The Mitsubishi Chemical Advanced Materials KyronMAX® Challenge invited designers and engineers to share designs that utilized KyronMAX®'s range of high-strength carbon fiber-based composites to solve an engineering or manufacturing challenge.&nbsp;Dozens of high-quality submissions were submitted to the challenge, making the Jury's task very difficult. Ultimately 14 finalists were selected, these designs were then further assessed on their prototype potential, fit with the KyronMAX materials, and sustainability profile.&nbsp;"The jury was impressed by the number of contestants and the quality of the submissions," Tim Vorage, Global Growth Manager at Mitsubishi Chemical Advanced Materials explained. "It was a challenge to narrow down the selection of finalists and chose a winner. Sustainability seems to be an intrinsic part of the solutions offered by the contestants and is entangled with the technical and commercial offering, resulting in some groundbreaking value propositions and potential business models. The enthusiasm of the teams behind the submissions was absolutely conveyed to the jury members and sparks an excitement that lays a strong foundation for future collaboration with the contestants and the Wevolver team."The winner of the KyronMAX® &nbsp;Challenge is The&nbsp;Ultra-Quiet Unmanned aerial vehicle (UAV) Blades designed by Michael Deloyer, Eitan Rotbart, and Ammar Jessa from <a href="https://delsonaero.com/" rel="noopener noreferrer" target="_blank">Delson Aeronautics.</a>Delson's novel blade design method can entirely eliminate the incessant buzzing sound of drones. The patent-pending blade design method results in an average 10 dB sound reduction (50% quieter) relative to equivalently sized conventional UAV propeller blades. The intention of these blades is to provide a simplistic and effective solution to eliminating the incessant noise of UAVs. &nbsp;Light-weight, high-strength materials are critical for UAV propeller manufacturing. Conventional injection molding results in significantly increased weight relative to carbon-fiber manufacturing methods, however, foam-core carbon-fiber manufacturing requires very high labor cost and is extremely difficult to recycle, if at all, often being disposed to landfills once beyond operational capacity.<iframe width="1000" height="563" src="https://www.youtube.com/embed/1LNKL92kMKE" title="YouTube video player" frameborder="0" allowfullscreen="" class="fr-draggable"></iframe>The Delson Ultra-Quiet UAV blades are a great match for the KyronMAX® platform due to the various stresses UAV blades experience.<ul><li dir="ltr">High centrifugal loading beyond 3000 N, requiring high tensile strength.</li><li dir="ltr">Temperature ranges from -30C (-22F) to +50C (+120F) in operating environments, requiring a low Coefficient of Linear Thermal Expansion.</li><li dir="ltr">Operation in both high and low humidity environments requiring low humidity absorption.&nbsp;</li><li dir="ltr">Individual blade loading in excess of 24.5 g/cm^2 (50 lb/ft^2) requiring high flexural strength and stiffness.</li><li dir="ltr">Low material density to result in the lightest weight possible to increase flight efficiency and reduce blade inertial weight to increase responsiveness and stability.</li><li dir="ltr">Operational hours in excess of 1000hrs, requiring high fatigue strength.</li><li dir="ltr">Operating in harsh and unpredictable environments requiring high impact strength.&nbsp;</li></ul>"UAV noise is being noted as a leading barrier to public adoption of drone delivery services in urban environments. We are seeking a light-weight, high-strength, low-cost, scalable, and sustainable manufacturing method to propel the UAV industry forward," the designers explain.The jury was by the attention to detail of the Dyson team and the potential for the blades to be recycled as part of a product take-back program. The Delson Aeronautics team will receive $25,000 in expert support and manufacturing services from Mitsubishi &nbsp;Chemical Advanced Materials to create a fully developed prototype of their idea.&nbsp;<h2 dir="ltr">Wevolver Community Vote</h2>We asked the Wevolver community to select their favorite KyoronMAX® Challenge finalist. The final voting was really competitive with community members casting votes from across the world. The winner of the KyronMAX® &nbsp;Wevolver Community Vote is the High-Performance Lacrosse Head designed by&nbsp;<a href="https://danielmitchell.info/" rel="noopener noreferrer" target="_blank">Daniel Scott Mitchell</a>&nbsp;and&nbsp;<a href="https://farbodmoghaddam183466341.wordpress.com/" rel="noopener noreferrer" target="_blank">Farbod Moghaddam</a>.&nbsp;The designers say their goal is to make one of the lightest, strongest, and most durable lacrosse heads on the market.&nbsp;“Our lacrosse friends have been begging us to engineer the perfect lacrosse head – and we think KyronMAX is the best way to get them off our backs!” the designers told us. "Our team is incredibly thankful to the Wevolver community for choosing our project as the community choice winner! We look forward to refining our design with the help of the Mitsubishi Chemical Advanced Materials (MCAM) team to truly create the best lacrosse head offering on the market. Daniel and I have also decided to build this product in public so that everyone can follow us along on the journey to commercialization."&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjE3NjEzMTc3NzA4LUxhY3Jvc3NlX0hlYWRfS3lyb25NQVguanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 788px;" class="fr-fic fr-dib">Daniel Scott Mitchell and &nbsp;Farbod Moghaddam will receive $10,000 of manufacturing support from Mitsubishi Chemical Advance Materials to begin the development of a prototype.&nbsp;<h1>About the sponsor:</h1>Mitsubishi Chemical Advanced Materials is a leading global manufacturer of high-performance materials in the form of semi-finished products and finished parts. The company has locations in 20 countries and more than 2,800 employees. Its specialty engineering thermoplastics and composites are superior in performance to metals and other materials and are used in a wide range of applications, primarily in the capital goods industry. The company is continuously developing new areas of applications in close cooperation with industry leaders in a broad variety of customer markets. The Mitsubishi Chemical Advanced Materials Group is well prepared to further expand its market leadership position.Supporting the vision of our holding company, <a data-saferedirecturl="https://www.google.com/url?q=http://www.mitsubishichem-hd.co.jp/english/index.html&source=gmail&ust=1610526498335000&usg=AFQjCNHetYAQ5hklIu3KUON9OmNDNWaPDQ" href="http://www.mitsubishichem-hd.co.jp/english/index.html" rel="nofollow" target="_blank">Mitsubishi Chemical Holdings Corporation (MCHC)</a>, Mitsubishi Chemical Advanced Materials is committed to the realization of KAITEKI, “a sustainable condition which is comfortable for people, society and the Earth”. To realize this vision, the MCHC Group engages in corporate activities that provide products, technologies and services based on the comprehensive capabilities of the Group in the Performance Products Domain, Industrial Materials Domain and Health Care Domain, with chemistry as the basis of our activities. We jointly express and promote our commitment under the corporate brand THE KAITEKI COMPANY.&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjE3NjEzNDEwNDE0LWt5cm9ubWF4LWJhbm5lci1sb2dvLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib">

The fully recyclable UAV blades cut drone noise by 50%. 

