It's All Possible - ELEMENTS - Evonik Industries
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ELEMENTS Research. Knowledge. The future. It’s All Possible 2/2018 From gas pipe to 3D printing: Polyamide 12 is the all-round plastic → p. 10 Singapore: The next Silicon Valley → p. 30 Artificial leather: Better than animal skin → p. 50
LEXICON Polyamide 12 High-performance polymer Polyamide 12 is a partially crystalline plastic with good dimensional and temperature stability and good damping characteristics for noise and vibrations. It has the lowest density of any polyamide and absorbs the least water. The suffix “12” refers to the molecular structure of the individual building blocks. They are composed of 12 carbon atoms and are distinguished by a particularly long alkyl chain. This fact, together with the interaction between specific parts of the molecule, make the plastic especially impact-resistant and resistant to oils, fuels, and other chemicals. Polyamide 12 is thus used in an extremely wide range of applications. Partially crystalline: composed of regularly arranged (crystalline) and irregularly arranged (amorphous) building blocks → More about polyamide 12 starting on page 10
EDITORIAL DEAR READERS, How can genuine leather be replaced with environmentally friendly artificial leather? How can we use the components of crude oil even more compre- hensively? How can we use the research findings of scientists to make new products? And how are these products changing our daily lives? Here at ELEMENTS, the connections between research, innovation, and society are the engine that drives us. For example, the possibilities opened up by 3D printing seem practically limitless. The stuff these 3D dreams are made of is called polyamide 12, or PA 12. What can it do? Where are its limits? We are working to answer these questions, and we’re starting our search in the city of Leuven in Belgium. This is where the 3D pioneers of the Materialise company do their work. In order to meet the growing demand for PA 12, Evonik is planning to build a new facility for € 400 million — not in Asia or the Americas but in North Rhine-Westphalia. Is that a sign of Germany’s appeal as an industrial location? According to the renowned US economist David Audretsch, Germany is one of the best industrial locations in the world. His French colleague Sylvain Broyer begs to differ: He points out that Germany is facing tremendous demographic problems. We invited the two researchers to engage in a debate. Outside Germany, innovations thrive most in places where creativity and capital combine and legislators create appealing framework conditions. In this context people automatically think of Tel Aviv or Silicon Valley. It’s easy to overlook Singapore, which is currently doing its utmost to top the list of the world’s most innovative locations. Will this ambitious city-state reach its goal? We decided to investigate this question on site. ELEMENTS magazine is published four times a year, in German and English, in a print version and digitally on the Internet. If you would like to continue reading ELEMENTS, you can order a subscription free of charge. I wish you pleasant and instructive reading, and I look forward to receiving your suggestions and comments at: elements@evonik.com Matthias Ruch Editor in Chief of ELEMENTS
CONTENTS 12 30 COVER STORY: POLYAMIDE 12 SINGAPORE 12 BACKGROUND 30 REPORT Especially Resilient The City That Constantly 14 DIAGR AM Reinvents Itself From Gas Pipe to Sports Shoe 34 FACTS & FIGURES 18 REPORT Innovation Hubs —Incubators for Layer by Layer New Ideas 24 DEBATE 37 OPINION How Attractive Is Germany as Success through Clear Planning an Industrial Location?
50 42 INNOVATION ELEMENTARY 38 CARBON 06 PEOPLE AND VISIONS The New C4 Formula 29 NEWS 40 DATA MINING 42 EVONIK COUNTRY Talented Crude Canada 50 ARTIFICIAL LEATHER 56 CORPORATE FORESIGHT Better than Real Freshly Picked Cadmium and Nickel 58 IN MY ELEMENT “My Fate Depends on Hydrogen” 59 RECOMMENDED READING
PEOPLE AND VISIONS “A Piece of Clothing That’s an Extension of the Skin” Source: The designer Behnaz Farahi (Model: Alexis Hutt) 1 “CARESS OF THE GA ZE” is the name of this piece of clothing created by the designer Behnaz Farahi. It’s not only an eyecatcher —it also reacts to the observer’s gaze. That’s because a tiny eye-track camera inside it records the observer’s angle of vision and aligns the spiky fibers accordingly. The fibers, which were made via 3D printing, are sure to pique people’s curiosity 06
“The World’s Smallest 3D Ballpoint Pen” 2 Source: Lix Pen Ltd. THE LIX PEN looks like a pencil, but it’s actually a miniature 3D printer. The plastic that is melted inside it cools off and hardens as soon as it leaves the pen. In the future, artists can use the Lix pen to “draw” three-dimensional works in space
PEOPLE AND VISIONS 3 “The Bridge Embodies the Endless Potential of 3D Printing” Source: Tim Geurtjens, CTO of MX3D THE PRINTING ROBOTS of the Dutch startup MX3D have successfully built the world’s first bridge via 3D printing in only six months. Starting in 2019, this steel construction, which weighs 4,500 kilograms, will span a gracht in Amsterdam —a symbol of technical progress in one of Europe’s most popular historical city centers
“A Revolution in Architecture” Source: Massimiliano Locatelli MASSIMILIANO LOCATELLI wants to get people excited about houses made by a 3D printer. At this year’s Design Week in Milan, the Italian architect used his time constructively. He had an assembly robot additively manufacture a complete house —thus demonstrating that the future of construction has already arrived 4
12 Especially Resilient Polyamide 12 demonstrates its capabilities under extreme conditions 14 From Gas pipe to Sports Shoe Additives and chemical modifications can be used to adjust the plastic’s properties 18 Layer by Layer The Belgian company Materialise has more experience in 3D printing than almost any other European company. We call in on a pioneer 24 Ideal Conditions? In order to meet the increasing demand for PA 12, Evonik is planning a large-scale investment—in North Rhine-Westphalia. Why not in Asia or the Americas? A debate about Germany as an industrial location The selective laser sintering printer at the Materialise company uses a laser to fuse polyamide 12 powder into solid structures 11
COVER STORY: POLYAMIDE 12 ESPECIALLY RESILIENT From 3D printing to gas pipes and the coolant pipes for batteries in electric cars—polyamide 12 keeps on opening up new areas of application. It demonstrates its capabilities under extreme conditions TEX T TOM R ADEMACHER ILLUSTR ATION MAXIMILIAN NERTINGER I t would be an almost normal construction site—if it wasn’t for the TV crew. In the small town of Neubeckum, Gas pipes made from PA 12 to the north of Germany’s Ruhr region, the local gas util- can be fused using simple heating elements ity company is replacing the old steel pipes of the high-pressure gas supply network. The media interest is focused on the new bright-yellow pipes that are being laid here. It’s a first in Germany—the pipes are made from the high-performance polymer polyamide 12, PA 12 for What the TV team doesn’t see, but the construction crew short. The German technical inspection association TÜV notices immediately, is that the PA 12 pipe is much eas- has issued an individual approval especially for this job. ier to lay than steel pipe. The individual elements are The pipes in the gas distribution network are about the maneuvered into the roadbed by hand. A couple of elec- thickness of a thigh, and they have to withstand an op- trical heating elements are sufficient to fuse the blunt erating pressure of 16 bar. Expectations are high, and not ends together. Basically, the new pipe could even be laid just on the part of the network operator. That’s because from a roll. Between 150 and 200 meters fit on a drum, the 300-meter-long stretch of new pipe could signal the while steel pipe segments that are transported by truck sector’s farewell to steel. It would mark a decisive change, can have a maximum length of 18 meters. Laying pipe and not the first one that PA 12 has triggered. from a roll can also be carried out without a trench— 12
