To address this challenge, FILK Freiberg Institute, an independent research institution with expertise in polymer coatings for textile applications, collaborated with Optotransmitter-Umweltschutz-Technologie (OUT) e.V. The joint project, funded under the German Industrielle Gemeinschaftsforschung (IGF) program of the Bundesministerium für Wirtschaft und Energie (BMWE), focused on developing flexible, conductive polymer surfaces for next-generation smart textiles.

The goal was to enable the free distribution of multiple LEDs and sensors across a textile surface by creating a uniform conductive “potential field” within the material. This technology enables greater flexibility compared to conventional conductor tracks.

Creating a flexible conductive PU film using Impranil^®

To achieve the required combination of conductivity, elongation, and flexibility, FILK and OUT e.V. used water-based Impranil^® polyurethane dispersions from Covestro, creating a flexible conductive PU film into which carbon nanotubes were incorporated as electrically conductive additives.

Laser structuring of the conductive polymer surface allowed precise tuning of the electrical properties of the potential field, enabling LEDs and sensors to be distributed freely across the textile surface without traditional wiring. The active control of embedded LEDs through the integrated sensors supports real-time monitoring and bidirectional communication via modulated voltage or Bluetooth, depending on the application.

Dr. Martin Heise, Deputy Head of Department Functional Layer Systems at FILK Freiberg Institute, said: “Our goal was to rethink how electronics are integrated into textiles. By creating a conductive surface instead of fixed wiring using Impranil^® polyurethane dispersions from Covestro, we can distribute sensors and light sources far more freely, enabling new smart textile designs and applications.”

Dr. Iris Vela-Wallenschus, Project Manager at OUT e.V. noted: “Distributed electronics, real-time sensing, and bidirectional communication within a flexible textile substrate represent a meaningful step forward for wearable technology. Working with FILK and Covestro, we've shown that this kind of adaptive functionality is achievable at a level of sophistication that is difficult to achieve with conventional wiring approaches.”

Enabling a new generation of smart textiles

The result is a technology platform that combines conductive polymer materials, sensor integration, and intelligent control. This platform unlocks possibilities for new applications such as sensor-controlled newborn bodysuits for jaundice phototherapy. Current standard treatments for neonatal jaundice rely on blue light at approximately 455 nm in hospital incubators. A flexible bodysuit integrating blue LEDs and sensors directly into the garment could continuously monitor therapy progress and adjust light intensity and distribution in real time. This approach may contribute to the development of more flexible treatment options with the support of midwives.

Beyond this application, Impranil^® PUD-based formulations can be used in applications including heated textiles, pressure sensors, and flexible conductor tracks for wearable electronics. This system can also be adapted for scalable manufacturing processes such as digital printing, supporting broader adoption in industries including sportswear, automotive interiors, protective equipment, and connected IoT devices.

Dr. Torsten Pohl, Global Head of Textile Coatings at Covestro added: “This project highlights how material innovation can unlock new functionality in textiles. Our Impranil^® water-based polyurethane dispersions provided the flexibility, durability, and processability needed to turn a complex concept into a scalable smart textile platform. We're proud to have supported FILK and OUT e.V. in developing a system with real-world impact, from neonatal care through to the broader wearables market.”

To see what this flexible, conductive smart textile system looks like, visit Techtextil 2026 in Frankfurt between April 21 and 24. A demonstrator of the sensor-controlled newborn bodysuit for jaundice phototherapy will be on display at the Covestro booth (C79) in hall 11.0.

The collaboration seeks to develop a circular economy model for medical devices by proving both technical feasibility and economic viability while navigating the complex regulatory landscape of medical waste management. In cooperation with additional partners in the United Kingdom – including Allmed’s distribution partner Kimal, a leading regional hospital trust and a specialized recycler – Allmed and Covestro are now preparing for their first recycling trials.

“The circular economy in healthcare is still emerging – but it holds tremendous potential. With this feasibility study, we want to demonstrate that even complex applications like artificial kidney filters can be circular and become a valuable source of high-quality polycarbonate recyclate instead of being incinerated or sent to landfill,” says Lily Wang, Global Head of Engineering Plastics at Covestro.

Allmed is equally committed to ambitious sustainability goals: “Blood purification devices are essential for life-saving treatments but also require significant resources. Our ambition is to show that high medical performance and ecological responsibility can go hand in hand,” explains Ahmed Sorour, Chief Executive Officer at Allmed.

Matt Press, Chief Executive Officer of Kimal Group added: "We are very proud that Allmed had chosen Kimal and the UK market to be at the forefront of this fantastic and groundbreaking initiative".

About Allmed:
Allmed is a leading innovator and supplier of groundbreaking blood purification devices. It encompasses the widest portfolio of such devices globally, from neonatal care up to the largest blood filters on the market. It is headquartered in the UK, with key technology centers in Germany, and exports its devices and technologies to over 40 countries worldwide. Allmed is committed to showcasing to the world that even life-saving medical devices can enter and exit the supply chain sustainably.

Find more information at Allmed – Delivering world class Dialysis Treatment
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Latest info on Covestro’s K fair presence:

• Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

Additional Press Releases:

• From Materials to Solutions: Covestro Brings "The Material Effect" to K 2025
• Digital Material Twins in Automotive Design: Imagio^® of Covestro Now Integrated into Autodesk VRED
• Covestro deepens collaboration with Ausell to advance end-of-life automotive plastics recycling
• More speed from design to series production
• From old tires to new car parts: Covestro, Neste and Borealis aim at closing loop for automotive industry 
• Covestro and Deloitte jointly develop Monetization Framework for Circular Economy
• Life Cycle Assessments digitalized: boosting transparency

Covestro at a Glance:

Are you looking for more information? Here you could find further facts about Covestro.

Monique Buch, Chief Commercial Officer at Covestro: "The chemical industry and many of its key customer industries face profound transformations – on the path to circular economy, through AI and digitalization, or due to geopolitics and the realignment of global markets. With our expertise in high-performance materials, process and application development, we remain part of the solution and support our customers in achieving their goals."

The solutions presented at "K" are organized across the booth in the areas of Automotive, Electronics, Healthcare, Sports and Leisure, as well as Sustainable Future. They showcase "The Material Effect" in application across various industries and underline the company's long-term vision of a complete alignment with the circular economy. This vision remains the North Star for Covestro and the industry – despite short-term challenges and overlapping crises that require resilience and adaptability.