Ultraquiet UAV Blades win The KyronMAX Challenge

IntroductionFor a startup manufacturer getting that first product right is crucial for your reputation and future sales. First impressions really do count when you are building up your company and brand equity.Time is another critical factor as you strive to get a product to market and begin to generate revenue. Yet it is a mistake to skip a thorough prototyping and testing programme because if you discover an error during manufacturer, the cost of putting it right is far higher in money, time and reputation. It is far better to make any adjustments in design, material, size, shape, colour, manufacturability and strength following testing and analysis. To balance this tightrope between testing time and cost, it pays to understand all of the rapid prototyping technologies that are available to you.There are numerous ways prototypes can be made. Some prototyping processes use traditional manufacturing methods. Other technologies have emerged and have been improved upon over a relatively short period of time. As prototyping processes continue to evolve, the product designer is constantly trying to determine what process or technology is best for their unique application.This technical brief explores the advantages and shortcomings of the major prototyping processes available to designers. It also describes the processes and discusses material properties of parts produced by each. In addition, a helpful decision tree highlights key questions designers must consider. Ultimately, the goal of this paper is to help you select the best prototyping process for your product development process.3D Printing - SL StereolithographySL is an additive fabrication process that builds parts in a pool of UV-curable photopolymer resin using a computer-controlled laser. The laser is used to trace out and cure a cross-section of the part design on the surface of the liquid resin. The solidified layer is then lowered just below the surface of the liquid resin and the process is repeated. Each newly cured layer adheres to the layer below it. This process continues until the part is completed. SL was the first ‘rapid prototyping’ technology.ProsFor concept models or patterns to be used as masters for other prototyping methods, SL can produce parts with complex geometries and excellent surface finishes when compared to other additive processes. If you need micro resolution features then there are materials, such as MicroFineTM Green and MicroFineTM Grey, that can achieve features down to 0.07mm (in X-Y direction) using SL. The cost is very competitive and the technology is available from several sources.ConsPrototype parts are not as strong as those made from engineering-grade resins, so the parts made using SL are normally unsuitable for functional testing. Also, since the resin is UV-curable, exposure to sunlight continues to cure the resin and parts can become brittle over time.3D Printing - Selective Laser Sintering (SLS)The SLS process uses a laser to build parts by sintering (fusing) powdered material layer by layer from the bottom up. SLS parts can be accurate and more durable than SL parts, but the finish is relatively poor with a grainy or sandy feel. Though SLS parts are fairly strong, there is reduced strength between the fused particles, so the parts will tend to be weaker than machined or moulded parts made from the same resin. Nylon-based materials are currently the primary resins available.ProsSLS parts tend to be more accurate and durable than SL parts. The process can make durable parts with complex geometries.ConsThe parts have a grainy or sandy texture and are typically not suitable for functional testing due to their reduced mechanical properties.3D Printing - Multi Jet Fusion (MJF)Multi Jet Fusion uses an inkjet array to selectively apply fusing and detailing agents across a bed of nylon powder. This is then fused by heating elements into a solid layer. After each layer, powder is distributed on top of the bed and the process repeats until the part is complete.ProsMJF offers engineering grade materials with great overall properties. Additionally, MJF offers an enhanced surface finish, fine features, consistent mechanical properties, and fast build times.ConsWhile the surface quality is good, it is rougher than that produced by photopolymer-based technologies (Stereolithography). The raw parts are grey, which can be dyed but this is an extra process.Direct Metal Laser Sintering (DMLS)Direct metal laser sintering is an additive manufacturing technology that produces metal prototypes and production-quality parts. DMLS uses a laser system that draws onto a surface of atomised metal powder. Where it draws, it welds the powder into a solid. After each layer, a blade adds a fresh layer of powder and repeats the process. DMLS can use most alloys, allowing prototypes to be a full-strength, functional part made out of the same material as production components. It also has the potential, if designed with manufacturability in mind, to transition into metal injection moulding for when you need to increase production.ProsDMLS produce strong (typically, 97 percent dense) prototypes from a variety of metals that can be used for functional testing. Since the components are built layer by layer, it is possible to design internal features and passages that could not be cast or otherwise machined.ConsIf producing more than a few DMLS parts, costs can rise. Due to the powdered metal origin of the direct metal process, the surface finish of these parts are slightly rough.3D Printing - Fused Deposition Modeling (FDM)The FDM process builds parts from the bottom up through the use of a computer-controlled print head. The feedstock for the process is a filament of extruded resin, which the machine selectively re-melts and deposits on the prior layer for each cross section of the desired part. FDM primarily produces parts in ABS or PC, so they tend to be stronger than parts from other additive processes. However, the parts are sometimes porous and have a pronounced stair-stepping or rippling texture on the outside finish, especially at layer junctions. It may also be difficult to achieve tight tolerances with the process.ProsFDM parts are relatively strong and can be good for some functional testing. The process can make parts with complex geometries.ConsThe parts have a poor surface finish, with a pronounced rippled effect. It is also a slower additive process than SL or SLS for build time.3D Printing - PJET PolyJetPJET uses inkjet heads to jet a UV-curable material in very thin layers at high resolution. The materials are jetted in ultra-thin layers onto a build tray, layer by layer, until the part is completed. Each photopolymer layer is cured by UV light immediately after it is jetted. The gel-like support material, which is specially designed to support complicated geometries, is easily removed by hand and water jetting.ProsThis process yields a good surface finish; one of the best of the additive processes. It is a good additive choice for complex parts with undercuts. The process can make parts with complex geometries.ConsPJET parts have poor strength (comparable to SL). While PJET can make parts with complex geometries, it gives no insight into the eventual manufacturability of the design.3D Printing - Three Dimensional PrintingIn 3DP an inkjet print head moves across a bed of powder, selectively depositing a liquid binding material, and the process is repeated until the complete part has been formed. After completion, the unbound powder is removed leaving the finished object.Pros3DP offers one of the fastest build times of any additive process, and is also among the least expensive options for prototype quantities. Coloured models can communicate more information and have aesthetic appeal. This plaster material is non-toxic, inexpensive and readily available. The process can make parts with complex geometries.ConsParts are rough and weak, and there are very few material options. While 3DP can make parts with complex geometries, it gives no insight into the eventual manufacturability of the design.IM - Injection MouldingRapid injection moulding works by injecting thermoplastic resins into a mould, just as in production injection moulding. What makes the process ‘rapid’ is the technology used to produce the mould, which is often made from aluminium instead of the traditional steel used in production moulds. Moulded parts are strong and can have excellent finishes. It is also the industry standard production process for plastic parts, so there are inherent advantages to prototyping in the same process if the situation allows. Almost any engineering-grade resin can be used, so the designer is not constrained by the material limitations of the prototyping process. Additionally, metal injection moulding (MIM) and liquid silicone rubber (LSR) moulding offer rapidly moulded parts in metals like stainless steel and LSR, respectfully. There is an initial tooling cost associated with rapid injection moulding that does not occur with any of the additive processes or with CNC machining. So, in most cases, it makes sense to do one or two rounds of rapid prototypes (subtractive or additive) to check fit and function before moving to injection moulding.ProsMoulded parts are made from an array of engineering grade materials, have excellent surface finish and are an excellent predictor of manufacturability during the production phase.ConsFront-end costs can be higher due to tooling costs.CNC Machining - Computer Numerically Controlled MachiningA solid block of plastic or metal is clamped into a CNC mill and cut into a finished part through a subtractive process. This method produces superior strength and surface finish to any additive process. It also has the complete, homogenous properties of the plastic because it is made from solid blocks of extruded or compression moulded thermoplastic resin, as opposed to most additive processes, which use plastic-like materials and are built in layers. The range of material choices allows parts to be made with the desired material properties, such as: tensile strength, impact resistance, heat deflection temperatures, chemical resistance and biocompatibility. Good tolerances yield parts suitable for fit and functional testing. Prototypes can be delivered in days just like additive processes. Because the process involves removing material instead of adding it, milling undercuts can sometimes be difficult. Machining also tends to be somewhat more expensive than the additive processes.ProsMachined parts have a good surface finish and they are very strong because they use real engineering-grade thermoplastics and metals.ConsThere are some geometry limitations associated with CNC machining, and it is much more expensive to do this in-house than the additive processes due to the cost of the programmers and machinists needed to create CNC toolpaths and fixturing for the parts.VC - Vacuum CastingThe process starts with making a mould by encapsulating a master model in two-part liquid silicone rubber. A vacuum is then applied to remove any trapped air, then it is cured in an oven. Master models can come from a number of 3D printing technologies including stereolithography. Vacuum casting allows the production of small batches of high quality mouldings in a range of polyurethane resins that replicate the performance of engineering plastics without the high costs of hard tooling associated with injection moulding.ProsVacuum casting can be used for small batches of high quality prototypes or low volume end use parts. A wide range of resins are available and master models can come from a range of sources, the most common being stereolithography models. Good dimensional stability.ConsRapid wear of the mould, only used for a few dozen parts.&nbsp;<h3><a href="https://get.protolabs.co.uk/start-up/whitepaper/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-startup-campaign-0221&utm_content=startup-prototyping-processes-wp-0321" rel="noopener noreferrer" target="_blank">CONTINUE READING -&gt;</a></h3>

