elongation at yield and glass transition temperature.
Custom-made
For over 50 years we have been developing and producing compounds and blends made of high-performance and construction polymers such as e.g. PA, POM, PET, PVDF, PPS, PESU, PPSU, PEI, LCP, PEK, PEEK, PEKK, TPI, PAI and PU.
To save development costs, in most cases we can also manufacture prototypes from semi-finished products – extruded from ZEDEX® or tailor-made granules – for the first tests.
If prototypes that require moulds are required, we can realise them in the shortest possible time using an inexpensive pre-series mould made of aluminum or in 3D printing.
We will inform you about the recommended material drying and processing for injection moulding.
In our section on processing methods you will find some key data on our injection molding options.
Development
The starting point for development are either
- defined material properties, or
- the load and function of a component.
Our experts analyse the material or component requirements and select the suitable polymer base and the required fillers and additives. If the material properties required for the component function are specified, then are the
- compounds manufactured according to the required customer specification and
- checked in our laboratory.
Targeted to the solution
By adapting the material to the application
- an optimal function is guaranteed and
- the material utilization and workability are
optimised and - the system costs are reduced.
Especially in the last 10 years, the modification and functionalization of plastics has developed rapidly, so that diverse properties can be set in a targeted manner and efficiency has been greatly improved. Thanks to that, technical and economic advantages are achieved even with low demand.
Special compounds portfolio
Based on many years of experience, our portfolio includes following special compounds:
Tribological sliding compounds
for dry and wet running
Additives: graphite, metal sulfides, silicone oil, MoS2, PFPE oil, boron nitride, PBI, bronze powder, fibres, nanofillers, oxides
PTFE free
Higher weld line strength, less tendency to creep, higher strength / elongation, no segregation, no deposits on the tool
Containing PTFE
Reduced mechanical strength, less friction, less wear, more ductile properties
Reinforced compounds
with increased mechanical properties such as strength, rigidity, hardness and heat resistance
Isotropic with better melt flow rates
Additives: glass spheres, ceramic and mineral powder (calcium carbonate, talc and mica) for higher compressive strength and surface hardness, short fibres for higher strength, rigidity, fatigue, creep behavior and higher HDT.
Anisotropic
Additives: as isotropic, additionally: glass fibres, carbon fibres, mineral whisker, aluminum oxide, ceramic and nanofibres each with different sizes. Carbon fibres are lighter than glass fibres and have a higher chemical resistance.
Depending on the fibre length and proportion, both fibres increase the tensile & bending rigidity and/or strength values.
The maximum possible increase in stiffness or strength values is by a factor of 6 from the base polymer.
Detectable compounds
for metal detection or X-ray detection
- metal detection with common metal detectors
- contrast agent for X-ray visibility such as BaSO4, tungsten, etc.
- colours (e.g. blue) and fill levels, for adaptation to different metal detectors, can be varied
Antimicrobial compounds
Additives: Silver-based active ingredients (biological agent, an electrochemical reaction releases silver ions upon contact with moisture, which stops growth)
Effect: Prevention of microbial growth and thereby attack (discolouration, odors and polymer degradation) of the plastics, reduction in the number of bacteria by killing mould fungus, algae, yeast, microbes
Low weight Compounds
to reduce weight and sink marks
up to 40% micro hollow glass spheres and foaming agents
Effect: density reduction up to 25% with the same or higher stiffness, reduced and isotope shrinkage, improved abrasion behaviour
Radiation-crosslinkable compounds
Additives: Crosslinking additive effect: after the finished part is manufactured, it is irradiated with ionizing radiation
and leads to partial crosslinking.
This improves chemical resistance and heat resistance. The substitution of a high performance material such as PPS through a partially crosslinked engineering plastic such e.g. PA6 is possible.
Conductive Compounds
with thermal and electrical conductivity and dissipation
Electrically conductive
Additives: carbo-nano tubes, carbon fibres, plastic/metal hybrids, graphite, conductive carbon black, nanofibres, copper fibres, bronze powder, stainless steel fibres, metals with a low melting point (solders)
Specific electrical conductivity:
up to 5 • 10^4 S/m, (approx. 30% based on steel)
Electromagnetic attenuation approx. 80 dB at 30 kHz up to 1.2 GHz
Thermally conductive
Thermal conductivity: up to 7 W/(m*K)
Additionally electrically conductive, highly filled graphite, up to 20 W/(m*K) plastic-metal hybrids up to 7 W/(m*K)
Additionally, electrically insulating ceramic fillers, thermal conductivity max. 6 W/(m*K)
Colour compounds
Additives: Inorganic, organic colour pigments
Effect: adjustment of the colour according to colour samples or RAL colour standard, with a high degree of accuracy and small deviation (delta E)
Special properties
On request we can also change other properties such as diffusion tightness, impact strength, mechanical damping or cost reduction.