Materials with Impact: "The Material Effect" in Practice

Jochen Hardt, Booth Manager and Vice President Global Marketing Mobility in the Engineering Plastics business entity at Covestro: "At our booth, visitors can experience first-hand how 'The Material Effect' becomes reality in concrete applications. We deliberately present not only materials and products but showcase well-designed system solutions that offer real added value to our customers. My team and I at Covestro look forward to engaging with visitors throughout the fair!"

Sustainable Future

In the "Sustainable Future" area, Covestro demonstrates its comprehensive commitment to the circular economy. This includes the "CQ" portfolio, which marks products containing at least 25% alternative raw materials. Another example is the technology developed by Covestro and partners for producing plant-based aniline. Also featured are several car-to-car recycling projects that advance circularity in the automotive industry. For example, the NALYSES project, where Covestro works together with partners like HELLA and BMW on the circularity of headlights. Or a pilot program with NIO, VW, and GIZ for recycling polycarbonate parts. For the latter, visitors will find materials labeled "RE", "RP", and "R" at the booth – these are partly made from alternative raw materials.

Automotive

Highlight in the automotive area: The SUE "People Mover" – a prototype vehicle for public transportation. The autonomous e-shuttle was designed and developed by UE | STUDIOS. It features large-scale, curved 3D polycarbonate glazing as well as seamless integration of driver assistance systems and sensors, also using polycarbonate. The lightweight, highly durable monomaterial Arfinio® is used in the interior, along with a recyclable TPU monomaterial seat. The IMAGIO® tool for digital, photorealistic material twins will also be on display. It is now implemented in Autodesk VRED and makes design processes faster and more efficient.

Electronics

In the electronics area, Covestro showcases innovative NIA-PFAS (not intentionally added PFAS) polycarbonates with flame retardancy for laptop covers and IoT device housings. Additionally, a recyclable antenna housing made of Makrolon® monomaterial will be on display, combining optimal signal transmission with weight reduction.

Healthcare

In the healthcare booth area, Covestro presents material solutions that combine sustainability with performance and reliability: From medication delivery with particularly thin-walled, more easily recyclable monomaterial injectors to resistant housings for diagnostic devices that withstand disinfectants. Such devices can furthermore be made with NIA-PFAS material types for flame retardancy, and support the seamless integration of functionality such as touch operation and signaling in an attractive design.

Sports and Leisure

In the sports and leisure area, visitors will find applications such as the e-surfboard by Awake. Covestro materials can be found, for example, in the easily and quickly replaceable battery, with thermally conductive and flame-retardant polycarbonate for improved battery performance. Durable TPU-based materials on the grip of the replaceable battery additionally provide pleasant haptics and comfort.

Press Tour for Media Representatives

Media representatives are cordially invited to experience Covestro's exhibition booth at K 2025 in person. A press tour will take place on the first day of the fair, October 8, 2025, at 3:00 p.m. at booth A75 in Hall 6.

The tour offers a comprehensive overview of all focus areas as well as the opportunity for discussions with technical experts about "The Material Effect" and the implementation of the circular economy strategy in concrete applications. There will also be opportunities for individual interviews.

For more information about Covestro at K 2025, please visit Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

“With rising healthcare standards worldwide and an aging population, we’re seeing accelerated demand for medical-grade TPU solutions. With our Changhua site, we can now serve customers with such materials at shorter lead times and with enhanced supply security,” says Kevin Ho, Head of Sales and Market Development TPU Asia Pacific at Covestro. “By leveraging our Zhuhai production site and the new application development center in Guangzhou, we are enhancing regional synergies to support our customers with high-performance, globally compliant TPU solutions.”

Local production, global standards

Produced at the Changhua site in accordance with Good Manufacturing Practice (GMP) principles, the new Desmopan® Rx grades are engineered to meet stringent international requirements for medical applications and minimize contamination risks. The materials are verified for biocompatibility in accordance with ISO 10993 and China’s YY/T 1557 standards for TPU used in infusion, transfusion and injection equipment. They are free from added plasticizers, exhibit low extractables and are compatible with multiple sterilization.

“Our Desmopan® Rx grades meet established industry requirements for medical applications,” explains Dr. Frank Yang, Head of Asia-Pacific Innovation TPU at Covestro. “We’re committed to ensuring product safety and regulatory compliance while helping customers across Asia Pacific unlock greater value in regulated medical markets.”

Enabling advanced healthcare solutions

Desmopan® Rx grades are specifically developed for medical device components such as thin-walled flexible tubing, catheters, connectors, component housings, endoscopes, healthcare devices and wearables. Tubing made with Desmopan® Rx can be effectively used in a wide range of clinical applications, including surgical procedures, hemodialysis, drug delivery systems and wound care.

In addition, Desmopan® Rx grades are well-suited for medical nonwoven applications due to their compatibility with melt-blown processes. Nonwovens made from these grades combine functional performance with compliance to medical waste regulations, making them ideal for surgical drapes, wound dressings, gowns, sterile packaging and protective equipment.

Key material benefits include:

• Biocompatible formulation suitable for direct patient contact applications
• High clarity for medical observation
• Excellent kink resistance to reduce tubing blockage risk
• Superior flexibility and dimensional stability
• Strong chemical resistance against oils, cleaning agents and disinfectants
• Outstanding abrasion resistance for demanding applications

Covestro is presenting the new Desmopan® Rx TPU grades at Booth N5E24 at CPHI & PMEC China, Asia’s premier pharmaceutical event, running through June 26 at the Shanghai New International Expo Center.

The more than 20 innovation stories that Covestro presents at its booth are closely linked to this guiding idea and the company's long-term vision of becoming fully circular. This vision is gaining additional importance under the current circumstances – short-term challenges and overlapping crises that require resilience and adaptability.

Covestro’s CEO Markus Steilemann emphasized this at the traditional K pre-press conference: "The world seems to have gone off track, and the chemical industry is feeling the full force of the current multiple crises. At the same time, the future will be ever greener and smarter. At Covestro, we are paving the way for that for many sectors with our recyclable, climate-neutral high-performance plastics – whether in e-mobility and autonomous driving, efficient buildings, or digitalization. We are excited to showcase the diverse and beneficial effects of our materials for our customers and partners at this year's K trade fair."