For a startup manufacturer getting that first product right is crucial for your reputation and future sales. First impressions really do count when you are building up your company and brand equity.

A Guide to Prototyping for Startup Manufacturers

The KyronMAX®&nbsp; range of materials is suitable for a wide range of applications across industries. This article looks at two case studies where the materials provided considerable benefits to the product's design.&nbsp;<a href="https://www.wevolver.com/article/mcam-challenge" rel="noopener noreferrer" target="_blank">Submit your ideas</a>&nbsp;about how to utilizes KyronMAX®&nbsp;’s range of moldable carbon fiber-based composites to the KyronMAX®&nbsp;&nbsp;Challenge for the chance to win $25,000 of manufacturing services.&nbsp;<a href="https://kyronmax.mcam.com/" rel="noopener noreferrer" target="_blank">KyronMAX®</a>&nbsp;prides itself on being more than just a materials provider. They are a collaborative manufacturing platform that can work with designers and companies at any stage of their design or production process to offer advice, testing, and prototyping. Early in the design process <a href="https://www.wevolver.com/profile/mitsubishi.chemical.advanced.materials" rel="noopener noreferrer" target="_blank">Mitsubishi Advanced Chemical Materials</a> can assist with concept design and simulated analysis, and later down the design pipeline, <a href="https://www.wevolver.com/article/new-manufacturing-platform-combines-agility-of-3d-printing-with-strength-of-injection-molding-for-rapid-prototyping" rel="noopener noreferrer" target="_blank">Mitsubishi’s SPRINT prototyping</a> process can deliver material accurate parts without injection molding tooling. The two featured case studies showcase two of the ways Mitsubishi Advanced Chemical Materials can support product development. The first utilizes a ready-to-go KyronMAX®&nbsp; material product which was directly swapped for the current composite material resulting in a finished part 21% lighter than its previous iteration. The second case study illustrates how KyronMAX®&nbsp; engineers can work from start to finish with a design team to redesign, test, prototype, and manufacture a complete product.&nbsp;<h1 dir="ltr">Material intervention meets the target</h1>Professional archery might not be a sport many of us think of. But the equipment used by archers combines many engineering principles that made reinventing a key part of the archer’s bow an <a href="https://kyronmax.mcam.com/dam/jcr:53cfd3e9-7aa9-4189-a378-794a87abcf57/MCAM-KyronMAX-Casestudy-Reinventing-The-Wheel.pdf" target="_blank">exciting challenge</a> for Mitsubishi Chemical Advanced Materials engineers. The design improvement focussed on the idler wheel of the bow. The idler wheel’s main function is to transfer stored energy from the bow’s limbs through the arrow’s string smoothly and rapidly. Understandably the idler wheels experience a significant amount of load and must be able to maintain high levels of intense use.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjE0NjA3Nzc3ODcwLWFyY2hlcnkgaWRsZXIgd2hlZWwuanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 788px;" class="fr-fic fr-dib">&nbsp;A competitive archery bow in action; the idler wheels sit at the top and bottom of the bow. Image: Pierre-Yves Beaudouin/WikiCommons<h2 class="fr-img-space-wrap">Material replacement with existing tooling</h2>The customer had already replaced the aluminum with a lighter weight 50% Nylon Long Glass Fiber (LGF) as the material for the idler’s construction but was experiencing a 14% failure rate due to breakage. The bow making company had purchased new molding tools and wanted to avoid further reinvestment with another material change. At this point, they approached Mitsubishi Chemical Advanced Materials for assistance in improving the idler design.&nbsp;The Mitsubishi Chemical Advanced Materials team immediately recommended using KyronMAX® S-2220, a 20% Carbon-Fiber filled product and offered to run the molding trials using the customer's existing tool. KyronMAX® polymer technology allows for fiber mixing, increasing the knit-line strength and decreasing failure rates inviting use for higher-strength parts and the production of difficult, complex geometries. In addition, KyronMAX® S-2220 has less than half the filler loading, which helps to increase toughness, improve knit-line strength, faster processability, and consistency while significantly reducing the part stress. Mitsubishi Chemical Advanced Materials were able to help the customer adapt their existing tooling for compatibility with KyronMAX® so they could continue production without new tooling investment. The video below shows the massive strength improvements by the use of KyronMAX® S-2220.&nbsp;<img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1614680757851-Wheels+Gif.gif" style="width: 788px;" class="fr-fic fr-dib"><h1 dir="ltr">Rapid prototyping delivers for bike suspension redesign</h1>Mitsubishi Chemical Advanced Materials worked with a leading bicycle manufacturer to develop a new suspension part that offers improved strength performance and significant weight reduction. Unable to achieve the desired performance using Long Fibre Technology (LFT) compounds, Mitsubishi Chemical Advanced Materials Engineered Solutions technical team, ran trials using KyronMAX® to test for possible improvements. &nbsp;Combining Mitsubishi Chemical Advanced Materials mold-flow software technology together with the KyronMAX® material files, the team developed favorable process conditions, gate design, validations, and testing of the final composite structure.