BACKGROUND “The automakers’ requirements through a horizontal borehole. That saves not only welds but also a great deal of digging. PA 12 pipes running for regarding materials tens of kilometers have already been installed in this way in Brazil. But it’s not only the laying but also the opera- tion of the new plastic pipes that promises to be much for fuel lines are easier. Corrosion protection is no longer necessary. And the pipe can even be temporarily squeezed closed when the network has to be extended or serviced. extremely high” The plastic has already long been used in automaking SANDRA REEMERS for brake and fuel lines. It’s especially resistant to hy- drocarbons such as gasoline, natural gas, and mineral oil. The pipes don’t swell, even after thousands of hours in contact with fuel, and almost nothing is washed out of the material. “The automakers’ and their suppliers’ requirements are extremely high and rising further,” says Dr. Sandra Reemers. She heads Innovation Management for the High Performance Polymers unit at Evonik. “The auto- But some of the growth in PA 12 also comes from new makers are controlling the combustion inside their en- markets. The powder variants are used in 3D printing. gines ever more exactly. That means the injection profile Growth in this area is in double digits. PA 12 is in demand is becoming increasingly complex and the injection here because it is ideally suited for use in various printing nozzles ever finer. The smallest amount of material processes and can produce components that are as deli- washed out of the polymer could block these nozzles.” cate as they are durable. Evonik recognized 3D printing Specially modified PA 12 solves this problem. long before the current hype and has been patiently ac- Hybrid and electric vehicles, in contrast, use quiring know-how in this area. For example, PA 12 ex- high-performance PA 12 lines for the batteries’ cooling perts from Marl worked together with renowned printer circuits. This is an area where PA 12 can utilize its weight manufacturers such as EOS, 3D Systems, HP, and voxel- advantages in the future. Range is a decisive criterion for jet to develop custom powders for their print technologies. electric vehicles, and every gram saved counts. PA 12 is It’s the material’s versatility that drives the rising lighter than steel and doesn’t need threads and nuts be- demand. “PA 12 is outstandingly easy to modify and to- cause connectors can be closed directly in the compo- tally well behaved,” says Reemers. “We can incorporate nent using compressed air. other monomers by polymerization and intervene di- rectly in the molecular structure. There are very many A GROWING GLOBAL MARKET compounds that work. That means we can control the The global market for polyamide 12 is growing constant- material properties by using additives.” Evonik has de- ly and strongly, most recently by five percent per year. veloped an especially large toolkit for this custom work. A number of forces are driving this development. In the emerging economies, demand for cars and other BIG DATA AND ARTIFICIAL INTELLIGENCE high-value consumer goods has been growing for years. In order to identify further areas of application, the re- PA 12 is in demand in sports equipment and for household searchers from Evonik intend to also use the methods of appliances—the baskets in dishwashers, for example, are big data analysis and artificial intelligence to evaluate powder-coated with PA 12. That’s what enables them to the immense amount of data that they have collected over withstand years of hot water, aggressive dishwasher tabs, decades of research and development work. Evonik is and pans and knives thrown in carelessly. already using artificial intelligence More on page 16 → 13
COVER STORY: POLYAMIDE 12 FROM GAS PIPE TO SPORTS SHOE Thanks to its wide range of possibilities for pro- cessing, its compatibility with additives, and its susceptibility to chemical modification, PA 12 covers an extremely wide range of applications 1 HIGH-PERFORMANCE POLYMERS This group of plastics comes into use where materials face special requirements, as they are distinguished by features such as S I LE an operating range of up to 300 degrees Celsius, for example in OB s ne automaking, in space travel, and in medicine. T O Muel li U .f Price per kilogram: €10 –250 A e.g 2 ENGINEERING POLYMERS If the requirements are not as high — for example, operation < 0.5 million t 1 temperatures below 150 degrees Celsius— engineering polymers are used: for example, in machine construction, in industrial applications, and in beverage bottles (PET). Price per kilogram: €5 –12 >10 million t 2 3 STANDARD POLYMERS Plastics from the lower segment are used for mass applications such as plastic bags, foams, and yogurt cups. Everyday products of this type are manufactured from standard plastics. Price per kilogram: €3 – 8 DIVERSIT Y THANKS TO A TOOLKIT The exact characteristics of PA 12 are set to match the requirements of the respective application by means of additives or chemical modification. The chemical, electrical, and mechanical properties of >200 million t 3 the material can be adapted in this way Additives Effect Nanotubes Provide electrical conductivity Long glass fibers Increase stiffness Teflon/graphite Improve sliding capability High-performance polymers such as PA 12 account for just around 0.25 of the global Chemical modification annual production of thermoplastics. Polymers Increase hardness Around 95 percent of the market is made up Aromatics Increase temperature resistance of low-priced standard plastics for mass- and raise melting point produced goods Short amides Lower melting point BREAKDOWN BY PRODUCTION VOLUMES worldwide, in metric tons per year 14
DIAGR AM OIL / GAS INDU ST RY e . g . g a s p i pe s CO AT IN e.g . di GS s hw FO AR ash R EA er M S O ba ET FA sk et AL PP s LI CA TI O 3 D e ye g e. N g. FO P R l a s se PI R I N s f r am PA TI N G es PEEK 12 PAI FPs PPSU PPA LCP SPO PEI PPS PMI RT AN e . g. spo PA 1012 PEBA PES PA 46 PA 11 r t s s h oe D LEISURE PMMI PSU PA 12 PAR PA 1010 PA 612 s transp. PA PA 610 PA610 PA610 CoPA PMMA PPE PLA PET PMA PBT PA 6/PA 66 POM MED e.g. PUR cath N E C I ete I r ABS SAN PP PS PVC PE PE-LD PE-HD Amorphous Crystalline BREAKDOWN ACCORDING TO TECHNICAL REQUIREMENTS (Plastics from Evonik—not from Evonik) 15