Covestro's Guiding Idea: "The Material Effect"

At booth A75 in Hall 6, Covestro will place special emphasis on progress and innovations in the areas of Sustainable Future, Automotive, Electronics, Healthcare, and Sports & Leisure. Among the highlights at the booth will be a new concept vehicle for public transportation: The SUE "People Mover". The self-driving urban e-shuttle has been developed by UE | STUDIOS. It features full polycarbonate glazing, polycarbonate for lidar sensors, as well as the lightweight and highly durable mono-material Arfinio^® and TPU. Also among the exhibits is the digital sampling tool IMAGIO^®, which enables realistic digital visualization of product designs, thereby replacing physical samples with digital material twins in early development phases.

With these and many other stories and exhibits at the booth, Covestro demonstrates under this year's guiding idea "The Material Effect" what role high-performance materials play in a sustainable world. "The Material Effect" combines best in class materials with process and innovation expertise, enabling the leap from laboratory to industry. "It is precisely this unique combination of material science, process- and application development that makes the decisive difference," said Jochen Hardt, K 2025 project lead and Vice President Global Marketing Mobility in the Engineering Plastics business entity at Covestro, at the press conference. “'The Material Effect' enables our customers and partners to achieve more – in terms of sustainability, circularity, and performance of their products.”

Progress Towards Corporate Vision and Strategy

Covestro pursues a clear strategic vision: to become fully circular and make the circular economy a global guiding principle. This includes the use of alternative raw materials, switching to green energy, and developing advanced recycling technologies. The company has set a goal to become climate-neutral in its own operations (Scope 1 and 2) by 2035 and to achieve complete climate neutrality along the entire value chain (Scope 1-3) by 2050. To this end, Covestro has already signed eleven power purchase agreements (PPAs) and now covers around 16 percent of its global electricity needs from renewable sources.

Furthermore, Covestro is consistently expanding the use of alternative raw materials – with the goal of largely avoiding the use of fossil primary raw materials in the long term. The company is to that end currently developing and testing novel recycling technologies for polyurethanes, polycarbonates, and elastomers.

The commitment to the circular economy is furthermore reflected in the product portfolio: Products with the brand suffix "CQ" – which stands for Circular Intelligence – contain at least 25 percent alternative raw materials. For polycarbonates, Covestro differentiates its offering with specific labels: "RE" stands for products based on renewable raw materials and produced with renewable electricity.^* "RP" identifies products with chemically recycled post-consumer waste.^* "R" designates products with mechanically recycled material content.

Such products aFor more information about the trade fair presence, visit:

For more information about the trade fair presence, visit:
Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

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Latest info on Covestro’s K fair presence:

• Experience “The Material Effect” at K 2025 at Covestro | Covestro AG

Additional Press Releases:

• Covestro deepens collaboration with Ausell to advance end-of
• More speed from design to series production
• From old tires to new car parts: Covestro, Neste and Boreali
• Covestro and Deloitte jointly develop Monetization Framework
• Life Cycle Assessments digitalized: boosting transparency

Covestro at a Glance:

Are you looking for more information? Here you could find further facts about Covestro.

"The new production facilities are equipped with state-of-the technology to enable an efficient production and thereby reduce our CO₂ emissions," says Thorsten Dreier, Chief Technology Officer of Covestro. “With the expanded capacity, we can meet our customers' growing demand for innovative specialty films, especially in medical technology, in the region Asia-Pacific and strengthen our Solutions & Specialties segment."

Covestro has been operating a production facility for Specialty Films in Thailand since 2007. The range comprises polycarbonate films from the Makrofol^® range and Bayfol^® products made from polycarbonate blends. These high-performance specialty films are used in many applications across multiple industries, such as healthcare, mobility and Identification Documents.

“The new production facilities are important to us because it enables faster time to market and at the same time expands our market access in Asia-Pacific.” says Aukje Doornbos, Global Head of the Specialty Films business entity. “With market-focused innovations and a stronger customer orientation we want to drive growth for Covestro.”

Since 2022, the Map Ta Phut site is ISCC PLUS certified, enabling it to manufacture and supply mass-balanced products. With the mass balance approach, bio-based or recycled raw materials are fed in at an early stage of raw material extraction and mathematically allocated to the finished products. This saves fossil raw materials and reduces CO₂ emissions, while the quality of the mass-balanced products remains identical to that of purely fossil-based products. With this drop-in solution, manufacturers can continue to use their proven formulations, equipment, and processes.

ISCC is an internationally recognized sustainability certification for biomass and bioenergy. The standard covers all stages of the value chain and is used worldwide. Customers can use these products in their established processes and apply them to meet their sustainability goals. In addition, Covestro already offers a range of films made partly with plant-based raw materials or partly from recycled plastics.

"This investment in our U.S. compounding plant is an important component of our 'Sustainable Growth' strategy. With this expansion, we can meet our customers' growing demand for specialized polycarbonate materials, grow together with our customers, and strengthen our position as a leading provider of polycarbonate materials in North America," says CTO Thorsten Dreier. "The move also aligns with our strategy to produce in the region for the region, to manufacture close to our customers and ensure reliable supply."

The capacity expansion is an important step to meet the growing demand for high-quality materials for the automotive, electronics, and healthcare industries in North America. "To be successful in these markets, you need the right portfolio, consistent quality, and supply reliability, as well as solution-oriented technical expertise,” says Lily Wang, head of the Engineering Plastics Business Entity. "The expanded production capacity for differentiated polycarbonates enables us to better serve our customers' complex needs for high-quality, high-tech materials with individualized properties.”

Covestro already has an established R&D center in Pittsburgh and is now doubling down on its U.S.-based compounding capability. In the future, both facilities will work even more closely together to drive the technology transfer from lab to industrial production to support major transformation processes, such as the electrification and automation of mobility, sustainable developments and digitalization.

“This investment, which follows our recent announcement of an almost 40 million Euro investment in our R&D capabilities in Pittsburgh, underscores how critical our U.S. sites and the U.S. market are to Covestro’s global strategy,” says Samir Hifri, chairman and president of Covestro LLC. “The expanded capacity of our polycarbonate compounding capabilities in Ohio will both help us better supply our customers as well as represent a commitment to our employees at the site, the Hebron, Ohio community, and the U.S. market as a whole.”

Construction of the new production lines is scheduled to begin in 2025, with operations starting by the end of 2026.

“Healthcare manufacturers are increasingly adopting sustainable materials to reduce their carbon footprint, and it is our goal to help customers reach their sustainability ambitions,” said Sam Shodi, Head of Specialty Films North America, Covestro.

According to Shodi, the Makrofol^® polycarbonate film provides the transparency, toughness and sterilization suitability needed for many medical applications an example of which is medical implant packaging. “This advancement meets the demands of our healthcare customers, where sustainable materials are crucial for reducing environmental impact while maintaining high quality and safety standards,” he concluded.

