DSM Engineering Plastics extends Diablo family for further
weight reduction in automotive under-the-bonnet applications

Following the successful introduction in 2007 of Stanyl® Diablo OCD2100, a high performance grade of Stanyl for under-the-bonnet (UTB) applications, DSM has introduced new Diablo high heat resins: Stanyl Diablo® OCD2300 and Akulon Diablo® injection and blow molding grades. These products are a direct response to some of the main trends in the automotive industry, including weight reduction. The new materials also facilitate system cost optimizations and productivity gains, long term sustainability and reduced environmental impact.

Stanyl Diablo OCD2300
Stanyl Diablo OCD2300 is a unique and inovative high heat PA46 material, developed specifically to meet the need for long term temperature resistance at elevated temperatures of up to 230°C. Stanyl Diablo OCD2300 joins the family of Stanyl Diablo grades that offer a key improvement in long term thermal stability. This technology, developed by DSM, extends the functional life of components well beyond the limits of other high temperature polyamides. By limiting thermal oxidative breakdown, Stanyl Diablo withstands more than 3,000 hours at aging temperatures of 230°C before its tensile strength is less than half of its initial value and short term temperatures of 260°C.

Requirements for Under the Bonnet (UTB) applications are changing constantly. Environmental requirements, EURO 5 and 6 legislation and the call for reduced fuel consumption have resulted in significant changes, e.g. the use of smaller engines with higher turbo pressures and EGR (Exhaust Gas Recirculation). As a consequence, automobile UTB components such as air ducts, air intake manifolds and charge air cooler end-caps are exposed to continuously rising operating temperatures. With increasingly critical temperature and tougher life time requirements, long term service life of components made from current thermoplastics can be at risk. Stanyl Diablo OCD2300 is currently the only high performance PA that can withstand these temperatures whilst offering better mechanical properties than other high performance polymers for these applications.

Stanyl Diablo OCD2300 was tested, validated and released by a German OEM for use in application up to 230°C CUT, where key applications include resonators, hot charge airducts and charge air cooler end-caps.

Christian Kilgus, Business Development Manager for DSM Engineering Plastics says: "Stanyl Diablo OCD2100 and OCD2300 outperform current high heat resins on high temperature stability, but also on weldability, weld strength and especially the weld's long term heat stability. Part design and function can be reached more easily and, more importantly, UTB part reliability can be guaranteed for the lifetime required." Stanyl materials are easy to process. During injection molding, tool temperatures of 80°C and melt temperatures around 300°C are normally used. Short cycle times can be achieved to reduce system costs.

Akulon Diablo
To complete its Diablo portfolio, DSM has also introduced Akulon Diablo, a high heat PA material that bridges the gap between Akulon PA6 and PA46 Stanyl Diablo. This high performance grade of Akulon was developed specifically for use in air/fuel systems, which may be subject to temperatures of up to 210°C continuous use, and even 230°C over shorter periods.

Kurt Maschke, Global Segment Manager, Turbo Systems for DSM Engineering Plastics, says: "The addition of both Stanyl Diablo OCD2300 and Akulon Diablo significantly increases metal replacement options and meets the trend for existing plastic solutions which needs high temperature materials for new applications. Our Diablo portfolio now allows us to meet all the needs of the supply chain for Air/Fuel and Turbo applications. In addition, we also offer our standard Akulon PA6 solutions, Akulon Flex PA6 specifically tailored for flexible ducts and Arnitel TPE for clean air ducts. So we can now offer single-source solutions for all ducts, end caps and resonators. And we have extensive application knowledge to support customers with CAE, design and design optimization so they can meet OEM requirements."

DSM has an established reputation for delivering eco-efficient automotive solutions, offering CO2/emission/fuel consumption reduction via metal-to-plastic conversion in applications such as air inlet manifolds and air ducts.

For further information, view website: www.dsm.com or e-mail: Mirelle.Kreeft-van-der@dsm.com 

A major move in sustainable solutions for the Automotive industry

DSM Engineering Plastics has commercialized  Akulon® RC, a portfolio of Recycle Content grades of PA6 for use in Automotive under-the-bonnet applications.

The first Akulon RC grades under development are a 30% and a 35% glass filled grade with 50% recycle content. These grades deliver a 35% reduction in carbon footprint versus their counterparts made from 100% virgin material. The development of Akulon RC aligns with the automotive industry's drive for ecologically sound and sustainable solutions.

