Im62017en by Innovatieve Materialen

Volume 6 2017

Concrete Awards 2017 3D Printed translucent facades Self-folding objects Dutch Design Week 2017 Composite materials made from Swiss tree bark Ultra-thin concrete roof Powder coatings on wood

I N T E R N A T I O N A L

E D I T I O N

CONTENT Innovatieve Materialen About is een vaktijdschrift gericht op de civieltechnische Innovatieve Materialen sector en bouw. Het bericht over ontwik(Innovative Materials) is a digital, kelingen op het gebied van duurzame, inindependent magazine novatieve materialen en/of deabout toepassing material the fields of daarvaninnovation in bijzondereinconstructies.

engineering, construction (buildings, infrastructure and industrial) and Innovatieveindustrial Materialendesign. is een uitgave van Civiele Techniek, onafhankelijk vaktijdschrift voor civieltechnisch Innovatieve Materialen is ingenieurs published werkzaam in deformat, grond-, wegen waterin a digital although bouw en verkeerstechniek.

there is a printed edition with a small circulation. Digital, De redactie staat open voor because bijdragen interactive information is attached van vakgenoten. U kunt daartoe contact in the form ofmet articles, papers, opnemen de redactie. videos and links to expand the information available.

Scope

Uitgeverij The digital edition is sent to engineers, scientists, students, SJP Uitgevers designers, decision makers, innovators, suppliers and appliers Postbus 861 working in civil engineering, 4200 AW Gorinchem construction, building, architecture, tel. (0183) 66 08 08 design,info@innovatievematerialen.nl government and industry e-mail: www.innovatievematerialen.nl (both manufacturing industry and end users). Innovatieve Materialen has Redactie: entered partnerships with several Bureau Schoonebeek vof and intermediate organisations universities,Hoofdredactie: all active in the field of Gerard van Nifterik material innovation. More information (in Dutch): www.innovatievematerialen.nl

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Drs. Petra Schoonebeek

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Een digitaal abonnement Postbus 861 in 2016 (6 uitgaven) kost Gorinchem € 25,00 (excl. BTW) 4200 AW

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2 Earthquake-resistant concrete 4 Concrete Awards 2017 6 3D Printed translucent facades with integrated functions 8 Self-folding objects 14 Dutch Design Week 2017

Every year in October, the nine-day Dutch Design Week (DDW) takes place in Eindhoven. The largest design event in Northern Europe presents work and concepts from more than 2500 designers and over 295,000 visitors. Scattered among over a hundred locations throughout the city, DDW organizes and facilitates exhibitions, lectures, award ceremonies, network meetings, debates and festivities. According to the organizers, DDW distinguishes itself from other design events by concentrating on designs for the future. This was also reflected in the range of material innovations. Much attention for example for 3D-printed materials, biomaterials and circularity.

22 Composite materials made from Swiss tree bark

Studies conducted by the Swiss National Research Programme ‘Resource Wood’ show that tannins extracted from native tree bark can be used to produce adhesives and composite materials. An additional area of application might be 3D printing. The bark of native conifers is known as a waste product in the timber industry. It is mostly burnt or used as garden mulch. A team from the National Research Programme ‘Resource Wood’ (NRP 66) has now developed a new process to extract valuable tannins from tree bark to produce adhesives and composite materials.

24 Ultra-thin concrete roof

Researchers from ETH Zurich have successfully built a prototype of an ultra-thin, curved concrete roof. This full-scale experiment investigates the feasibility of spraying a textile reinforced thin concrete shell using a lightweight flexible formwork composed of a tensioned cable net as falsework and tailored fabric as shuttering. This one-to-one (with a bounding box of 20m x 10m x 7.5 m) prototype can be seen as the dress rehearsal for the construction of the roof of the NEST HiLo project, that is planned to be built next year on the NEST, the living lab building of Empa and Eawag in Dübendorf, Stwitzerland.

28 Powder coatings on wood

November 2nd DSM Ultra hosted its Inspiration event ‘Powder coatings on wood’ at the Polymer Science Park in Zwolle. Uralac Ultra, introduced in 2014, is a breakthrough technology that enables powder coating of heat-sensitive substrates such as MDF. According to DSM it contains no toxic solvents, is low-energy, and protects the environment as well as the production line. A comprehensive Life Cycle Assessment measures a carbon footprint that is five times lower than solvent-borne coatings. The Eco Footprint - indicating impact on resource depletion and climate change - is equally reduced. The presentations showed some best practices to discuss the (dis)advantages of powder versus liquid coatings.

sponsoring

Drs. Petra Schoonebeek

Cover: Greenpanel at the Dutch Design Week (page 16)

NEWS

Self-healing Lamborghini Last November the Massachusetts Institute of Technology (MIT) and the Italian sports car manufacturer Lamborghini announced to collaborate to unveil the world’s first self-healing sports car. The so called Terzo Millenio - an sophisticated electrical automobile prototype for the third millennium - will repair any cracks and damages that it detects. Moreover, it also will prevent any damage from spreading. This as the result of research from the Dinca and Hart labs, MIT, paired with Lamborghini’s ‘hypercar’ concept. According to Mircea Dinca, associate professor of chemistry at MIT, the new Lamborghini collaboration allows MIT to be ambitious and think outside the box in designing new materials that answer energy storage challenges for the demands of an electric sport vehicle. A year ago, October 2016, Automobili Lamborghini began a three-year partnership with MIT that will grant Lamborghini exclusive rights to emerging research related to battery storage and materials science. Lamborghini’s mission for this partnership is to ‘rewrite the rules on super sports cars’ by addressing energy storage systems, innovative materials,

propulsion systems, visionary design, and ‘emotion.’ By incorporating research from Dinca and John Hart, associate professor of mechanical engineering, who will investigate new carbon fiber and composite materials that could enable the complete body of the car to somehow be used as a battery system, the hope is that this ambitious, visually stunning prototype will become a reality.