With the mass balance approach, bio-based or recycled raw materials are fed in at an early stage of raw material extraction and mathematically allocated to the finished products. This saves fossil raw materials and reduces CO₂ emissions, while the quality of the mass-balanced products remains identical to that of purely fossil-based products. With this drop-in solution, manufacturers can continue to use their proven formulations, equipment and processes.

ISCC is an internationally recognized sustainability certification for biomass and bioenergy. The standard covers all stages of the value chain and is used worldwide. Covestro has major sites across all regions that are ISCC PLUS certified. Among them are world-scale sites like Baytown, Texas; Leverkusen, Dormagen and Krefeld-Uerdingen, Germany; Shanghai, China; Map Ta Phut, Thailand; and Antwerp, Belgium.

Customers can discover more about Covestro’s mass balance films and other premium material solutions, including how they support sustainability goals and drive advancements in medical devices, at the upcoming MEDICA 2024 and COMPAMED 2024 trade fairs, November 11-14 in Düsseldorf, Germany.

The first applications for the new grades could be in the electrical and electronics industry, as well as in healthcare. Both sectors are particularly well represented in Asia. For their use in housing parts, plastics of the new Apec^® XT line must above all offer freedom of design, dimensional stability, impact as well as chemical resistance and, in some cases, good flame retardancy.

There are also promising prospects for the copolymers in telecommunications and photovoltaics, for example in antenna housings, where weather-resistant, electrically insulating, ductile and flame-retardant materials are needed.

Further product innovations based on the new copolymer technology platform could focus on the automotive industry and infrastructure, where plastics from the new series have good prospects for use in housings for residential energy storage systems, charging stations and wall boxes, for example, thanks to their good electrical insulation properties, weather resistance and flame retardancy.

Apec^® XT grades will be designed to remain resilient even in the harshest conditions. The new copolymer technology enables the production of products that exhibit high impact strength even at temperatures as low as minus 40 degrees Celsius. In addition, these copolymers have improved chemical and ageing resistance, making them ideal for applications that require contact with aggressive cleaning agents and long durability in outdoor applications.

More sustainable products also available

APEC^® XT will also be part of the Covestro CQ portfolio of more sustainable product solutions. In that regard, Covestro will offer copolymer-based products in a version with up to 80 percent of ISCC PLUS-certified mass-balanced raw materials attributed from biowaste and bio-residues.

In addition, the company will offer products that incorporate recycled materials in order to also further reduce its environmental footprint. Moreover, due to its superior weatherability performance, the extended service life of APEC^® XT based products will improve product carbon footprint over its entire life cycle.

In addition to the reduced complexity of the new production process, the connection to the existing infrastructure in Antwerp with four production lines for polycarbonate also has an advantageous effect, as it combines global scale in production with the flexibility of a stand-alone unit.

"The new production process is the first and only one of its kind in the world and enables us to offer a broad portfolio of material innovations," says Sucheta Govil, Chief Commercial Officer at Covestro. "With the new plant, we can now produce and launch new polymer materials on an industrial scale much faster than before. This is the result of several years of development work by our research and process technology teams, as well as our long-term experience with polycarbonates. In our Solutions & Specialties segment, we focus on sophisticated products with a high pace of innovation, which is a key success factor since customer requirements change quickly. The new production line is a prime example of how we implement this strategy and support our customers to the best extent."

"Compared to pure polycarbonates, the copolymers open up new possibilites for us to integrate further functionalities and properties into our materials," explains Lily Wang, Global Head of the Engineering Plastics business unit. "These can range from improved mechanical properties, a higher resistance against chemical attack to an enhanced flame retardancy. By that, we can offer innovative materials that meet the high requirements of our customers in a wider range of applications. We will focus first on materials for the electrical, electronics and healthcare industries, while future innovations might focus on mobility and other trends." To understand its customers' needs, Covestro will showcase some of the products that could be produced with the new plant at the Chinaplas exhibition in Shanghai in April and looks forward to talking to customers about these innovative material solutions.

"Covestro understands the value chain and is not only a film producer but also an innovator and integrator," says Karine Benbelaid, Global Head of Medical Segment, Specialty Films, Covestro. "The company has a long, successful track record driving industrial collaboration with converters, printers, OEMs, research labs and designers. We’re highlighting a few of these collaborations at LOPEC 2024."

Covestro is participating at LOPEC, the International Exhibition and Conference for Printed Electronics, in Munich, Germany from March 5-7 at Hall 0, Booth 612 (B0.612). The company will showcase a diverse range of polycarbonate (PC) films and thermoplastic polyurethane (TPU) films for printed electronics manufacturing in healthcare and HMI (human-machine interface) applications in automotive and electronics design.

Smart patches and other healthcare applications

In the healthcare sector, smart medical skin patches help improve patient comfort and allow for enhanced remote monitoring, such as Electromyogram (EMG). While electronic patches are already used in many areas, such as patient monitoring, there is a growing need for digitization. With this in mind, Covestro will display a smart patch for early detection of ostomy bag leaks, developed with Witte Technology GmbH and Lohmann GmbH & Co. KG.

People with artificial intestinal outlet (stoma) use ostomy bags, which collect the gut and bowel liquid. These bags can sometimes leak, which can be associated with discomfort for the patient. For that reason, early detection is crucial to patient comfort. Using a sensor array printed on a medical grade Platilon^® TPU film, the smart patch on display can detect any leakage between the artificial intestinal outlet and the ostomy bag. The patch is designed for retrofitting an ostomy bag and can be integrated into existing ostomy bag solutions.

"The excellent collaboration among Witte Technology, Lohmann, and Covestro has yielded a groundbreaking solution: a smart patch for early ostomy bag leakage detection," says Dr. Volker Lutz, Head of New Business Development, Lohmann GmbH & Co. KG. "With its innovative sensor array on medical-grade Platilon^® TPU film, this smart patch promises enhanced comfort and peace of mind for ostomy patients around the world."

The following applications are also on display:

• Smart EMG wearable patches for biosignal acquisition made with Platilon^® 5302 MR7X, courtesy of Nile AB (Linxens Healthcare)
• Platilon^® TPU films with excellent printability for silver-based inks, which ensure high conductivity

HMI for automotive and electronics applications

LOPEC attendees will also see HMI applications for automotive and electronics designs enabled by in-mold electronics (IME). The feasibility of these technologies for mass production will be demonstrated using examples of the design of intelligent surfaces and innovative lighting.

