Hanser Publications

This book introduces the reader to the concepts of Scientific Molding and Scientific Processing for Injection Molding, geared towards developing a robust, repeatable, and reproducible (3Rs) molding process. It explains the underlying principles of polymer science: the properties that are important to injection molding and their application to molding process development. The effects of polymer morphology, thermal transitions, drying, and rheology on the injection molding process are explained in detail. The development of a robust molding process is broken down into two sections: the Cosmetic Process and the Dimensional Process. Scientific molding procedures to establish a 3R process are provided.

The concept of Design of Experiments (DOEs) for and in injection molding is explained, giving insight into the cosmetic and dimensional process windows. A plan to release qualified molds into production with troubleshooting tips is also provided. Topics that impact a robust process such as the use of regrind, mold cooling, and venting are also described.

Readers will be able to utilize the knowledge gained from the book in their day-to-day operations immediately.

This third edition includes a completely new subchapter covering melt preparation, as well as much additional, revised, and updated material throughout the book. The revisions are deeply informed by the author’s long and ongoing experience as a trainer, resulting in improved ways to conduct a study, perform experiments, or explain a concept.

"Practical Rubber Rheology and Dynamic Properties" provides a unique overview of rubber rheology from a practical perspective. Written by expert authors with many years of experience in the rubber industry, it focuses on applications of rubber rheology testing to solving industrial problems, rubber compound development, predicting changes in processability in the plant, quality assurance, and research and development. However, basic principles are also covered.

Aimed at practitioners in the rubber industry, this book promotes understanding of the material to support efficient production of the high-quality rubber products demanded in today's market. It is also suitable for students and their instructors on rubber courses taught in universities.

This book closes a fundamental gap in the field of mold design. The use of injection molding coatings extends the technical possibilities in the field of plastics production, such as the achievable flow path length, the use of abrasive and corrosive plastics, and the achievable tool life. This possibility of functionalization has so far been somewhat neglected due to a lack of available information on the state of the art and possible applications. This book therefore brings together the available knowledge of various experts in a way that is understandable for engineering students and tool and mold makers.

The book covers the individual steps of coating technologies. First, the steel materials that are mainly used for the construction of tools in plastics processing are presented. This is followed by the current status of the various coating technologies. The existing coating technologies are presented and characterized with regard to their suitability for use in tool technology in the plastics processing environment. The third part deals with the characterization of the deposited coatings. On the one hand, the focus is on the characterization of the actual coating, such as chemical composition, coating layout and coating thickness. Secondly, the measurement methods for determining the functional properties of the deposited coatings, such as hardness and wear resistance, thermal properties, thermal conductivity and tribological properties, are presented. Finally, the use of appropriate coatings is illustrated using practical examples from plastics technology.

Reliable and meaningful methods of polymer testing are necessary to support the plastics industry, being essential for understanding material and part properties, and evaluating materials for a part design, with important implications for product safety as well as operating conditions and lifetime. This book covers all the most important testing methods, from long-established basic techniques to recent developments, including the latest polymer testing standards.

By means of examples for the optimization of materials as well as for the evaluation of part properties, an insight into modern polymer testing and its interdisciplinary character is provided.

Included in this third edition is an all-new chapter on the testing of polymer films; additionally, many small updates and corrections have been made throughout the book.

This book provides an insight into the thermal analysis of thermosets and presents a large number of practical examples. The main techniques used for sample measurement are differential scanning calorimetry (DSC), thermogravimetric analysis (TGA), thermomechanical analysis (TMA) and dynamic mechanical analysis (DMA). In special cases, combined on-line techniques such as SDTA, visual monitoring, and evolved gas analysis (EGA) have also been employed.The more modern method of chip calorimetry by Flash DSC is also demonstrated.

Thermosets are polymers that have undergone a permanent chemical reaction known as curing or crosslinking to form a giant crosslinked network structure. They are rigid, typically insoluble materials of high mechanical strength and high temperature stability, with a broad range of applications that benefit from these properties. In contrast to thermoplastics, thermosets cannot be remelted or remolded into another shape after curing.

This is the first book focusing on the subject of injection mold sampling.

A standardized, structured, and systematic procedure for sampling injection molds is essential for a successful injection molding process. This work provides everything you need to know, guiding you from the placing of an order for a mold sampling to the transfer to series production. With the complete sequence of the individual sampling steps, lots of background information, notes, practical examples and tips, and a colorful, well-illustrated design, the sampling procedure is conveyed in a reader-friendly way.

The main topics covered are the structured procedure of a mold sampling, taking into account energy efficiency, documentation, and communication; a mold sampling analysis; optimum machine setup using strategic procedures and methods on the injection molding machine; process optimization with subsequent investigation of process capability; and a Run@Rate process.