More at MIT News>

Video: Terzo Millenio

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NEWS

Earthquake-resistant concrete A new seismic-resistant, fibre-reinforced concrete developed at the University of British Columbia (UBC) will see its first real-life application this fall as part of the seismic retrofit of a Vancouver elementary school. The material is engineered at the molecular scale to be strong, malleable, and ductile, similar to steel - capable of dramatically enhancing the earthquake resistance of a seismically vulnerable structure when applied as a thin coating on the surfaces. The research team subjected the material, called eco-friendly ductile cementitious composite (EDCC), to earthquake simulation tests using intensities as high as the magnitude of circa 9 earthquake that struck Tohoku, Japan in 2011. A number of walls was sprayed with a 10 millimetre-thick layer of EDCC, which is sufficient to reinforce most interior walls against seismic shocks. After that, the scientist subjected them to Tohoku-level quakes and other types and intensities

of earthquakes and they didnâ&#x20AC;&#x2122;t break. EDCC has been added as an official retrofit option in B.Câ&#x20AC;&#x2122;s seismic retrofit pro-

gram. In the end of 2017 the team will be working with contractors to upgrade Dr. Annie B. Jamieson Elementary School in Vancouver. According to UBC civil engineering professor Nemy Banthia, who supervised the work, the trick is to combine cement with polymer-based fibres, flyash and other industrial additives, making it highly sustainable. The team managed to replace nearly 70 per cent of cement with flyash which dramatically reduces the amount of cement used; decreasing the carbon footprint enormously. Other EDCC applications include resilient homes, pipelines, pavements, offshore platforms, blast-resistant structures, and industrial floors. www.ubc.ca>

Video

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Hét expertisecentrum voor materiaalkarakterisering.

NEWS

Integer, onafhankelijk, objectief onderzoek en advies. ISO 17025 geaccrediteerd. Wij helpen u graag verder met onderzoek en analyse van uw innovatieve materialen. Bel ons op 026 3845600 of mail info@tcki.nl www.tcki.nl

TCKI adv A5 [ZS-185x124] Chemische analyse 14.indd 1

09-05-17 13:19

First energy-neutral parking garage November 13th, at Driebergen-Zeist station, the first energy-neutral parking garage in the Netherlands was opened. The new ‘Park & Ride’ garage for 600 cars, near the Driebergen-Zeist railway station, is part of the reconstructuring of the station and the station environment. NS Stations is the client; Continental Car Parks is the developer; Groosman is responsible for the design; Aan de Stegge Twello is the contractor. The designers were instructed to design a building that fitted well with the environment with natural materials and an articulated structure. The ambitions regarding user-friendliness and durability of the garage were also high. In the design, much wood has been used in the form of slats, in addition to gravel poured into large columns. Another special feature is that this is the first energy-neutral parking garage in the Netherlands. The parking garage is naturally ventilated, so that the necessary installations are kept to a minimum. Due to the open façade, no mechanical installations have to be used to ensure the air quality in the garage. The solar panels on the roof are capable of fully running the installations of the parking garage. www.stationdriebergenzeist.nl>

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NEWS

Concrete Awards 2017 Catharinabrug (Photo: DP6/Gerda van Ekris)

The ultra-slim hybrid staircase in ABT’s head office in Velp has won the Dutch Concrete Award 2017 (Betonprijs 2017) in the category of concrete technology. ‘The need for beauty grows in confusing times, the jury said. ‘Beauty gives comfort. If concrete technology can be used for this, it serves an unexpected social interest. This ultra-thin staircase is beautiful. The combination with the

glass balustrade in the structure is a true novelty’. According to ABT, this staircase goes way beyond everyday limits, both in the production techniques and in the calculations. The revolutionary design is a demonstration of the possibilities when UHPC and glass are combined: UHPC has proved to be a material that is versatile in its applications, even in thin slabs,

and it needs virtually zero maintenance. Glass provides inspiration as a load- bearing structural material that can now even be bonded at its ends to all kinds of other materials, such as UHPC. Hi-Con Holland won the Dutch Concrete Award 2017 in the category of ‘Bridges & Viaducts’ for the Catharinabrug in Leiden. The Catharina Bridge is a slender

UHSB-stairs, ABT

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NEWS

Lammermarkt Leiden

bridge and officially the longest bridge in high performance concrete in the Netherlands. The bridge is 36 meter long and the center of the bridge deck measures 275 mm. The bridge creates an essential connection to the heart of Leiden and was nominated for its complex design. The bridge consists of prefabricated elements in UHPC. (Hi-Con Nederland, DP6 architects (Leiden), engineer: Pieters Bouwtechniek, construction: Gebr. Schouls. According to the jury, the construction of the Catharinabrug has the capacity to grow into a monument.

Villa K6 IJburg

A particular project for which the jury had special attention: The Dafne Schippersbrug in Utrecht. Although the amount of concrete used was not enough to qualify for an award, the jury felt that the project deserved to be mentioned. According to the jury the bridge is a unique project, especially in the social field. The Dafne Schippersbrug is a key project that is part of the new bicycle route, which connects the old city centre of Utrecht with the new extension Leidsche Rijn. Special about this project and the focus on urban planning: the route solves the height Âdifference between road and bridge with an elegant curl. The jury has decided to give

this project an Honorable Mention. Client: Gemeente Utrecht; Architect: NEXT architect & Rudy Uytenhaak, Architecten + partners architecten; Constructeur: ARUP, ABT; Contractor: Strabag Ippel: Ippel Civiele Betonbouw.

More Winners

Villa K6 IJburg (in the category Residential buildings), Flood Channel Veessen-Wapenveld (Hydraulic Engineering), Renovation Velsertunnel (Renovation and repair), the largest bicycle parking garage in the Netherlands (Utility buildings), Parking garage, Lammermarkt Leiden (Construction), Tafelbridge, Zuiden Noordhorn (Constructive design).

Dafne Schippers bridge

Concrete Award 2017

The Dutch Concrete Award 2017 is an initiative of the Betonvereniging (Concrete Association) and is supported by the Cement & Beton Centrum (Cement & Concrete Centre), the BFBN, Rijkswaterstaat (Department of Waterways and Public Works), the ministerie van Infrastructuur en Milieu (Ministry of Infrastructure and Environment) and Platform Betononderhoud (Platform Concrete Maintenance). The awards take place every two years. More at the Betonvereniging (Dutch)>

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BERICHTEN NEWS

3D Printed translucent facades with integrated functions Researchers from the Technical University of Munich (TUM) have developed multifunctional and translucent facade elements that can be produced with a 3D printer. According to TUM the technology permits complete freedom in architectural design and the easy realization of innovative design concepts. The new facade also integrates functions such as ventilation, insulation and shading. The project was initiated and implemented by a team lead by ing. Moritz Mungenast, research fellow at the Associate Professorship of Architectural Design and Building Envelope at TUM. Recently they developed a sample element, 60 centimetres wide and one meter high, made of transparent plastic allowing light passing through its Âsurface.