COVER STORY: POLYAMIDE 12 The experts want to use big data analyses to evaluate the data from research and development to comb through the patent literature. Similar systems says Reemers. That’s why Evonik keeps examples of all should also soon be searching through the company’s common production machines at the technical center in own data on cause-effect relationships between molec- Marl. The Group has to be able to master processes such ular structure and additives, on the hunt for promising as coextrusion—the simultaneous extrusion of pipes combinations. “We want to use computer support to made up of multiple polymer layers—at the production further investigate what our developers can sometimes speeds required. intuit on the basis of their decades of experience,” says The Group is the only supplier on the market that is Reemers. also completely backward-integrated, i.e. it produces Being on the ball early and working together closely all of the precursor products itself at its Marl location. with the users are also essential ingredients in the reci- “We can tune the properties of PA 12 both physically by pe for success. “At the end of the day, we ‘just’ deliver using additives and chemically,” says Reemers. “Start- the polymer, but we have to ensure that it is going to ing from the monomer, we have various building blocks work without problems in our customers’ machines,” and can develop a complete molecular architecture with respect to the degree of branching, chain lengths, end groups, density, and copolymers.” This is one of the main reasons why Evonik has long been able to maintain its Molding compounds position as the world leader in PA 12. based on PA 12 improve the damping charac- teristics of sports shoes LIGHTER, FURTHER, FASTER As Reemers explains, the Group is frequently already working in standardization groups on the establishment of new technical standards. “When we develop a better solution it eventually becomes the legal minimum re- quirement—often just because this better solution exists.” For example, the first test rigs for determining the chem- ical resistance of plastic pipes were developed in Marl. Today’s industrial standards are based on that work. So Evonik is in demand as a consultant not only about what’s going to be possible tomorrow but also about what’s going to be needed. “We talk about the trends of the coming years with shoe and sports equipment manufacturers, and about stricter future regulations with automakers,” says Reemers. “If we didn’t start devel- opment until the customer came to us with his problem, it would usually be too late.” The developers behind PA 12 also want to teach the material new tricks, so that it can enter new markets. “In the area of electronics, for example, plastics that work well with metals are in demand. PA 12 can do that per- fectly,” says Reemers. “If we were to modify the polymer 16
BACKGROUND Fuel lines made from PA 12 are especially resistant to washing out with additives so that it could stand up to the waste heat year 2030 in order to anticipate trends and scenarios in and conduct it out of the component, that would be an the areas of technology and legislation. The energy sector attractive market.” in particular is anything but fickle. “Oil and gas applica- tions require a 30-year service life in the hardest offshore GROWING CAPACITIES environments,” says Reemers. The steel pipes being re- In order to be able to keep up with the increasing demand placed in Neubeckum had been in operation for almost for PA 12, Evonik has substantially expanded PA-12 pro- 70 years. If PA 12 is going to take over from steel in the duction in Marl. In addition, a completely new produc- long term in this sector as well, then the bright-yellow tion line is to be set up at this location in 2019. The facil- replacements will have to last a long time. ity will go into operation in 2021 and boost the capacities by more than 50 percent in one move. The Group has budgeted around €400 million for the project—Evonik’s biggest investment in Germany. Locations such as Sin- gapore and Thailand were discussed, but the final deci- sion went to Marl. “Nowhere else has such a good supply of all of the precursor products—and nowhere else has a Glossary better understanding of the material and the target mar- kets,” says Marcus von Twistern, who heads the project. Compound A plastic in which fillers and/or additives have been Understanding the markets also requires patience. Oil admixed in order to make specific changes to its properties is called and gas extraction, automaking or power grids—the hur- a compound. dles for new materials and technologies are often high. Copolymer Copolymerization enables the properties of a plastic Automobile companies have optimized their production to be influenced by uniting different plastics with different properties processes over 50 or even 100 years. “We talk with end in one polymer. customers such as VW, Opel, and Ford, but also with Extrusion/coextrusion A forming process that is used for thermo- Petrobras and Shell about where this journey is going,” plastics, among other materials. Coextrusion is a process in which says Reemers. She and her team are looking ahead to the multiple materials are brought together in the production process 17
COVER STORY: POLYAMIDE 12 LAYER BY LAYER TEX T GEORG DAHM PHOTOGR APHY SEBASTIAN VOLLMERT
REPORT The Belgian company Materialise has more expe- rience with 3D printing than almost any other European company. It produces innovative prod- ucts made of polyamide 12. A visit to the pioneers in the university city of Leuven in Belgium I f you were to put a blindfold on Bart Van der Schueren and lead him through his company’s widely branching only for the medical sector, and that area is closed to visitors. But Van der Schueren mainly wants to direct our halls full of 3D printers, he would know which area he was attention to the plastics. And we do see plastic every- in by the smell alone. That way he’d know which of the where, from the exhibits in the lobby to the building’s many printing techniques was being used there to create many delicate ceiling lamps, whose seemingly organic airplane parts, medical implants, shoe insoles, eyeglasses, structures are based on mathematical formulas. “Many lamps or prototypes—layer by layer, out of nothing. of our visitors are fascinated by the fact that we can print For example, there’s the slightly pungent smell of metals such as aluminum, titanium, and steel,” says Bart the big stereolithography printers, which look like gi- Van der Schueren, the Chief Technology Officer (CTO) of gantic terrariums with flickering blue lights. And there the Materialise company. “But our workhorse is plastic. are the warm plastic fumes of the fused deposition mod- We produce about one million items annually, and eling printers and the selective laser sintering printers, 800,000 of them are made of PA 12.” which are lined up in rows like incubators. Further along are the hospital-disinfectant vapors of the Multi Jet Fu- A NEW APPROACH FOR INDUSTRY sion devices, which look like oversized laser printers. The CTO is still bemused by the fact that the company Every morning the technicians take the rollboxes, inside produces so many different things from polyamide 12— which objects have grown overnight in successive layers prototypes as well as finished products for end consum- of powder, out of the printers. ers, medicine, and automobile and airplane construc- We were unable to find out what a metal printer tion. “Actually, this material is overqualified for many smells like, because in Leuven metal 3D printing is used applications,” he says. “It’s a bit too robust, too stiff, too temperature-resistant. For many applications you’d be better off using polypropylene, which is cheaper. But 3D printing has to create added value, says Bart Van der Schueren (left photo). we’ve discovered time and again that PA 12 is more The selective laser sintering printers stand in long rows (bottom) practical to use for additive manufacturing because it can do so many things.” Many aspects of additive manufacturing—the term this expert uses instead of “3D printing”—contradict conventional experience and expectations. “Normally, a company would keep pestering its materials suppliers with all kinds of wishes for better material properties,” he says. But at Materialise, almost every time the tech- nicians calculate how much it would cost to manufacture a certain design, they find out that PA 12 will produce exactly what they need—everything from lacy lamp- shades to metallic-looking precision parts for automo- bile construction, for which the PA 12 powder is mixed with aluminum particles. “In additive manufacturing, we don’t alter the prop- erties of the material,” says Van der Schueren. “We give items the desired properties by creating the structure we’ve developed for them at the computer. For industry, this is a whole new approach.” → 19