Development partner, Mark IV Systèmes Moteurs, a leading Tier 1 automotive, supplier, is evaluating these grades for usage in under-the-bonnet applications. Raw Materials Buyer Valérie Tiddia says: "At Mark IV we are currently evaluating DSM's new Akulon RC grades for our applications. We appreciate DSM's continuous efforts to work with us on more sustainable solutions. DSM is clearly leading in their environmental approach to customers."

PA6 for use in Automotive under-the-bonnet applications.

Speaking for DSM Engineering Plastics, Keith Siopes, Global Segment Manager says: "DSM Engineering Plastics is committed to expanding its environmentally aware portfolio. By focusing on eco-efficiency and sustainability, DSM drives its innovation cycle to ensure that key new product innovation and/or development meets the evolving needs of customers, whilst ensuring that products meet key sustainability objectives."

Regarding the positioning, Richard Pieters, Global Business Director Akulon/Novamid said that DSM aims "to deliver a material at quality standards that are as close as possible to virgin materials. We see this as a clear need from the industry and a change from the past, when recycle grades were often positioned as lower quality and lower cost materials."

Furthermore, Mr. Pieters mentions that today, the industry supply chain is at a level where some premium is required for high quality materials to make the RC grades feasible. The two materials, that are being launched now, have properties that are similar to those of typical standard grades. The premium pricing reflects the cost position for such grades, which Richard Pieters sees as a key investment for the future. He expects that by working with our customers and suppliers further efficiency improvements can be made.

As a strong partner to the automotive industry, DSM Engineering Plastics has introduced a range of both new materials and specific grades of existing materials, designed to deliver the required performance, whilst meeting the overall industry trends for lighter, more effective and greener solutions. Engineering plastics play an important role in this segment as they offer significant opportunities for system cost reduction, improved reliability and weight reduction for fuel economy.

As major supplier of many polymers for use at higher temperatures, DSM Engineering Plastics has a long track record in this industry, and is able to match the highest quality and reliability demands.

On part component level, DSM contributes to the industry drivers by offering innovative solutions for parts integration (e.g. Laser Direct Structuring Technology), reduced wall thicknesses (e.g Stanyl® High Flow PA46), cycle time reductions (e.g. Akulon® Ultraflow® PA6) and base polymer cost-down alternatives like PPA replacement by Arnite® PET. Most recently, DSM Engineering Plastics has further expanded its Green Portfolio with the introduction of EcoPaXX™, a bio-based, high performance engineering plastic based on polyamide (PA) 410. The new material has a zero carbon footprint from cradle to gate.

Akulon®, Arnite®, Arnitel®, EcoPaxx™^, Stanyl®, Stanyl® ForTii™, Novamid®  and Yparex® are registered trademarks of Royal DSM N.V.

DSM Engineering Plastics in profile
DSM Engineering Plastics is one of the world's leading suppliers of quality engineering thermoplastics providing customer value through sustainable solutions that reflect the DSM People, Planet and Profit strategy. DSM Engineering Plastics delivers innovative opportunities for customers who design or produce electrical applications, electronic equipment, cars, barrier packaging films as well as many mechanical and extrusion applications. These markets are served with a broad portfolio of high performance materials including Akulon® and Novamid® 6 and 66 polyamides, Arnitel® TPC, Arnite® PBT and PET polyesters, Yparex® extrudable adhesive resins, and Stanyl® high heat 46 polyamides. Most recently, DSM Engineering Plastics has introduced the first new polymer of the 21st century: Stanyl® ForTii™ and has expanded her portfolio with two bio-based, high performance engineering plastics, EcoPaXX™ and Arnitel® Eco. DSM Engineering Plastics had sales in 2009 of EUR 648 million and employs some 1600 people worldwide.

For further information, view website: www.dsmep.com or e-mail: Mirelle.Kreeft-van-der@dsm.com

DSM - the Life Sciences and Materials Sciences Company in profile
Royal DSM N.V. creates solutions that nourish, protect and improve performance. Its end markets include human and animal nutrition and health, personal care, pharmaceuticals, automotive, coatings and paint, electrical and electronics, life protection and housing. DSM manages its business with a focus on the triple bottom line of economic performance, environmental quality and social responsibility, which it pursues simultaneously and in parallel. DSM has annual net sales of about € 8 billion and employs some 22,700 people worldwide. The company is headquartered in the Netherlands, with locations on five continents. DSM is listed on Euronext Amsterdam.

For further information, view website: www.dsm.com or e-mail: Mirelle.Kreeft-van-der@dsm.com