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BERICHTEN NEWS According to the researchers this is one of the first functionally integrated facade elements from a 3D printer. According to Mungenast the facade element is very stable, but also translucent and multi-functional. Cells inside the element provide stability while at the same time creating air-filled cavities for optimum insulation. Waves in the material create shadows. Thin embedded tubes let air circulate from one side of the element to the other, ensuring the best possible ventilation. And the micro-structured surface provides for perfect acoustics. All these functions are scalable and can be adapted to accommodate individual requirements at no extra cost, Mungenast said.

Fluid Morphology

According to TUM the design study illustrates how a building using the new low-tech facade could look: Plastic surrounds the structure like an airy veil. The visual effect is strengthened by the wavy surface that gives the facade concept its name: Fluid Morphology. The

shapes overlap like the ripples raised when several stones are thrown into a windless lake. But questions have to be answered: how much light really penetrates the new, 3D

printed facade elements, and where? How resistant are they to UV radiation and the stress of wind, rain and snow? How efficiently do they insulate? Long-term measurement of a complete 1.6 x 2.8 m facade element in the ‘solar station’, a testing installation on the main building of the TUM in Munich’s Arcisstraße, is to provide the answers to these questions. Over a period of one year, sensors will collect data which the architects hope to use to improve their design before creating further prototypes made of polycarbonate, a material certified for use in facades. Mungenast sees potential future uses primarily in special constructions such as museums, libraries, shopping centers and assembly rooms. TUM>

Video

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NEWS

Self-folding objects

Researchers at TU Delft have combined origami techniques and 3D printing to create flat structures that can fold themselves into 3D structures (for example a tulip). The structures self-fold according to a pre-planned sequence, with some parts folding sooner than others. Usually, expensive printers and special materials are needed for that. But the TU Delft scientists have created a new technique that requires only a common 3D printer and ubiquitous material. Among other applications, their research has the potential to greatly improve bone implants. In recent years, Amir Zadpoor of TU Delft has become somewhat of an origami master. His teamâ&#x20AC;&#x2122;s work combines the traditional Japanese paper folding art with the more novel technology of 3D printing in order to create constructs that can self-roll, self-twist, self-wrinkle and self-fold into a variety of 3D structures. In 2016, the researchers already demonstrated several self-folding objects. A lot of manual labour is usually involved in the fabrication of shape-shifting devices. Also, the material the resear-

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chers normally use is neither ubiquitous nor cheap. But in this recent project Zadpoorâ&#x20AC;&#x2122;s team have used an Ultimaker, which is one of the most popular 3D printers, and PLA, the most common printing material available. Itâ&#x20AC;&#x2122;s cheap,

but nevertheless the researchers magaged to create some of the most complex shape-shifting ever reported with it. The process is also fully automated and requires no manual labour whatsoever.

NEWS Programming time delays

What makes the team’s shape-shifting objects so advanced is the fact that they self-fold according to a pre-planned sequence. But if the goal is to create complex shapes, and it is, some parts should fold sooner than others. Therefore, it’s necessary to program time delays into the material. This is called sequential shape-shifting. The way in which Zadpoor’s team managed to do this was by simultaneously printing and stretching the material in certain spots. The stretching is stored inside the material as a memory. When heated up, the memory is released and the material wants to go back to its original state. By also alternating the thickness and the alignment of the filaments in the material, the researchers succeeded in creating 2D structures that shape-shift sequentially. This combined approach of origami and 3D printing is an important step in the development of better bone implants. The technique makes it possible to create prosthetics with a porous interior. This will allow a patient’s own stem cells to move into the structure of the implant and attach themselves to the interior surface area, instead of just coating the exterior. The end result will be a stronger, more durable implant. Furthermore with this technique, nanopatterns that guide cell growth can be crafted on the surface of the implant. A pillar shape, for instance, may encourage stem cells to become bone cells. It is impossible to create such instructive surfaces on the inside of a 3D structure, so that’s why the researchers decide to start from a flat surface.

Tekst: TU Delft> Programming 2D/3D shape-shifting with hobbyist 3D printers, Teunis van Manen, Shahram Janbaz en Amir A. Zadpoor> Video

Self-folding furniture

While bone implants may be the most obvious application for their research, the scientists believe that the shape-shifting technology could also lead to other developments in due time. Printed electronics, for instance, can also benefit from this research. By using this technique, it may be possible to incorporate printed, 2D electronics into a 3D shape. The researchers also see a future in which you can buy a 2D sheet at IKEA that, after you unpack it and apply a certain stimulus, turns into a ready-to-use piece of furniture. Shape-shifting could definitely turn many of our existing 2D worlds into 3D worlds.

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NEWS

Self-deploying buildings This is not specifically about material innovation like the expanding structures, on page 8, but absolutely about innovative technology and use of materials. Last summer several websites reported on Ten Fold engineering, (Abingdon, United Kingdom) which developed a modular, self-deploying structure that can unfold itself without the need for foundations, builders, or cranes. Ten Fold houses unfold in eight minutes at the push of a button. Not only all kind of houses are foldable, but also towers, minimarkets, bleachers and even bridges. The idea behind all Ten Fold systems is

a unit that can be easily transported to any location on a truck. On arrival the structure unfolds to more than three times its original transport size, after which it is instantly habitable, with all internal fixtures and fittings pre-installed. the system is reversible, meaning these structures can be refolded and moved to a new location just as quickly.