&nbsp;<h2 dir="ltr">Addressing weld lines</h2>Weld lines occur when part or tool design features such as holes divide the melt flow, and the separate flows do not mix completely when they meet. At these points, little or no polymer chain entanglement occurs across the flow-front boundaries. Weld lines can be the weakest points for plastic and compound material parts. Mitsubishi Chemical Advanced Materials have developed several proprietary technologies for reducing weld-lines and therefore increasing the overall mechanical strength of the part. KyronMAX® engineers applied these technologies to the bike suspension part to assess weld line prediction and mitigation.<h2 dir="ltr">Finite Element Analysis</h2>Fiber matrix structure mapping then allowed for a full Finite Element Analysis (FEA) which mechanically tested the structure to predict what the product will do when it encounters real-world forces and wear.&nbsp;For example, load-cases were simulated in the FEA software using advanced fiber matrix analytics. 400,000 data points were applied for each FEA node to help assess the part. The software then calculated the fiber placement at each node, working out the associated strength based on pre-programmed data. The mesh was then refined using stress analysis.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjE0NjgxMDQ0ODgzLWltYWdlMTAgKDEpLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib"><h2 dir="ltr">Making the design reality</h2>Once the part had been structurally improved, it needed to be analyzed to ensure the design could be fabricated and perform as intended. This entailed testing any geometry alterations to ensure the component was designed to meet its requirements. A prototype of the design was then created in the same material as the final product using Mitsubishi Chemical Advanced Materials <a href="https://www.wevolver.com/article/new-manufacturing-platform-combines-agility-of-3d-printing-with-strength-of-injection-molding-for-rapid-prototyping" rel="noopener noreferrer" target="_blank">SPRINT technology</a> (based on AddiFab technology). The SPRINT technology enables the production of functional prototypes in the material of choice and can be used for small production volumes. The flexibility, freedom of design, and speed of 3D printing (of the mold) are combined with the high quality of injection molding. This prototype then underwent real-world testing including simulating the exact load case using a customized jig at one of the Mitsubishi Chemical Advanced Materials innovation labs. This ensured the design process was accurate and the part performed as intended.The combination of the customer’s application expertise with KyronMAX's material knowledge led to a successful collaboration that resulted in a stronger, more durable part manufacturable. This collaborative approach supported the customer to rapidly test and trial several prototype materials, designs, and solutions to determine what was needed for the final component.The broad application of the KyronMAX® &nbsp;materials and the Mitsubishi Chemical Advanced Materials collaborative approach to problem-solving opens the possibility for engineers in all stages of the design process and scale to improve their design through testing, prototyping, and material selection.&nbsp;<h1 dir="ltr">The KyronMAXⓇ Challenge</h1><a href="https://www.wevolver.com/article/mcam-challenge" target="_blank">The KyronMAX®&nbsp;Challenge</a> invites you to submit a design that utilizes KyronMAX®’s range of breakthrough, high-strength carbon fiber-based composites to solve an engineering or manufacturing challenge. The winning designs will receive $25,000 worth of manufacturing support from KyronMAX® to create a fully developed prototype.Your submission can be a stand-alone product or a component of a larger design. Successful submissions will need to show how the design utilizes the unique properties of KyronMAX® materials and complements the platform’s capabilities. The KyronMAX® challenge will reward projects that prioritize sustainability while maintaining a high level of feasibility and ingenuity.<a href="https://www.wevolver.com/challenge/mcam" rel="noopener noreferrer" target="_blank">Submit your entry here.</a>For full challenge details, see <a href="https://www.wevolver.com/article/mcam-challenge" target="_blank">The KyronMAX® Challenge homepage.</a><hr><h1>About the sponsor:</h1>Mitsubishi Chemical Advanced Materials is a leading global manufacturer of high-performance materials in the form of semi-finished products and finished parts. The company has locations in 20 countries and more than 2,800 employees. Its specialty engineering thermoplastics and composites are superior in performance to metals and other materials and are used in a wide range of applications, primarily in the capital goods industry. The company is continuously developing new areas of applications in close cooperation with industry leaders in a wide variety of customer markets. The Mitsubishi Chemical Advanced Materials Group is well prepared to further expand its market leadership position.Supporting the vision of our holding company, <a href="http://www.mitsubishichem-hd.co.jp/english/index.html" target="_blank">Mitsubishi Chemical Holdings Corporation (MCHC)</a>, Mitsubishi Chemical Advanced Materials is committed to the realization of KAITEKI, “a sustainable condition which is comfortable for people, society and the Earth”. To realize this vision, the MCHC Group engages in corporate activities that provide products, technologies, and services based on the comprehensive capabilities of the Group in the Performance Products Domain, Industrial Materials Domain, and Health Care Domain, with chemistry as the basis of our activities. We jointly express and promote our commitment under the corporate brand THE KAITEKI COMPANY.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjE0NjA2ODUzNzIyLWt5cm5tYXggbG9nby5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 788px;" class="fr-fic fr-dib"><h2> </h2>