COVER STORY: POLYAMIDE 12 customers to look for its practical applications. For in- stance, additive manufacturing is ideal for batch sizes that are so small that it’s not worthwhile to make injec- tion molds and other processes such as milling would not provide the desired properties. One example of that is flying drones, in which a fi- berglass support frame provides stability. Materialise prints plastic guides in which tiny channels precisely align each of the razor-thin fibers in the right order, so that they can be glued. “Considering the batch sizes in which these drones are sold, no other process would be economically feasible,” says Van der Schueren. 3D printing also creates added value in segments where it enables the mass production of unique items. Many customers (of Materialise) are looking for Examples of that include orthopedic insoles and eyeglass detailed advice about 3D printing frames: “Here you can see the added value more clearly than in series-produced eyeglasses. We can calculate exactly where the lenses should be in front of your eyes APPLICATION: MEDICAL TECHNOLOGY and where the frame should sit on your nose so that the This new approach has caused a minor revolution in the glasses will precisely match your skull. And we can pro- field of orthopedics, for example. People who wear or- duce the glasses in any design and color you want.” thopedic insoles in their shoes know that these are ex- pensive customized items consisting of a combination LIGHT WEIGHT CAR SEATS of cork and leather or various plastics, depending on the Another example of potential value creation can be seen stresses they will bear. Alternatively, they are inexpen- in the lobby: an experimental car seat for Toyota that sive models made from a single piece of plastic on the weighs only seven kilograms—a normal seat weighs 30 basis of the user’s footprint. kilograms—and is made entirely of PA 12. Only when you Materialise prints orthopedic insoles made of PA 12 look at it up close can you see that it’s made in one piece that are based on 3D impressions of the user’s gait. “We but combines a variety of structures. A weblike body analyze the user’s movements and calculate how much gives the seat rigidity, and small feathery structures on support he or she needs at which part of the foot,” says the surface provide flexibility. Van der Schueren. “Our software then designs a struc- The seat is only a prototype that shows how much ture that has the right properties at every point—firm- weight could already be saved today in automobile con- er in some places, more elastic in others. Then we print struction. But before it can be series-produced a great it in one piece, using one single material.” Does such an deal of technology will have to be developed. At the mo- insole wear well? “Let me put it this way: We made a ment, the technology for large components is still too fairly big mistake with our business model. Our cus- expensive—and here the manufacturers and engineers tomers need to reorder their insoles much less often than have to do some rethinking. we expected.” “With injection molding, you simply multiply the cost He says that many companies still need to have some- of the material by the density by the quantity and you’ve one explain to them how 3D printing can contribute to got your costs,” says Van der Schueren. In additive man- value creation. “Many companies come to us saying they ufacturing, the structures are produced in a powder bath, want to do ‘something with 3D printing’, but they don’t and there are no fixed formulas for calculating how much know exactly what. They often have completely unreal- raw material is ultimately discarded as scrap. In addition, istic expectations.” The most frequent misconception is the energy costs increase exponentially. “Normally, if that 3D printing can replace the traditional injection you double the size you also double the costs, but in 3D molding process in mass production. The technology will printing, doubling the size means multiplying the costs someday be advanced enough to do that, but today the by eight,” he explains. additive manufacturing of many series-produced items is still more expensive than many people realize. CUSTOMIZED SKI BOOTS In additive manufacturing, products are created grid NEW BUSINESS MODELS point by grid point. The raw material is heated, melted, Value creation by means of 3D printing is different, and and cooled, and then it takes shape. In processes such that’s why Materialise cooperates with each one of its as selective laser sintering and Multi Jet printing, the → 20
REPORT COMPLEX STRUCTURES THAT WOULD OTHER- WISE REQUIRE EXPENSIVE HANDCRAFTING 1 1 Materialise printed this replica of a robot for a trade fair 2 3D printing also inspires artists: Nick Ervinck’s sculpture AGRIEBORZ is based on tomographic images of blood vessels 3 Customized orthopedic insoles 4 The 3D-printed lining of ski boots precisely fits the wearer’s legs 5 For the medical sector, Materialise produces implants, surgical tools, and replicas of organs that surgeons use to plan and practice operations 6 A non-proprietary prototype with a delicate structure 7 Eyeglass frames are produced to match the wearer’s head measurements 8 Workpieces are made light, yet stable, through their interior structures —like those of human bones 2 4 5 3 7 8 6 21
COVER STORY: POLYAMIDE 12 A PRINTED CAR SEAT IS per component are so small that injection molding isn’t ONE FOURTH AS HEAVY worthwhile here, and other production processes would be too expensive.” AS A CONVENTIONAL A REPLICA OF THE ÖTZI MUMMY ONE. AN ADVANTAGE Most of the 3D printers that Materialise works with at its production facilities all over the world come from FOR RECYCLING: NO manufacturers such as HP. If no printers for specific applications are currently available on the market, the COMPOSITE MATERIALS company develops such devices on its own. One exam- ple of that is printers for very large components. In this area, Materialise has built printers that created a repli- ca of the “glacier mummy” Ötzi, copies of Greek stat- raw material is a powder that is laid on layer by layer and ues, and more mundane items such as complete ins heated at the specific points that are to remain. trument panels. “In the course of developing these By contrast, the 3D printers you can buy in an electrical printers we learned a lot about what works and what supplies store work with a strand of plastic that is un- doesn’t,” Van der Schueren says. rolled from a spool, heated, and laid on through a nozz- Plastics such as PA 12 sometimes reach their limits in le that resembles a hot glue gun. This process, which is the area of medicine. For example, permanent implants