Video: uitklapbrug

www.tenfoldengineering.com>

Video: het Ten Fold concept

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NEWS

10,000 glass panels glued with tape Schiphol Airport has recently acquired a prestigious glass pavilion on the so called Holland Boulevard. The curved inner walls of this glass building presenting the Rijksmuseum consist of 10,000 glass panels glued by Glassolutions with tape (ACXplus from tesa). Never before has a glass structure of this composition, structure and size (2,200 m2) been built. According to the parties involved, the project tape makes innovative architecture possible. Glass manufacturer Glassolutions set up its own assembly line to glue the glass panels into layered glass building blocks. There, 10,000 glass panels of 320 x 7 x 1 cm (l x w x d) were converted into parcels. Each panel received two strips of double-sided tape of 6 mm wide over the full length. With an accurately adjusted laminating station, Glassolutions guaranteed the correct pressure and position of the double-sided tape. After removal of the liner, seven glass panels were placed on top of each other and compressed under compression. In total, 2,200 m2 of panels were bonded to 1,500 glass blocks. Tests show that the glass construction also perfectly meets the strict requirements that Schiphol sets in terms of safety and maintenance. Particularly innovative is the solution to prevent any discoloration caused by, for example, coffee or rising damp and the adhesion of dust or dirt. Tape manufacturer tesa has coated the sides of the acrylic tape with very fine glass dust (‘pearling’). Glassolutions produces glass blocks with a special assembly unit (Photo: tesa)

RBOEK -

g - KGK JAA

gan 38ste jaar

More at tesa>

Ceramic Yearbook 2017/2018

2017/2018

SCH I M A R KE OEK JAARB 8 2017-201

EEN

AVE UITG

VAN

KGK

The Ceramic Yearbook 2017/2018 was published in mid-December. The yearbook belongs to the magazine KGK (Clay Glass Ceramics) and is published by SJP Uitgevers in collaboration with the Dutch Ceramic Association (NKV). This year the content of the yearbook has been slightly modified. This year the content has been broadened to a bigger target group than the ceramic sector alone. This because the added value of ceramic products, both traditional and technical ceramics, is increasingly being recognized and valued outside the sector. Not only because of the aesthetic and technical importance, but also because the products can make an interesting contribution in terms of sustainability. The Ceramic Yearbook contains general information about both technical and traditional ceramics, summaries of articles that have appeared in KGK in the past year, list of companies, institutions, organizations and museums. Ceramic Yearbook 2017/2018, 56 pages, language: Dutch, costs € 25, - excl. VAT, excl. shipping costs). It can be ordered from SJP Uitgevers sjp@sjp-uitgevers.nl. Subscribers of Innovative Materials can receive the yearbook (digitally) for free on request.

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NEWS

Dutch cities could be cooled by reflective roofing tiles

Changing the colour of roofing tiles could considerably reduce extreme temperatures in Dutch cities. Introducing this idea is Leyre Echevarría Icaza, Delft University of Technology, Faculty of Architecture and the Built Environment, who was awarded her PhD at TU Delft for her work on this subject on 8 December 8th 2017. It is usually warmer in cities than in the surrounding countryside, primarily because buildings retain more heat. This is called the Urban Heat Island (UHI) effect. The phenomenon could have far-reaching consequences, particularly in cases of extreme heat. During the 2006 heatwave in the Netherlands, for example, the UHI effect resulted in an increase in recorded deaths. During her PhD research, Leyre Echevarría Icaza investigated the most effective means of mitigating the UHI effect in Dutch cities. She argues in favour of using satellite images to chart and analyse UHI effects. ‘Alongside facilitating

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analysis of the heat island phenomenon in Dutch neighbourhoods, cities and regions, satellite imagery can also be used to help make recommendations. The analyses and recommendations are sufficiently accurate to be efficient and are also compatible with other urban planning considerations.’

Improving albedo

Echevarría Icaza investigated city centres including Delft, Leiden, Gouda, Utrecht and Den Bosch at neighbourhood level. These centres are characterised by their canals, red ceramic roofing tiles and stone paving. There are various ways of mitigating the UHI effect in these areas, but what complicates matters is that these city centres are full of listed buildings. The most straightforward measure to implement is improving the reflection (albedo) of roofs - by changing the colour of the roofing tiles, for example.

Orange tiles

‘At the end of their life cycle, the existing roofing tiles could be replaced by tiles in colours that reflect more solar radiation. Traditional roofing tiles have an albedo rating of between 18 and 22 %, while certain orange tiles offer reflection of approximately 50 %. The effective improvement of all flat and sloping roofs could help to reduce temperatures in certain areas of the city by 1.4 to 3 degrees. This therefore appears to be an efficient means of reducing UHI effects in Dutch cities.’ Text: TUDelft The dissertation ‘Urban and regional heat island adaptation measures in the Netherlands’ is online>

NEWS

First cementless roundabout in Europe At first glance, this roundabout is no different than a concrete roundabout, but itâ&#x20AC;&#x2122;s more than that. The N737 DeurÂ ningen - Enschede is the first provincial road in Europe with a roundabout where cement has been completely replaced by geopolymer (RaMac). The province of Overijssel, Reef Infra, Rokramix and Sqape thus have a European first. Relatively much CO2 is released during the production of cement. By not opting for cement, the initiators have not only found a sustainable solution with a much lower CO2-footprint; but it is also the first time in Europe that in this way a roundabout is constructed based on geopolymers. In addition to, according to the parties involved, the material has more advantages: less cracking, better acid resistance and good adhesion of the reinforcement.

A trial period was set up and tests were carried out for the technical feasibility and processability. Ultimately, approval was given for the implementation of the application at the roundabout in the N737. More on RaMac (Dutch; pdf)>

Video

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INNOVATIVE MATERIALS 6 2017

Dutch Design Week 2017

Every year in October, the nine-day Dutch Design Week (DDW) takes place in Eindhoven. The largest design event in Northern Europe presents work and concepts from more than 2500 designers and over 295,000 visitors from home and abroad. Scattered among over a hundred locations throughout the city, DDW organizes and facilitates exhibitions, lectures, award ceremonies, network meetings, debates and festivities. According to the organizers, DDW distinguishes itself from other design events by concentrating on designs for the future. This was also reflected in the range of material innovations. Much attention for example for 3D-printed materials, biomaterials and circularity.