The ´smart surface´ demo, jointly developed by Covestro and TactoTek^®, will demonstrate the use of Makrolon^® polycarbonate resin and Makrofol^® PC film technology to bring electronics into thin, durable and seamless 3D plastic surfaces by Film Insert Molding (FIM) technology.

An innovative lighting project for surfaces called ‘Jenny’ will also be on display. Jenny was developed by TactoTek^® and Novem using Covestro materials and consists of real wood laminate and areas of triangular PC overmolds and wood. This structure provides seamless, even lighting in a high-quality design.

"We are thrilled to reveal ‘Jenny’, our extraordinary lighting concept. The A-Surface can be customized for an ultra-premium feel and finish", says Paavo Niskala, SVP IMSE Technology, TactoTek^®. "By integrating Makrofol^® and Makrolon^® layers, along with different surfaces, we have achieved an unparalleled fusion of innovation and elegance."

At LOPEC 2024, Covestro will display a LiDAR cover lens, engineered with Canatu, featuring Makrolon^® AG polycarbonate resin and Makrofol^® PC film with an integrated heater. This collaboration enhances Light detection and ranging (LiDAR) systems for modern vehicles, ensuring reliability in harsh weather by combining Covestro's thermoplastics expertise with Canatu's carbon nanotube (CNT) transparent film heater.

Hear from a Covestro expert

At LOPEC 2024 Congress, Covestro expert Karine Benbelaid will give a lecture on March 5, room 13b at 9:05 a.m. CET, entitled, “Turning Medical Devices Smart and Circular".

"We work closely with our healthcare customers and recognized that we could offer a polycarbonate made for highest curing temperatures in silicone over-molding, helping them more than double production volumes in the same amount of time due to shorter cycle times," said Pierre Moulinie, Global Healthcare Technology Lead, Covestro LLC.

"Our experts provide support every step of the way," he continued, “helping our customers calculate possible savings when switching to this new high-heat Apec^® copolycarbonate grade – for example, simulating material performance in specific applications and calculating cost benefits with our LSR calculator tool.”

In addition to offering high heat resistance and high productivity, Apec^® 2045 copolycarbonate offers other important benefits for this market. These include:

• Durability: Tough engineering plastic with the highest heat resistance in the medical polycarbonate portfolio
• Transparency: Produces transparent parts with high optical clarity
• Biocompatible: Biocompatibility testing according to ISO 10993-1 and USP Class VI for contact of 30 days or less
• Sterilizable: Supports sterilization methods most prevalent in the healthcare industry, including irradiation, autoclave and hot air
• Processability: Consistent and efficient processing

Furthermore, using this new material may contribute to customer sustainability goals, as it can enable circular business models by supporting close- and open-loop recycling, as well as the possibility of attributed bio-circular content.

Attendees at MD&M West, February 6-8 in Anaheim, California, can visit the Covestro booth (#2221) to learn how the company’s materials push boundaries in healthcare applications.

Polycarbonates from Covestro are found in some of modern technology’s most essential medical devices and play a major role in developing next-generation, life-saving technology. Used in applications where strength, clarity and toughness are necessary, polycarbonates from Covestro exemplify the innovation, safety and biocompatibility that healthcare and life sciences designers and manufacturers across the world have come to know and trust. To learn more about how your company can use Covestro’s material expertise to enhance your medical and healthcare manufacturing, visit our Solution Center.

This site of Epurex Films, a wholly owned subsidiary of Covestro, houses research & development, application development and production for the semi-finished products. The company has invested a low double-digit million Euro amount in the expansion of the center of excellence for TPU-Films.

The new capacity is intended to meet the growing global demand for multilayer TPU films. They are used in automotive interiors and construction, among other applications. Breathable, water-impermeable specialty films have also proven their worth in wound care and outdoor clothing.

"With this capacity expansion, we are strengthening our Bomlitz site and our position as a leading supplier of technical specialty films," said Dr. Thorsten Dreier, Covestro's Chief Technology Officer, at the inauguration. "At the same time, we are investing in promising technologies and applications and creating new jobs."

For Aleta Richards, global head of the Specialty Films business entity, the expansion offers opportunities to respond even better to individual customer needs and offer more sustainable products. "For some time now, we have also been developing customer-specific solutions with films made from alternative raw materials, as we are also seeing increasing demand in this area. The development and production of partially biobased products is therefore to become a new focus at the Bomlitz site."

Covestro is fully geared toward the circular economy and aims to become climate-neutral by 2035. In 2022 the Bomlitz site has switched its power supply completely to green electricity. Epurex Films is one of Covestro's three competence centers for specialty films in Germany, along with Leverkusen and Dormagen.

DIP, also supported by The Worshipful Company of Horners, and the Institute of Materials, Minerals and Mining (IOM3), is the longest running plastics design competition of its kind for university undergraduates in the UK and Ireland. This year’s contestants were asked to design a product for the kitchen or bathroom. 

A third year product design undergraduate, Chris takes away the first prize of £1,000, plus a placement or course with a DIP sponsor, a year’s membership of IOM3 and an invitation to the Lord Mayor’s Banquet as a guest of the Worshipful Company of Horners. 

Chris’ winning product is ‘Flossie’, a teeth cleaning device which allows people with hand deterity conditions to floss their teeth more easily. It utilises flossing sticks and a specially designed gripping handle. He used a combination of ABS (acrylonitrile butadiene styrene), polyurethane and polypropylene for the different components of his product. 

Chairman of the judging panel, Richard Brown, said: "This is a great product which is inspired by a real life challenge. We were impressed not just by the clever design, but by the user testing carried out by Chris, to show how it can help people with lifelong conditions that affect movement and co-ordination. He also gave us a detailed analysis of manufacturing ideas and costs, as well as considering its marketing." 

Chris said the inspiration for his product came from wanting to help his brother, who has cerebral palsy in his right hand and said he was very proud that other people also liked his idea. "It is a real honour to be recognised in this competition," he said. "I definitely want to work with materials and mechanisms in the future, as designing for usability really excites me." 

The judges awarded second place to Kyle Farquhar, Edinburgh Napier University, with his product ‘PlateMate’, a foldable plate which shows children how to create a variety of Mexican and other international dishes in a more fun way. In third place came Scott Rutherford, also from Edinburgh Napier, with his ‘Rotary Bottle Opener’, which helps people with hand weaknesses to open twist top bottles more easily. 

