Nominating Company: Placon | OEM: Placon

Gold award for Packaging Design Innovations | SPE Thermoforming Conference 2018

Process used to mold part: Thermoforming

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): PET - made with Placon's EcoStar material that is made from post-consumer recycled bottles and thermoforms. Our EcoStar material is 100% recyclable.

Category that best describes part function: Sustaining Life (environmental, conservation, sustainability, recycling, reduction)

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Product Description

This product transports badges securely in a compact space and then opens quickly and easily into multiple option badge displays for meeting registration.

Innovation

• The package demonstrates an application of a "new idea."
  The Flex is as much a display solution as it is a distribution solution. This efficient unit moves from transit to modular display in seconds. The thermoformed trays act as the shipping package and the display product to locate badges quickly.
• The package demonstrates a creative use of existing ideas.
  The Flex is a next generation product built upon the OneWay® family of name tag organizers and created by pc/nametag, a leading source of customized name badges and event supplies. The unit evolved from the standard tray and lid design and developed into a compact, foldable cube. The perforation allows the tray to easily fold for shipping and to permit multiply badge display alternatives.
• The package makes use of new design, material or technique.
  The folding design and technique is used for unique containment and display. The interlocking design tabs allow the two trays to be easily joined or separated depending on the badges display required for event check-in. The design includes two trays that connect or disconnect providing multiple ways of displaying name badges for event check-in.
• The package reflects important new marketing strategies.
  The Flex’s compact design not only provides enhanced security during shipping, but also a smaller package size and overall dimensional weight for reduced shipping costs than the previous lid and tray design of the OneWay® Stack,™ the Flex’s forerunner.
• The package reflects new manufacturing advances.
  The Flex is leading the way in sustainable packaging by using environmentally conscious packaging materials. The package is made with from Placon's EcoStar® recycled material, offering superior clarity, high-quality strength and performance. The EcoStar material is made from post-consumer plastics.

Nominating Company: Placon | OEM: Placon

Gold award for Packaging Design - Best Consumer Package | SPE Thermofomring Conference 2018

Process used to mold part: Thermoforming

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): PET - made from Placon's EcoStar post-consumer PET recycled material made from post-consumer bottles and thermoforms. EcoStar is 100% recyclable.

Category that best describes part function: Quality of Life (mobility, communication, luxury/comfort, recreation, entertainment)

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Product Description

The Pokémon XY Collection trading card game package includes a rigid setup box with printed litho foil paper wrap and three RPET thermoformed trays inside made with Placon’s environmentally conscious, EcoStar® recycled PET material from curbside-collected bottles and thermoforms.

The versatile packaging configuration is intended for retail, but also converts into a storage device for players after the content is unloaded. The plastic clamshell in the cover allows for high level promotional cards to be displayed in the front of the box for retail presentation and also allows consumers to change the cards to include their favorite cards to display. The supreme clarity of the RPET EcoStar material allows for enhanced visibility of the promotional card in the front of the package.

There are three card and accessory content thermoformed storage trays included in the packaging that can be filled by the consumer and stored inside the outer box. The magnetic closure on the front panel helps to keep the box closed and product protected.

For over 20 years, kids all over the world have been discovering the enchanting world of Pokémon. Today, the Pokémon family of products includes video games, trading cards, animated TV series, movies, toys and much more. The games encourage strategic thinking and math skills, while putting a strong emphasis on good sportsmanship and respect for others.

In the Pokémon Trading Card Games, one of the most popular Pokémon products, players build decks around their favorite Pokémon and then play against each other, sending their Pokémon into battle to prove who the best Pokémon Trainer is. Players begin with theme decks and can augment their card collections with booster packs that provide more cards. With thousands of cards to choose from, the game is never the same twice. The Pokémon Company releases four sets of cards, called “expansions,” each year and over 100 incremental projects in 37 countries worldwide in a given year.

See Placon Press Release.

