Summary

The Panel Discussion provides an overview of Hyundai-Kia's sustainability strategy and efforts towards achieving carbon neutrality through enhanced product sustainability. It highlights the company's commitments and goals, including plans for electrification, hydrogen mobility, and incorporating eco-friendly materials in their vehicles. The presentation covers various aspects of sustainability, such as raw material recycling, bio-materials, and the challenges faced in implementing these initiatives. Specific examples are provided, including the use of recycled plastics, reclaimed ocean materials, and bio-derived materials like bio-TPO, bio-PET, and bio-paints in their latest electric vehicle models. The document also touches upon future goals, such as exploring real wood sheets, natural reinforcements, and mycelium materials for bio-fabrication.

About the Speakers

Drew Geda works as a member of the Strategic Materials Development team at the Hyundai America Technical Center, Inc. His focus is on sustainable interior plastic material development. He holds a Bachelor’s degree in Chemical Engineering from Michigan State University, and has spent time within the automotive and aerospace industries over the past 15 years, working with such companies as DuPont, General Motors, Meggitt Polymers and Composites, and Hyundai. Drew is an active member of the Society of Plastics Engineers, sitting on the board of directors for the automotive division, and participating in many of the SPE Conference planning committee teams. He has coauthored a handful of papers related to advanced material research and development, and holds a few patents in similar technologies.

Jeff Weny works as a member of the Exterior Engineering Design team at the Hyundai America Technical Center, Inc. He has extensive background in Exterior Trim plastic application including fascias, underbody shields, appliques and close out panels. He has worked for multiple OEM’s as well as suppliers over the past 25 years.

Izzy Newton works as a member of the Strategic Materials Development team at the Hyundai America Technical Center, Inc. Her focus is on sustainable interior soft trim material development, and her areas of interest include bio-based materials, process optimization, and design for end-of-life recyclability. She holds a Bachelor’s degree in Materials Engineering from Brown University, and a Master's degree in Materials Science & Engineering from the University of Michigan.

Angelo DiLisio is an engineering manager, with more than 15 years of engineering experience with various polymeric materials. He holds two bachelor’s degrees from Ferris State University: the first in Plastics Engineering Technology, and the second in Rubber Engineering Technology. Angelo is a member of the Materials Development team at the Hyundai America Technical Center, Inc. and manages the Strategic Materials section within. He and his team are responsible for all plastic materials sourced in the Western Hemisphere, identifying and locally developing sustainable plastic materials for automotive use, and supporting various local assembly plants for cost savings and quality improvement activities. Angelo’s technical accomplishments include test method development and new technology/materials development, with a keen focus on communication.

Moderators

Matt Vandyke
General Motors

Mark Allen
Dow

Summary

The panel discussion provides an overview of a panel discussion on Life Cycle Analysis (LCA), its process, challenges in material data tracking, and its application and future in the automotive industry, specifically for thermoplastic olefins (TPO). It covers the LCA framework, from goal definition to interpretation and reporting, highlighting its power in assessing overall sustainability across various environmental impact categories beyond just carbon emissions. The discussion also explores the difficulties in efficiently tracking material data and how proper tracking can be a valuable tool. Additionally, it examines the scope, development, application, and future potential of LCA in the TPO industry, considering the evolving regulatory landscape and the need for manufacturers to comply with regulations incorporating LCA elements.

About the Speakers

Brian Leen is a Sustainable Materials Engineer at General Motors. He has three years of work experience in conducting Life Cycle Assessments (LCA) as well as two years of experience working to develop Sheet Mold Composites. Within his role at General Motors, he works with subject matter experts in Plastics, Metals, Textiles, and Batteries from a sustainability and LCA perspective. Brian has undergraduate degrees in Chemistry and Bio-medical Sciences from Central Michigan University and a MS in Chemical Engineering from Wayne State University.

Jade Beauregard is a Sustainable Materials Engineer at General Motors. She has worked at GM for four years, joining the Sustainable Materials team in 2022. In this role, Jade is responsible for implementation and tracking of sustainable material content.