called fused deposition modeling (FDM), is used by pro- are still made of titanium. “PA 12 is biocompatible,” says fessionals, even though it is slower and less efficient. Van der Schueren, “but there are still no long-term stud- However, it can be used to make closed structures that ies that prove this material can safely remain in the hu- are hollow inside. For example, Materialise uses FDM man body permanently.” In the area of metal printing machines to produce the lining of ski boots on the basis there are other disadvantages, such as the good thermal of 3D scans of the wearer’s feet. conductivity, which the engineers have to compensate Besides, more different kinds of plastic can be pro- for. According to Van der Schueren, “If you close up a cessed by FDM printers. That’s a crucial advantage in hole in a patient’s skull with a titanium plate, the patient industries where every raw material, or every production can no longer hold his head in the sun, because the plate process, must be individually approved. For example, in will get too hot. And he can’t go swimming, because that a closed-off area FDM machines are printing components would cool off his brain too much.” Materialise therefore for the Airbus A350, because this process has been certi- prints metal implants that have a fine mesh structure, fied for the manufacture of airplane parts. “A couple of which acts as a temperature buffer. hundred components from Materialise are installed in every airplane,” says Van der Schueren. “The batch s izes DRILLING AND SAWING TEMPLATES Compared with these delicate workpieces, some of the most important medical applications of PA 12 look com- This car seat, which is on show at Materialise headquarters, was pletely unremarkable: individually produced drilling and printed in one piece from PA 12 and weighs only seven kilograms sawing templates that are used by surgeons doing com- plicated bone operations. The templates help them to place their cuts and screws in such a way that the newly aligned bones grow together in exactly the way the sur- geons have previously calculated at the computer. This process enables several thousand patients per month to avoid a trial and error process on the operating table. Medical technology is one of the three specialist areas of Materialise. The two other areas are the industrial con- tract manufacture of prototypes and end products and the development of software for 3D printing. The latter area represents the roots of this company, which was founded in the 1990s in the university city of Leuven. “Back then we quickly realized that 3D printing is actually quite easy in itself,” says Van der Schueren. “The only problem was that we had to figure out how to prepare a design we could print in 3D.” In view of today’s boom 22
REPORT One of the company’s specialist areas is the development of software for 3D printing in virtual reality applications, it’s strange to remember A GIANT PLASTIC JELLYFISH that back in the 1990s industry was a two-dimensional One of the big development-related themes in the field world. “There wasn’t a single company in Belgium that of 3D printing is the recycling rate. 3D printing has a could create a design in 3D,” Van der Schueren recalls. huge advantage when it comes to recycling finished Materialise decided early on that it would not keep products after they can no longer be used. PA 12 is so its inventions to itself. Thanks to this policy of openness, versatile that it can be used on its own for manufacturing the company is now one of the market leaders. “Our even complex products. As a result, no composite ma- software is the backbone of a large segment of industry,” terials have to be separated during recycling. he adds. What the field of 3D printing needs today is technical innovation and, even more importantly, innovative de- signs. “Most designers in product development still think in terms of blocks from which they can carve out indi- Glossary vidual components and then assemble them. We are teaching them a new approach,” Van der Schueren tells Additive manufacturing Stereolithography printer us. It’s also possible to design components that have This technical term expresses how Here too, a laser creates the many more functions than conventionally produced this production process differs component. However, instead parts. He illustrates this by picking up an object that from processes such as injection of a powder, a plastic solution looks like a plastic replica of a giant jellyfish. In fact, it’s molding: It does not involve is laid down and then hardened a folding stool consisting of many hinged components material being poured into a mold by means of UV light. that a flick of the wrist can transform into an elegant or a workpiece being carved Multi Jet Fusion This is a chair. “It slides right out of the powder bath this way. out of a block of material. Instead, further development of the selec- All you have to do is to brush it off and fold it out.” the component is calculated on tive laser sintering process. The Through its search for new employees, Materialise a computer and the 3D model is difference is that the shape that has also become aware of the appeal of tangible products built up layer by layer — in a is to be printed is sketched out in and the fascination of 3D printing. “At our location in process of addition, so to speak. black paint, and then the entire Bremen we initially did only software development, and Selective laser sintering powder layer is exposed to a heat it was very hard to attract new employees, even though In this 3D printing process, the source. The dark areas heat up we were located directly next to the campus. That’s the product is created when a plastic quickly and melt. kind of positioning we like to have at all of our locations.” or metal powder is laid on in Fused deposition modeling Today, Bremen is also a production location—and sud- layers and melted at the key spots (FDM) This printer works in denly it has become much easier to find new program- with a laser. The finished product the same way a baker uses an icing mers. “That’s because now they can not only tell people finally lies in a bath of powder bag: A strand of plastic is rolled that they’ve programmed something, but also pick that has not yet been melted and off the spool, heated, and applied something up and say, ‘I’ve programmed something, is then separated from it. with a nozzle, layer by layer. and that’s why this cool thing exists today.’” 23
COVER STORY: POLYAMIDE 12 “GERMANY IS LIVING ON ITS CAPITAL” The US economist David Audretsch praises Germany as a highly attractive industrial location. His French colleague Sylvain Broyer begs to differ. A debate about the industrial engine of Europe