Two case studies demonstrate how both material selection and collaborative design play a role in product outcome. 

Professional sports equipment showcase potential of moldable carbon fiber-based composites

In the drive to accelerate new product development and time to market, the pressure to validate a design can be intense. With a prototype of a product or component, designers’ finally move designs from the screen to physical objects that can be handled. Does it fit? Will it function as intended? Can a 3D printed part be manufactured by injection moulding? And—in the case of prototype products, rather than parts—what might potential customers think of it? Increasingly, smart manufacturers—and their design teams—are looking ahead, past the prototyping phase of the product design process, and are thinking in terms of the end product and its required performance characteristics.<a name="first" target="_blank"></a><h2>Right first time</h2><h2><a data-lightbox="/media/1015734/lifecycle-inforgraphic2.png" data-title="" href="https://www.protolabs.co.uk/media/1015734/lifecycle-inforgraphic2.png" target="_blank"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEzMDMyNDc0OTMyLTE2MTMwMzI0NzQ5MzIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii" style="width: 300px;"></a></h2>In product development, parts or products generally move through three phases of evolution: first, prototyping; second, low-volume production; then third—and final—serial production.Prototyping is about crystallising a proven, working design. A prototype can be one of several (or many) such iterations, or just a final one-off physical validation of an on-screen design before design sign-off. On the other hand, low-volume production is less about the product itself, and more about its market or production process: a phase of low-volume production can help to refine a manufacturing process, or alternatively get test products or launch products to market in order to gain and validate customer perceptions. Finally, the precise volumes that are associated with serial production will depend on the product itself, and its market, and will typically range from thousands each year, to millions each year.In each case, the goal at each stage is to move smoothly from each phase of development to the next, refining the product and its manufacturability. Overall, the objective is to minimise the total time and cost of the overall process, bringing a product from initial concept to serial production smoothly and efficiently, and as quickly and cost-effectively as possible.In some industries bringing a product to market involves extensive compliance testing, often involving third-party certification. Aerospace and defence product development, for instance, calls for such compliance, and no manufacturer will want to finalise a product design and get ready for serial production, only to discover that the product in question does not meet its design requirements in terms of durability, usage cycles, or some other testable attribute. Making use of the prototyping stage to carry out such testing—a process known as pre-compliance testing—is therefore prudent. In such circumstances, it makes excellent sense for a designer to seek guidance from the prototyping provider in order to use a prototyping material that will yield meaningful information on attributes such as strength, flexibility and durability.Finally, as well as these development and testing stages of bring a product to market, a manufacturer may wish the prototyping and development process of a product to take into account a number of broader business considerations.Decisions about packaging, for instance, can impact packaging cost, vulnerability to damage during shipment, and the cubic utilisation of both primary and secondary packaging. Ultimately, of course, cubic utilisation will affect vehicle and container requirements, as well as shipping cost. It can be prudent to, wherever possible, use product prototypes in order to inform packaging decisions as early as is practicable.Similarly, a business may have sustainability and branding objectives in addition to those impacted by packaging and shipping utilisation. A decision to use a particular means of packaging, for instance, may again impact damage statistics, or product aesthetics during a long shelf-life. An objective of using high levels of reclaimed plastic may not prove practical when injection moulding a specific part. And sourcing both prototypes and production parts over long distances will impact a business’s carbon footprint, as well as drive costs higher.<a name="prototyping" target="_blank"></a>Quality, reliability, and business resilience are other important considerations. These are generally trade-offs: the cheapest prototyping provider will not usually be the fastest, or produce the highest-quality prototypes, for instance. Maintaining a close business relationship with a prototyping provider is becoming a strategic consideration for many businesses; value is placed on sourcing a recommended manufacturer as an outsource partner with the ability to satisfy prototype needs, plus low- and medium-volume product requirements. These suppliers provide the support that fully understands the need for DFM (design for manufacture) and are key to smoothing the way.In short, successfully bringing a new product to market can call for a multi-faceted approach to design and development, embracing a wide range of issues, priorities, and trade-offs. In this paper we look at how an intelligent approach to prototyping strategy at each phase of the development process can help with this. The objective: an approach to prototyping that shortens overall development time, and brings to market a better product with a better performance, and at a lower overall development cost.<h1><a href="https://get.protolabs.co.uk/prototype-to-production-whitepaper/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-white-paper-0221&utm_content=prototype-to-production-0221" rel="noopener noreferrer" target="_blank">Continue reading -&gt;</a></h1>