This book is ideally suited for practical users working at the injection molding machine as well as serving as a textbook at vocational schools, further education institutions, and universities.

In plastics technology, a wide variety of computer programs are used for the design and optimization of molded plastic parts and for mold design. These programs calculate the filling process, the holding pressure phase, and the cooling phase of the molded part in the mold. The results include, for example, pressures, temperatures, weld/knit lines, and voids. The shrinkage and warpage behavior of the molded part can also be predicted. Understanding and interpreting these simulation results is not trivial, although they are colorful representations with numerical values. Regardless of whether one has many years of experience as a designer, a mold maker, or an injection molder, or whether one is in training or studying, simulation is becoming increasingly important. For this reason, experts who know how to use these programs correctly are increasingly sought after in the market.

This book is intended to expand readers’ specialist knowledge in the field of simulation, thereby increasing their ability to recognize and avoid molding errors at an early stage. Readers will also learn to draw the right conclusions from the simulation results and develop their own solutions.

This book creates a new perspective on the design of plastic parts. In many books there is a strong focus on the material, the material properties, and the calculation or dimensioning. What is often not taken into account is that very many plastic components only have to withstand low loads; in very many applications, the focus is on the actual design. This requires a good understanding of the injection molds that must be built to produce the plastic components. Depending on the design of the injection molded component, these molds become more complex and more prone to failure during production.

The complex process of manufacturing a plastic part becomes holistically understandable as a link is created between the molder, the mold maker, and the part designer. The focus is on injection molds and therefore on thermoplastics. 

Everything that is necessary for the design and manufacture of an injection molded component is presented in a simple, extremely practical manner and limited to the essentials. Many descriptive pictures as well as examples based on the demonstration component "Polyman" facilitate the understanding enormously.

Single-screw or twin-screw extruder? When the need to produce a homogeneous polymer melt occurs in the industrial environment, both product attributes and equipment cost must be evaluated. For many applications both the single and twin-screw extruder will produce the desired homogeneous melt needed to form the product through an extrusion die. Some applications such as dispersive mixing of solids in a polymer matrix are best accomplished in a twin-screw extruder. On the other hand, applications involving chemical reactions, color concentrate distributive mixing, and in line polymer-polymer distributive mixing can be accomplished with either device.

However, for the same production rate, twin-screw extruders are generally more expensive than single-screw extruders with a diameter less than 200 mm. Therefore, a thorough understanding is needed for the concepts of solids conveying, melting, and mixing for the two types of extruders to make appropriate process acquisition decisions. This book covers engineering and technology concepts that should aid the practitioner in comparing these two types of extrusion equipment relative to process requirements.

PVC differs in its stabilization compared to other commodity plastics. Various metal compounds are suitable for the stabilization of PVC: lead, tin, calcium, magnesium, zinc, rare earths, and also almost-metal-free systems. These differences are described in the introductory part of this book, with their advantages, possibilities, and problems, from the perspective of the chemist but made understandable for salespeople and technicians.

Numerous tables and figures are included, providing structures and physico-chemical data. A special section for beginners is dedicated to guiding formulations and test methods. A relatively short section deals with development trends in Europe. Sustainability is a major theme, and it is demonstrated that PVC has a strong potential to develop into a fully sustainable material.

Another section deals with the everyday problems in the processing of PVC, such as the formation of specks, photo-effects, and plate-out. Plate-out is a common problem in the processing of PVC but only relatively few publications cover it. The causes, influencing factors, and mechanisms are still poorly understood. This section, unique in the literature, provides assistance in the selection and dosage of raw materials to PVC processor, based on the influencing factors during processing.

More than half of all injection molded plastic parts can be produced more cost-effectively and with better tolerances using foam injection molding compared to traditional compact injection molding.

For the part designer, the focus is on the functionality of the molded part, not on the plastic-compatible design, which is precisely what compact injection molding requires. This book describes the necessary fundamentals of physical foam injection molding, clearly illustrated by means of detailed, industrially proven examples to show the technology’s potential. Machine and mold technology are also explained in detail, and polymers suitable for the process are discussed. The focus is always on the question of whether the potential of physical foam injection molding has already been exhausted or whether it is emerging as a second standard process alongside compact injection molding.

The experienced authors make it possible to look beyond the end of one’s nose. The reader can see which plastic parts can be converted from compact to foam injection molding, and is encouraged to rethink the part design. With this book, specialists are able to examine an application for their own company and analyze it with regard to its economic implementation. However, the book also shows the clear limitations of this technology.