Nominating Company: Ford Motor Company | OEM: Ford Motor Company

TPO Part Competition Winner - Interior Category | AUTO TPO Conference 2017

Process used to mold part: Melt Compounding Followed by Injection Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): rPP+HC (CF/LGF), Recycled Polypropylene +Cellulose and Long Glass Fibers

Category that best describes part function: Sustaining Life (environmental, conservation, sustainability, recycling, reduction)

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Product Description

Hybridization of cellulose fiber with long glass fibers in polypropylene composites reduced the use of inorganic fibers in console substrate, leading to robust properties and significant weight and cost savings, while contributing to sustainability of composites. Largest injection molded part to include natural fibers resulting in a weight savings of over 1.5 pounds. The hybrid composite meets all Ford requirements (materials and performance level) while significantly reducing CO2 emissions (14M kg CO2 reductions. That's the same as the CO2 emissions from 16M lbs of coal burned). Cellulose is a renewable source and offers an environmentally friendly alternative for composite reinforcement without sacrificing performance. Cellulose production requires little energy and CO2 is used while oxygen is given back to the environment. Cellulose fiber is a side product of the lumber industry. This is a high value use of cellulose fiber. A high degree of flexibility, which makes cellulose fibers to bend rather than fracture, in association with low density and non-abrasive surface, are practical isotropic advantages for its hybrid composites as compared to current short glass -mineral filled PP. There is no need for new design or mold modifications. Hybrid composites reduced tool wear versus short glass -mineral filled PP, and reduced operating temperatures save energy. No issues with thermal degradation and odor due the purity of the cellulose fibers. 24% weight saving versus current short glass -mineral filled PP. 13% cost saving versus current short glass -mineral filled PP. In addition to the reduced environmental impact, cost effective and lightweight, hybrid composite flows very quickly at relatively low temperatures and pressures. As a result, hybrid composites reduce the energy costs associated with production, and produce an end-product with great structural rigidity and new, highly marketable performance capabilities.

See Plastics Engineering article.

Nominating Company: Therma-HEXX Corporation | OEM: Therma-HEXX Corporation

First Place (Gold) in the Heavy-Gauge Twin Sheet Division

Process used to mold part: Twin Sheet Thermoforming

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Dow Intrepid 2499 – Bimodal Polyethylene Resin with raised temperature capability (PE-RT).

Category that best describes part function: Quality of Life (mobility, communication, luxury/comfort, recreation, entertainment)

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Product Description

ThermaPANEL is a highly efficient modular hydronic heat exchange system used for radiant heating and cooling applications. The patented turbulent flow channel design transfer 250% more energy than traditional heat exchange systems with laminar flow properties. Panels are formed and tested to be capable of holding pressure up to 50 PSI at temperatures of up to 145° F. Individual panels are interconnected using plastic pipe in a secondary process that fusion welds the panels together using extruded PE-RT pipe. The fusion welding process reduces the amount of mechanical unions or joints needed during system installation, reducing both labor and materials cost for contractors and the opportunity for mechanical joints to fail. Each ThermaPANEL unit is individually insulated in a secondary process using EPS of varying density depending on the load requirements of the application.

ThermaPANEL systems are used in a variety of applications, from comfort radiant heating and cooling to snow and ice melting for egress for ground and pedestal mounted paver hardscapes. ThermaPANEL is the only modular heat exchange system designed specifically to radiantly heat or cool pedestal mounted pavers. Pedestal paver systems are quickly becoming the most popular construction method for creating amenity and utility spaces on flat roofs. These systems are used in all types of construction from residential units to commercial and industrial buildings. ThermaPANEL also replaces tubing systems for ground mounted pavers, providing highly efficient heat transfer for locations with high snow loads or intense sun exposure.

ThermaPANEL doesn’t just improve quality of life, it helps protect life by providing safe pedestrian surfaces. It also helps to improve and sustain life as it can harvest solar thermal energy, reducing the need for electric or gas heaters for pools, spas, and domestic hot water. Furthermore, every component of ThermaPANEL is recyclable or reusable and is made 100% in the USA.

