GE - Plastics Announces Special Equipment For Molding And Thermoforming Large Parts

Bergen op Zoom, Netherlands — At an open house, GE - Plastics announced a major new enhancement to its Global Application Technology Center here that will enable the development of new materials for large parts such as exterior automotive body panels and glazing. GE's investment in a state-of-the-art Krauss-Maffei 2700 MX injection compression molding machine will help the company address customer needs for lighter materials and greater design flexibility in large parts. The KM2700 machine is the latest in an array of technology capabilities and services - ranging from design to processing to analysis - offered through six centers of excellence within the Global Application Technology Center. In addition to the Krauss-Maffei molding machine, GE plans to install a new thermoforming machine with twin sheet capacity at the Bergen op Zoom facility in early 2006.

"Our continued investment in this facility allows GE to offer customers the best plastics expertise and capabilities in the world," said Rick Pontillo, general manager Global Application Technology at GE - Plastics. "The new injection-compression molding and thermoforming equipment are important additions that will save customers time and resources in product development, while helping us create and test new materials for automotive glazing and body panel applications, transportation applications, and much more."

Advanced Molding Capabilities
The advanced injection molding capabilities of the new KM2700 MX machine can deliver important benefits to automotive manufacturers and suppliers. First, injection-compression molding is one of a limited number of processes for creating large, optical-quality parts for automotive glazing, such as moon and sunroofs, which can add design innovation. Second, the equipment promotes the use of premium lightweight plastic materials in larger parts such as fenders, door skins, and tailgates to reduce weight and improve fuel efficiency. Finally, large injection-molded parts can enable integration of assembly features and attachment points, reducing system costs.

The new machine will allow GE - Plastics experts to optimize material processing conditions; produce real parts for testing; and validate materials for real applications in terms of impact, paintability, stiffness and strength, surface appearance, and dimensional accuracy. GE - Plastics resins to be molded using the KM2700 include Noryl GTX resins for fenders, Xenoy resins for horizontal panels, and Lexan GLX resins for glazing, plus a new line of high modulus ductile (HMD) materials that feature proprietary nano-filler technology. These HMD materials offer the potential to reduce gaps between automotive body panels through increased stiffness and lower coefficient of thermal expansion.

The leading features of the Krauss-Maffei MX-series injection molding machine are high production output and excellent part quality. For many years Krauss-Maffei has been one of the first-class suppliers to the automotive industry. The company has extensive expertise in the field of plastic automotive parts. "This order from GE - Plastics underscores our role as a leading machinery manufacturer for automotive applications in Europe," said Josef Märtl, chairman of the Krauss-Maffei board of management.

Next-Generation Thermoforming
The thermoformer planned for 2006 will be used to develop applications for new GE materials such as high-performance thermoplastic composite (HPPC) for horizontal auto body panels; Rail-Lite composite from Azdel, Inc. for large semi-structural panels in train interiors; no-paint systems featuring Lexan SLX, Geloy XTW, and Xenoy resin grades; high-heat and flame-resistant resins such as Ultem and Noryl resin grades; and Lexan and Lexan Margard sheet for large glazing applications. These and other GE innovations address the leading trends in thermoformable materials, including reduced component weight and system cost, long-term durability, and improved styling.

GE's Global Application Development Centers in Shanghai, China; Moka, Japan; Bangalore, India; Southfield, Mich.; and Pittsfield, Mass., as well as Bergen op Zoom, offer customers new process solutions and next-generation technologies. The Bergen op Zoom facility, established in 1978, provides specialty development and support capabilities in six areas, including automotive glazing and vertical and horizontal body panels, secondary operations, and fluid engineering. A virtual laboratory connects to the other GE centers to share knowledge and conduct trials in real time.

GE plans to install additional large injection molding machines in the United States and Asia in 2006.

SOURCE: GE - Plastics