Manufacturing throughout the product life cycle

From Prototype to Production

Testing and <a href="https://www.wevolver.com/article/mcam-challenge" rel="noopener noreferrer" target="_blank">prototyping</a> is a crucial part of the design process. For products manufactured using injection molding, the prototyping phase has its own set of challenges. Due to the high cost of creating molds, prototypes are often produced in another material, the design and form and iterated, before the final high-cost molds are crafted. Even if cost wasn’t an issue, getting an injection molded prototype can take months from initial idea to holding a prodcuct in your hand. This extremely long lead time stalls the design process and delays time to market.<a href="https://kyronmax.mcam.com/" rel="noopener noreferrer" target="_blank">Mitsubishi Chemical Advanced Materials</a> has developed a prototyping and manufacturing process that allows functional, material-accurate prototypes to be produced quickly at a considerable reduction in traditional injection molding manufacturing costs. The process involves two overlapping chapters. The first is engineering support that elevates the existing design through an intensive design evaluation and improvement process. The second is the prototyping stage at which the design is further iterated through real-world testing.<h1>Chapter 1: Engineering Support</h1><h2>Stage one: Assessing technical and commercial viability</h2>The first step is the conceptual design phase. This involves close collaboration with the product designers to identify the technologies that are best suited to the part or product that will allow them to deliver a commercially viable product. Once a clear definition and a thorough understanding of the application are understood, the product moves into stage two.<h2>Stage Two: Collaborative design engineering</h2>Stage two centers around collaborative design engineering. Many KyronMAX® users are exploring opportunities to shift from existing metal design to a carbon fiber based composite solution. Making this move can be beneficial for many reasons, including lightweighting, particularly in transportation applications or moving parts (like robotic arms and grippers), reducing carbon footprint, and reducing manufacturing costs. To successfully exchange metal for a compound material, the design must be comprehensively evaluated to take optimal advantage of the new material’s properties. Mitsubishi Chemical Advanced Materials engineers bring extensive expertise in the polymers and composite space. They can offer valuable insight for customers into materials and modeling simulation to really improve their design and meet the desired cost and produce ability targets.<h1>Chapter two: Prototyping and batch part testing</h1><h2>Stage Three: Rapid Prototyping</h2>This stage sees the customer’s designs come to life. The Mitsubishi Chemical Advanced Materials SPRINT (Soluble Printed Injection Tooling) technology uses 3D printed molds that are later rinsed off the injection molded part using a solvent. The technology is based on AddiFab’s Freeform Injection Molding (FIM). The SPRINT process encourages designers to test <a href="https://www.wevolver.com/article/mcam-challenge" rel="noopener noreferrer" target="_blank">designs quickly and accurately</a>, which speeds up the development process and can help bring products to market faster. The SPRINT process works specifically in conjunction with the KyronMAX® &nbsp;range of high strength carbon fiber-based composites.SPRINT accelerates the design cycle by reducing the number of iterations in the design process. Many of the common prototyping processes that are available today provide engineers with quick access and some insight into the basic form and fit aspects of their design, but the SPRINT process provides customers with prototypes from the technologies that the final product will be produced from. Because the prototypes are produced using real injection molding its performance is representative of the final application so this means that the prototype parts can be fully functionally tested in the application’s environment.<iframe src="https://www.youtube.com/embed/q_IwE8YeO4g?&amp;wmode=opaque&amp;rel=0" frameborder="0" allowfullscreen="" class="fr-draggable" style="width: 767px; height: 438px;"></iframe> &nbsp;This is a critical step in really linking the design with performance and getting products to market faster. Mitsubishi Chemical Advanced Materials aim to build relations with each of its customers and offer a full suite of the capabilities needed to provide the right material solution, the engineering know-how and analytics, and the prototyping services that are necessary to translate these concepts into real solutions. The SPRINT process opens the doors to designers and creators who would otherwise be unlikely to have the ability to use injection molding as a prototype material.The expertise of the team also means customers in the final phase of their product can get assistance in commercialization. Where relevant, Mitsubishi Chemical Advanced Materials can fulfill actual part production as a certified supplier and manufacturing partner. Mitsubishi Chemical Advanced Materials also has expertise located regionally in the U.S, Europe, and Asia so customers can get immediate and global access to the knowledge and support they need along their development journey.<h2>The SPRINT technology in detail</h2>Once the part’s design is ready, it’s time to start prototyping using the SPRINT (Soluble Printed Injection Tooling) technology, based on AddiFab’s Freeform Injection Molding (FIM).<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjExOTE1NjA2OTExLUt5cm9uTUFYIHBsYXRmb3JtIHN0ZXBzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 788px;" class="fr-fic fr-dib"><h2>Step 1: 3D Print the mold</h2>The mold for the part is built as a 3D model and printed using a 3D printer. This mold <s>has</s> can have steel pins inserted into it to stabilize the mold during the injection. The mold is also placed inside a metal frame for further stabilization. Even metal inserts, like screw threads can be included directly and overmolded.<h2>Step 2: Inject the mold</h2>The mold is injected with the selected KyronMAX® material using standard injection molding machinery. The injected mold is removed from the machine and inspected.<h2>Step 3: Retrieve the part</h2>The 3D mold is then washed off the molded part using a solvent. Once the solvent is removed, the part is inspected and ready for testing!This process can be repeated multiple times to iterate a design. In some cases, multiple cavities are injected at once with different designs to shorten the design cycle even further. As the cost and speed of printing the mold are very low, the benefits of engaging in a more hands-on design iteration process are very high. As the prototype is molded in the exact material of the final product the prototyping process allows for iteration in finish and detail of the product as well as functionality.<div class="fr-img-space-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjExOTE1OTcxNTQxLTE2MTE5MTU5NzE1NDEuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" class="fr-fic fr-dii">The sacrificial 3D printed mold (far left), the mold after injection (middle) the part released from the mold.<h1 class="fr-img-space-wrap2">The KyronMAX® Challenge</h1></div><a href="https://www.wevolver.com/article/mcam-challenge" target="_blank">The KyronMAX®&nbsp;Challenge</a> invites you to submit a design that utilizes KyronMAX®’s range of breakthrough, high strength carbon fiber-based composites. The winning designs will receive $25,000 worth of manufacturing support from KyronMAX® to create a fully developed prototype.Your submission can be a stand-alone product or a component of a larger design. Successful submissions will need to show how the design utilizes the unique properties of KyronMAX® materials and complements the platform’s capabilities. The KyronMAX® challenge will reward projects that prioritize sustainability while maintaining a high level of feasibility and ingenuity.For full challenge details see <a href="https://www.wevolver.com/article/mcam-challenge" target="_blank">The KyronMAX® Challenge homepage.&nbsp;</a><div align="center"><hr size="1" width="100%" align="center"></div><h1>About the sponsor: Mitsubishi Chemical Advanced Materials&nbsp;&nbsp;</h1>Mitsubishi Chemical Advanced Materials is a leading global manufacturer of high-performance materials in the form of semi-finished products and finished parts. The company has locations in 20 countries and more than 2,800 employees. Its specialty engineering thermoplastics and composites are superior in performance to metals and other materials and are used in a wide range of applications, primarily in the capital goods industry. The company is continuously developing new areas of applications in close cooperation with industry leaders in a broad variety of customer markets. The Mitsubishi Chemical Advanced Materials Group is well prepared to further expand its market leadership position.Supporting the vision of our holding company, <a data-saferedirecturl="https://www.google.com/url?q=http://www.mitsubishichem-hd.co.jp/english/index.html&source=gmail&ust=1610465953419000&usg=AFQjCNFACQRncQmFf1bOAoQ_uuE9Ax8efA" href="http://www.mitsubishichem-hd.co.jp/english/index.html" target="_blank">Mitsubishi Chemical Holdings Corporation (MCHC)</a>, Mitsubishi Chemical Advanced Materials is committed to the realization of KAITEKI, “a sustainable condition which is comfortable for people, society and the Earth”. To realize this vision, the MCHC Group engages in corporate activities that provide products, technologies and services based on the comprehensive capabilities of the Group in the Performance Products Domain, Industrial Materials Domain and Health Care Domain, with chemistry as the basis of our activities. We jointly express and promote our commitment under the corporate brand THE KAITEKI COMPANY.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjExOTE2MjU0NzE1LTE2MTE5MTYyNTQ3MTUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii">&nbsp;