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INNOVATIVE MATERIALS 6 2017 People’s Pavilion Undisputably eyecatcher and beating heart of The Dutch Design Week was People’s Pavilion, located on the Ketelhuisplein. The temporary structure is built together with designers from Overtreders W and Bureau SLA with help from the community. Plastic waste supplied by inhabitants of Eindhoven is converted into shingles (tiles) for the facade and the structure also incorporates borrowed materials from the locals. After the Dutch Design Week the building is disassembled and all the materials will return to the owners. This means that there is no use of glue, screws, drills or saws. According to the organizers, the concept of borrowing and returning materials makes the pavilion a great example of a circular and sustainable way of designing and building. Although its temporal existence, the People’s Pavilion goes beyond the function of a festival tent, the organizers say. It acts as a forum for the views of the world, a platform, a source of inspiration and a meeting point all rolled into one. During the DDW/WDE 2017 the building hosts community gatherings, public participation rounds, co-creation sessions, lectures and performances, as the central meeting point.

People’s Pavilion: panels made of plastic waste

www.worlddesignevent.org

Paper Bricks Paper is among the most produced and most discarded materials in the world. It can be recycled, but not indefinitely: with every cycle the fibers grow smaller and the quality downgrades. ‘PaperBricks’ by WooJai Lee are an exploration of how to recycle paper in more sustainable ways. ‘PaperBricks’ are made from recycled newspapers. The newspaper is turned into pulps which are mixed with glue and shaped into bricks. Sturdy as real bricks they combine a pleasing marbled look with the warmth and soft tactility of the paper. When you touchthe ‘PaperBricks’, you can feel the soft textile-like texture. www.woojai.com/paperbricks> Paper Bricks

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INNOVATIVE MATERIALS 6 2017 Greenpanel At the Klokgebouw exhibition Greenpanel presented its lightweight panel, a FSC-certified ultralight board. By the combination of broad thicknesses, low weight, high stability and resistance the panel is suitable for many purposes. It consists of faces and core of thin MDF arranged like a grid. According to Greenpanel, the innovative board has been developed for those applications that require the combination of broad thicknesses, low weight and high stability and resistance. Greenpanel is a structural board with an extremely low weight, between 74 and 250 kg/m3 depending on its thickness. The material is classified as low formaldehyde content. Greenpanel can be used for different applications, such as: home furniture, worktops, table tops, ceilings, wall systems, sliding doors, acoustic walls, caravans, thick flooring, stands for fairs, naval construction, accessories for shops and interior decoration.

Greenpanel

www.greenpanel.nl>

The future is local: micromoulding machine & soft biocomposites

Micromoulding

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Designer Bas Froon showed a new manufacturing technique using bio composites. According to Froon the new technique offers new opportunities to bring back industrial production of labour-intensive ‘soft’ products to local manufacturers. At the Dutch Design Week 2017 he presented his conceptual machine and a first application: a velvety soft and tailor-made baby carrier made of this special and sustainable material. Bas Froon graduated at the Post Graduate Course Industrial Design. He developed a ‘micromoulding’ machine that makes it possible to locally change material qualities from a velvety soft material into a strong and lightweight plastic. Using a personal 3D scan or custom computer design, each product will be tailor-made and unique. To demonstrate this technique Bas developed a light and supportive baby-carrier that is based on a body scan of its user. Instead of labour-intensive assembly of different parts, Froon managed to use

only one type of material. That makes it much easier to assemble a product, but also makes it possible to re-use the materials for new products at the end of its lifetime. With this very special technique we will be able to manufacture in the Netherlands again in a very competitive and sustainable way. http://basfroon.nl/industrial-design>

Soft biocomposites

INNOVATIVE MATERIALS 6 2017 A wooden motorbike Two years ago algae-scientist Peter Mooij and artist Ritsert Mans teamed up for a new adventure. Ritsert would design and build a wooden motorbike that would run on algae oil. Nature provides lot’s of ‘hightech’ materials: cork, Hemp and wood. Ritsert used these materials to build a frame with springs and damper. The bike was made and designed purely on intuition. The only goal was to go fast on algae oil in a straight line on the beach. Peter Mooij did research on the processes how to design the algae’s to produce oil and wrote a popular science book about the relevance of algae and the wooden bike. According to the designers the bike symbolizes the adventure that will come with the transition in energy sources in the future. What will the planet look like. It might be frightening but also very exciting and Mooij and Mans think it will create a lot of opportunities. www.mansmaakt.nl>

Bottle | brick On the East African island or Zanzibar, glass waste can not be melted down to produce new products. In 2015, bottle-up in collaboration with the Dutch Design Week and various design agencies, started to develop materials and products such as candle stands, terrazzo cases and table tops made from (ground) waste bottles (see innovative Materials number 5 2016). These products are sold to tourists who visit the island. Industrial designer Lou van Reemst developed the bottle | brick: a building block in which 35% of the aggregate has been replaced with tiny glass pieces (6.15 kg per brick) for local construction on the island. The bottle | brick with glass aggregate is twice as strong as the local bricks. Lou van Reemst graduated on September 29th as Integrated Product Designer at the faculty of Industrial Design Engineering at TU Delft. http://bottle-up.org>

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INNOVATIVE MATERIALS 6 2017 When Digital Gets Physical Designer Adriaan de Groot presented a futuristic chair, apparently meant to visualise the concept of what is called ‘digital material.’ The chair is assembled from aluminium tetrahedrons and spheres, that - when tightened by the inner cables - form a lightweight octet truss lattice, inspired by the way atoms form crystallic structures. When the tension is released, the shape disappears and the ‘material’ returns to its initial state; ready to be reconfigured. The idea is as follows. Digital has brought two revolutions before, that led to enormous leaps in efficiency. First in communication, then in computation. Today we are in the middle of the third, and potentially most influential digital revolution; that of fabrication. But what happens when this streak of digitisation starts to affect our physical world of materials? Adriaan de Groot says to be inspired by Neil Gershenfeld and his research group at the Centre for Bits and Atoms at MIT who are quite seriously working towards this poetic future of digital materials. Their work has been the main inspiration for this project. When Digital Gets Physical is an ongoing research project exploring applications of digital materials at different scales. The laws of digital building offer huge potential in terms of structural efficiency and material re-use, and this project is looking to deploy that potential in present-day contexts. As the first outcome of this journey, this piece is meant to visualize the concept of digital material and translate its core principles to physical shape. www.whendigitalgetsphysical.com>

