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APRIL 2022 ETHICAL SMARTPHONES CHALLENGE DESIGN NORMS ANTEC 2022 REVS UP FOR JUNE EVENT Show adds DEI conference, co-locates with Plastec South PLUS 2022 TRENDY Awards Most Improved MagazineINSIDE PLASTICS ENGINEERING VOLUME 78 NUMBER 4 APRIL 2022 10 Wearables FEEL THE POWER Plastics spur growth in wearable diagnostics including self- healing electronic skin and self-powered devices. 16 GET YOUR OWN! Plastics Engineering keeps plastics industry professionals informed of the latest news and in-depth reporting on state-of-the-art and emerging technologies that impact the R&D and processing of plastics products. This is the magazine every plastics industry professional NEEDS to read. 4spe.org/Subscribe 4 LETTER FROM THE EDITOR SUSTAINABLE Novel eco-friendly designs challenge smartphone norms and promote circularity. COVER STORY www.plasticsengineering.org | APRIL 2022 | PLASTICS ENGINEERING | 136 | As I See It WINNING FORMULAS Corporate executive and SPE overachiever Donna S. Davis shares her outlook on critical plastics issues. 28 | ANTEC Preview READY TO GO ANTEC to launch first live event since 2019; will include DEI conference and be co-located with Plastec South. 9 | Data Points Polymer and composites markets hold growth opportunities for industry. 22 | Conference Recap BIG AND BOLD Polyolefins Conference highlights the growth and challenges of a dominant industry sector. 47 | Calendar 48 | Ad/Editorial Index INSIDE PLASTICS ENGINEERING VOLUME 78 NUMBER 4 APRIL 2022 41 | New Product News 36 5 | Set Point Celanese wants DuPont’s M&M grades; Borealis project achieves waste reduction. 42 | SPE News SMALLER IS BETTER, AND DOABLE Advances in microinjection molding technology are improving electronic component design. 30 Case History LASTING EFFECT Innovative deflection elbows are designed to prevent wear and downtime during resin conveying. Sustainability OCEAN MELODY A YouTube creator works with conservation group 4ocean to turn plastics waste into a guitar. 40 2 | PLASTICS ENGINEERING | APRIL 2022 | www.plasticsengineering.orgPatrick Toensmeier Editor-in-Chief (203) 777-1474 ptoensmeier@4spe.org Michael Greskiewicz Director, Sales & Advertising (203) 740-5411 mgreskiewicz@4spe.org Ryan Foster Art Director (203) 740-5410 rfoster@4spe.org Sue Wojnicki Director of Communications (203) 740-5420 swojnicki@4spe.org Editorial & Publishing Staff President Jason Lyons CEO Patrick Farrey President-Elect Bruce Mulholland Vice President – Chapters & Secretary ScottEastman Vice President – Business & Finance / Treasurer James Waddell Vice President – Professional Development Pavan Valavala Vice President – Sustainability Conor Carlin Vice President – Member Engagement Lynzie Nebel Vice President – Publications Raymond Pearson Vice President at Large Paul Martin Past President Jaime Gómez SPE 2021-2022 Executive Board Contributing Editors NANCY D. LAMONTAGNE ndlamontagne@gmail.com Nancy D. Lamontagne reports on science, technology and engineering. Topics she covers for Plastics Engineering include thermoforming, blow molding, medical plastics, packaging, and education and career development. ROBERT GRACE bob@rcgrace.com Robert Grace has been in B2B journalism since 1980. He covers design and business for Plastics Engineering and is editor of SPE’s Journal of Blow Molding. Professional memberships include the Industrial Designers Society of America. JENNIFER MARKARIAN technicalwritingsolutions@comcast.net Jennifer Markarian focuses on technology. A chemical engineer, she began her career in product development with Mobil Chemical’s polyethylene group. She is also newsletter editor for SPE’s Palisades-New Jersey Section. CATHY NESTRICK Cathy Nestrick is the former vice president and general counsel of Berry Global Group Inc., a Fortune 500 manufacturer and marketer of plastics packaging and engineered materials. She is the founder and co-host of Parity Podcast, which focuses on accelerating gender equality. www.plasticsengineering.org | APRIL 2022 | PLASTICS ENGINEERING | 3 PEGGY MALNATI peggy@malnatiandassociates.com Peggy Malnati has over 30 years’ experience covering plastics, composites and automotive. She has organized technical conferences for SPE and served as board member and communications chair for SPE’s Automotive Division. GEOFF GIORDANO geoffgio@verizon.net Geoff Giordano has been a contributor to Plastics Engineering since 2009, covering a range of topics, including additives, infrastructure, flexible electronics, design software, 3D printing and nanotechnology. FROM THE G ood organizations set lofty goals. In publishing and education, these include developing vital information and insight for groups they serve, effective communications, and a commitment to promote the personal and professional growth of audiences. The ability to change with the times and meet new and evolving challenges is