Prior to GM, Jade received a BS in Mechanical Engineering, with a concentration in Sustainable Engineering, from the University of Michigan. She is currently pursuing a MS in Sustainable Engineering from Villanova University.

Rachel Burland is a Sustainable Materials Engineer at General Motors. She has two years of Life Cycle Assessment (LCA) experience within material processing, manufacturing, and end of life for various materials and sustainable materials development. Rachel graduated in 2016 with a BS in Materials Science and Engineering from Michigan State University. After graduation she worked at Magna Powertrain for five years in material lab practices, failure analysis, and international work experience.

Rob Mimms is a Sr. Material Development Manager at Advanced Composites, Inc., located in Nashville, Tennessee. He is responsible for overseeing the design of material formulations to meet the emerging needs of the automotive industry, including sustainable TPOs. Since joining Advanced Composites in 2012, his efforts have been focused primarily on material solutions for North American and European OEMs. He holds BS in Chemical Engineering and Master of Business Administration degrees from Tennessee Technological University.

Shirell Klein is a Research Chemist at HRL Laboratories, an LLC co-owned by Boeing and General Motors. Her background is in materials science, optics, and sustainability, working in tandem with GM on LCA frameworks of automotive materials for the last few years. Most recently she has focused on evaluating bio-based polymers / fillers to determine their potential benefits and drawbacks when considering a future circular industry. Shirell graduated with a Masters in Chemistry from Columbia University.

Susan Kozora, Director of Advanced Materials Engineering at IAC Group, brings over 39 years of expertise in plastics and adhesives technologies, particularly within the aerospace and automotive sectors. A University of Detroit graduate with a Bachelor’s degree in Chemical Engineering focused on polymers, she began her career in advanced composite design for turbine engine components at Textron Aerospace. Later, she joined Ford Motor Company, providing materials engineering expertise across multiple systems, and then Visteon Corporation as Materials Engineering Manager, where she led polymeric materials, recycling initiatives, End of Life Vehicle considerations, and joining technologies. Currently at IAC Group, she directs innovation with a focus on sustainability and recycling, serving as the Sustainability champion for IAC's Troy Campus. Susan is an active member and former Division Chair of the Society of Plastics Engineers’ Sustainability Division, a session co-chair for the Sustainable Materials track of the SPE Automotive TPO conference, and holds three patents, along with several publications on plastics and recycling.

Moderators

Mark LaPain
Advanced Composites

Neil Fuenmayor
LyondellBasell (Retired)

Summary

The panel discussion provides insights from the founders of the TPO Conference, highlighting its inception, growth, and future prospects. It delves into the key positions and educational backgrounds of industry leaders like Norm Kakarala, Rose Ryntz, Robert Eller, and Bill Windschief. The founders emphasize the conference's role as a cost-effective platform for discussing challenges, exchanging ideas, and fostering collaboration between OEMs, tiers, and sponsors. The document traces the transition to TPO materials, driven by factors like cost and appearance, and presents data on the projected growth of PP-based materials in the automotive industry. It showcases the conference's success through attendance, session, and exhibitor statistics from 1999 to 2023. Additionally, it outlines current market trends, including environmental concerns, processability, and the impact of electric vehicles, offering advice for the conference's next 25 years.

About the Speakers

Norm Kakarala is the President of the SPE Detroit Section when the TPO conference got started and has been Co-Chairing the Conference Technical Program for all 25 years. He is the Founding Member of the SPE Auto EPCON and the SPE EAV Conferences. He has received Lifetime Achievement Awards from both the SPE Detroit Section and SPE Automotive Division. He continues to be active as an Emeritus Board Member for both Detroit Section and the Automotive Division.

During his career Norm worked at Uniroyal Tire Company, General Motors, Delphi and as a Senior Technical Fellow – Inteva Products.

Norm has B. Tech., Chemical Engineering from Andhra University, India; a Master’s Degree, Chemical Engineering from Wayne State University and a Doctor of Engineering, Chemical Engineering from University of Detroit Mercy.