See Landscape Business article.

See PoolPro article.

Nominating Company: Valeo Lighting Systems | OEM: General Motors

2018 SPE Automotive Division Innovation Awards Gala Winner

Process used to mold part: Multi-Shot Injection Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Makrolon LED2245 PC

Category that best describes part function: Quality of Life (mobility, communication, luxury/comfort, recreation, entertainment)

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Product Description

This application incorporates a new high transparency LED2245 PC used in a thick light bar to allow a sculptured ice appearance that meets a legal Daytime Running Lamp function in an automotive headlamp. The novel light-pipe design incorporates non-standard multi-shot thick molding, tooling and process to provide unique styling and function. This part required the development of a proprietary multi-shot molding process to produce a low stress PC thick light bar with high clarity and minimal material shrink and warpage. Due to the large complex shape of the part, the tooling required a modified surface and special ejection design to properly eject the thick light bar. To meet the color and optical clarity required by the product design, the resin was manufactured in a different process method than standard PC to provide very high optical clarity in extremely thick cross-sections. This new PC material from Covestro provided crystal color development to reduce yellowness in typical thick PC parts in the un-lit state. Enhanced CAE tools were required for the complex part and tooling design.

Nominating Company: Toledo Mold & Die | OEM: Fiat Chrysler

2018 SPE Automotive Division Innovation Awards Gala Winner

Process used to mold part: Injection Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Zytel ST 801 AW PA66

Category that best describes part function: Sustaining Life (environmental, conservation, sustainability, recycling, reduction)

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Product Description

This hybrid composite technology utilizes magnesium injection molding for higher structural strength with reduced weight & polymer over molding for improved impact and corrosion resistance. A 60% weight savings is achieved compared to metal stamping and a 20% weight savings is achieved compared to die casting processing methods. A cost savings of 20% is achieved with an improved load rating from 85 lbs to 115 lbs. The new design eliminates the need for a steel bracket for an indirect cost savings. The system makes is easier for consumer to remove and install spare tire and contributes to a reduction in noise transmission and improved impact resistance due to polymer/mg composite system.

Nominating Company: George Russel/Stratasys | OEM: Ford Motor Company

2018 SPE Automotive Division Innovation Awards Gala Winner

Process used to mold part: 3D Printing

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Multiple, Nylon12 infused with Carbon Fiber manufactured by Stratasys is the main structural material used for the lift assist. ASA and ABS were also used where structural performance was minimal.

Category that best describes part function: Improving Life (education, energy, opportunity, health)

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Product Description

The nominated part represents the first lift assist is produced with an Additive Manufacturing process, specifically FDM (Fused Deposition Modeling) process. Additive Manufacturing allowed Ford to create more complex geometries resulting in better assembly interfaces with the casting at a significantly reduced cost versus a standard work cell lift assist system. The part used a triangular shape to support more weight with minimal deflection. No special machining tools were needed to make the parts used in the lift assist. Nylon12 infused with Carbon Fiber manufactured by Stratasys is the main structural material used for the lift assist. ASA and ABS were also used to reduce cost when strength was not important. The benefits to the OEM were significant savings in weight, cost and lead time to produce a complete lift assist assembly. The end effector of the lift assist weighs less than 36 lbs, with product, compared to the traditional steel lift assist of 258 lbs. Current lift assist cost is roughly 35K, where the additive cost is under 1K in materials for a savings of over 34K per application. An additional ergonomic benefit was the lighter system was easier for the assembly plant operators to use, resulting in less repetitive motion injuries in that work station.