a given. People in these occupations don’t expect awards. When they happen, though, it’s gratifying and worthy of mention, especially to recognize those who make them possible. SPE and the University of Akron, two stalwarts of plastics, have won awards that reflect their commitments to the industry and to the individuals who are or will be part of it. On March 11, SPE received four awards from Association TRENDS (AT), a group that provides association executives and their industry partners with training, data and insights to better serve their organizations. AT’s annual awards, called TRENDYS, recognized SPE with Gold Awards in three areas for 2021: Plastics Engineering as “Most Improved Magazine or Journal”; PlastChicks—The Voices of Resins! podcast and co-hosts Mercedes Landazuri and Lynzie Nebel for “Best Podcast”; and the SPE ANTEC Exhibitor Sales Kit as best in category. AT also announced at the Washington, D.C., ceremony that PlastChicks—The Voices of Resins! podcast won the 2022 Pinnacle Award. The University of Akron (UA) School of Polymer Science and Polymer Engineering, meanwhile, is ranked No. 1 in the world by EduRank for the education it provides in these disciplines. EduRank assesses thousands of universities around the world for an annual standings list and put UA first among the 1,039 schools ranked in polymer studies. SPE redesigned PE magazine last June, broadening coverage, adding departments, expanding features and highlighting interpretive information from sources including the Society’s global membership. Our editors do a masterful job of writing about the industry. Features cover technology and applications, of course, as well as socio-business topics like gender bias in design (June) and SPE’s diversity, equity and inclusion initiative (September). With Art Director Ryan Foster’s vision and talent for layout, the result is insightful coverage of an industry whose products improve the quality of life for people worldwide. The PlastChicks—Voices of Resins! monthly podcast discusses popular plastics topics and interviews people who are making an impact on the industry, business, education and society. It takes a lot of work to put the podcasts together, but the results are informative, engaging and well worth hearing. The ANTEC Exhibitor Sales Kit marked the second year that SPE’s signature technical conference was virtual due to the pandemic. Marketers nevertheless received astute guidance in the kit for developing virtual booths, setting up and enhancing exhibitor centers and creating digital networking opportunities. This was a successful effort and no small feat considering that handling products and talking personally with exhibitors are mainstays of ANTEC. All the people behind these awards deserve recognition as well: they are a supportive and valued team that includes CEO Pat Farrey and SPE President Jason Lyons, both of whom were at the awards ceremony; the immensely capable Sue Wojnicki, director of member experience; and many others throughout the organization. Bravi for all their efforts. UA has an important connection to SPE: Dr. Sadhan C. Jana, professor and associate dean in the School of Polymer Science and Polymer Engineering, is executive editor of all SPE journals as well as editor-in- chief of the Polymer Engineering and Science Journal. Jana says UA offers “in-depth course curricula that integrate sciences and engineering of polymers, first-rate research conducted by exceptional faculty members and strong connections of the program with polymer industries.” The focus is on “experiential learning … at all levels through laboratory courses, internships and capstone projects supported by strong foundations in theory.” He adds: “Almost all our master’s and PhD candidates find employment.” Expansion is on the horizon. Jana says UA is “awaiting State of Ohio approval for a B.S. degree in polymer science and polymer engineering,” an offering that “will meet the longstanding demand of … industries and prospective students and prepare students for graduate programs and careers ...” Honors are important, but they’re just one stop on a long road of achievement and, notably, a challenge to do better—a challenge that SPE and the University of Akron continue to embrace. PAT TOENSMEIER Editor-in-Chief ptoensmeier@4spe.org AWARDS AND WINNERS 4 | PLASTICS ENGINEERING | APRIL 2022 | www.plasticsengineering.orgTwo storied names in polymer development and applications engineering have announced a deal with the potential to reshape resin supply and product development. Celanese Corp. of Dallas reported on Feb. 18 that it has signed a definitive agreement to acquire a majority of the Mobility and Materials (M&M) business of DuPont, Wilmington, Del., for $11 billion in cash. Celanese will acquire a portfolio of engineered thermoplastics and elastomers, product brands and intellectual property, along with global production