Rose Ryntz has received the SPE and Detroit section Lifetime Achievement awards; the Ward’s Automotive 100 Leading Women in Automotive; the Henry Ford Technology Award for Paint Adhesion Improvements to TPO Fascias; and the University of Detroit Spirit Award for Contributions to the industry.

Rose worked at Dupont Performance Coatings, Visteon. Was a Global Vice President at IAC Group and is currently the president of Ryntz & Associates.

She has a Bachelor’s Degree, Organic Chemistry from Wayne State University, a PhD in Polymer Organic Chemistry from University of Detroit Mercy and an MBA from the Eli Broad College at Michigan State University.

Robert Eller has been consulting on the technology, economics and markets for TPOs, TPEs and TPVs for 30 years. This work has included several multiclient as well as single client strategy studies, in addition to directing the interiors session of the TPO Conference for 20 years, During his career Bob worked at Athur D Little, was a vice president at Phillip Townsend Associates, MultiBase Inc, and Charles River Associates, and is currently the President of Robert Eller Associates. Bob has a masters degree in Chemical Engineering and Polymer Science from Brooklyn Polytechnic and a Bachelors degree in Chemical Engineering from the Massachusetts Institute of Technology

Bill Windscheif During his long career, Bill worked as a market development manager at GE Plastics, Director of Business Development at Vista Chemical, vice president at Basell, Director of Automotive at Flint Hills Resources and President of Advanced Innovative Solutions.

Bill has a Bachelor’s degree in Engineering and Material Science from Kettering University and studied business at The Wharton School, University of Pennsylvania.

Summary

The presentation presents a solution to address the industry's need for chrome-like effect coatings for exterior TPO applications, driven by design trends, material trends towards TPO, environmental concerns with traditional chrome plating, and performance and cost issues with existing chrome alternatives. It highlights the benefits of Mankiewicz's Alexit® Chrome effect coatings, including their ability to achieve a better liquid look, improved processability, and enhanced durability while meeting OEM requirements. The coatings offer a cost-effective and sustainable alternative to electroplating, reducing the carbon footprint and addressing legislative concerns. The document provides supporting data on paint performance testing, examples, and a cost comparison with electroplating, demonstrating the viability of the proposed solution.

About the Speakers

Guy LaRouche, Senior Materials Engineer at General Motors, has worked in exterior polymers, paint, and materials for the entirety of his 24-year career at GM. His current role at GM carries responsibility for Fascia, Grille, Hood Moldings, Bumpers, Aero Shutter Systems, and Wheel Liners, as well as leading the Materials Exterior Expert Team and supporting the Virtual by 2025 Initiative for exterior plastics. Guy is also the GM Material Specialist for Polycarbonates, Styrenics, Paint over Chrome, and Powder Coatings. Prior to his assignment in GM materials engineering, Guy held positions as Design Release Engineer in the exterior trim organization, as Resident engineer at the Bowling Green (Corvette) Assembly Paint Shop, and as a Paint and Polymer Manufacturing Engineer. Guy has authored several patents and defensive publications in exterior coatings tech

Bill Coy is a Key Account Manger in the Automotive Technical Services Group at Mankiewicz Coatings, LLC. His primary focus is working with General Motors on technology approvals, new innovations, and understanding the market trends for the future.

Bill has been in the automotive coatings industry for 12 years, which he started by working on a lab bench supporting customer issues. He has held various roles from Development Chemist to Global Sales Manager, but has always stayed in the realm of coatings for plastics. Bill has a continued interest in coating innovations and what it can offer for the overall sustainability goals for the future. He continues to serve as a committee member for the SPE Electric and Autonomous Vehicles Conference as well as the SPE TPO Conference.

Bill earned a bachelor’s of science degree in Chemistry from Adrain College in Adrian, MI along with a minor in mathematics.

Summary

The presentation discusses Advanced Composites' sustainable interior polyolefin materials containing post-consumer recycled (PCR) content, designed for automotive applications. It highlights ADX-8302, a 50% PCR material suitable for interior trim applications where impact performance is not critical, and ADX-8341, a 25% PCR grade with improved impact resistance enabling its use in door panels. Both materials offer comparable performance to incumbent virgin materials in terms of shrinkage, scratch resistance, thermal stability, and UV resistance. The document emphasizes the importance of industry collaboration to meet emissions reduction and recycled content targets, and presents a case study evaluating the materials' properties using a mini-door panel tool.