Highly Commended Awards go to:

• Freddy Blake, Bournemouth University, with ‘Bubble Buddy‘, a bathroom soap dispenser and hand wash device in one package, which makes hand washing more fun for children. 
• Teresa Zheng, Loughborough University, with ‘Sianel‘, a portable shelf which enables people to change their colostomy bags more easily.

A sixth student, James Forrest-Smith, has received the inaugural Robin Jones Award. Robin was a key member of the DIP committee who sadly died last year. A tutor at London South Bank University, he always passionately shared his presentation expertise to the finalists to help them showcase their products in the best possible way. This award therefore recognises both the skill in achieving this as well as the quality of the design. 

James, from Northumbria University, created ‘STEPA‘ a fully adjustable stool for children to use in the kitchen, encouraging them to get involved in kitchen activities. 

All this year’s award candidates receive cash prizes along with placements or industrial courses and a year’s membership of IOM3. 

DIP is also supported by work placement sponsors, Brightworks, Innovate Product Design, PDD and Sumitomo Demag, along with media partners, British Plastics & Rubber, Mould Technology and Materials World. 

Since Coronavirus disease (COVID-19) outbreak entered Taiwan, Covestro Taiwan made two donations of batches of protective goggles with indirect ventilation systems and anti-fog lenses in February and March 2020 to the Taiwan Centers for Disease Control (CDC), who distributed the goggles to medical institutions in need across Taiwan. Last month, Covestro Taiwan was rewarded by CDC with a golden ‘End Covid’ medal for helping to stop the spread of the disease in Taiwan. Covestro Taiwan was one of the first companies to contribute at the very early stage when the disease initially entered Taiwan. The first local case happened in February 2020, which was also when Covestro Taiwan donated the first batch of goggles for Airport CDC staff to wear during that period of time. 

“The pandemic could not have been controlled and ended in Taiwan without CDC’s outstanding guidance and efforts,” said Carsten Wildebrand, Managing Director of Covestro Taiwan. “Every single person counted during this battle against Covid. We are glad we could also contribute to this with our polycarbonate made protective goggles. We sincerely appreciate all the healthcare professionals for devoting themselves to Taiwan.” The total number of protective goggles donated by Covestro to CDC was 20,000. 

CDC officially announced that Covid had ended in May 2023. 

"Thanks to this new milestone, Covestro will soon be able to serve even more customers around the world with an easily accessible, more sustainable product portfolio," says Sucheta Govil, Chief Commercial Officer of Covestro. "Customers in North America can now reduce their carbon footprint and Scope 3 emissions with drop-in, mass-balanced materials derived from recycled and bio-attributed products."

Learn more about Covestro’s ISCC PLUS certification in the US: https://www.covestro.com/en/company/covestro-worldwide/united-states/covestro-in-the-united-states/sustainability-and-innovation/iscc-plus-certification

Covestro is the first manufacturer of polyurethane and polycarbonate raw materials to receive this certification in the United States. The certification is an important milestone for both Covestro and the industries it serves, including the automotive, construction, comfort, electronics and appliance industries, which will now have access to ISCC PLUS-certified products made from more sustainable raw materials in North America.

To underscore how the products support both the company’s vision to become fully circular and its customers' journey to greater sustainability, Covestro has introduced a specially branded product line with the suffix "CQ". CQ, which stands for ʺCircular Intelligenceʺ, is a portfolio of products with attribution of at least 25 percent alternative raw materials derived from biomass or recycled plastics. 

Covestro is also introducing the name Evocycle^® CQ for all evolutionary recycling processes. The first project of this kind is called Evocycle^® CQ Mattress and denotes an innovative chemical recycling technology for polyurethane mattress foam. Covestro currently has more than hundreds of CQ products and is continuously expanding this portfolio.

The ISCC PLUS certified products produced at Covestro’s Baytown facilities will include: 
• Methylene diphenyl diisocyanate (MDI) – used primarily in the production of rigid polyurethane foam for efficient insulation of refrigeration equipment and buildings
• Toluene diisocyanate (TDI) – used in the production of flexible foam for the automotive and furniture industries
• Makrolon^® RE – polycarbonate, a high-grade plastic used in the automotive, electronics and medical industries, among others
• Hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), Desmodur^® W and Desmodur^® Z – used in various coatings and adhesive applications

Covestro expects to begin supplying select ISCC PLUS-certified products from its Baytown facility in the second half of 2023.

The products will be produced using a mass-balance approach. Sustainable raw materials will be accounted for throughout both the value chain and production process, allowing for an accurate attribution in the end products. The existing production infrastructure will be utilized while reducing the carbon footprint of the final products.

ISCC is an internationally recognized sustainability certification for biomass and bioenergy. The standard applies to all stages of the value chain and is recognized worldwide.

“We are happy to meet all stringent GMP requirements in our Changhua site. This allows us to broaden our product portfolio and offer our Desmopan^® GMP product range also to our customers in the Asia-Pacific region,” said Dr. Andrea Maier-Richter, Head of TPU at Covestro. “We have a robust track record of producing high performance TPU materials under GMP conditions in other regions, and we are committed to utilizing our expertise to meet our customer’s needs here in the region, too.”

The Desmopan^® GMP portfolio offers durable, high-performance materials that resist erosion, abrasion and fatigue. They are water-resistant and can withstand regular wiping without degradation over time. Their dimensional stability, flexibility, and durability make them ideal for applications under forces of various kinds, such as dental aligners that withstand the forces of teeth movement without breaking or cracking. Additionally, they meet regulatory compliance for plastic materials and articles intended to come into contact with food, such as EU10/2011 (Text with EEA relevance), and FDA regulations in 21 CFR 177.1680 (Polyurethane resins) and 21 CFR 177.2600 (Rubber articles intended for repeated use).

“Besides adhering to rigorous food contact and health and safety standards, our Changhua production site is already ISCC PLUS certified,” adds Lisa Ketelsen, Head of TPU in APAC. “This means that products from our Changhua site will help our customers reach their sustainability targets, since we can offer our new grades in mass balanced versions that contain alternative feedstock. This reduces their carbon footprint while keeping the same properties or performance as fossil-based materials.”

Mass balancing allows for the allocation of alternative, non-fossil-based feedstock to individual products through a chain of custody method. This enables tracking material contents through the value chain.

