Newswire & Press Release / BASF Presents Decorative Marbling for Ultrasonic® Injection Molded Parts – Manufacturing / Robotics – BASF
• Now possible for the first time: reproducible marbling patterns for unique serial production;
• BASF polyarylethersulfone offers unlimited color possibilities for household appliances, catering bowls and containers as well as visible parts;
• Marbled bowls presented at Fakuma 2021, Friedrichshafen, Germany.
The staining technique offers designers virtually unlimited possibilities to use BASF’s polyarylethersulfone to color household appliances, catering bowls and containers as well as visible components. For the first time, surface effects such as color nuances, color streaks and patterns can be reproduced: injection molded parts of the same series look alike but are not completely identical. The technique has proven itself with the two injection molding grades Ultrason® E (PESU: polyethersulfone) and Ultrason® P (PPSU: polyphenylsulfone) for the production of unique parts, which at the same time benefit from the exceptional properties of Ultrason® in terms of mechanical, thermal and chemical resistance as well as approval for food contact.
The new process, which was developed at BASF’s pilot plant for injection molding and extrusion in Ludwigshafen, makes it possible to produce marbled molded parts on conventional injection molding machines more easily and with greater safety. process than before, using new types of insert nozzles and a special metering technique. With its slightly honeyed hue, Ultrason® granules are suitable for light shades and shades as well as abstract patterns by solid coloring that resemble natural materials such as wood or marble. “Marble effects have always attracted attention in the plastics world,” says Georg Graessel of Global Business Development Ultrason® at BASF. “Until now, these effects were only possible with a complex two-component injection molding and did not guarantee reproducibility. With marbling, we add another way of coloring to Ultrasound’s already versatile design possibilities. ®. With proper temperature control of machine injection molding, attractive and high contrast patterns are possible for our injection molding grades P and E. So far, our customers have been able to mold transparent, translucent components. and, of course, solid color from Ultrasound®. “
The Ultrasonic® marbled components can be used in different ways: in household items such as bowls, cups, plates and catering utensils, also for microwave use. In addition, marbling effects can be applied to spectacle frames, handles as well as visible components of electrical and electronic devices, decorative panels and lids. These applications benefit from the excellent properties of BASF polyarylethersulfone: vapor resistance up to 180 ° C, excellent strength and toughness over a wide temperature range, very good resistance to industrial cleaning agents and repeated sterilization. Ultrason® also has the relevant food approvals for the EU and the US.
Marbling according to the BASF process is possible on conventional injection molding machines equipped with a single plasticizing unit and an open nozzle. The precolored base material and the high contrast color masterbatch must be fed synchronously to the injection molding cycle. The patterns in the molded part are then made by separating and merging the melt streams. This is done with nozzle inserts, which are made by 3D printing. These inserts offer great design freedom: not only mirror patterns can be created, but also rotational symmetry patterns. This has not been possible with conventional methods to date. Other factors influencing the model design are the design of the nozzle itself, the mold gate system, the location of the gate, and the flow behavior of the melt during mold filling. In addition to PESU and PPSU, the new BASF technique is also suitable for Ultrason® S and other thermoplastics.
Ultrason® (ultrason.basf.com) is the trade name for the BASF product line of polyethersulfone (Ultrason® E), polysulfone (Ultrason® S) and polyphenylsulfone (Ultrason® P). The high performance material is used to manufacture lightweight components in the electronics, automotive and aerospace industries as well as in water filtration membranes and in parts that come into contact with hot water and food. Due to their extraordinary property profile, Ultrason® grades can replace thermosets, metals and ceramics in many applications.
About BASF’s Performance Materials division
BASF’s Performance Materials division (plastics.basf.com) brings together all of BASF’s know-how in innovative and personalized materials under one roof. With a global presence in four major industrial sectors, transportation, construction, industrial applications and consumer goods, the division has a strong portfolio of products and services combined with a deep understanding of application-oriented system solutions. . The main drivers of profitability and growth are our close collaboration with customers and a clear focus on solutions. Strong R&D capabilities form the basis for the development of innovative products and applications. In 2020, the Performance Materials division achieved worldwide sales of 5.63 billion euros.
At BASF (basf.com), we create chemistry for a sustainable future. We combine economic success with environmental protection and social responsibility. More than 110,000 BASF Group employees contribute to the success of our customers in almost every industry and almost every country in the world. Our portfolio is organized into six segments: Chemicals, Materials, Industrial Solutions, Surface Technologies, Nutrition & Care and Agricultural Solutions. BASF achieved a turnover of 59 billion euros in 2020.