DEBATE reform agenda of the Schröder administration since 2005. Back then, Germany regained its competitiveness. But since then, it has improved as an industrial location in only one important respect: the qualifications of its workforce and its high school graduates. Educational policy is the thing that Germany has done best in the past 15 years. In every other area, its economic policy has been characterized by stagnation. INTERVIEW MATTHIAS RUCH AND JÖRG WAGNER AUDRETSCH Mr. Broyer, you’ve used the word “stagnation.” PHOTOGR APHY BASTIAN WERNER I would prefer to talk about Germany’s stability. And that’s a positive concept. Germany’s stability also includes the model of consensus, Mr. Audretsch, Mr. Broyer, Evonik is planning to build a in which political decision-makers, companies, and labor production plant for a high-performance plastic for about unions work together to find solutions. Isn’t that a fairly € 400 million. After examining possible locations all over strange concept for an American? the world, it decided to build this complex in the German state of North Rhine-Westphalia. From your standpoint as AUDRETSCH You’ve got a point there. Americans typically economists and scholars who are familiar with Germany, reject such models, which look suspicious to them. On the other is this a step you can understand? hand, thinking and planning with the long term in mind is a very positive approach, especially in the current global situation. The SYLVAIN BROYER Evonik is following a current trend, so I’m weakness we’re seeing in the USA today is of course due to very not surprised by this decision. Among the established industrial short-term thinking. This is a very narrow mindset. By contrast, if nations of the world, the G7 countries, Germany is the only one you include the perspectives of the employers, the workers, and that can successfully maintain its industrial production. The che- the government, you’ve got large segments of the society on board. mical sector is a good example of the fact that the trend of moving I could even compare that with what the Chinese are doing with production facilities abroad has been ebbing since 2013. their planned economy. They too are capable of very long-term DAVID AUDRETSCH Germany is a very attractive industrial thinking and planning, and of developing clever strategies. location. The level of its human capital—in other words, its work- BROYER Mmm. When many parties have to take responsibility force—is very high. That also applies to the level of its infrastruc- for a decision, Germany’s philosophy of consensus really does have ture and the level of its medium-sized companies. These are advantages. When people in Germany say, “We’re going to do the driving forces that determine the advantages of an industrial this,” the thing really does get done. However, I would criticize the location. comparison with China. I wouldn’t say that China has a philosophy BROYER Mr. Audretsch, you’ve brought up an important point, of consensus, because China is definitely not a democracy. that of the infrastructure. I agree that the level of Germany’s However, China does have the possibility of enforcing the govern- infrastructure is good. But how long will it continue to be good? ment’s will through commands. That works in many centralized For years now, this country has been living on its capital! Just take nations, including France. But from my viewpoint, the crucial a look at the international rankings: Germany has slipped down thing is that China has a plan, a grand idea! Germany has a philoso- in the rankings for essential categories, by comparison to all of its phy of consensus, but no fundamental idea about the direction in important competitors. In terms of the quality of its flight infra- which it wants to develop. Germany is not developing a real structure, the USA now ranks higher than Germany. The Americans industrial policy. were much quicker than the Germans to invest in this area. In AUDRETSCH What do you think is missing? terms of railroad infrastructure, even Singapore now ranks higher BROYER For example, let’s look at the process of digitalization. than Germany. And in terms of road infrastructure, Germany In Germany not enough is being invested in this area, because the has been overtaken by South Korea. Germany urgently needs responsibility for developing ideas is being left to the companies. massive investments. That’s a real weakness, because what’s needed is public investment. At the European level as well, we need a kind of public invest- Why have they been neglected for so long? ment, for example in the form of the Juncker plan and the Europe- an structural funds, in order to improve infrastructures all over AUDRETSCH That has been a matter of politics. The decision- Europe, especially in Germany. makers have postponed this matter for a while. But as a wealthy AUDRETSCH All the same, we are observing greater dynamism, and developed country, Germany still has a very good infrastruc- especially in the area of digital enterprises. At the end of the 1990s, ture—especially by comparison with its neighboring countries many people considered Germany much too stolid, not only in its in Europe, such as Italy and France. politics but also in its entrepreneurship. Back then, Joschka BROYER Germany’s economic policy has basically rested on the Fischer complained, “If Bill Gates had been a German, Microsoft → 25
COVER STORY: POLYAMIDE 12 would not exist.” But since the turn of the millennium, the times David B. Audretsch (*1954 in the USA) is a professor have changed. Today Germany has both: economic stability as of economic development at Indiana University and an well as flexibility and dynamism among its entrepreneurs. My honorary professor of industrial economics and entre- thesis is that Germany has successfully overcome this lack of preneurship at the WHU-Otto Beisheim School of entrepreneurial spirit—and that it has done so by decentralizing its Management in Germany, as well as a co-author of the economic policy. It has developed focal points in its various book The Seven Secrets of Germany. regions, possibly at the expense of a centralized industrial policy. And that kind of centralization has in fact disappeared. BROYER Mr. Audretsch, on that point I agree with you. The only example of a grand idea in the area of industrial policy that I can think of is the energy transition. But unfortunately, it too is not proceeding according to a well-developed long-term plan. It was developed as a result of the Fukushima crisis. As non-Germans, what do you think of the German invention of the “energy transition”? BROYER Here I’d like to differentiate between short-term and long-term effects. In the short term, the subsidies for renewable energies are causing enormous costs for electricity customers. These costs have increased by more than 20 percent in the past five years. I also think that the indirect costs of this reform include the fact that big energy companies such as RWE can no longer pay good dividends to their shareholders. In the long run, the energy transition is opening up new markets for German companies. Germany is now the leading producer of wind and solar energy. The only thing that’s now missing, in my opinion, is the medi- um-term perspective: How are such decisions affecting the exist- ing business processes? I don’t see any overarching concept for answering this question. AUDRETSCH Here’s an interesting thought: In general, Germa- ny’s economic policy is regarded as being very risk-averse. But the decision to launch the energy transition was a very risky one, wasn’t it? Nobody was able to say where it would lead. But I see a positive short-term aspect. Through its phaseout of nuclear energy “Germany’s economic and its energy transition, Germany represents an environmentally friendly policy. Today this image is definitely a locational advan- policy is regarded as tage, especially in the competition for the talents of the young generation. Young people from the so-called “creative class” want being very risk-averse” to live in healthy and environmentally friendly surroundings. For many young people, that’s the top priority. As a result, talented young people—what we call “human capital”—are happy to move to Germany. DAVID B. AUDRETSCH When international companies invest in the USA, one of the reasons they give is that the energy costs there also applies to Germany as an industrial location. The energy costs are very low. That’s a clear competitive disadvantage for there are very high, but in exchange German companies benefit Germany, isn’t it? from other advantages: the stability and, above all, the excellent workforce. AUDRETSCH Yes, it certainly is. But just take a look at Silicon BROYER Rising prices for electricity would be a real problem for Valley. I’m always very impressed by it. Silicon Valley is one of the energy-intensive sectors such as the chemical industry. And as far world’s most expensive locations, but that isn’t scaring off the as education is concerned, the German educational system for companies and people in the digital industry. It’s true that there skilled workers is fantastic. However, Germany is only in the middle they have very high costs, but they also get a lot back! And that rankings of European countries when it comes to the number of 26
