The project, carried out by Kautex Textron GmbH & Co. KG from 1 January 2016 to 31 December 2018, aimed to develop an innovative, energy‑ and material‑efficient manufacturing process for lightweight, impact‑resistant, permeation‑tight plastic containers. The core objective was to evaluate the potential of injection‑molding technology relative to blow‑molding, and to identify new material combinations and joining techniques that would meet stringent performance criteria.
During the first phase, a specification sheet was drafted based on legal regulations and customer requirements. Key performance targets included high stiffness, excellent cold‑impact resistance at –40 °C, and sufficient barrier properties against permeation. Suitable base thermoplastics were identified, and impact‑modifier additives were selected for their ability to enhance toughness while remaining compatible with the base polymers. The selection process was grounded in theoretical predictions of mechanical and chemical behavior, with economic feasibility as an additional criterion.
The second phase focused on material research. Various compounds were formulated by blending the chosen base polymers with impact modifiers in different proportions. Each compound was produced and subjected to mechanical testing and permeation measurements. The goal was to raise impact strength without exceeding permeation limits. Although the report does not provide explicit numerical results, it indicates that the developed compounds achieved the required balance of toughness and barrier performance, enabling the production of containers that meet the –40 °C impact criterion.
In the third phase, joining methods were investigated to assemble the injection‑molded shell into a complete hollow part. Laser welding and two‑component (2K) application technologies were explored, with a focus on maintaining structural integrity and barrier properties across the joint. The study demonstrated that laser welding could produce strong, leak‑tight seams, while 2K coatings improved adhesion and provided additional protection against environmental degradation.
Energy and material savings were a central theme. Injection‑molding was shown to consume less energy and use less material compared to blow‑molding, although specific quantitative savings are not disclosed in the report. The project also highlighted material savings achieved through optimized compound formulations, reducing the overall polymer usage in the final product.
The project’s collaboration structure involved two key partners. The Süddeutsches Kunststoff Zentrum (SKZ) in Würzburg provided expertise in material selection, compound formulation, test specimen production, mechanical and analytical testing, and weld‑seam inspection. The Institut für Kunststoffverarbeitung (IKV) at RWTH Aachen contributed laser welding technology, 2K application methods in injection molding, and additional material‑selection advice. Both partners brought specialized facilities and knowledge that enabled a comprehensive investigation of the manufacturing process.
The funding source is not explicitly mentioned in the excerpt, but the project duration and structure suggest support from German federal or European research programmes aimed at advancing lightweight plastic technologies. The collaboration, spanning three years, culminated in a demonstrator container that satisfies the defined stiffness, impact, and barrier requirements while offering a more energy‑efficient production route. The findings provide a foundation for scaling the process to industrial production and for further optimization of material blends and joining techniques.