About the Speakers

Ben McComb is a Material Development Engineer in the Research and Development group at Advanced Composites based in Nashville, Tennessee. His role involves the formulation, validation, and approval of new TPO materials for North American automotive OEMS. He works with a range of materials including recycled, flame retardant, mold-in-color, painted, and those intended for interior or exterior applications. He has worked at Advanced Composites for 5 years.

Ewa Lebert is a Senior Materials Engineer at General Motors, where she provides expertise in polymeric materials to various departments, including product development, design, quality, and purchasing. She currently serves as an Interior Program Materials Engineer, the material specialist for TPO and long glass fiber PP, and Plastics Global Subsystem Leadership Team Co-Lead. Ewa joined GM in 2022 with over twenty years of experience in the automotive industry, with prior roles at both another OEM and Tier 1 supplier, supporting interior and exterior applications along with various sustainability related actvities. Ewa holds a Master of Science degree in Chemistry from the University of Detroit Mercy (2003) and a Bachelor of Science degree in Chemistry from Wayne State University (1998).

Summary

The presentation discusses single-side lamination adhesives for interior trim applications, specifically the ThermonexOne product line from H.B. Fuller. It covers the different lamination processes (press, vacuum, and premium), the benefits of single-side adhesive application, and the performance characteristics of ThermonexOne adhesives. The document also provides application guidelines, including drying, pre-fixing, cleaning, and disposal instructions. Additionally, it showcases lamination trials with ThermonexOne 301-01A, demonstrating its compatibility with various materials like artificial leather, genuine leather, spacer fabric, and foam-backed textile.

About the Speakers

Brent Landis is a Product Manager for the Automotive market in the Americas for H.B. Fuller. He has been with the company for over 25 years in various roles starting in operations where he began as a process engineer and later spent time as a production manager. In these positions he gained a great appreciation for the importance of process optimization for production efficiency. He moved into product management 11 years ago and began work in the Automotive Interior Trim segment in 2020.

Rick Snyder is the North American Automotive R&D laboratory Manager for H.B. Fuller. Throughout his 35 plus year career, Rick has focused on product development of adhesives, sealants and coatings for the automotive industry. He describes himself as problem solver with an emphasis on creating win-win solutions. Rick is from Toledo, Ohio, a graduate of Adrian College and currently resides in the Greater Detroit Metro area.

Summary

The presentation provides an overview of Materi'Act's NAFILean product line, a sustainable material ecosystem aimed at decarbonizing plastic production. It highlights the company's global initiatives to secure bio-based and recycled feedstocks, including collaborations for transforming biomass, introducing recycled plastic compounds, and exploring the use of ocean-bound plastic waste. The NAFILean family offers alternatives to traditional materials like PP glass fiber, TPOs, and styrenics, with lower carbon footprints and recyclability. The document presents a case study demonstrating NAFILean's successful integration into the standard recycling process without negatively impacting the quality of the recycled feedstock. It compares the mechanical and thermal properties of NAFILean with competitive materials, showcasing its stability over multiple recycling loops. Overall, the document positions Materi'Act as a leader in sustainable materials, driving the transformation towards carbon neutrality.

About the Speakers

Todd Hughes, as Sr Sales Manager for MATERI’ACT North America, is responsible for all Sales activities within MATERI’ACT in the North American Division of Forvia. In his 17 years with Forvia, Todd has held roles within Program Management and Sales, and is located in Auburn Hills, MI.

As General Manager for MATERI’ACT North America, James Leo Mazurek is directly responsible for the business and operations of MATERI’ACT in the North American division of FORVIA. In his nearly 15 years with FORVIA, Leo has held roles within engineering, operations, purchasing, and sales. Leo is currently located in Sunnyvale, CA.