Plastics extrusion is one of the most important industrial processes worldwide. Over past decades, understanding of extrusion technologies has advanced by the global research efforts, but, due to the fact that the metal barrel hinders direct visualizations to be made by the naked eye, the “true” dynamic processing characteristics of extrusion processes remain unclear. Analytical attempts have thus been carried out either by indirect, static empirical approaches or theoretical mathematical analyses. None of them offer a realistic depiction of what takes place inside the barrel during an extrusion process. As such, the barrel can be considered as a “black-box”.

This book reveals the “true” dynamic extrusion processing characteristics, accumulated from years of research experience based on the novel visualization technique developed by Professor Zhu of the Beijing University of Chemical Technology. The qualitative discussions within provide not only insight into the scientific aspects of the subject, but also information of practical significance for those in the industry who need to perform process and hardware designs and optimizations.

Included are conventional mathematical representations of the single- and twin-screw extrusion technologies. This provides a comprehensive foundation for undergraduate courses in, e.g., plastics processing engineering. Other topics covered are specifically selected to provide a comprehensive technical and market-trend background to readers at all levels. The current status and future potential of sustainable and biodegradable polymers are also emphasized.

This book provides a structured methodology and scientific basis for engineering injection molds. The topics are presented in a top-down manner, beginning with introductory definitions and the big picture before proceeding to layout and detailed design of molds. The book provides very pragmatic analysis with worked examples that can be readily adapted to real-world product design applications. It will help students and practitioners to understand the inner workings of injection molds and encourage them to think outside the box in developing innovative and highly functional mold designs.

Injection molding continues to be a core plastics manufacturing process, but now has competition from additive manufacturing for certain applications, and environmental concerns are in the spotlight. The 3rd edition addresses these issues, in particular with a new chapter on mold manufacturing strategy to provide an overview of the most common machining and additive manufacturing processes with cost and time models to guide the manufacturing strategy; updated and simplified break-even cost models to assist in the mold layout design (number of cavities and type of mold) vs. 3D printing; a new section on environmental concerns include mold design for recycled resins; and updates to the International Tolerance standards, and the new technology and simulation sections.

This book offers an up-to-date, platform-independent introduction to injection molding simulation, which plays a very important role in the design of molds and molded parts as well as process development and optimization. The content is structured and conveyed within an engineering framework. Complicated mathematical derivations are avoided as far as possible.

The necessary environment of the injection molding simulation is illuminated alongside, so that the creation of a suitable simulation model, the knowledge of the model-specific limits, and the interpretation of the results are possible. Guidance is also provided regarding the interpretation of results so that they can be better evaluated quantitatively.

The book is designed as a textbook and thus is suitable to accompany courses covering injection molding simulation. The content is largely independent of any particular software package; however, introductory practice examples for Autodesk Moldflow Insight and Moldex3D are included as step-by-step instructions.

An injection mold is the heart of any plastics molding workcell. Understanding the principles of an injection mold design and its importance to a successful plastic part is fundamental to the success of the product. This book helps guide the designer, engineer, project manager, and production manager in making sure that the injection mold to be designed will work as intended.

This book will take the reader through the process of conceptualizing and designing an injection mold that will produce the desired plastic part. Since it all starts with the plastic part, the book will first focus on key features and details of the plastic part which are necessary for good mold design. The design of the main components of an injection mold will be discussed and good design practices will be shared. Finally the process of testing and gaining customer acceptance of the mold for production will be detailed. A comprehensive appendix and detailed drawings will provide the required detail for completing a mold design.

Plastics production comprises the main process steps "synthesis (reaction)", "preparation/compounding" at the raw material manufacturer and compounder, and "processing" (shaping into semi-finished or finished products). 

In this handbook, the central middle step, preparation and compounding, is discussed. 

The preparation tasks include the removal of components, the incorporation of additives, and the change of particle size. Compounding is the incorporation of additives into a polymer or plastic.

The process engineering fundamentals and the specific equipment and machines used are described. The specialist authors impart their knowledge from the fields of research, polymer production, and equipment/machine production with applications in plastics technology.

This book provides a user-friendly guide to the implementation of Scientific Injection Molding, a proven methodology to ensure robust and reliable mass production of plastic parts.

Readers will gain a clear understanding of their machines and especially their condition and behavior through on-site tests, of the polymers that will be processed, and of the necessary equipment for the application of this methodology in production plants. All the tests and tools that Scientific Injection Molding proposes are explained in detail so they can be readily applied.

Performing the validation of a mold or process correctly, establishing the limits of the process window or molding area through the design of experiments, and transferring processes from one machine to another, assuring their repeatability, are skills presented as fundamental tools of the modern injection molder.

