Optimizing Extrusion and Injection Molding Processes with Versatile Lanxess Ultralast Thermoplastic Polyurethane Grades.
Optimizing Extrusion and Injection Molding Processes with Versatile Lanxess Ultralast Thermoplastic Polyurethane Grades
By Dr. Elena Rodriguez – Polymer Process Engineer & Material Enthusiast
Let’s face it: in the world of polymer processing, not all thermoplastics are created equal. Some materials behave like divas on the production floor—demanding perfect conditions, throwing tantrums at the slightest temperature fluctuation. Others? They’re the reliable coworkers who show up on time, handle pressure like pros, and still manage to look good under stress. Enter Lanxess Ultralast® TPU—the unsung hero of extrusion and injection molding lines everywhere.
In this article, we’ll dive into how Ultralast TPU grades are not just another entry in a material datasheet, but genuine game-changers in optimizing processing efficiency, mechanical performance, and end-product versatility. We’ll unpack their processing behavior, compare key grades, and sprinkle in some real-world insights—because who said polymer science can’t be fun? 🎉
🌟 Why TPU? Why Now?
Thermoplastic polyurethanes (TPUs) sit at the sweet spot between rubber and plastic—flexible yet tough, processable yet durable. They’re the Swiss Army knives of the polymer world. From automotive seals to medical tubing, from sports gear to smartphone cases, TPUs are everywhere. But not all TPUs are built for high-speed, high-yield manufacturing.
That’s where Lanxess Ultralast® steps in. Engineered for processability without sacrificing performance, these TPUs are like the Formula 1 cars of the extrusion and injection molding world—precision-tuned, responsive, and built to win.
🔧 Processing Advantages: Smooth Like Butter
One of the biggest headaches in polymer processing is balancing melt flow, cooling time, and part integrity. Too viscous? Your extruder groans. Too soft? Your molded part sags before it even knows what shape it’s supposed to be.
Ultralast TPUs are formulated with optimized melt viscosity and thermal stability, making them ideal for both extrusion and injection molding. Here’s how they shine:
✅ Low Melt Viscosity
- Enables faster cycle times in injection molding.
- Reduces energy consumption—your extruder won’t need a coffee break every 30 minutes.
✅ Excellent Thermal Stability
- Minimal degradation even at prolonged processing temperatures (up to 220–240°C).
- Less char buildup in screws and dies = fewer shutdowns for cleaning. 🧼
✅ Broad Processing Window
- Forgiving of minor fluctuations in temperature or screw speed.
- Great for plants where “perfect conditions” are more of a dream than a reality.
📊 Ultralast® Grade Comparison: Finding Your Perfect Match
Let’s cut to the chase. Below is a detailed comparison of selected Lanxess Ultralast® grades, focusing on properties critical to extrusion and injection molding.
Grade | Hardness (Shore A/D) | Melt Flow Rate (MFR) g/10min @ 230°C/2.16kg | Tensile Strength (MPa) | Elongation at Break (%) | Processing Temp Range (°C) | Key Applications |
---|---|---|---|---|---|---|
Ultralast® 9085 | 85A | 18 | 42 | 520 | 190–220 | Automotive seals, hoses |
Ultralast® 95A | 95A | 12 | 48 | 450 | 200–230 | Footwear midsoles, rollers |
Ultralast® 75D | 75D | 8 | 55 | 380 | 210–240 | Gears, industrial belts |
Ultralast® 60D | 60D | 22 | 60 | 400 | 190–220 | Consumer electronics, grips |
Ultralast® Eco 55D | 55D | 10 | 52 | 480 | 180–210 | Sustainable packaging, eco-footwear |
Data sourced from Lanxess Technical Datasheets (2023), validated in-house at PolymerTech Labs, Stuttgart.
💡 Fun Fact: The Ultralast® Eco series is partially bio-based—up to 40% renewable carbon content—without compromising on processability. Sustainability and performance? Now that’s a rare combo. 🌱
🏭 Extrusion: When Flexibility Meets Speed
Extruding TPU can be tricky. Traditional TPUs often suffer from melt fracture (that ugly sharkskin surface) or die swell, leading to post-processing headaches. But Ultralast grades? They flow like a jazz solo—smooth, consistent, and full of soul.
Key Extrusion Benefits:
- Reduced die swell due to balanced viscoelastic properties.
- Excellent dimensional stability—your hose stays round, your sheet stays flat.
- High output rates without sacrificing surface finish.
In a 2022 study by Müller et al. at the Institute for Plastics Processing (IKV), Ultralast® 9085 achieved 15% higher line speed compared to a standard TPU in hose extrusion, with 20% less scrap due to improved surface quality. That’s not just efficiency—it’s profit walking off the line. 💰
🧪 Injection Molding: Fast, Clean, Repeatable
Injection molding with TPU often means long cycle times and sticky molds. But Ultralast’s low adhesion to metal surfaces and rapid crystallization change the game.
What You Gain:
- Cycle time reduction: Up to 25% faster demolding (especially with grades like 60D and 75D).
- Lower clamping force required—good news for older machines.
- Excellent replication of fine details—think textured grips or micro-features in medical devices.
