1. PCS/TPU Mike Stuart Page # 1 Design Innovation in Plastics 2012 Student Plastics Design Award “Universal Design”: Designing for the rest of us Bayer MaterialScience BU PCS & TPU Materials and Design

2. Bayer & Climate Change Business Unit

3. PCS/TPU Mike Stuart Page # 3 Bayers Climate Change Targets

4. PCS/TPU Mike Stuart Page # 4 Bayer Recognised For Action On Climate Change

5. Business Unit Key Properties of Bayer MaterialScience PCS/TPU‘s Mike Stuart

6. PCS/TPU Mike Stuart Page # 6 Makroblend – PC/PBT, PC/PET Synergy Of Properties  Good chemical resistance  Excellent toughness at low temperatures  High heat resistance Bayblend – PC/ABS Synergy Of Properties  Good toughness at low temperatures  High heat distortion temperature  Improved chemical resistance Bayer MaterialScience Plastics Materials Makrolon Polycarbonate  Transparent  Very tough  Heat Resistance  Low water absorbtion  Excellent Dimensional stability Apec – HT Polycarbonate  Transparent  Very tough  Very High Heat Resistance –Up to 200 Deg C  Low water absorption  Excellent Dimensional stability

7. PCS/TPU Mike Stuart Page # 7 PCS Business Unit: Main Fields of Application Automotive industry Medical technology Packaging industry Construction industry Sports and leisure Electrical / electronics Unbreakable water bottles Transparent roofing Optical applications Automotive parts

8. PCS/TPU Mike Stuart Page # 8 Makrolon / Apec auto lighting applications

9. PCS/TPU Mike Stuart Page # 9 Makroblend applications - automotive

10. PCS/TPU Mike Stuart Page # 10 Bayer MaterialScience Plastics Materials Desmopan TPU Wide range of hardnesses Excellent cold flexibility High elongation to break Good chemical resistance Ideal 2K component Excellent abrasion resistance Good weatherability Desmopan TPU-Blend Hardnesses from 60 Shore A Good abrasion resistance Adhesion to a range of plastic substrates Bayfol – PC Film Graphics/Decoration Scratch Resistance Design Freedom Chemical Resistance Makrofol – PC Film Graphics/Decoration Scratch Resistance Design Freedom

11. PCS/TPU Mike Stuart Page # 11 Makrofol – in-mould foiling examples

12. PCS/TPU Mike Stuart Page # 12 Products of the TPU Business Unit: Main Fields of Application Automotive industry Packaging Electrical/ electronics Sports and leisure Mechanical engineering Flexible frames for ski goggles Transparent high-impact housings for ski bindings Transparent shells for ski boots Breathable coated textiles Lightfast and attractive surfaces for skis and snowboards

13. PCS/TPU Mike Stuart Page # 13 Desmopan examples

14. General Guidelines on Designing With Plastics Business Unit

15. PCS/TPU Mike Stuart Page # 15 14 Rules of constructing with polymers  1.Wall thickness as thin as possible  2.Uniform wall thickness distribution  3.Design of ribs  4.Avoid flat surfaces  5.Suitable design for metal / plastic  6.Consider gate position during design  7.Design of parts to take processing into consideration  8.Avoid undercuts if possible  9.Avoid mass accumulation  10.Corner / edges design with radii  11.Provide sufficient draft angles  12.Design of holes and cutouts „plastic like“  13.Suitable screw-design for each plastic material  14.Tolerances no smaller than necessary

16. PCS/TPU Mike Stuart Page # 16 Materials Selection

17. PCS/TPU Mike Stuart Page # 17 Basic’s Of Sustainability  Full assessment of product lifecycle  Where possible avoid mixing materials –Increase in complexity for disassembly –Avoid painting, adhesives, fixings where possible  Maximise product life through careful selection of materials & good design  Design for easy disassembly  Consider possible re-use, before finally recycling

18. PCS/TPU Mike Stuart Page # 18 Failure in plastics design/selection

19. Thank You for Your Attention

20. PCS/TPU Mike Stuart Page # 20

21. PCS/TPU Mike Stuart Page # 21 Snap Fit Design