assets and a world-class organization in the deal. The businesses generated net sales of approximately $3.5 billion and operating EBITDA of some $800 million for DuPont in 2021. The M&M business is a leading global producer of engineering resins and elastomers serving a variety of applications including automotive, electrical and electronics, consumer goods and industrial. The product portfolio includes numerous materials in nylons (PA 66, PA 6), specialty nylons, polyesters (PET and PBT) and elastomers (copolyesters and ethylene acrylic elastomers). The M&M portfolio is highly functionalized for a wide variety of application specifications and is supported by an intellectual property portfolio and technology organization. The transaction, which is subject to regulatory approvals and closing conditions, is expected to close around the end of 2022. Celanese acquisitions from the deal will include: » A global production network of 29 facilities, including compounding and polymerization. » Customer and supplier contracts and agreements. » An intellectual property portfolio including some 850 patents and associated technical and R&D assets. » Approximately 5,000 manufacturing, technical and commercial personnel. Not included in the deal is Delrin acetal homopolymer, a material with high tensile strength, stiffness and creep, fatigue and impact resistance. DuPont is separately seeking to divest the Delrin business. Delrin generated net sales of approximately $550 million and operating EBITDA of approximately $180 million in 2021. DuPont is targeting a closing date for the sale of Delrin in the first quarter of 2023. The Auto Adhesives, Multibase and Tedlar product lines within the M&M segment are also not included in the intended divestiture either. Beginning in the first quarter of 2022, DuPont will report the retained M&M businesses for current and historical periods. In aggregate, the retained businesses generated net sales of approximately $950 million and operating EBITDA of approximately $120 million in 2021. “The acquisition of the M&M business is an important strategic step forward and establishes Celanese as the preeminent global specialty materials company,” says Lori Ryerkerk, chairman and chief executive officer. “This acquisition greatly enhances the EM (Engineered Materials) product portfolio [of Celanese] by adding new polymers, renowned brands, leading product technology and backward integration in critical polymers,” says Tom Kelly, senior vice president of Engineered Materials. He adds that Celanese will combine the products and technologies of the M&M brands “with the commercial excellence and customer engagement model of EM to accelerate growth in high-value applications including future mobility, connectivity and medical.” Within the first four years following the close, Celanese expects to achieve run-rate synergies of approximately $450 million from the complementary fit of the businesses. The acquisition is expected to be fully financed with committed debt financing at the time of closing. Significant expansion of free cash flow and swift deleveraging are expected to support a reduction of total debt to below 3 times EBITDA within two years of closing. “Robust and growing cash generation and a strong balance sheet enable us to fully finance this acquisition with committed debt financing while maintaining our investment grade credit profile,” says ScottRichardson, executive vice president and chief financial officer of Celanese. “M&M has historically been a strong generator of cash flow. We are confident in our ability to capture synergies that would allow us to double Celanese total free cash flow within the next five years.” This is the second major materials acquisition Celanese has announced since the end of 2021. On Dec. 1, the company said it had completed the acquisition of the Santoprene TPV (thermoplastic vulcanizate) Elastomers Business of ExxonMobil Corp. Celanese announced plans to acquire the Santoprene business in June 2021 for $1.15 billion. As part of the transaction, the company gained: » Santoprene, Dytron and Geolast trademarks and product portfolios. » Customer and supplier contracts and agreements. » Two world-scale production facilities, in Pensacola, Fla., and Newport, Wales, U.K., with over 190 kilotons of annual production capacity. » A comprehensive TPV intellectual property portfolio with associated technical and R&D assets. » Approximately 320 personnel including world-class manufacturing, technical and commercial organizations. SET POINT CELANESE LOOKS TO ADD DUPONT M&M GRADES Future mobility applications including autonomous urban air taxis are one target for Celanese’s increased portfolio of engineered resins. Courtesy of Joby Aviation www.plasticsengineering.org | APRIL 2022 | PLASTICS ENGINEERING | 5A waste recovery and recycling initiative founded in 2017 by polyolefin resin producer