Summary

The presentation explores innovative approaches to end-of-life management for durable goods, focusing on sustainable practices that close the loop and promote a circular economy. It delves into strategies for responsible disposal, reuse, and recycling of materials, highlighting the environmental and economic benefits of effective resource management. The authors share insights and real-world examples from industry experts, showcasing successful implementations and best practices in durable goods end-of-life management.

About the Speakers

Kari Bliss leads Sustainability at PADNOS, an industrial recycler of paper, plastics, metals, and electronics. She is a GreenBiz certified professional, Leading the Sustainability Transformation, GRI Certified Sustainability Professional, a board member of the Michigan Sustainable Business Forum, Board Vice President of Public Thread, Co-PI on a DOE Grant with U of M and Ford. She is a results-driven leader skilled at bringing stakeholders together to develop sustainability initiatives and solve complex circular economy challenges.

Hayden Latham is an Account Representative at PADNOS, a diverse processor/recycler of paper, plastics, metals, and electronics. His specialty is in business development for the Plastics division, working with OEMs, Tier-1s, and injection molders to replace their virgin resins with recycled, carbon-reducing materials. PADNOS Plastics represents a long list of automotive approvals and supplies material to agriculture, packaging, automotive, and many other industries. He is also a member of the Society of Plastics Engineers, SAE International, and the cochairman of the Sustainable Materials Group for Suppliers Partnership for the Environment.

Summary

The presentation discusses improving the impact properties of PureFive recycled homopolymer polypropylene (rPP) resin through compounding with appropriate additives and blending with impact copolymer PP (ICP). It explores compounding PureFive rPP with different impact modifiers at varying ratios, observing significant improvement in impact resistance, particularly at sub-ambient temperatures for certain modifiers. Additionally, blending PureFive rPP with ICP is presented as another approach to enhance impact resistance. The study evaluates various mechanical properties, including melt flow rate, notched Izod impact, multi-axial impact, tensile strength, stiffness, and heat deflection temperature, for the compounded and blended formulations.

About the Speakers

Susan E. Blackson, Director of Strategic Accounts at Pure Cycle Technology, Inc., ,has an extensive career in the plastics industry, having held roles in Global Strategic Sourcing at Amcor Rigid Packaging and Corning Incorporated, and in Product and Engineering Services at Nova Chemical and Arco Chemicals. As a certified Continuous Improvement Black Belt Program Manager, she has driven impactful results by applying technical and commercial best practices across multiple industries. Currently, she is dedicated to delivering sustainable solutions through PCT's licensed purified PP resins to the packaging, textile, and automotive markets.

Katie May, Senior Account Manager, Milliken Plastic Additives, has over 10 years of experience working with polymers. Five years spent with Milliken on the North America Plastics Additives team, most of which has been focused on reactive extrusion additives for recycling processes. Katie has previous experience with Johns Manville and Bridgestone Tires. She holds a degree in Chemistry from Georgia Tech and an MBA from Clemson University.

Summary

The presentation discusses improving the impact properties of PureFive recycled homopolymer polypropylene (rPP) resin through compounding with appropriate additives and blending with impact copolymer PP (ICP). It explores compounding PureFive rPP with different impact modifiers at varying ratios, observing significant improvement in impact resistance, particularly at sub-ambient temperatures for certain modifiers. Additionally, blending PureFive rPP with ICP is presented as another approach to enhance impact resistance. The study evaluates various mechanical properties, including melt flow rate, notched Izod impact, multi-axial impact, tensile strength, stiffness, and heat deflection temperature, for the compounded and blended formulations.

About the Speakers

Mr. Yosuke Furuya graduated from Kyoto University with master's degree of Applied Chemistry. He is currently working as a researcher at Sumitomo Chemicals Co., Ltd. and engaged in developing new polymer products and providing their technical customer supports by use of my expertise in the polymer science.

Mark Herrema, CEO of Newlight Technologies, co-founded Newlight in 2003 with a vision of using greenhouse gas as a resource to make high-performance, sustainable materials. Mark graduated magna cum laude from Princeton University, and after a decade of research, Mark and his team developed a technology using a process found in nature to convert greenhouse gas into a material called AirCarbon (meltable energy storage material).