Photo courtesy of Sarah Goehrke, Fabbaloo.

The combination of 3D printing and injection molding creates a start-up friendly approach to fast, low-risk prototyping.

Collaborative manufacturing process delivers rapid materially accurate prototypes

<a href="https://kyronmax.mcam.com/" target="_blank">KyronMAX®</a> is a range of high strength thermoplastic composite compounds from Mitsubishi Chemical Advanced Materials, specifically designed for rapid, complex high-spec injection molding. KyronMAX® is also an engineering platform where engineers collaborate with experts who understand the material, allowing prototyping to be completed within days. The KyronMAX® technology is designed to be applicable in low, medium, or high-volume parts production.&nbsp;<h1>Stronger than steel, lighter than aluminum, and sustainably recyclable</h1>KyronMAX® is among the most robust injection moldable products available in the world today. The series of products significantly changes the way design engineers can think of plastic materials. The unique combination of KyronMAX®’s high-pressure molding technology with advanced material technology produces high-strength structural thermoplastics that offer mechanical properties that meet, and in some comparisons, exceed those of metals.KyronMAX® features:<ul><li>Light, reduced material volume required (75% lighter than steel and almost 40% lighter than aluminum).</li><li>Easily processable (can be molded using the same equipment and tooling as standard or unfilled resins).</li><li>Compounds can be customized to meet application requirements, in addition to standard, readily available product offerings.</li><li>Retains high strength in complex part geometries (with multiple knit lines), where traditional Long Fiber Thermoplastics struggle.</li><li>55k+ PSI tensile strength.</li><li>&lt;30% lower component cost per unit.</li><li>Metal to plastic conversions, without the cost and lead time of traditional metal tooling or penalties for multiple design changes.</li><li>Prototype parts using the same resins as production injection molded parts.</li><li>Surface finishes and features that cannot be replicated by machining or 3D printing.</li></ul>The KyronMAX® series of structural thermoplastic materials outperform the mechanical strength of long fiber thermoplastic (LFT) materials, especially when measuring a molded part’s performance. The material overcomes the limitations of LFT compounds while yielding stronger molded parts that are also lighter in weight.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMTA0NDExNjMzLWltYWdlMTIuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 800px;" class="fr-fic fr-dib">KyronMAX® is suitable for, but not limited to applications including<ul><li>Automotive</li><li>Prosthetics</li><li>Drone and UAV casings</li><li>Sports and leisure equipment</li><li>Industry</li><li>Robotics</li><li>Consumer product design</li><li>Wearables</li><li>Aerospace</li></ul>What makes the KyronMAX® material technology unique is its short fiber technology, which means the polymer behaves more like the isotropic nature of metal and eliminates the processing and fiber breakage concerns associated with LFT compounds. The technology enables very complex parts to be molded with high mechanical performance and consistency.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMDk2NDk5NDA4LUt5cm9uTUFYIHNob3J0IGZpYmVyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 800px;">Image 1: KyronMAX® short fiber technology versus LFTCompetitive structural compounds use high fiber loadings and long fiber lengths to achieve the desired mechanical performance. Unfortunately, these materials’ performance does not translate into the molded parts, due to weld line strength loss and fiber length reduction during processing. In contrast, the KyronMAX® material technology outperforms other thermoplastic compounds using short fiber technology and much lower filler loadings. The lower filler content results in a tough, structural plastic that can be utilized in extremely aggressive applications yet is still processing friendly and does not require specialized molding equipment.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMDk5MDI3NjMzLUt5cm9uTUFYIHRlbnNpbGUgc3RyZW5ndGggVE0uanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 800px;" class="fr-fic fr-dib">The KyronMAX® platform features a range of high-strength carbon fiber-based composites that allows you to buy-off-the-shelf, top-performing materials or customize your own formulation to match your requirements. Each formulation has specific properties that make it suitable for different applications. See here how the <a href="https://kyronmax.mcam.com/about-kyronmax" target="_blank">KyronMAX® range compares</a> to each other and other common injection molding materials.<h1>The KyronMAXⓇ&nbsp;platform</h1>KyronMAX® is more than a material; it is also an engineering partnership. From design to functional prototype, to production and all the way through to zero waste, engineers work together with Mitsubishi Chemical Advanced Materials to solve materials engineering challenges. The KyronMAX® collaboration happens in three phases.Phase 1 - Diagnostics: content deep dive, feasibility check, AI-based business intelligence.In this phase the overall feasibility of the project is assessed from both a materiality and business perspective.Phase 2 - Design Sprint: MVP designMVP (minimum viable product) design is a process for creating functional, production-ready products that serve to test ideas and complete a design process. Puts functional parts with true properties into customer’s hands quickly to accelerate the design cycle and lock-in material specifications.Phase 3 - Delivery Sprint: functional prototype creation and testing, plus approach to recyclingSPRINT (Soluble PRinted INjection Tooling) technology means functional prototypes can be developed in just a few days. SPRINT allows for rapid injection molding of functional parts in the right material. Alongside digital twinning, it means real world designs can be tested quickly and accurately, shortening design timelines and meeting production deadlines faster.&nbsp;SPRINT combines the speed and agility of 3D printing with the accuracy of injection molding. Unlike other injection molding processes, the KyronMAX® SPRINT can produce material accurate prototypes in just days rather than weeks. A 3D Resin mold is first 3D printed, this is then injected with the chosen polymer. The resin is then ‘washed’ away to reveal the prototype part.