Making Metal Replacement a Competitive Advantage

Manufacturing and new-product development are both faster-paced and more complex than ever, with metal replacement often a key to reducing weight, cost and production times.

DuPont has a range of high-performance resins for ultra-high strength, temperature resistance and cost-efficient production, in industries ranging from automaking to energy production.

A Growing Opportunity

Currently, approximately 16% of weight in a vehicle is plastic, with a growing trend to possibly reach 25% within the next five years. This increase in light weighting will  require engineering plastics for demanding components exposed to stress, vibration, heat and aggressive media.

DuPont sees opportunities for metal replacement in a range of uses such as manufacturing equipment to automotive engines; oil and gas exploration and extraction rigs to mobile phones and tablets.

Multiple Innovation Strategies

An opportunity this big can’t be met with one product, or one approach. That’s why DuPont has material science resources in 40 manufacturing, development and research centers spread across four continents, offering dozens of high-quality thermoplastic and elastomer products, and thousands of grades.

But not only this. In addition, DuPont Performance Polymers has proactively put in place science and collaboration systems that assist the many value chains it serves to be successful in reducing dependence on fossil fuels. We’re committed to discovering and developing lighter-weight alternatives to metal.

Automotive Innovation Centers

Through a global network of Automotive Innovation Centers, DuPont is providing a global collaboration space for customers, government, academia and business partners with access to the DuPont scientific community and real-time, science-powered innovation.

From Pune, India to Troy Michigan; Geneva, Switzerland to Shanghai, China, Innovation Centers allow DuPont to collaborate with clients on practical, day-to-day metal replacement projects and larger goals. Focus areas include developing new products, components and systems, to help reduce dependence on fossil fuels.

Next-Generation Materials

Engineering thermoplastic materials provide consistent strength and stiffness, and outstanding impact performance for metal replacement. They also offer excellent creep resistance, can maintain structural performance at high temperatures and resist corrosion, qualities metal can’t always match.

Zytel^® HTN

DuPont^™ Zytel^® HTN is one example, a high-performance polyamide resin which is a partially aromatic nylon. Most Zytel^® HTN resins are polymers known as PPA (polyphthalamide), offering the  combination of highest performance and processibility.

Zytel^® HTN grades are next-generation products, delivering an excellent balance of strength, stiffness and impact performance, compared to not just metal, but to other glass-fiber reinforced polyamides, as well.

Compared to PAMXD6, a Polyarylamide, Zytel^® HTN53 offers:

Superior impact and elongation-to-break values.

• Lower density.
• Lower mold tool temperature, 90^°C versus 140^°+C.
• Less flash.
• Faster set-up.