Nominating Company: Bhavani Thota/Ford Motor Company | OEM: Bhavani Thota

2018 SPE Automotive Division Innovation Awards Gala Winner

Process used to mold part: Injection Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Profax SG702 PP

Category that best describes part function: Protecting Life (preservation, safety, containment, protection)

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Product Description

This application combines 2 unique side impact bolster designs to meet the requirements for 5th and 50th percentile occupants. Integrating them into the map pocket resulted in tooling cost savings estimated at $100K. There was an additional $100K indirect savings in testing time and $8 per vehicle cost avoidance if add on bolsters were used. An approximate 105 weight savings was achieved. Modular features were added to improve performance, by increasing flexibility of design, and reduce use of multiple bolster parts.

Nominating Company: Dave Davis/MacLean-Fogg, Engineered Plastics Company | OEM: Tom McCarthy

2018 SPE Automotive Division Innovation Awards Gala Winner

Process used to mold part: Injection Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Delrin, Minlon 520MP, 73M30 POM+PTFE, PA6

Category that best describes part function: Improving Life (education, energy, opportunity, health)

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Product Description

The open/close valve actuation is accomplished via two complimentary resin systems acting in concert to provide for critical no “stick-slip” and no measurable wear after 2,500,000 hot/cold test cycles. Injection molding of Minlon allows for very close machining type tolerances of critical functioning component details necessary for total system performance.

Injection molding. Moreover, the monitoring and controlling of cavity pressure and temperature allows for scientific molding techniques to ensure consistent critical dimensions and internal functional sealing surfaces.

A 40% weight savings and a 25% cost savings over current pump systems was achieved. The system design mandates great internal component detail otherwise only achievable in the machining world which would be cost prohibitive.

This is the first vacuum generation system in the world to achieve these aggressive Ford F-150 performance requirements utilizing a highly efficient aspirator/venturi design.

Dayco uses precision infra red welding to perfectly join together difficult geometry Minlon components with 100% leak-proof quality. Critical venturi core pins are guided and stabilized with proprietary methods to provide a perfect and consistent alignment necessary for high capacity amplification of available vacuum. The materials used were:

• POM+PTFE 20% micro-powder (no 'stick-slip' against PA6), PA6+30% Mineral (good flow for intricate internal component detail, extremely good dimensional stability and low shrinkage for tight tolerances).
• The customer perception is smoother experienced braking function and improved vehicle fuel economy.

Nominating Company: CMI Plastics, Inc | OEM: CMI Plastics, Inc.

SPE Thermoforming Conference® Winner

Process used to mold part: Thermoforming

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): ABS

Category that best describes part function: Quality of Life (mobility, communication, luxury/comfort, recreation, entertainment)

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Product Description

Features and Benefits
The proposed tray design by the customer was to have a rigid thermoformed tray from HIPS with a printed SBS mask applied. Our proposed tray alternative eliminates the need for a printed mask saving both material and assembly cost. Our design further enhances the appearance of the final shelf presentation with a realistic representation of wood grain barrel slats used for whisky.

Our tray is comprised of a co-extruded ABS which provides better structural properties over the proposed HIPS design. 60% is recycled utility black and the 40% is color match brown. This mix was carefully engineered with the goal of a natural gradient of black and brown colors, giving the tray a natural weathered look. This also provided each tray with a unique finish so that each tray appears slightly different. The material was developed in conjunction with Impact Plastics of Putnam, CT.

The design aspect of the wood grain was achieved though reverse-engineering natural wood to pattern the surface. The master patterns were pain-painstakingly sculpted and sampled to ensure the proper look and maneuverability using aluminum cast molds.

There were significant challenges with this tray design. The mold design itself required extraordinary detail and testing. It had to provide superior aesthetics while performing under rigorous drop and ship testing parameters. A primarily challenge in the tray design was capturing the ceramic promotional mugs. These mugs were provided as “fired”, causing them to have a wide range of tolerance. The mugs needed to be captured into the tray while accounting for this wide range of tolerance. The manufacturing itself posed challenges due to draw ratio, stress whitening and material distribution.

The concept was proposed by CMI Plastics to Supremia International and Beam Suntory. Through a strong partnership and collaborative process our teams came together to provide a unique and beautiful package in the spirits category.