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMzU5NzYwNTk2LTEuMS0wMS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 800px;" class="fr-fic fr-dib">Throughout the three-stage journey, KyronMAX® experts support engineering teams on:<ul><li>Material selection</li><li>Part design</li><li>Test and production of functional prototype with SPRINT (Soluble PRinted INjection Tooling) technology</li><li>Setup of production scale up plan</li><li>Assessment of the project’s recycling possibilities in order to create zero waste</li></ul>Designers and engineers working with KyronMAX® are supported throughout the whole process from ideation to final product no matter if the project is a small-batch prototype or fully commercial product. Read more about the collaborative KyronMAX® platform h<a href="https://kyronmax.mcam.com/working-with-us" target="_blank">ere</a>.<h1>A new standard in sustainability</h1>KyronMAX® injection moldable composites can be returned to create zero waste using their end-of-life recycling program, while their vertically integrated and closed-loop supply chain is key to all KyronMAX® engineering partnerships. Their commitment to sustainability goes beyond simple recycling their materials and minimizing their impact. KyronMAX® uses digital twins to test new ideas, their focus on small batch prototyping means their entire production process is further designs to minimize waste and maximize speed to market.The key advantages to this focus on sustainability includes:<ul><li>Faster production lowers overall energy costs while lightweight formulations reduce the overall manufacturing footprint as well as and improves fuel economy, energy use and longevity in applications from aviation to robotics.</li><li>The KyronMAX® tailor-made injection moldable carbon-fiber composite compounds can be reused and returned to create zero waste using our end of life recycling program.&nbsp;</li></ul>The production process allows for any scrap, waste, or unused products to be taken back and recycled without down cycling.<h2>Light weighting and metal replacement</h2>Plastic replacement of metal generally offers advantages to designs, including the potential to be lighter, cheaper, or more quickly produced. However, most high-strength moldable plastics are nowhere near the strength of metals so the metal part geometry must be altered and re-engineered to utilize plastic materials. This often involves adding more material volume of the plastic which can increase the weight and cost of the part. Thanks to KyronMAX®’s high strength properties and complex geometries, component design can more easily replicate the original metal design, reducing material volume while realizing all the benefits of the plastic material.A great example is the KyronMAX® #10-32 bolt that responds to multiple requests from OEMs for an injection moldable thermoplastic composite bolt that exhibits metal-like strength. These end-users were looking for a plastic fastener to replace traditional titanium metal fasteners for weight savings but could not find a polymer with enough mechanical performance, or that was economically viable. The KyronMAX® #10-32 bolt meets both the strength and the cost target requirements for the application while reducing the weight of incumbent titanium bolts by approximately 60%! Read more about KyronMAX®'s commitment to full life-cycle sustainability <a href="https://kyronmax.mcam.com/" rel="noopener noreferrer" target="_blank">here.&nbsp;</a><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMzc0NDEzMDE4LUt5cm9uTUFYIGJhbm5lci5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 788px;" class="fr-fic fr-dib"><h1>The KyronMAXⓇ&nbsp;Challenge</h1><a href="https://www.wevolver.com/article/mcam-challenge" rel="noopener noreferrer" target="_blank">The KyronMAX®&nbsp;Challenge</a> invites you to submit a design that utilizes KyronMAX®’s range of breakthrough, high strength carbon fiber-based composites to solve an engineering or manufacturing challenge. The winning designs will receive $25,000 worth of manufacturing support from KyronMAX® to create a fully developed prototype.Your submission can be a stand-alone product or a component of a larger design. Successful submissions will need to show how the design utilizes the unique properties of KyronMAX® materials and complements the platform’s capabilities. The KyronMAX® challenge will reward projects that prioritize sustainability while maintaining a high level of feasibility and ingenuity.For full challenge details see <a href="https://www.wevolver.com/article/mcam-challenge" rel="noopener noreferrer" target="_blank">The KyronMAX®&nbsp;Challenge homepage.&nbsp;</a><hr><h1>About the sponsor:</h1>Mitsubishi Chemical Advanced Materials is a leading global manufacturer of high-performance materials in the form of semi-finished products and finished parts. The company has locations in 20 countries and more than 2,800 employees. Its specialty engineering thermoplastics and composites are superior in performance to metals and other materials and are used in a wide range of applications, primarily in the capital goods industry. The company is continuously developing new areas of applications in close cooperation with industry leaders in a broad variety of customer markets. The Mitsubishi Chemical Advanced Materials Group is well prepared to further expand its market leadership position.Supporting the vision of our holding company, <a data-saferedirecturl="https://www.google.com/url?q=http://www.mitsubishichem-hd.co.jp/english/index.html&source=gmail&ust=1610465953419000&usg=AFQjCNFACQRncQmFf1bOAoQ_uuE9Ax8efA" href="http://www.mitsubishichem-hd.co.jp/english/index.html" target="_blank" title="http://www.mitsubishichem-hd.co.jp/english/index.html">Mitsubishi Chemical Holdings Corporation (MCHC)</a>, Mitsubishi Chemical Advanced Materials is committed to the realization of KAITEKI, “a sustainable condition which is comfortable for people, society and the Earth”. To realize this vision, the MCHC Group engages in corporate activities that provide products, technologies and services based on the comprehensive capabilities of the Group in the Performance Products Domain, Industrial Materials Domain and Health Care Domain, with chemistry as the basis of our activities. We jointly express and promote our commitment under the corporate brand THE KAITEKI COMPANY.<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjEwMzc5ODcyNzM3LWxvZ28gZm9vdGVyIE1DQU0uanBnIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 788px;" class="fr-fic fr-dib">

prototyping

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From Prototype to Production

Collaborative manufacturing process delivers rapid materially accurate prototypes

New manufacturing platform combines agility of 3D printing with strength of injection molding for rapid prototyping