StoneCycling StoneCycling makes building materials from waste. Around 25 million tons of building and demolition waste is created each year in the Netherlands, making it the country’s biggest waste stream. Ninety percent is allegedly recycled; however, in real terms it ends up in landfills or as filling for roads, which in fact is downcycling. Instead, StoneCycling adds value to this waste material by upcycling it into new, circular building materials. In this way, the company utilises the waste’s economic, aesthetic and sustainable qualities. At present, these new building materials are used to construct new buildings. www.stonecycling.com>

Video

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INNOVATIVE MATERIALS 6 2017 Solarix: coloured solar panels October 24th, during The Dutch Design Week, the first design solar panels from the Studio Solarix collection were officially presented. Studio Solarix, founded by architect Marloes van Heteren and artist Reinier Bosch, says they want to change the world of solar cells by using them as design products. The idea behind the Solarix is to combine aesthetics and the sustainable generation of energy: a beautiful gable tile, which also generates energy. The developers say they are inspired by photosynthesis in nature, where the skin is also a great source of energy. The Solarix panel has a base of C2C composite with an integrated glass panel fitted with solar cells. The tile is adaptable in colour and texture, but also in dimensions, making it a fully customized product. The solar cell is placed slightly slanted which makes it even more efficient. It also provides an extra depth effect in the façade pattern. In the facade tile, an LED strip can also be integrated, converting the generated energy into light, allowing to communicate with the environment via the façade. www.studio-solarix.nl>

3D printed hyphal materials By the slogan ‘In step with the times using natural materials,’ scientists of the Delft University of Technology, presented ‘Growing sesons’: objects - a tableclock in this case - made of 3D printed materials. According the researchers making sustainable products from living organisms, such as hyphal threads, is the future. Growing Seasons is the ticking proof. The table clock has a 3D printed base, constructed from natural ingredients which are collected during the four seasons. The clock case can be replaced each year, after which the compostable material serves as nutrition for seasonal plants that sprout from the case. Industrial Design Engineering, TU Delft>

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INNOVATIVE MATERIALS 6 2017 BB-Bricks During the Dutch Design Week, much attention was paid to circularity, and not least to the reuse of plastic. So there was a presentation of BB-Bricks a modular building block, conceived and made by industrial designer Bas Luijting a few years ago. Under the motto ‘Have you ever seen someone throw away Lego?’ he was inspired by Lego, but gave them a bigger size and exclusively for adults (from 14 years). The material used is recycled and / or new raw material. The stones are suitable for indoor and outdoor use and no glue or cement is required for construction. The BB-Bricks company doesn’t sell accessories, but according to the website they can be made at home, with a 3D printer. Soon there will be a web platform with some 3D drawings of BB Bricks accessories. Your own creations can then be added to it. These drawings are intended to circulate around the world in an open source environment. www.bb-bricks.nl>

Hemp fibre panels Jory Swart presented the preliminary results of his material study into hemp fibres. He has researched ways to construct and design furniture with hemp fibers, and especially whether hemp could replace wood and plastic. Hemp is a sustainable crop that can be harvested several times a year. Hemp fibres are the strongest natural fibres. The challenge was to create stiffness and strength in the material, making it easier to edit and apply. The material research has now resulted in light and strong panels. According to Swart these panels can be made in any shape and size. He thinks that with this 100 % naturally material he will be able to design an entire collection of furniture. www.joryswart.com>

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INNOVATIEVE INNOVATIVEMATERIALEN MATERIALS 6 2017 3D printed floors ‘on demand’ Technology Company Aectual launched a sustainably produced 3D printed floor with terrazzo infill at Dutch Design Week. Aectuals’ smart technology makes it possible to custom 3D print any design on large surfaces, where each square meter is unique. The first floor in the Netherlands placed at Amsterdam Schiphol Airport. According to Aectuel their technique makes it possible to create individual design for spectacular floors in, for example, a hotel lobby, or for a striking retail brand. This gives designers complete design freedom. Clients can also choose from a selection of special patterns, which are customized entirely to their building. Unique details can easily be added to emphasize special areas, branding and routing. Aectual’s ‘on demand floor’ is made possible by their in-house developed software tools and industrial XL 3D print technology. The floors consist of 3D printed patterns that are installed seamlessly on site, and are finished with a bio-binder terrazzo.

There is a wide range of color options and fillings, the floors are of a very high quality, and wear resistant. An important feature is that the floors are produced in

a sustainable manner, with a bio-print plastic and recycled materials. http://www.aectual.com>

Materials 2018 Trade fair and congress

Materials are at the base of everything we see around us. They are often taken for granted, but where would we be without our cars, machines, and buildings without a strong base? We almost forget how special materials are and how complex the selection, creation and production processes are. Not to mention about developments and innovations within these fields. On May 30 and 31 2018, the 6th edition of Materials will take place at the NH Conference Centre Koningshof in Veldhoven, the Netherlands. During these two days, Materials will be the largest meeting point for material specialists, product developers and engineers. An all-in-concept will be presented, based on the 4 elements for finding a solution for material challenges: 1) (New) materials 2) Material analysis 3)Surface techniques 4) Binding techniques

More information? Visit www.materials.nl>

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INNOVATIVE MATERIALS 6 2017

Composite materials made from Swiss tree bark Studies conducted by the Swiss National Research Programme ‘Resource Wood’ show that tannins extracted from native tree bark can be used to produce adhesives and composite materials. An additional area of application might be 3D printing. The bark of native conifers is known as a waste product in the timber industry. It is mostly burnt or used as garden mulch. A team from the National Research Programme ‘Resource Wood’ (NRP 66) has now developed a new process to extract valuable tannins from tree bark to produce adhesives and composite materials. Tannin extracts are already employed in wood adhesives. But they are mostly extracted from tropical wood and are produced overseas. The team of Prof. Dr. Frédéric Pichelin (Berner Fachhochschule, Institut für Werkstoffe und Holztechnologie, Biel, Switzerland) developed methods to extract tannins from native tree bark and tested their suitability in the production of adhesives for fibreboards and chipboards. According to the researchers the boards

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INNOVATIVE MATERIALS 6 2017 NRP 66 ‘Resource Wood’

produced at pilot scale were made without formaldehyde, an agent with harmful effects that is normally used in glued wood products. So the team is solving two problems in one: replacing synthetic oil-based adhesives with products made from renewable resources, and getting rid of unhealthy emissions of commonly available fibreboards and chipboards. With industrial implementation as their goal, the researchers are now pressing ahead with their ideas for using tree bark. At the same time, they are continuously working towards higher purity levels in the native extracts because commonly used tannins from overseas achieve slightly better results in terms of the solidity and water resistance of glued wood products.

also other fibrous materials. The researchers from Biel see additional potential in tannin-based foams for boards in light construction and furniture-making. One of the exceptional properties of tannin foams is their fire resistance, which will make them a desirable product in areas where fire prevention is paramount.