Content:

1 Scientific Injection Molding – Advanced Steps toward Implementation

2 Knowing Our Machines

3 Knowing the Reliability and Performance of Injection Molding Machines

4 Understanding Plastic Materials

5 Required Information for Defining the Process

6 Necessary Equipment for Advanced Injection Molding

7 Tools for Scientific Injection Molding

8 Top Ten Key Parameters in the Definition of the Injection Molding Process

9 Process Portability, DOE (Design of Experiments), Mold Qualification and Process Validation

10 Melt Preparation

11 Process Variability, Self-Adaptation, and Corrections

12 Data To Be Collected for the Calculation and Performance of a Scientific Injection Molding Process Methodology

13 Reference Data Tables

In this single handbook, the editors aim to give a diverse audience of readers a complete account of all aspects of PVC - from monomer manufacture to polymerization; the gamut of such additives as stabilizers, lubricants, plasticizers, impact modifiers, fillers and reinforcing agents; blends and alloys; compounding and processing; characterization; combustion resistance and weatherability; product engineering design; applications; environmental and safety; and finally the PVC industry dynamics.

The handbook contains both practical formulation information as well as a mechanistic view of why PVC behaves as it does.

The 2nd edition is comprehensively updated throughout, with all-new chapters on PVC recycling, sustainability, and decarbonization.

This practical book is aimed at companies that want to integrate thermoplastic-based 3D printing into their manufacturing processes and need to build up know-how in the selection of suitable plastics. It presents the thermoplastics relevant for additive manufacturing and their process-specific features as well as a wide range of applications. 

The book covers the following topics:

- Functional principle and build-up strategy of thermoplastic-based additive manufacturing processes, in particular fused layer modeling (FLM) and selective laser sintering (SLS)

- Classification and formulation of thermoplastic polymer materials

- Mechanical, thermal, and chemical properties of thermoplastics that must be considered for use in 3D printing

- Material, design, and process specifics of thermoplastics for successful processing 

- Support materials, multi-material processes, fiber-reinforced components

- Bio-based or biodegradable thermoplastics, recycling of thermoplastics

- Recommendations for occupational safety, environmental protection, and product safety

Numerous practical examples showing recommended combinations of plastics and additive manufacturing methods make this book an indispensable guide for all those who use 3D printing and need sound knowledge of materials selection for this purpose.

Rheology describes the flow and deformation of materials. Plastics in particular are characterized by their special flow behavior. The viscosity of plastics is not only dependent on temperature and pressure, but also on the flow velocity. This flow behavior, known as structural viscosity, is clearly described in this textbook. In addition, due to their molecular chain structure, plastics have visco-elastic properties that affect the flow processes. Understanding of all of these aspects is highly important for developing and maintaining effective, reliable, efficient, and economical plastics processing procedures to produce high-quality products.

In this book, firstly different measurement methods that are suitable for measuring these properties are presented and their measurement results are also discussed. The laws that describe the special flow behavior of plastics are then explained. After deriving the flow equations, these are then used to calculate flow processes for the extrusion and injection molding processing methods.

In addition to the general basics, there are practical calculation examples for each chapter. The reader thus has the opportunity to study the basics and at the same time apply the knowledge gained.

Many full-color explanatory figures are provided, as are QR codes link to videos that explain the content even more clearly. It is therefore ideal for a wide range of people working with plastics in industry, such as injection molders, mold makers, and simulation experts.

Calendering is an industrial process in which materials, especially plastics or rubber, are processed into thin layers or films by rolling. Plastic films play a major role as homopolymer films, as multilayer films, or as mixed films in the packaging industry as well as in technical and agricultural applications and are an integral part of our current value chain.

This book present innovations and practical experiences in plastics processing using the example of the calendering process, which can also be used in other plastics technologies, such as extrusion, injection molding or coating. All calculation methods presented are applicable or can be transferred to other plastic technologies.

Important topics covered include defect types, detection, and countermeasures; rheology and its application to optimized products; mathematical methods and software applications for film production; measurement technology; further film processing technologies; digitalization and Industry 4.0; recycling technologies; and future outlook. It is written by specialists in plastics technology, especially calendering technology, and is based on around 20 years of professional experience and scientific collaborations with international universities and research institutions.

"Basics of Engineering and Technology with Natural Rubber" offers a comprehensive overview of natural rubber, from its extraction and processing to its wide-ranging applications in modern engineering. The book has been prepared to link the theoretical principles and the practical procedures and therefore will be useful to professionals, students, and researchers in the field of rubber technology.