DEBATE Germany has experienced a strong wave of immigration. What effect will this have on the country as an industrial “In Germany not enough location? is being invested in AUDRETSCH Immigration is like the World Cup in soccer… digitalization” … We want to hear more about that! SYLVAIN BROYER AUDRETSCH No, no, I’m not making a comment about sports. I’m referring to the international competition in this regard. The best players are in demand all over the world. And in exactly the school and university graduates in the MINT subjects. And the same way, today every location, every city, and every country has competition isn’t napping. Other G7 countries such as Canada and to struggle to attract the best minds to work there. This is a chal- Japan are making huge efforts to incorporate younger generations lenge for Germany too, but it applies to every country in the world. into their aging societies, give them a better education, and strengthen their social bonds. Germany is certainly doing this But many people with fewer qualifications are also coming. better than other European countries. Italy has implemented a reform of its educational system, but it hasn’t achieved anything. AUDRETSCH That’s true. But if Germany can’t solve this In France, President Macron has yet to initiate his reform of the problem, what country can? Basically, no other country in the school system and the trainee system. world can match its system of education and integration. BROYER A high level of education is a key to future success. That’s especially true if an hour of work in German industry costs $ 25 more than an hour of work in Korea. In Korea, the workers are also highly qualified, but currently they are campaigning for the introduction of a 52-hour week instead of the 68-hour week they have now. Will the integration of immigrants into the workforce be successful in the medium term? BROYER From a historical standpoint, all of the major growth phases of national economies all over the world were caused by demographics and immigration. What we’re seeing in Germany at the moment is the biggest wave of migration since the one caused by the war in the former Yugoslavia in 1992. At the moment, the integration of immigrants into the workforce is still too low. The likelihood that a refugee will find a job in German is 35 percent as a long-term average. Today, during this wave of immigration, it is less than 20 percent. In spite of the immigration of young people, the average age of our population is constantly increasing. Does this development make you uneasy? BROYER During periods when a population is aging, there are only two other opportunities besides immigration to safeguard the substance of the national economy. The first one is robotization. Germany is extremely progressive in this area, even though it isn’t doing so well in terms of digitalization in general. Incidentally, Sylvain Broyer (*1971 in France) works in Frankfurt as there’s a strong correlation between the average age of a country’s the Head of Economics of Natixis, the investment bank of workforce and the number of robots being used in industry. Three French savings banks and credit unions, which is one of countries lead the world in terms of the robotization of industry: the biggest bank groups in France. He is a member of the Japan, South Korea, and Germany. These are exactly the three ECB Shadow Council of Handelsblatt magazine. industrialized countries whose population is aging the fastest. → 27
COVER STORY: POLYAMIDE 12 consumption. Instead, it’s due to the fact that German companies have to plow back their profits into payments on their pension obligations, because of the low interest rate. Mr. Audretsch, perhaps someone ought to explain that to Mr. Trump: If we want to reduce the current account surplus in Germany, we have to raise the interest rate. That’s all. In this connection, what role is played by the preservation of the euro zone? BROYER Germany is one of the countries that benefits most from the euro. If Germany were still using the Deutsche Mark, the exchange rate would be between 10 and 20 percent higher, and Germany’s export trade would therefore be more problematic. Audretsch and Broyer met in the Electoral Palace in Koblenz Moreover, the euro has strongly expanded Germany’s sales markets. And the euro is also important because it enables Europe to assert itself in a bipolar world that is dominated by the USA and China. AUDRETSCH That’s certainly a huge advantage! Without the euro, Germany would have to change completely. I can’t even imagine the abolition of the euro. BROYER US economists already predicted that when the euro was established. The second opportunity to safeguard the substance of a national AUDRETSCH That’s right, especially the most famous ones. economy is to keep older people working longer. However, this But I have to admit that I was also unable to imagine that the UK process works only once. Where should additional growth come would ever leave the EU. from if all of the “silver workers” are still occupying all the jobs? BROYER In historical terms, the euro and the EU are not the first That’s why educational policy and immigration policy simply attempts to create a unified Europe. So far, all of these attempts belong together. have failed—after the Peace of Westphalia and after the Congress of Vienna. Unfortunately, the history of the continent of Europe Let’s talk about taxes—an important factor for industrial is a simple one: We’ve got a bunch of small nations that beat other locations. US President Trump has created a new situation nations up in order to win supremacy over the continent. Some- by radically reducing corporate taxes. times it’s the British, sometimes the Germans, sometimes the French. And every time, an alliance of other nations forms in order BROYER President Trump isn’t the only one. And to a certain to stop these bullies from becoming dominant. At the moment, extent other countries will probably have to join in this taxation Germany is dominating the continent within the euro zone. contest. I’m convinced that, at the latest, the next German government will put the topic of corporation taxes and municipal Let’s end this conversation by having you imagine your- business taxes on its agenda. selves in the role of Germany’s Minister of Finance. You AUDRETSCH Here too, you can justify a high level of taxes if this are now allowed to invest € 10 billion to strengthen revenue is invested in the industrial location. Consequently, the Germany as an industrial location. Where will you invest crucial question is: Are the high tax revenues in Germany being this money? In the infrastructure? Or in digitalization? invested in a strategically effective way? If the answer is yes, the level of taxation balances out. BROYER Neither one. I would invest the € 10 billion in the BROYER Look, President Macron has already begun to reduce stabilization of the euro zone. This is extremely important, and the corporate taxes. Above all, he wants to significantly increase the consequences of a breakup of the euro zone would be very bad for tax incentives for venture capital. That too makes a lot of sense, Germany. The money should be used strategically for this purpose. because it counteracts the biggest problem we have at the moment: AUDRETSCH I agree. Germany has benefited tremendously the low interest rate. This factor is often overlooked. Especially from the euro zone, and it now has to deal considerately with its in an aging society, low interest rates mean that big companies European partners in order to stabilize the euro. When the crisis have to significantly increase their payments into pension funds. with Greece broke out, most German politicians said, “The Greeks That reduces their ability to invest, and that in turn reduces have to put their national budget in order.” It was a great mistake the capacity for innovation. The main reason for the tremendous to leave the Greeks to do this alone. The EU is like a marriage, growth of the current account surplus in Germany since 2007 in good times and bad ones. That’s why Germany has to invest in thus really has nothing to do with the Germans’ low interest in Europe, in this partnership. 28
NEWS “Evonik is moving in the right direction and is ing or regenerating bones or diseased tissue, EVONIK NEWS successful in its business operations,” Tönjes for example. says. “As Evonik’s largest shareholder, the Experts estimate that the market for the mate- RAG-Stiftung has a keen interest in ensuring rials needed in the field of tissue engineering that this situation continues.” Tönjes described is growing by roughly 30 percent per year and the planned sale of the methacrylate business will reach the US $3 billion mark by 2021. Up as the right step. But he also expressed some to 20 scientists will work at the Evonik Project clear expectations: “Evonik must grow profit- House in Singapore. Their aim is to develop ably and pay reliable dividends.” The dividend materials for biological implants used in med- Werner Müller Bows Out from Evonik is the chief source of income for ical applications. the RAG-Stiftung, which holds around 68 Evonik has extensive experience with mate- percent of Evonik stock. The remaining 32 rials such as biodegradable polymers. These percent are freely traded on the stock market. will now be developed further in the Project Tönjes expressed deep gratitude to his prede- House. A key area of work will be reproduc- cessor as Chairman of the foundation and the tion of tissue structures using 3D-printed scaf- Supervisory Board: “I have profound respect fold materials. for Dr. Werner Müller and his outstanding life’s work.” Evonik’s Value to the German Economy Werner Müller had been Chairman of Evonik’s Experts have now calculated the value that Supervisory Board since the end of 2012 Evonik adds to the German economy. Accord- ing to their analysis, each euro created in the At the annual shareholders’ meeting, the Exec- Group results in an additional € 1.50 in value utive Board and shareholders of Evonik bade to society, for example in the form of invest- farewell to the departing Chairman of the Su- ments or consumer spending by employees pervisory Board, Dr. Werner Müller (71), and of Evonik or of its suppliers. There is a similar paid tribute to his outstanding achievements. effect on public revenue and jobs: Every euro “You were and will always remain our founding Tönjes introduced himself to the shareholders that Evonik pays in taxes and charges in Ger- father,” the Chairman of the Executive Board, at the annual shareholders’ meeting many results in an additional € 0.14 in public Christian Kullmann, said. CEO Kullmann also revenue. This is the result of tax payments by praised Müller’s “strategic vision.” Shareholder suppliers or employees, for example. Similarly, representatives expressly thanked Müller for each Evonik employee secures a further 2.7 his entrepreneurial acumen, his personal com- A World Record in Weiterstadt jobs outside of the company. mitment, and his outstanding services to Evonik. These calculations are based on what is known Müller had announced at the beginning of the Evonik has commissioned the world’s most as an impact analysis. year that because of health reasons he would advanced stretching and polishing plant for no longer be available for a further term of aviation materials made of PLEXIGLAS®. Lo- office. Müller has also resigned from his po- cated in Weiterstadt, the new facility produces sition as Chairman of the Board of Executives stretched sheets of polymethyl methacrylate Investments in the Future of the RAG-Stiftung. The RAG-Stiftung holds (PMMA) that are 5.4 meters long and 3.7 me- around 68 percent of Evonik stock. Stable in ters wide—the largest format available world- Through its venture capital unit, Evonik has in- value and dividend-paying, Evonik stock forms wide. This format will enable the aviation in- vested in two young companies that develop an important part of the RAG-Stiftung’s capi- dustry to develop entirely new aircraft designs. and utilize future-oriented technology. The tal base. Back in March, the Supervisory Board Before production can start, an external vali- technology startup mySkin, Inc. is based in Jer- of Evonik appointed Müller to the position of dation phase must first be completed. This will sey City (New Jersey, USA). It has developed Honorary Chairman. certify the material for use in the US and the a breakthrough hand-held device for analyzing European aerospace markets. Initial tests are and improving skin properties, combined with already under way. The market for stretched tips for suitable skin care. Evonik is one of the aviation parts is showing healthy growth. world’s leading suppliers of ingredients for the Bernd Tönjes Is the New personal care industry. Supervisory Board Chairman In addition, Evonik has invested in Velox, a dig- ital printing company based in Israel. Velox has Bernd Tönjes, a 62-year-old mining engineer, A New Project House a new technology for the cost-effective high- is the new Chairman of the Supervisory Board speed printing of photo-quality images and of Evonik. He was appointed to the Supervi- Evonik has set up a Tissue Engineering Proj- other decorative elements on metal, plastic, sory Board by a large majority at the annual ect House in Singapore. In tissue engineering, and glass packaging. The process can be used shareholders’ meeting. The Board subsequently living cells are grown on a scaffold material either for extremely small series or for large- appointed him to the position of Chairman. As outside of the organism. It is a process that scale industrial applications, both at competi- of May, Tönjes also succeeded Dr. Werner requires special nutrients and growth factors. tive prices. In addition, Velox supplies systems Müller as Chairman of the Executive Board of This externally grown tissue can then be im- for printing on cylindrical containers such as the RAG-Stiftung, Evonik’s largest shareholder. planted in the organism as a way of preserv- plastic tubes. 29
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