Tests and approvals
We carry out the tests required for development in our laboratory. If approvals such as UL, FDA, NSF, EU Food, BGA, etc. are required, we can obtain and offer these in the form of fee-based service.
If technically feasible
the mentioned properties can be combined and the material can be provided with approvals (FDA, EU10 / 2011, UL, etc.).
Manufacturing
If technically feasible, we offer the manufacturing of semi-finished products and profiles, machined and injection-moulded components or tribo filament for 3D printing, from a single source.
Examples of special compounds
Inkuform MDTF
Goal: detectability
This detectable plastic material was developed for applications in the food sector in order to be able to track even the smallest particles in food production with metal detectors.
ZX-324® ESD3
Goal: electrostatic discharge
By modifying PEEK, an electrical surface resistance in the range of 1MW to 1GW could be achieved.
A further reduction of the electrical surface resistance up to the electrical conductivity is possible.
ZX-530® LR6
Goal: electrical conductivity
For medical applications, ZX-530® has been modified in order to make it conductive, without losing its remarkable tribological properties.
ZX-530® LR6 was developed to eliminate the static discharge problems of the previous material and at the same time extend the life of the bushing.
ZX-100® ESD
Goal: electrostatic discharge
For applications in the semiconductor industry, ZX-100K® has been modified in order to make it electrostatically dissipative without losing its remarkable mechanical properties.
ZX-100® ESD was developed to eliminate the static discharge problems of the previous material.
ZX-100K® blue
Goal: Dyed blue and food compliant
For applications in the food sector, ZX-100K® was coloured in blue and approved by EU 10/2011. The material is also FDA compliant.
ZX-100K® blue was developed to directly recognise material traces in food and to use it in direct contact with food.
Polymer blend
Polymer blends (also called alloys) are mixtures of at least two macromolecular substances, polymers or copolymers. Miscible polymer blends are miscible down to the molecular level and have a single-phase structure.
Its properties lie between the values of the properties of its components. This is identifiable by the glass transition temperature (Tg).
Immiscible
These are polymer blends with a two-phase structure and two glass transition temperatures (Tg). The two components are phase separated
Homologous polymer blend
These are mixtures of the same polymer with different molecular weight distributions (processing aid).
Isomorphic polymer blend
These are mixtures of several components, that are miscible in the molten and crystallized state.
Compatible polymer blend
These are miscible polymer mixtures of several components in which inhomogeneities occur
- with only a slight manifestation
- at certain mixing ratios or temperatures
By means of compatibility techniques such e.g. chemical bonding (modified boundary surface and morphology), these inhomogeneities can be made compatible.
Mixing methods
Melt mixing
Melt blending is the most widely used process for making polymer blends in practice.
The mixture components are mixed in the molten state in extruders or batch mixers.
Mixing solutions
Often used for the production of polymer blends on a laboratory scale. The mixture components are dissolved in a common solvent and stirred vigorously.
The mixture is separated by precipitation or evaporation of the solvent.
The advantages of the process are a quick mixing of the system without high energy consumption and the possibility to avoid unfavorable chemical reactions.
Cryogenic mechanical alloying
The polymers are crushed in powders at cryogenic temperatures and nano-scale morphologies are achieved
Examples of polymer blends
ZX-324V1T®
Gaol: TG shift and better CTE
Extends the operational range of unreinforced PEEK to higher temperatures and reduces material costs without any fibre or filler reinforcement.
ZX-324V1T® has been developed for applications where the dimensional stability and mechanical strength of unfilled PEEK are not sufficient due to the high temperature of the application.
ZX-324V11T®
Goal: high elongation at break with high rigidity
Extends the operational range of PEEK to lower temperatures and reduces material costs.
ZX-324V11T® has been developed for applications where high elongation at break along with high rigidity is required. The material has high PV values at low speeds and has a high resilience down to -196°C.
What is your challenge today?
Ask the right questions to let us develop the ideas to win it!