The content has been divided into five major chapters, covering latex processing, viscoelasticity, filler dispersion, and advanced rubber applications like elastomer bearings and flex seals of rockets. The book explores latex carbon black masterbatch production and its economic and processing advantages in rubber products manufacture. It also covers the mathematical derivation for applications like shock and vibration isolation. This work aims to empower readers with a deep understanding of natural rubber’s behavior and potential in engineering, while also addressing the latest industry trends and technological advancements. This book will be valuable to individuals at any level, whether they are beginners or experienced practitioners, serving as a step-by-step guide to mastering the art of rubber engineering.

This is a practical guide to injection molding based on sound engineering fundamentals. It is an ideal course book for mechanical engineers with limited plastic material and injection molding experience, but is also well applicable to self-study or reference. 

It starts with an overview of plastic material fundamentals. Each section includes material considerations associated with the injection molding process. For example, the molecular weight section shows that use of lower molecular weight plastics are commonly used for the injection molding to minimize orientation, reduce fill time, improve knit line strength. Then, the basics of the injection molding machine, tooling, auxiliary equipment and molding process are introduced. The machine components and component selection for a given application are next considered in more detail.

The process/procedure for establishing optimum process conditions for a “new” mold and material (not run previously by the reader) are next described. Finally, a range of other more specialized injection molding processes that are still of practical importance are covered.

From a leading author and educator in the area of injection molding, this book gives engineers and process technicians the knowledge and confidence they need to produce high-quality parts reliably and efficiently.

In this book, the concept of the circular economy is examined from the point of view of textile-to-textile recycling, with strong consideration of the latest political objectives. Readers will gain an understanding of the basic principles and implementation possibilities, and discover which textile-to-textile recycling solutions have already been implemented in industry and which solutions are promising for the future. Thus, this work is the starting point for readers who want or need to contribute to saving our environment through concrete actions.

The process chain of textile production and recycling is first presented. Based on this, concepts for textile-to-textile recycling are explained and deepened using industry examples. These concepts are further developed and finally implemented as strategies for a transformation into a circular economy.

Global fiber production is growing continuously and with it its negative impact on our environment. Although the share of recycled fibers is also increasing, it is mainly linear bottle recycling; the share of pre- or post-consumer textile recycling remains less than 1% of the fiber market. With and international authorship from both industry and academia, and reader-friendly presentation including many illustrations and in-depth practical examples, this book identifies possible solutions to these challenges.

The use of polymers as barrier materials is one of their widest and most important fields of application (e.g., fuel tanks and hoses, water circuits, food packaging, raincoats and umbrellas, electrical insulation, drug delivery), and their performance also has environmental implications. In consequence, the problems of sorption and diffusion in polymers are important and ubiquitous in everyday life as well as in a number of high-tech applications. This book covers the science involved in these topics, which are often studied only from an engineering point of view.

“Sorption and Diffusion in Polymers” presents the different models generally used to describe sorption and/or transport properties and also a new physical model for them. It provides an overview of relevant applications, related polymer families, and the strategies used to control or reduce sorption and diffusion in polymer materials. 

This edited work details the latest research on the topic, with chapters written by experts in the field.

This hands-on reference book covers the development and design of electrical power systems for lunar and space exploration. It focuses on the equipment of manned space flight missions to the moon and the equipment of the lunar base itself, using the example of the Artemis program, the current moon exploration program led by NASA. The practical guide is mainly aimed at space engineers, but is also suitable for students of aerospace engineering.

The book starts off with an introduction to lunar exploration and the Artemis Program - from general mission topologies over planned missions within the Artemis-Program to scheduled technical systems. It then explains spacecraft electrical power systems, such as power distribution systems, energy generation, storage systems and grounding concepts, and moves on to an overview of space power technologies, particularly with regard to a lunar base. These lunar electrical power systems consist of subsystems, such as photovoltaics, nuclear generators, battery storages, regenerative fuel cells, power regulators and converters, power switches and DC systems. The author provides important technical background information for these subsystems. Furthermore, he shows methods of designing electrical power systems and subsystems for lunar applications. In addition, he includes an analysis of the electrical power system of the International Space Station (ISS) as a design reference, as well as an overview of different studies focusing on lunar base electrical power systems. To wrap it up, he presents an overview of technical standards and requirements as well as important documents for space systems.

What Matters When Implementing ISA 6 and TISAX®!

This hands-on guide explains what is essential for implementing ISA 6 and TISAX®, walks you through the requirements step by step, and provides concrete support in meeting them. Numerous examples and practical implementation tips make it easier to transfer the concepts into practice.

TISAX® and the associated ISA 6 catalog have become well-established in recent years and are now widely used across industries by companies collaborating with the automotive sector. As a result, a valid TISAX® label is increasingly becoming a prerequisite for securing contracts in this industry.