Nominating Company: Eric Hohmann/FGH SYSTEMS | OEM: GoBout

Packaging Division Award—1ST, Packaging Category Award - Other—1ST; People's Choice Award - Packaging | Annual Blow Molding Conference 2018

Process used to mold part: Blow Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Eastman EB062

Category that best describes part function: Quality of Life (mobility, communication, luxury/comfort, recreation, entertainment)

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Product Description

Carry all your essential toiletries in multiple internal extrusion blow bottles for dispensing all out of one bottle. Customize, store and dispense multiple toiletries like shampoo, body wash, face wash, lotion and conditioner, all from one portable device. GoBout is the world’s first portable multi-dispenser that is completely customizable so that you can go anywhere, anytime.

1. Several extrusion blow EPET bottles need to fit inside and locate with the dispensing unit. A triangular bottle design was required.
2. Clean and orientated neck finishes for leak free pump and location required.
3. Bottles produced on a Uniloy-Milacron all electric UMS 4 machine, a W. Muller extrusion head, and FGH mold & tooling package.
4. Before GoBout, we have been carrying separate travel size bottles, usually inside a plastic bag, for lack of a more suitable, smart and sustainable alternative.
5. Each product bottle has its own pump and when the body is rotated to the selected product is dispensed when pressing the top GoBout cap. This top cap is held in position by Neodymium magnets.
6. GoBout is also available in a small size (less than 100ml) which means it can pass through airport security.
7. Traveling with separate bottles take valuable space and the bottles often leak. No matter how organized you try to be, keeping track of too many containers can be difficult.
8. Millions of people discard empty or half-used plastic bottles around the world. Many of these toiletries end up in landfills.
9. GoBout makes it easy to pack all the liquids you need in one simple container. It is compact, spill-free, environmentally friendly and perfect for camping, road trips and traveling.
10. GoBout is the world’s first portable multi-dispenser

More Information at www.gobout.com

Nominating Company: Gerald Christian/TricorBraunBre | OEM: Brewcraft USA

Industrial Category Award - Other—1ST Place | Annual Blow Molding Conference 2018

Process used to mold part: Blow Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description):

Category that best describes part function: Quality of Life (mobility, communication, luxury/comfort, recreation, entertainment)

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Product Description

• Clearly legible embossed graduations in both standard and metric volumes
• Integrated needle blown handles provide strength and rigidity through unique pinch off design for carrying full carboy while not compromising comfortable grip
• Wide neck opening for use of brewing equipment and aid in cleaning
• Smooth land to provide great seal which is critical in brewing process
• Inside of carboy is smooth and free of any voids or crevasses which could house bacteria, especially where the handles meet the carboy which allows for cleaning after the brewing process is completed
• Chamfered base designed to allow carboy to tilt at an angle to siphon last bits of product out of container
• Embossed company name and made in USA logo
• Designed to replace glass carboys, which can break when dropped producing sharp glass and lost product and have narrow necks making it hard to clean
• Natural HDPE allows for product to be seen through plastic for graduation readings

More information at Brewcraft USA.

Nominating Company: Surendra Agarwal/Creative Group of Industries | OEM: Creative Group of Industries

Packaging Category Award - Food—1ST Place

Process used to mold part: Blow Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Reliance

Category that best describes part function: Sustaining Life (environmental, conservation, sustainability, recycling, reduction)

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Product Description

Normally, oval bottles are designed with parting lines on the side of the bottle. This innovation puts the parting line in the center of the bottle. By designing the parting line in the center of the bottles, the number of mold cavities is increased by 33% as the center distance between molds is reduced significantly. This leads to increase in 33% higher production from the same machine. Hence, this innovation provides Productivity and Sustainability benefits.

Nominating Company: Jeff Wardat/Indorama Ventures | OEM: The Coca-Cola Company

Packaging Category Award - Beverage—1ST Place

Process used to mold part: Blow Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): Indorama PolyclearR EBM 5507 PET resin

Category that best describes part function: Sustaining Life (environmental, conservation, sustainability, recycling, reduction)

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Product Description

89 oz. Simply Orange Juice bottle designed from the high performance PolyclearTM EBM PET 5507. Manufactured by Indorama Ventures with the collaboration with Coca-Cola and CKS Packaging.