"In our studio, we offer solutions for current challenges, but also want to inspire our customers with visions for ambitious future goals. True to our motto 'Status Next,' we are our customers' partner in driving the circular economy in the coatings and adhesives industry to make our lives more sustainable," says Dickon Purvis, Head of Marketing in the Coatings and Adhesives segment at Covestro. "Only in close exchange with external stakeholders can we identify trends early on and offer products and technologies tailored to future requirements."

In focus: circular economy, productivity and regulations

For the coatings and adhesives sector, as well as downstream industries, the transformation to a circular economy is key to combating climate change and conserving resources. As a leading raw material manufacturer, Covestro is aware of the great responsibility it bears for optimizing these products so that they make an important contribution to the transformation as fundamental building blocks for coatings and adhesives formulations.

At the same time, it is important to maintain or even increase productivity at a high level to ensure growth and profitability in these industries. And last but not least, Covestro wants to support customers in complying with stricter regulations and standards, with the aim of improving occupational safety and industrial hygiene. For all these goals, the company has set up the Status Next Studio platform to ensure lasting and strong customer relationships in an increasingly digitalized world.

The spectrum of applications and industries for Covestro solutions is wide, ranging from future mobility, smart living and infrastructure development to sports and leisure, health and beauty, architecture and construction, printing and packaging. The Status Next Content Warehouse offers highlight topics and best practice examples on the aforementioned focus areas and industries.

Webinars on key trends

Covestro invites customers, partners and anyone interested to dive into the key trends impacting the world of coatings and adhesives. To this end, the company is offering three webinars in English on the following key topics:

Circular Economy 
Tuesday, March 21, 2023, from 14:00 CET. 
Register at https://solutions.covestro.com/en/webinars/2023-03-21-circular-economy/?utm_medium=offline&utm_source=press_release&utm_campaign=ca_2023_status_next&utm_asset=26225&utm_content=status_next_q1_corp_press_release_ce_webinar_registration_page

Regulations 
Wednesday, March 22, 2023, from 14:00 CET 
Register at https://solutions.covestro.com/en/webinars/2023-03-22-regulations/?utm_medium=offline&utm_source=press_release&utm_campaign=ca_2023_status_next&utm_asset=26225&utm_content=status_next_q1_corp_press_release_regulations_webinar_registration_page

Productivity 
Thursday, March 23, 2023, from 14:00 CET 
Register at https://solutions.covestro.com/en/webinars/2023-03-23-productivity/?utm_medium=offline&utm_source=press_release&utm_campaign=ca_2023_status_next&utm_asset=26225&utm_content=status_next_q1_corp_press_release_productivity_webinar_registration_page

In its Status Next Collaboration Suite, Covestro invites participants to further webinars on overarching and strategic coatings and adhesives topics for various industries, where participants can directly exchange ideas with experts from the company.

Covestro will showcase a comprehensive range of specialty films for printed electronics at LOPEC 2023 in Munich, Germany, from February 28 to March 2. Attendees can find Covestro in Hall B0 Booth 418 (B0.418).

"We’re excited to participate for the first time in LOPEC, which is considered one of the world’s leading gathering places for exchanging ideas and introducing technologies related to printed electronics," said Karine Benbelaid, Global Segment Lead, Medical, Specialty Films business, Covestro. "We look forward to demonstrating our technical expertise and ability to drive industrial collaboration as we highlight our PC, TPU and specialty elastomer films that are tailored specifically for automotive, electronics, healthcare and consumer applications."

New TPU films and applications for smart skin patches

Covestro will debut its new Platilon^® TPU grades for smart skin patch applications at LOPEC 2023. Not only can the new ranges of TPU films be printed with standard inks, but they also show good printability with silver-based inks. Printability with silver-based inks is important as it ensures good conductivity and allows sensor technology to be integrated more reliably. Additionally, the new TPU film grades can be equipped with a stiffer polypropylene carrier, which provides stability throughout the conversion process, especially during curing.

One of the new Platilon^® TPU grades is specifically suited for humid environments, often required for 24/7 worn medical patches. This range of substrates in medical quality is also available in a partially bio-based version. Another new Platilon^® TPU range features high mechanical strengths, opening up applications in a variety of devices. Nile AB (powered by Linxens Healthcare) selected this new material to produce wearable sensor patches.

"The future of printed wearables belongs to pioneering patches aimed at better patient comfort and enhanced accuracy," said Peter Nilson, CEO at Nile AB. "We chose to work with the new TPU substrate from Covestro because it has been perfectly adapted for our unique converting process and printing of silver-based flexible circuits."

Booth visitors can also check out smart skin patches made jointly with accensors, featuring two products: a Disposable patch, which houses sensors and is designed to be used once; and a ReUse patch, which houses the electronics and can be used repeatedly.

Smart material solutions for automotive and electronics

Covestro will also highlight key Human Machine Interface (HMI) applications for automotive and electrics designs enabled by in-mold electronics (IME), including:

• A future-forward integrated automotive frontend concept for creating premium- and base-model designs
• Smart 3D plastic surfaces featuring injection molded structural electronics (IMSE^®) technology from TactoTek^® combined with Makrofol^® PC film and Makrolon^® PC resin
  • A fully functioning, sleek automotive overhead control panel demonstrator
  • A smart surface controller device that meets tomorrow’s design, sustainability and technology requirements

Hear from Covestro experts

Covestro will share its technical expertise through presentations given by Covestro subject matter experts:

• Mikko Silvennoinen, global account representative, Specialty Films business, will give an oral presentation on TPU films for use in smart medical skin patches on Tuesday, February 28, in ICM Room 13b at 12:50 CET.
• Dirk Pophusen, global segment manager, Specialty Films business, will give an oral presentation on in-mold electronics film technology enabling future HMI solutions in automotive and electronics design on Thursday, March 2, in ICM Room 13a at 14:00 CET.

• Durability from cryogenic to steam sterilization conditions with high impact strength and ductility 
• Best-in-class chemical resistance to everyday chemicals 
• Limited medical grade with biocompatibility testing according to USP Class I, ISO 10993-5 and ISO 10993-10 and meets the requirements for skin contact applications 
• Food contact quality 
• Ability to be sterilized using methods most prevalent in the healthcare industry 
• Design freedom for applications that are tough and transparent, yet attractive 
• Consistent and efficient processing for both injection and blow molding methods 

"Every day, the healthcare and life sciences industries are hard at work delivering new life-enhancing and life-saving devices and therapies. We recognized the opportunity to meet a need by offering a tailored material with the property profile desired for these rigorous applications," said Emily Shaffer, Americas healthcare marketing manager, Engineering Plastics, Covestro LLC. Shaffer points out that by harnessing its global resources, Covestro is able to provide its medical-grade polycarbonates wherever they are needed all over the world. "This global availability, combined with our robust portfolio and technical expertise is why we’ve been a supplier of choice to the healthcare industry for more than 50 years," she concluded. 