This book shows the true and often-underestimated market potential of plastics recycling, with analysis from economic, ecological, and technical perspectives. It is aimed at both technical and non-technical readers, including decision makers in material suppliers, plastic product manufacturers, governmental agencies, educators, and anyone with a general interest in plastics recycling.

An overview of waste handling systems with a focus on the U.S. market is provided. Different methods of waste handling are compared from both economic and ecological perspectives. Since plastic waste recycling is essential from an ecological point of view, common strategies and new approaches to both increase the recycling rate and improve recycling economically and technically are presented. This includes processing and material properties of recycled plastics. Finally, a worldwide outlook of plastic recycling is provided with analysis of additional worldwide markets, encompassing highly developed, fast-developing, and less developed countries.

This extensively revised and expanded 3rd edition includes an overview of new recycling methodologies, as well as the influence of digitalization. It contains new chapters providing, respectively, characterization methods for plastic waste, and policy overview and its influence on the economics of recycling. Economic and environmental analysis are more general, comparing the economic benefits of the different recycling methods based on, e.g., volume, contamination, etc. Finally, extension of the global recycling chains is discussed.

The spreadsheets used in the economic analyses are also provided as a bonus for the reader.

The transportation landscape is undergoing a rapid transformation, driven by innovative business models and cutting-edge technologies like automated driving and new propulsion concepts. This book explores the critical intersection of legal, social, and safety requirements that are shaping the future of mobility, with a focus on automated driving. It addresses the fundamental question of how societal expectations influence the development of these technologies and provides practical guidance for engineers and managers on incorporating collective needs into product development while ensuring robust safety.

AI-driven mobility solutions, especially safety-critical and automated driving functions, introduce new risks and require new approaches to security and safety. Packed with best practices and real-world use cases, this book serves as an invaluable resource for manufacturers, producers, operators, and service providers navigating the landscape of vehicle safety and automated driving.

This book provides the background needed to understand not only the wide field of polymer processing, but also the emerging technologies associated with the plastics industry in the 21st century. It combines practical engineering concepts with modeling of realistic polymer processes. Divided into three sections, it provides the reader with a solid knowledge base in polymer materials, polymer processing, and modeling.

"Understanding Polymer Processing" is intended for the person who is entering the plastics manufacturing industry and as a textbook for students taking an introductory course in polymer processing. It also serves as a guide to the practicing engineer when choosing a process, determining important parameters and factors during the early stages of process design, and when optimizing such a process. Practical examples illustrating basic concepts are presented throughout the book.

New in the third edition are chapters on data-driven modeling and physics-driven modeling, as well as new sections on manufacturing and dimensional analysis. In addition to a number of other smaller improvements and corrections throughout the book, bonus code downloads are also provided. 

Part I: Polymeric Materials

This section gives a general introduction to polymers, including mechanical behavior of polymers and melt rheology.

Part II: Polymer Processing

The major polymer processes are introduced in this section, including extrusion, mixing, injection molding, thermoforming, blow molding, film blowing, and many others.

Part III: Modeling

This last section delivers the tools to allow the engineer to solve back-of-the-envelope polymer processing models. It includes dimensional analysis and scaling, transport phenomena in polymer processing, and modeling polymer processes.

THE AI ACT HANDBOOK //

- Detailed overview of the AI Act

- Impact of the AI Act on various areas (including fi nance, employment law, advertising and administration)

- Related areas of law (data protection, IP and IT law)

- Practical overview of AI governance, risk and compliance in companies

- Information on standards, norms and certifications

By experts for practitioners – with this handbook, you can prepare yourself for the requirements of the European AI Act in a practical and compliant manner. Get comprehensive information on the effects on the various application fields of artificial intelligence in the private and public sectors. After a brief introduction to the history and technology of AI, you will receive a detailed subsumption of the content of the AI Act based on the various risk categories. Subsequently, areas of law closely related to the use of AI, in particular data protection, IP and IT law, will be dealt with in detail. By providing case studies, the book shares insights about the impact of the AI Act on various areas such as autonomous driving, work, critical infrastructure, medicine, insurance, etc. The correlation with the areas of law relevant to these areas will also be considered. A practical overview of the topic of AI governance, risk and compliance (GRC) in companies, tips on the application of guidelines and governance frameworks, implementation ideas for trustworthy AI as well as standards, norms and certifications complement the book.

The TEAM OF AUTHORS consists of lawyers specializing in IT and data protection law and the use of AI. It includes, among others, one of Austria's representative in the AI Act negotiations at EU Council level and the founder of the Austrian association Women in AI.

