DSM Engineering Plastics has introduced a range of High Flow & High Productivity materials, which enable significant system cost reductions, when compared to standard resins. Added value for the customer is generated by these materials via shorter production cycles leading to lower processing costs per part, greater design freedom leading to lower material and/or processing costs per part and more room for innovation, such as metal replacement. To demonstrate the potential for cost reduction and annual savings, DSM Engineering Plastics is able to provide customers with Product Cost Analysis spreadsheet tools.

Key new materials that have been introduced are:
• Akulon XP - HV PA6 for packaging applications
• Akulon Ultraflow - PA6 for injection molding applications
•  Stanyl High Flow and Super Flow - PA46 for injection molding applications

Akulon XP - HV PA6 for packaging applications
Akulon XP, a high viscous PA6 which delivers substantial productivity gains during processing of packaging films. Key benefits include less “neck-in” or side trim waste reduction and improved machine efficiency.

In addition, Akulon XP offers better web stability for higher production speed, improved layer thickness distribution to reduce material use and deliver better quality, a wider processing window, reducing down time and providing higher possible output as well as shear thinning, requiring lower motor power at high rpm and higher possible output

Akulon XP is also excellently suited for thermoforming processes: it has an improved thermoformability compared to standard PA6, since it exhibits more even thickness patterns in the corners and it allows a higher elongation. Overall, Akulon XP is able to deliver a significant reduction in system costs.

Akulon Ultraflow - PA6 for injection molding applications
Due to to their excellent flowability (80% more flow compared to standard PA6) Akulon Ultraflow PA6 grades yield around 25 % cycle time reduction and great surface appearances, especially for highly reinforced grades. This results in higher productivity, lower investment costs, greater freedom of design and more opportunities for metal replacement.

Akulon Ultraflow is available in different grades: 15-60% GF, 30-40% GF/mineral, FR/mineral, FR/GF. Akulon Ultraflow has been approved in almost all automotive applications, including critical ones such as Air Bag Containers. In E&E, key applications include Miniature Circuit Breakers and Contactors and there are many possible applications in both Consumer Goods and Industrial Goods.

Stanyl High Flow and Super Flow - PA46 for injection molding applications
Thanks to its unmatched melt flow performance, Stanyl is already the high-temperature polyamide of choice for demanding, innovative connector designs. Cost savings can be achieved through shorter cycle times, superior strength and ductility, and high regrind rates without excessive loss of flammability and mechanical properties. The introduction of Stanyl High Flow and Stanyl Super Flow provides opportunities for even greater processing and performance benefits.

Stanyl Super Flow was co-developed with leading connector manufacturers to provide a suitable alternative to High Flow LCP. The material outperforms high flow LCP in a number of aspects: no micro cracking, outstanding weld line strength, outstanding toughness for pin retention, excellent retention of strength after lead free soldering and possible high regrind levels. This leads to very low rejects during assembly and after lead free soldering and thus to lower system costs for the connector manufacturer, combined with high productivity through short injection molding cycle times.