Borealis and Systemiq LLC, a specialist in building public-private business partnerships in land use, materials and energy, is marking a milestone. Project STOP (for STop Ocean Plastics) has achieved autonomy in its first city partnership, in this case with Muncar in Banyuwangi Regency of East Java, Indonesia. (A regency in Indonesia is an administrative division directly under a province.) STOP has met all financial, governance and technical targets and successfully demonstrated that a public-private partnership can work to reduce waste and plastics leakage into the environment and oceans. Project STOP's Muncar program is now managed solely by local government and the community. The Muncar program reaches 90,000 people with regular waste collection services and is recycling and composting waste in two materials processing facilities at a full system cost of $30/metric ton. The program has achieved a double-digit profit margin due to high community participation—more than 90 percent of households—and waste fee payments coupled with efficient operations. Based on this success, the Banyuwangi government has asked Project STOP to expand waste operations to the entire regency. A memorandum of understanding was signed last Dec. 21, formalizing this ambitious program of waste control. “We are pleased to be partnering with Project STOP through the Banyuwangi initiative, to align and develop cooperation in comprehensive waste management resulting in economic benefits, health for the community and safety for the environment,” says Ipuk Fiestiandani, BOREALIS INITIATIVE ACHIEVES WASTE REDUCTION IN INDONESIA SET POINT Teijin Ltd. has agreed to a business alliance with Fuji Design Co. Ltd., a Japanese manufacturer of recycled carbon fibers, to establish a structure for the production, supply and commercialization of carbon fiber- reinforced plastic (CFRP) products made from recycled carbon fibers using a low environmental impact process. Fuji Design’s proprietary precision pyrolysis technology produces high- quality carbon fibers from used CFRP by removing matrix resins. As a green technology, it produces some 90 percent fewer CO 2 emissions than carbon fibers produced with virgin raw materials. Fuji Design, which operates a commercial plant partially subsidized by Japan’s Ministry of the Environment, has been looking to expand the business by developing applications for its technology. Teijin, meanwhile, has been working to lower its groupwide environmental impact, including by reducing its fiscal 2018-level CO 2 emissions by 30 percent as of fiscal 2030 and to net-zero by fiscal 2050. Along with efforts to reduce in-house energy consumption, Teijin also has been developing technologies to recycle materials including carbon fibers. Through the new business alliance, Teijin intends to strengthen its contributions aimed at realizing a more sustainable world. Teijin also is working to achieve the United Nations’ sustainable development goals. Lightweight and high-strength CFRP, already used widely in aircraft, industrial and sports applications, is expected to attract increasing demand as a way of improving the fuel efficiency of vehicles and other products. The challenge, however, is to establish technologies for the reuse of carbon fibers, thereby helping to eliminate the material’s high-impact disposal in landfills or via incineration. Dignitaries at ceremony in Indonesia mark the successful public-private waste management partnership between Muncar and Project STOP. All photos courtesy of Project STOP TEIJIN WORKS WITH FUJI DESIGN IN RECYCLING CARBON FIBERS continued on p. 8 Borealis CEO Thomas Gangl addresses the ceremony remotely. Borealis joined with Systemiq LLC and others to develop and fund the Project STOP initiative. 6 | PLASTICS ENGINEERING | APRIL 2022 | www.plasticsengineering.orgAUTO DIVISION SEEKS AWARD CANDIDATES SPE’s Automotive Division has issued a call for nominations for its 51st annual Automotive Innovation Awards Gala, the oldest and largest such recognition event (established in 1970) in the U.S. This year’s Awards Gala will be Nov. 2, at the Burton Manor in Livonia, Mich. Winning part nominations will be accepted in 11 categories, and the teams that developed them will be honored with a “Most Innovative Use of Plastics” award. This year’s program includes a new category, “EV and AV Systems,” to recognize innovative polymer components for electric and autonomous vehicles. Additional categories are additive manufacturing; aftermarket and limited edition/specialty vehicles; body exterior; body interior; chassis/hardware; environmental; materials; powertrain; process/ assembly/enabling technologies; and safety. A Grand Award will be presented to the winning team from each category award winner. An application that has been in continuous use for 15 years or more and has made a significant and lasting contribution to the application of