"INDUMAT" INDUMAT. DEVELOPMENT OF PROCESSES OF TRANSFORMATION FOR THE INDUSTRIALIZATION OF NEW MATERIALS: SOLID SURFACE AND LIGHTED MATERIALS DESCRIPTION The continuous appearance in the market of new materials with improved properties and new structures allows the development of innovative technical solutions in various fields of activity, whether at the industrial or consumer level. The use of these advanced materials, especially when used in consumer products, requires developing transformation processes that confer economic viability to the processing industry. Among the various families of new materials that are already beginning to be used in everyday products, two groups stand out: Solid Surface and Lightened Boards. Considering this premise, the general objective of the project is to develop new transformation processes applicable to these groups of materials, easily incorporated by the SMEs of the Valencian Community, so as to reduce their cost of industrialization and expand their fields of application, allowing introduce new product developments with greater added value From a business point of view, the project is valued from a double perspective: the developers of new materials and their transformers. The first group of companies, relatively small, are facilitated by opening new markets by providing new applications for their materials. The second group, much more numerous, is given the possibility of developing new applications with materials of special characteristics, solving the problem of their industrial treatment, with the consequent lowering of costs OBJECTIVES The specific objectives of the project are: 1- Develop new industrialization systems for Solid Surface materials in the following processes: - 3D formed by thermoforming technology. - Bonding processes through welding technologies. - Processes of localized application of dyes by means of printing technology. 2- Develop new industrialization systems for lightened materials in the following processes: - Formed by machining and continuous bending. - Insertion of elements and fittings in the material by injection of support resins. 3- Develop and / or adapt the technology necessary to perform the indicated processes on an industrial scale. The processes indicated for each type of material are those that have been identified as more interesting from the point of view of the development of new applications, as well as those that would provide more value when applied to them. Project Number: 21400014 Grant Agreement: IMDEEA / 2014/31 Duration: From 01/01/1900 to 31/12/2014 Coordinated in AIDIMME by: SÁNCHEZ ASINS, JOSÉ LUIS R&D Line: PRODUCT DEVELOPMENT AND OPTIMIZATION RESULTS OBTAINED 2015 Year: Solid bending and forming: the cycle time of a forming process on a Solid plate, currently ranges between 20 and 40 minutes and the whole process involves manual manipulation of the plate. The proposed alternative process is to perform a vacuum thermoforming, reducing the heating time, handling and cooling time. Tests were carried out at different temperatures to see the plasticity of the material, the heat transmission to the center, cooling times, etc. With this information a team was designed to perform the thermoforming, and the prototype is available for testing during the second year of the project. Year 2015: Joining Solid parts: initially it was proposed to develop a welding process similar to that used in plastic materials. However, when carrying out a test to determine the plastic melting points of the material in a differential calorimeter, it was observed that it only had one deformability point above 300ºC and another at a higher temperature (about 400ºC). Given that it was not possible to “weld” the material and that at a business level there was an interest in improving this process, work was carried out by maintaining the adhesive joining method but trying to reduce the process time. Finally, a portable device was designed that allows two flat surfaces to be held together by pressure. Two prototypes were built that will be tested in the factory this year 2015. 2015 Year: Curved lightened boards: the main problem to bend this type of board is its different composition in the faces and in the soul. Alternative technologies were sought and finally it was decided to test the "scratch" of the board. To design the process, it was necessary to calculate the relationship between cutting widths, cut surface length, folding angles, etc. Year 2015: Assembly of lightened board pieces: the latest process that has been developed is the joining of lightened board pieces together, and the insertion of various types of hardware on faces and edges. The objective of this process is to be able to manufacture modular furniture for different uses with lightened boards, so that its weight is reduced by up to 50%. Several tests have been carried out with boards of different wall thickness and honeycomb core, although the result can be extended to any type of material with which the core is made. To evaluate the problems that appeared in the construction of modules, two units were manufactured with two types of hollow board, one of 20 mm with 2 mm thick walls, and another of 26 mm with 5 mm thick walls. Based on the results obtained, alternative process options have been developed that are pending validation in the second phase of the project. PUBLISHED NEWS general broadcast https://www.facebook.com/PLATECMA/posts/740300196055219 (...) http://www.noticiashabitat.com/2014/aidima-propone-innov (...) PARTNERS AIDIMME - METAL-MECHANICAL TECHNOLOGICAL INSTITUTE, FURNITURE, WOOD, PACKAGING AND RELATED, GRANT € TARGET AUDIENCE AND IMPACT MEASUREMENT 3060 Access to the project website 0 Access to news published on own websites. Total Accesses: 3060 TRACTOR COMPANIES Thanks to its support and signature of the "declaration of participation" the project has been funded. COMPANIES DIFFUSION R&D PROJECTS They want to know first-hand the evolution of the project, and its progress to the final result. COMPANIES TRANSFER KNOWLEDGE They will implement technologies, develop strategies or look for new models based on the results.