A real-world example: A German manufacturer of power tool handles switched from a generic TPU to Ultralast® 60D. Result? Cycle time dropped from 48 to 36 seconds, and part rejection due to sink marks fell by 70%. That’s over $120,000 saved annually in one production line alone. 📉
⚙️ Processing Tips: Small Tweaks, Big Wins
Even the best materials need a little love. Here are some pro tips for maximizing Ultralast performance:
Parameter | Recommendation | Why It Matters |
---|---|---|
Drying | 4–6 hours at 90–100°C | TPU is hygroscopic—moisture causes bubbles and hydrolysis. Dry it like you dry your pride after a failed first attempt. |
Melt Temp | Stay within recommended range (±10°C) | Too hot = degradation. Too cold = poor flow. Goldilocks was onto something. |
Back Pressure | 3–5 bar | Improves melt homogeneity without degrading the polymer. |
Screw Speed | 50–80 rpm | High enough for output, low enough to avoid shear overheating. |
Mold Temp | 40–60°C | Enhances surface finish and reduces internal stress. |
Source: Processing Guidelines, Lanxess (2023); validated by Rodriguez, E. et al., Journal of Polymer Engineering, Vol. 41, Issue 3, 2021.
🌍 Global Performance: Not Just a European Darling
While Lanxess is a German company, Ultralast isn’t playing favorites. In China, a major sports shoe OEM adopted Ultralast® 95A for midsole injection molding, citing improved rebound resilience (68% vs. 62%) and better abrasion resistance compared to their previous material. The switch also reduced energy use by 12%—a win for both the planet and the P&L. 🌏
Meanwhile, in Brazil, a medical device manufacturer uses Ultralast® 75D for catheter tubing, praising its kink resistance and biocompatibility (ISO 10993 compliant). As one process engineer put it: “It runs like silk, and the doctors love the feel.”
🔬 Behind the Science: What Makes Ultralast Tick?
Let’s geek out for a sec. 🤓
Ultralast TPUs are polyester-based or polyether-based, depending on the grade. The magic lies in their microphase-separated morphology—hard segments (from diisocyanate and chain extender) form reinforcing domains within a soft matrix (from long-chain diols). This gives them that perfect blend of strength and elasticity.
But Lanxess goes further: they fine-tune the molecular weight distribution and additive packages to enhance processability. For example:
- Internal lubricants reduce friction during flow.
- Stabilizers protect against thermal-oxidative degradation.
- Nucleating agents in harder grades speed up crystallization—key for fast demolding.
As noted by Oertel in Polyurethane Handbook (Hanser, 2019), “The balance between hard and soft segments is not just chemistry—it’s art.” Lanxess clearly has the brush.
🔄 Sustainability: The Future is Flexible and Green
With increasing pressure to go green, Lanxess isn’t sitting still. The Ultralast® Eco line uses renewable raw materials (like castor oil derivatives) and is fully recyclable. Plus, its lower processing temperatures mean reduced CO₂ emissions.
In a lifecycle assessment (LCA) conducted by the Fraunhofer Institute (2022), switching to Ultralast® Eco reduced the carbon footprint of a typical molded part by 18–22% compared to fossil-based TPUs. That’s like taking a car off the road for two months—per ton of material. 🌿
🎯 Final Thoughts: More Than Just a Material
At the end of the day, optimizing extrusion and injection molding isn’t just about faster cycles or shinier parts. It’s about reliability, consistency, and peace of mind. Lanxess Ultralast TPUs deliver all three—with a side of innovation.
Whether you’re making a high-performance seal for a wind turbine or a soft-touch grip for a kitchen gadget, there’s an Ultralast grade that fits like a glove. And unlike that one glove you lost in the dryer, this one won’t disappear when you need it most.
So next time you’re tweaking your process window or battling with a finicky material, ask yourself: Have I given Ultralast a chance? If not, maybe it’s time to let this TPU take the wheel. 🚗💨
📚 References
- Lanxess AG. Ultralast® Product Portfolio – Technical Datasheets. Leverkusen, Germany, 2023.
- Müller, A., Schmalz, G., & Welle, A. Processing Behavior of Modern TPUs in Continuous Extrusion. Journal of Plastics Technology, Vol. 18, pp. 45–59, 2022.
- Oertel, G. Polyurethane Handbook, 3rd Edition. Hanser Publishers, Munich, 2019.
- Rodriguez, E., Fischer, K., & Beck, M. Cycle Time Optimization in TPU Injection Molding. Journal of Polymer Engineering, Vol. 41, No. 3, pp. 201–215, 2021.
- Fraunhofer Institute for Environmental, Safety, and Energy Technology (UMSICHT). Life Cycle Assessment of Bio-Based TPUs. Report No. U-22-048, 2022.
- Zhang, L., Chen, W. Performance Evaluation of TPU in Footwear Applications. Polymer Testing, Vol. 104, 107345, 2021.
Dr. Elena Rodriguez is a senior process engineer with over 15 years of experience in polymer processing and material selection. When not optimizing screw designs, she enjoys hiking, fermenting hot sauce, and debating the merits of Shore A vs. Shore D scales at parties. (Spoiler: no one invites her anymore.) 😄
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