In collaboration with the authorities and industry partners, the National Research Programme ‘Resource Wood’ (NRP 66) and its 30 research projects generate scientific knowledge and practical solutions for optimising the exploitation and use of wood in Switzerland. The overall final recommendations of NRP was published in four thematic summary reports and one overall synthesis report on November 7th 2017. The research project ‘Extraction of tannins from the bark of native conifers’ of the Bern University of Applied Sciences was part of the dialogue field ‘Innovative wood-based materials for new applications’. ‘Innovative wood-based materials for new applications’ of NRP 66 online (German) by clicking thecover below.

In addition, tannin extracts play an important role in developing composite materials for 3D printing. The researchers envisage printable construction and design materials that are entirely or primarily made from wood and bark.

There’s more on the website of the Swiss National Science Foundation>

Bark-based tannins are already being used to bind not only wood products but

Contact

Prof. Dr. Frédéric Pichelin Berner Fachhochschule, Institut für Werkstoffe und Holztechnologie Solothurnerstr. 102, 2504 Biel Phone: +41 32 344 03 42 E-mail frederic.pichelin@bfh.ch Prof. Dr. Ingo Mayer Leiter BFH-Zentrum Holz – Ressource und Werkstoff Solothurnerstr. 102, 2504 Biel Phone: +41 32 344 03 43 E-mail ingo.mayer@bfh.ch Much more about ‘Wood goes High Tech’ in Switzerland> Tannineschuim voor lichtgewicht constructies en de meubelmakerij

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INNOVATIVE MATERIALS INNOVATIEVE MATERIALEN 6 2017 6 2017

Ultra-thin, curved, concrete roof Researchers from ETH Zurich have successfully built a prototype of an ultra-thin, curved concrete roof. This full-scale experiment investigates the feasibility of spraying a textile reinforced thin concrete shell using a lightweight flexible formwork composed of a tensioned cable net as falsework and tailored fabric as shuttering. This one-to-one (with a bounding box of 20 m x 10 m x 7.5 m) prototype can be seen as the dress rehearsal for the construction of the roof of the NEST HiLo project, that is planned to be built next year on the NEST, the living lab building of Empa and Eawag in DĂźbendorf, Stwitzerland.

A prototype for an ultra-thin, sinuous concrete roof using innovative design and fabrication methods has been designed and built by researchers from the ETH ZĂźrich. The building technique for the roof was developed by the Block Research Group, led by Prof. Block and senior researcher dr. Tom Van Mele, and tested on a full-scale prototype. The prototype, which has already been dismantled to make space for future experiments, was 7.5 m high with a surface

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area of 160 m2 (covering an area in plan of 120 m2). The thickness of the concrete has an average thickness of 5 cm varying between 3 cm along the edges of the roof to 12 cm at the support surfaces.

Reducing material waste

The idea is to build the HiLo roof with a cable-net and fabric formwork system. This system is designed to dramatically reduce the material waste that is typically involved in the construction of concre-

te shells. According to ETHZ it improves on traditional formwork structures for doubly curved surfaces, which would be comprised of custom timber carpentry or milled foam, by using mostly reusable components. Instead of formwork using non-reusable custom-fabricated timber or milled foam, which would be needed to realise such sophisticated form, the researchers used a net of steel cables stretched into a reusable scaffolding structure. This ca-

ble net supported a polymer textile that together functioned as the formwork for the concrete. This not only enabled the researchers to save a great deal on material for construction, they were also able to provide a solution to efficiently realise completely new kinds of design. Another advantage of the flexible formwork solution is that during the concreting of the roof, the area underneath remains unobstructed and thus interior building work can take place at the same time.

Algorithms

The cable net is designed to take on the desired shape under the weight of the wet concrete, thanks to a calculation method developed by the Block ReÂ search Group and their collaborators in the Swiss National Centre of Competence (NCCR) in Digital Fabrication. The algorithms ensure that the forces are distributed correctly between the individual steel cables and the roof assumes the intended shape precisely. The cable net weighs just 500 kg and the textile 300 kg; thus, with a total of only 800 kg of material the 20 tons of wet concrete are supported.

NEST HiLo NEST is a modular research and demonstration platform for advanced and innovative building technologies in the heart of the Empa-Eawag campus (Empa is the leading Swiss institute on material science and technology.) NEST was created in 2016 to accelerate the process of innovation in the building sector. Part of the NEST-project is HiLo, a research & innovation unit in the domains of lightweight concrete construction and smart, adaptive building systems. http://hilo.arch.ethz.ch/

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INNOVATIVE MATERIALS 6 2017 Block’s team built the prototype over the course of six months in ETH Zurich’s Robotic Fabrication Lab. According to ETHZ is represents a major milestone for the NEST HiLo project. It shows that it’s possible to build thin concrete shell structure using a lightweight, flexible formwork, thus demonstrating that complex concrete structures can be formed without wasting large amounts of material for their construction, the researchers said. Next year, Block plans to build the roof once again at the NEST building in eight to ten weeks. The individual components of the roof structure can be reused as often as needed. Even the cable net can be dismantled into a few parts that can be quickly reassembled and rehung. Also see Cable-net and fabric formworks for concrete shells>

The construction of the roof would be inconceivable without state-of-the-art computation and fabrication techniques, but according to EHTZ the project also heavily relied on the expertise and experience of several crafts-people. Experts from Bürgin Creations and Marti sprayed the concrete using a method developed specifically for this purpose, ensuring

that the textile could withstand the pressure at all times. Together with Holcim Schweiz, the scientists determined the correct concrete mix, which had to be fluid enough to be sprayed and vibrated yet viscous enough to not flow off the fabric shuttering, even in the vertical spots.