FROM THE CONTENTS //

- What Is AI and How Do Data Science and Data Analytics Differ?

- Geopolitics of Artificial Intelligence

- AI Act: Rights and Obligations

- Data Protection

- Intellectual Property

- AI and IT Contract Law

- Private Sector

- Public Sector

- Ethics

- Governance in the Company

Powder bed-based additive manufacturing with polymers (PBF-P) has a special position in the world of 3D printing. On the one hand, the components are manufactured without support structures, and on the other hand, the property profile of the components is similar to that of series components, as is also known from injection molding, but with clear advantages in terms of component complexity.

In laser sintering (LS), individual component layers are fused with the aid of suitable laser radiation. In recent years, LS components have gained widespread use in industrial applications, so that today one can already speak of an established technology. Nevertheless, there are still many hurdles for LS to overcome in the future in order to free itself from the status of a niche technology. Material diversity and industry-compliant, quality-assurance measures are among the challenges to be mentioned here.

To this end, the second edition of this book sheds light on the current state of the art in terms of machine technology and process flow, and specifically on the requirements for the materials used. In addition, the following topics are presented:

- Implementation of LS in industrial process chains

- Status of international standardization

- Innovations in the field of LS materials

- Properties of LS components

- Selected application examples

The second edition has been updated throughout; in particular, the material and machine specifications have been extensively revised.

Biodegradable polymers (BDPs) based on renewable sources have been drawing scientific as well as industrial attention due to their potential to replace fossil derived polymers (FDPs) for a large number of applications. Furthermore, BDPs introduce the viability of bio-degradation at the end of their life cycle, thus reducing the environmental impact of most FDPs.

This book covers the basic properties of BDPs according to their classifications, the rheology of BDPs and their blends, and their numerous applications, with an emphasis on processing: As BDPs possess attractive attributes compared to FDPs (which is discussed in the book), their processing has been investigated using conventional processing technologies. However, BDPs are sensitive to the processing conditions due to their composition, which is tuned to bio-degradation. Hence, special attention has been directed to minimize the in-process degradation and enhance their final processed properties. To remedy some of the BDP processing shortcomings, special additives, fillers, and blends have been incorporated and developed with minimal effect on the BDPs’ bio-degradation rate. All of these aspects of BDP processing are considered in this book, including their characteristics in extrusion, injection molding, thermoforming, blow molding, and 3D printing, as well as the processing of recycled BDPs.

Plastics have a very important role to play in energy-efficient and low-carbon technologies of the present and future, but for them to be classified as sustainable materials, there is a great need for practical and economic recycling methods and infrastructure. This book fills the gap for a modern comprehensive technical guide to recycling of plastics, covering the whole value chain from raw materials to recycled materials.

All important recycling technologies (mechanical, chemical/feedstock, dissolution) are discussed and compared to each other and alternative disposal methods such as energy recovery and gasification. Collecting, sorting, and purification methods are also covered, as are economic, legal, and political aspects.

A strong emphasis is placed on data comparability, e.g. by standardized methods in measuring data. Although this is a challenge to implement, comparing data across technologies, regions, and stakeholders along the value chain yields important benefits. Key instruments for such a target are lifecycle assessments (LCAs), which are calculated in a standard way across the chapters to “calibrate“ the messages among the numerous expert co-authors.

This applications-oriented book describes the construction of an injection mold from the ground up. Included are explanations of the individual types of molds, components, and technical terms; design procedures; techniques, tips, and tricks in the construction of an injection mold; and pros and cons of various solutions.

Based on a plastic part ("bowl with lid") specially developed for this book, easily understandable text and many illustrative pictures and drawings provide the necessary knowledge for practical implementation. Step by step, the plastic part is modified and enhanced. The technologies and designs that are additionally needed for an injection mold are described by engineering drawings. Maintenance and repair, and essential manufacturing techniques are also discussed.

With full-color illustrations, this third edition builds on the success of the previous ones, with significantly expanded coverage of molding simulation, including many new figures, and updates and small corrections throughout the book.

Phase separation in polymer blends has achieved a tremendous techno-commercial importance. Most of the applications of polymer blends, such as tissue engineering, membrane technology, electromagnetic shielding, energy harvesting, structural materials, packaging, smart multiphase polymer coatings, depend on the morphologies developed during processing.

This book outlines the fundamental aspects of polymer blend thermodynamics, the state-of-the-art processing techniques for specific polymer blend systems currently in use, and the design and fabrication of multiphasic polymeric materials, which will present a multiplicity of opportunities in the water remediation, packaging, and electronic industries, to mention a few. It emphasizes recent research developments, processing techniques, characterization methods, factors influencing phase separation temperature in phase-separated, including partially miscible, polymer blends, and key research challenges in the development of phase-separated polymers materials.

