AIJU has developed a new plastic compound made with natural dry biomass, specifically the almond shell, for industrial purposes. The result is a compound material with a wooden appearance and new properties which have been analyzed in-depth.
This new material provides other eco-efficient alternatives which reduce the plastic content, derived from non-renewable sources, and at the time give value to this natural waste which is produced in great quantities in Mediterranean countries, and whose only other use is for incineration purposes.
A complete characterization of this material has been done in the study with distinct quantities of almond shell powder, determining the influence of this content on the physical, mechanical, thermal and rheological properties of these formulations.
“The almond shell is a natural waste which is valid for reinforcing common plastic materials. A material with a wood-like appearance is obtained and in general the material has better properties than the non-reinforced plastic material,” explains Suny Martínez responsible for the Material Area at AIJU. “The tensile, bending, hardness, density and temperature resistances increase in reference to polyethylene without the additive. The viscosity at non-elevated temperatures increases as well.”
The obtained formulations can be transformed by injection processes in a similar way to non-compound materials, although the pellets must go through a drying process to eliminate the absorbed moisture in the shell before the transformation, and the temperature must not exceed 220ºC in the process to avoid the almond shell decomposition.
In parallel, AUJU is developing a new material with almond shell for transformation in Rapid Manufacturing processes. Test specimens, in a halter shape, have been successfully sinterized for their characterization, and the enhancement of the recycling characteristics are being worked on as they lose properties and must be rejected after several uses in the process without being sinterized.
These tasks have been carried out within the frame of the IBE-RM Project, partially funded by MICINN and the EU with FEDER resources (Expedient PSE-020000-2009-001) and MatSinter funded by IMPIVA (Expedients IMIDIC/2009/80 y IMIDIC/2010/45). Additionally, we would like to thank the Cooperative “la Trencaora” from Castalla for providing the almond shell.
AIJU
The Toy Research Institute (AIJU) is a non-profit making organisation, located in Ibi, the geographic centre for the manufacture of toys in Spain. It was founded in 1985 with the collaboration of the Spanish Toy Manufacturers Association (AEFJ) and the Regional Government (IMPIVA).
Its aim is to transfer and allow toy manufacturers access to knowledge and information regarding new technologies in order to improve their competitivity, while offering technological and financial assessment and supporting the professional development of people involved in the sector. For this purpose, it has a staff of 75 professionals which develop their work in the different areas which make up AIJU.
The department where these tasks will be carried out is that of Product Development – Laboratory Department, specifically the Processing and Materials area. This department is closely linked to the Rapid Prototyping Area, which has been working on the research of SLS Equipment for 10 years now, studying its feasibility for use in the manufacturing of functional prototypes and mould prototypes with the objective of reaching sets of final materials.
AIJU is an active member of the Rapid Manufacturing European Platform and the Spanish Mirror led by ASERM, the Spanish Rapid Manufacturing Association. It is also a member of EuMAT and Manufuture. AIJU is the coordinator of the working group, “Rapid Prototyping Proposal SP3 (materials) Lab,” and a member of the “Materials” group promoted by REDIT among the RDT Centres of IMPIVA’s Network.
In the field of standardisation, the entity is working on the potential feasibility of proposed rules as well as new safety criteria for toys, with participation in several proficiency testing schemes both on a National and European Level. Thus, it is participating in the development of new standards for toys in the European Committee of Normalization (CEN).