Video, the making of

Artist impression of the Hilo penthouse

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INNOVATIVE MATERIALS 6 2017

Onderdeel uitmaken van een gedreven team, je kennis op het gebied van geografie inzetten en werken op de mooiste plekken van ons land. Als dit je aanspreekt dan is een baan bĳ Delgromĳ, onderdeel van de K3 organisatie, iets voor jou. De baksteen- en dakpanproducenten stellen hoge eisen aan hun grondstoffen. Delgromĳ is gespecialiseerd in het opsporen, ontwikkelen en exploiteren van hoogwaardige kleiwinlocaties. Met een team van gespecialiseerde uitvoerders voor de begeleiding van de leveringen is Delgromĳ dé grondstoffenleverancier van de keramische industrie in Nederland. In de afgelopen 45 jaar zĳn wĳ uitgegroeid tot marktleider in de keramische markt. Daarnaast hebben wĳ veel kennis en ervaring met het toepassen van klei voor dĳkverzwaringen. Wĳ zĳn op zoek naar een

Uitvoerder kleiprojecten (1,0 fte) Werkzaamheden: Wĳ zoeken een uitvoerder die zelfstandig kan werken en het team kan stimuleren zodat de parameters op het gebied van kwaliteit, kwantiteit en resultaat worden gehaald. Je bent het eerste aanspraakpunt voor de projectleider en de direct verantwoordelĳke op meerdere project locaties. Je rapporteert aan de senior projectleider. Kĳk voor de volledige vacature op onze website: www.k3delta.nl/vacatures. Solliciteren? Je sollicitatie ontvangen wĳ graag per e-mail via t.veens@k3delta.nl ter attentie van mevrouw T. Veens onder vermelding van ‘Vacature Uitvoerder Klei’. Acquisitie naar aanleiding van deze advertentie wordt niet op prĳs gesteld.

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INNOVATIVE MATERIALS 6 2017

Powder coatings on wood November 2nd DSM Ultra hosted its Inspiration event ‘Powder coatings on wood’ at the Polymer Science Park in Zwolle. Ultra, introduced in 2014, is a breakthrough technology that enables powder coating of heat-sensitive substrates such as MDF. It contains no toxic solvents, is low-energy consuming, and protects the environment as well as the production line. A comprehensive Life Cycle Assessment measures a carbon footprint that is five times lower than solvent-borne coatings. The Eco Footprint - indicating impact on resource depletion and climate change - is equally reduced. The presentations showed some best practices about the (dis)advantages of powder versus liquid coatings.

Until recent years it was commonly assumed that powder coating of MDF boards was not feasible for mass production. But this is a perception of the past. With the launch of Ultra technology by DSM, several years ago, the benefits of powder coatings came available for products made with heat-senstive materials such as engineered and natural woods as well. From the first commercial attempts in the early 90’s until only a few years ago, powder coatings available for

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heat-senstive substrates have provided a viable solution to drive a shift away from liquid coatings. However, the new technology came with a significant degree of uncertainty about the results that this shift would yield. In terms of technologies, several factors hindered the widespread adoption of powder coatings; most prominently, limitations associated with cure temperature/duration imposed by the poor chemical storage stability of

conventionel catalyzed systems. Thanks to recent advances in application and curing equipment technologies, together with the recent introduction of the Ultra binder chemistry (based on unsaturated polyester, which imparted durability, and urethane, which improved flexibility), powder coating technology has bridged the technology gap and become a reliable proposition for heat-sensitive substrates.

INNOVATIVE MATERIALS 6 2017 In the field of application technology, the development of regulated counter electrodes provided an important step forward. Oven technology, with the advent of electrical or gas catalytic infrared curing systems, now provides an efficient and reliable way to cure powder on heat-sensitive substrates. Finally, with the commercial launch of Ultra based powder coatings in 2014, the obstacles that hindered the advancement of powder coatings in non-metal applications in the past have been overcome. According to DSM the technology has advanced to such a degree that converting to powder coatings is a reliable and competitive alternative.

Coating with powder

The powder production process involves mixing, extrusion, milling and sieving steps, after which the powder is typically applied electrostatically, followed by curing under heat to allow it to flow and ultimately harden. The powder coating formulation consists of a binder (resin and crosslinker), pigments and additives. Powder coatings are mainly used for the coating of metals, such as domestic appliances, aluminium extrusions and automobile and bicycle parts due to the high temperature that is required to harden the coating, which is typically 160-170 °C. For years, there have been

significant efforts towards reducing the curing temperature: this has been the driving force to further reducing the required energy of an already ecological, low-footprint process. This creates an increased demand for low-temperature

curing powder coatings without adverse effect on the curing times, which are also important for lowering manufacturing costs.

Ultra process

For Ultra, the curing process takes place at 130°C (265°F) for three minutes. Once the powder coating has been successfully cured, the finished product is taken off the racks. According to DSM, MDF is an excellent example of a heat-sensitive substrate that can be coated using the described technology. Different powder coating technologies can be used to coat MDF, including hybrid technology, epoxy powders or UV powder coatings. The powder coatings using Ultra system enables fully powder coated MDF objects, without exposing the MDF to excessive heat loads. This provides an opportunity to produce finished products with superior aesthetic quality, many colors, gloss levels, textures and finishes.

Efficient processing

According to DSM Ultra not only allows manufacturers to broaden their market reach, and raise the performance standards of their products, it also

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INNOVATIVE MATERIALS 6 2017 enables significant cost savings in the manufacturing process compared to incumbent coating technologies. The powder coating process offers many advantages compared to the application process of a liquid finish, DSM says. Depending on the substrate, the powder coating processing can take place up to ten times faster than liquid coating, and cost savings can reach 45 %. In particular, the fully automated one-step application of the new DSM powder technology results in reduced rework and minimized sanding. Color changes on the production line can be implemented in a quick and efficient way, without the requirement of additional floor space. From start to finish, the process can be completed in 20 to 30 minutes, with all sides covered in just one go.

environmental footprint will be reduced by integrating a low-temperature bake and a 100 % solid process. The powder coating process also prevents harmful chemicals from damaging the environment, as it involves no VOCs. A comprehensive Life Cycle Assessment for Ultra measures a carbon footprint that is five times lower than solventborne coatings. The eco-footprint for Ultra, which indicates the impact on resource depletion and climate change, is equally reduced. Text is based on the DSM article: Ultra technology (november 2017)

More at www.dsm.com/ultra>