Part Features / Benefits:

• Lightweighted part- Reduction of the overall weight from previous container, made of PETG.
• 100% recyclable - compared to the non-recyclable PETG.
• High gloss - Met or exceeded OEM requirements for clarity and gloss.
• High Impact resistance - Met or exceeded OEM requirements for drop impact.

Nominating Company: John Doster/SPI Blow Molding LLC | OEM: TSP Enterprises, LLC

Industrial Division Award—1ST, Industrial Category Award Auto/Trans—1ST, People's Choice Award - Industrial | Annual Blow Molding Conference 2018

Process used to mold part: Blow Molding

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): HDPE 5502

Category that best describes part function: Quality of Life (mobility, communication, luxury/comfort, recreation, entertainment)

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Lightweight & portable cargo organization system for the bed of a pickup truck. Product installs/un-installs in the bed of your truck in minutes, without the need of any tools, creating a temporary and secure “trunk” for your truck. Completely folds together and stores behind the seats when not wanted or needed.

Product Features:

1. Installs and uninstalls in minutes with no tools required.
2. Folds and stores behind seats when not wanted or needed.
3. Light weight (weighs less than 30 lbs)
4. Secures items from sliding around in the bed of your truck and keeps them accessible near the tailgate.
5. Water Resistant – provides some protection to items inside the compartment.
6. Accommodates pickups with and without bedliners or covers.

Design Features:

1. Unique, patent-pending features were adapted across the whole product to minimize additional components and reduce labor costs.
   1. Integral snap-on single molded in hinge between back to side panels.
   2. Integral twist-on combined with snap-detents multi hinges between both back panels
   3. Integral twist-on multi hinges housing metal tubing structure through both top panels
2. The part design is engineered with exact cavity tooling to mold either side panel and either back panel. (i.e. the tooling configuration replaces left and right parts with a universal part.)
3. Molded in strap pocket (side panel), accessory pockets (side panel), snap-lock latches (top panel) and designed detent for the strut (back panel) to minimize:
   1. Metal hardware
   2. Additional components
   3. Labor costs
   4. Recycling waste

Nominating Company: Profile Plastics, Inc | OEM: MPE, Inc

SPE Thermoforming Conference Parts Competition 2018 Winner

Process used to mold part: Heavy Gauge Pressure Forming

Resin / Reinforcement used to mold nomination (tradename, grade, generic description): PC-ABS

Category that best describes part function: Improving Life (education, energy, opportunity, health)

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Part Description

The Medical Carts shown is an innovative surgical system providing flexibility during various surgical procedures.

Features and Benefits -
The primary cart unit consists of seven (7) pressure formed enclosure parts and the secondary cart unit consists of three (3) pressure formed enclosure parts, both utilizing PC-ABS material in order to meet a stringent rigidity, chemical, heat, and highly cosmetic requirements. Customer parameters required zero or minimum mechanical attachment features, which presented many unique forming challenges. As shown, many of the attachment features were innovatively molded-in to meet the customer’s requirements. Bonded in fastening features on the non-cosmetic side of the part were also required to be kept at zero or at a minimum.

The final design incorporated numerous movements on each tool to provide fastening features as well as cosmetic finished seams. The primary cart’s interaction between the rear top cover and the side covers presented numerous challenges to achieve a hidden fastening system and maintain cosmetic alignment between the parts. Complex core pulls were utilized on the upper cover to incorporate slots for a work surface table. While the secondary cart’s large front cover presented numerous challenges with 4-way undercuts due to the extreme draw depth. The final design on this part allowed the elimination of additional side panels and reduced overall tooling cost.

With the application being utilized in a surgical environment, the customer also required stringent and detailed validation and thorough quality procedures and documentation.