plastics in automotive vehicles (nominations due May 31) will be honored with a “Hall of Fame” award. Additional criteria for the HOF award are that the nomination be: game changing; successful worldwide; innovative in materials, process and application; and still in use. Nominations must be submitted online via: https://speautomotive.com/wp-content/ uploads/2022/02/2022-SPE-Innovation-Awards- Program-Part-Nomination-Form-V1.pdf “Plastics have always enabled innovative advancements in automotive vehicle design, manufacturing and lightweighting,” says Jeffrey Helms, global automotive director, Celanese Corp., who returns as the 2022 Automotive Innovation Awards chair. “Now plastics are enabling an evolution in mobility including electric and autonomous vehicles and other applications,” he adds. “We’re looking forward to recognizing the evolving automotive innovations made possible with plastics and returning to full attendance, 800 attendees approximately, at the event.” There is no cost to nominate parts, however, nominations that are accepted need to be presented (in person or via webinar) by their nominating teams to the Automotive Division’s Board of Directors during the first round of judging, Sept. 15 to 16, at Celanese Corp., Auburn Hills, Mich. Finalists from that round advance to a second presentation before a panel of judges made up of media, retired chief engineers and other experts on Sept. 23, also at Celanese Corp. Winners of each category, the Grand Award, Hall of Fame and Lifetime Achievement winner will be honored during the gala on Nov. 2. Funds raised from the event support SPE educational programs including technical seminars and conferences. For more information, see speautomotive.com. Arkema announced on Feb. 28 that it has acquired Ashland’s Performance Adhesives business. This marks a major step in Arkema’s strengthening of its Adhesive Solutions segment and aligns with the group’s strategy to become a pure specialty materials player by 2024. The company also reports plans to buy Shanghai Zhiguan Polymer Materials of China, which specializes in reactive hot-melt adhesives for the consumer electronics market. With a range of key technologies and widely known brands, Ashland Performance Adhesives is a major player in pressure-sensitive adhesives especially decorative, protection and signage films for automotive and buildings. It also holds leading positions in structural adhesives and offers a range of products for flexible packaging. Ashland’s adhesives business employs approximately 330 people and operates six production plants, mainly in North America. Sales of around $360 million were posted in 2021, along with an EBITDA margin above 25 percent. The business complements the commercial, technological and geographic operations of Bostik, an Arkema company, and will allow it to expand its offerings and position itself as a major player in high-performance industrial adhesives. This operation is based on a $1.65 billion enterprise value—8.7 times the 2026 EBITDA after taking into account the expected growth in coming years and the synergies evaluated at 12.5 percent of sales. A key milestone in its long-term growth ambition, this acquisition allows Bostik to aim for an EBITDA margin above 17 percent by 2024. Meanwhile, Arkema looks to expand its product offerings in engineering adhesives with the proposal to buy Shanghai Zhiguan Polymer Materials (PMP). This is in line with Bostik’s strategy to build a strong position in the attractive engineering adhesives market and to accelerate its development work in the fast- growing electronics market, especially in Asia. PMP specializes in reactive hot-melt polyurethane adhesives and reportedly generates more than €1 million ($1.09 million) in annual sales. These adhesives are mainly dedicated to consumer electronics and are used in the bonding of mobile phones, tablets, laptops and connected objects. With its expertise in formulating innovative solutions and recognized know-how in processes and R&D, PMP has developed solid positions in the demanding and high-added-value consumer electronics market. With this acquisition, Bostik will strengthen its portfolio of technologies in engineering adhesives, where the group already has robust formulation experience in cyanoacrylate, MMA and UV technologies, developed through the acquisitions of Afinitica, Nitta and AEC Polymers. This bolt-on acquisition offers many development synergies and will contribute to substantially accelerating Bostik’s expansion in the fast- growing consumer electronics market in Asia. The acquisition is scheduled to close early this year. ARKEMA PURCHASES ASHLAND ADHESIVES, EYES CHINA BUY Arkema’s purchase of Ashland Adhesives and plans to buy PMP in China will strengthen the product capabilities of its Bostik business. Courtesy of Arkema www.plasticsengineering.org | APRIL 2022 | PLASTICS ENGINEERING | 7Next >