With unique and systematic coverage of the journey from fundamentals to applications in polymer blends, this book is ideal for polymer scientists and engineers, material scientists, researchers, engineers, and under- and post-graduate students who are interested in this exciting field of research. It will help industrial researchers and R&D managers bring advanced phase-separated polymer materials/products to the market.  

Measurement uncertainty is an important component of modern materials analysis: it indicates the boundaries within which the test results can be trusted. Such results are necessary for understanding of, for example, material and product tolerances and lifetimes, vital for plastic product reliability and safety.

Determination of measurement uncertainty is normally quite laborious, but this book shows how the available interlaboratory test data for plastics can be used to calculate measurement uncertainty much more simply. It contains many interlaboratory test results in the fields of thermoanalysis, molar mass determination, and quantitative analysis of the composition of material, presented in tables and graphical charts, discussed in the text, and elaborated by practical examples.

In addition to the evaluation by means of the presented data (top-down approach), the relationship to the bottom-up approach specified in the Guide to the Expression of Uncertainty in Measurement (GUM) is explained based on an example. Further sections deal with sampling, and the issue of whether or not the difference between analytical results is significant.

The validation of equipment, processes and methods is a basic requirement that nowadays has to be met in most industries. This handbook deals with the validation of computerized systems in general as well as with analytical method validation. The many detailed practical examples focus on thermal analysis of materials, such as plastics and rubber.

The handbook is intended for newcomers interested in the theoretical and regulatory aspects of validation and for thermal analysis practitioners who have to validate their equipment and methods.

The demands for processing power, software, and communication are continuously increasing; in all industries and also in the automotive one. In vehicles, the need for higher data rates is driven by more electronic functions in general, but especially by ever more potent (camera) sensors, displays, and high performance ECUs.

This book provides a holistic view on new SerDes and Ethernet high-speed communication solutions for cars. It addresses core physical components such as cables, connectors, or PCB design, as well as physical layer processing, use-case-specific protocols, and the use cases as such. It is important to the authors not only to explain the technologies, but also to provide context and background in respect to various technical choices. The intent is to help readers understand the current eco-system end-to-end, whether they are new to the automotive industry or experts who want to deepen their understanding on specific items, whether they are working for a car manufacturer directly or any of the suppliers, whether they are already involved or evaluating to get involved.

This practical introductory guide to injection molding simulation is aimed at both practicing engineers and students. It will help the reader to innovate and improve part design and molding processes, essential for efficient manufacturing.

A user-friendly, case-study-based approach is applied, enhanced by many illustrations in full color. The book is conceptually divided into three parts:

Chapters 1–5 introduce the fundamentals of injection molding, focusing the factors governing molding quality and how molding simulation methodology is developed. As they are essential to molding quality, the rheological, thermodynamic, thermal, mechanical, kinetic properties of plastics are fully elaborated in this part, as well as curing kinetics for thermoset plastics.

Chapters 6–11 introduce CAE verification of design, a valuable tool for both part and mold designers toward avoiding molding problems in the design stage and to solve issues encountered in injection molding. This part covers design guidelines of part, gating, runner, and cooling channel systems. Temperature control in hot runner systems, prediction and control of warpage, and fiber orientation are also discussed.

Chapters 12–17 introduce research and development in innovative molding, illustrating how CAE is applied to advanced molding techniques, including co-/bi-Injection molding, gas-/water-assisted injection molding, foam injection molding, powder injection molding, resin transfer molding, and integrated circuit packaging.

The authors come from the creative simulation team at CoreTech System (Moldex3D), winner of the PPS James L. White Innovation Award 2015. Several CAE case study exercises for execution in the Moldex3D software are included to allow readers to practice what they have learned and test their understanding.

In the 2nd edition, the concept of Cyber-Physical Systems (CPS) in injection molding is introduced. In order to integrate molding simulation and injection machines, the workflow of machine response characterization is illustrated. By taking into account the real-world machine response, users can more accurately reflect the real-world manufacturing conditions in simulations. The optimized processing conditions obtained from the simulation can then be directly applied on the shop floor, bridging the gap between simulation and manufacturing. In addition, a new flow-fiber coupling model, i.e., the informed-isotropic (IISO) viscosity developed by Dr. Favaloro and Prof. Pipes of Purdue University, to simulate the anisotropic flow for fiber-reinforced thermoplastics is introduced. The IISO coupling is available to simulate some peculiar, irregular filling patterns for fiber-reinforced melts at high fiber concentrations: the free surface advances faster along the side cavity walls.