It is Covestro’s aim to become fully circular. Shaffer notes this material can enable circular business models by supporting closed- and open-loop recycling. It can also contribute to a lower carbon footprint with the possibility for attributed bio-circular content. 

Polycarbonates from Covestro are found in some of modern technology’s most essential medical devices and play a major role in the development of next-generation, life-saving technology. Used in applications where strength, transparency and toughness are necessary, polycarbonates from Covestro exemplify the innovation, safety and biocompatibility that healthcare and life sciences designers and manufacturers across the world have come to know and trust. To learn more about how your company can use Covestro’s material expertise to enhance your medical and healthcare manufacturing, visit our Solution Center.

"By switching to mass-balanced renewable raw materials, we aim to significantly reduce our indirect emissions in the supply chain and offer products with a reduced carbon footprint," says Sucheta Govil, Chief Commercial Officer of Covestro. "In doing so, we’re helping our customers to meet their climate goals and advance the transition to a circular economy."

New label for circular intelligent solutions

Lily Wang, global head of the Engineering Plastics segment, emphasizes the further benefits for customers: "We offer them a drop-in solution that they can quickly and easily integrate into existing production processes without requiring any technical changes. The products show the same good quality as their fossil-based counterparts." As part of the CQ family of circular intelligent solutions, Covestro offers them under the names Makrolon^® RE, Bayblend^® RE, Makroblend^® RE, and Apec^® RE. With its new CQ concept, Covestro highlights the alternative raw material basis in products and thus gives a clear indication to customers who are looking for such products.

INVIRIDIS™ brand phenol and acetone are produced from bio-attributed cumene at INEOS’ Gladbeck and Antwerp sites – without competing with the food supply. Both sites are certified according to the internationally recognized ISCC PLUS as well as the RSB standard. The raw materials have a lower carbon footprint than petroleum-based products.

Certification by ISCC PLUS and RSB underlines INEOS’ strong commitment to working with the bioeconomy and reflects the strong sustainability of INVIRIDIS™.

Gordon Adams, Business Director of INEOS Phenol, said, "As part of our sustainability strategy, we have developed these more sustainable phenol and acetone products, which we have named INVIRIDIS™. This new product range provides our customers with drop-in product options that meet their stringent quality and performance requirements. At the same time, we’re moving the industry toward a more climate-friendly economy for phenol and acetone without compromising its unique product attributes."

DIP, which is headline sponsored by Covestro, is the longest running plastics design competition of its kind for university undergraduates in the UK and Ireland.

Product design undergraduate, Zara King, designed EasyMode, a re-usable bedpan for a pulp liner to fit inside, providing a safe and comfortable base for people to use in any healthcare setting. The bedpan is moulded with a wide base so that it sits comfortably into the bed and presses down into the mattress, and when the patient is rolled off, it doesn’t tip.

Zara used reaction injection moulding to create her product, which is made from polyurethane. She designed it after hearing first hand from a nurse about the awkwardness of using existing bedpans, and the distress it often causes.

Chairman of judges, Richard Brown, said Zara was a worthy winner who had tackled a sensitive issue and come up with a product which was already fit to go to market.

“She impressed the judges with her methodical approach to solving a major problem in the NHS,” he said. “Her holistic approach incorporated both user and patient issues, to come up with a solution which met both needs. She gave due consideration to sustainability, manufacturing and the materials used and has registered this product as her intellectual property, so that it is market ready, should she want to take it forward.”

Zara said: “Since entering this competition, I have enjoyed every moment, especially the thought of helping people with a product I’ve designed. Healthcare is definitely a field I’d like to stay involved in. This is one of the proudest moments of my life.”

The judges awarded second place to Kenneth Thornton, (Edinburgh Napier University), with his product Catheter Bag Carry, a reusable portable catheter bag holder which conceals and protects the catheter bag. Kenneth used silicone (NinjaFlex) for the bag holder and polypropylene for the belt.

In third place came Charlie Gould-Hocking (Bangor University), with Crutch, a shower stand for amputees with a lower limb loss that allows them to stand whilst showering. He used a combination of reinforced PET with a 30 per cent blend, SEBS and silicone rubber, to create his product.

Highly Commended awards go to three students from London South Bank University: Daniele Di Paolo, who created Cirrus, a device to help with breathing exercises to promote relaxation; Dimitri McGrath-Karvelis with Anap, a double capacity inhaler for asthmatics, that combines the preventer and reliever medication in one compact twist-and-carry device; and Daniel Warren, with Cura, a first aid kit for first responders, incorporating a new way of assessing and treating burns. Students were asked to design a product made primarily of plastics, for the healthcare sector, which can be used in demanding applications, but which also exploits the longevity of plastics.

The competition winner receives a £1,000 cash prize, a placement with a DIP sponsor or an industrial course and an invitation to the Lord Mayor’s Banquet as a guest of the Worshipful Company of Horners. Zara will also be given a year’s membership to the Institute of Materials, Minerals, and Mining (IOM3). The other five finalists also receive cash prizes along with placements or industrial courses and a year’s membership of IOM3.

DIP is supported by IOM3 and the Worshipful Company of Horners. It is headline sponsored by Covestro, along with work placement sponsors, Brightworks, Innovate Product Design, PDD and RJG Technologies.

The final results are:

1^st        Zara King, Teesside University, with EASYMODE, a reusable bedpan, for use in any healthcare setting

2^nd       Kenneth Thornton, Edinburgh Napier University, with CATHETER BAG CARRY, a reusable portable catheter bag

3^rd        Charlie Gould-Hocking, Bangor University, with CRUTCH, an adjustable shower or bath stand for amputees

Highly Commended:

• Daniele Di Paolo, London South Bank University, with CIRRUS, a training aid to improve breathing
• Dimitri McGrath Karvelis, London South Bank University, with ANAP, a double capacity inhaler for asthmatic
• Daniel Warren London South Bank University, with CURA, a burns kit for first responders

About the Design Innovation in Plastics Award:

• Established in 1985, Design Innovation in Plastics is the longest running student plastics design award in Europe. For more information visit www.designinnovationplastics.org
• The Institute of Materials, Minerals and Mining (IOM3) is a major UK engineering institution and is the professional body for the advancement of materials, minerals and mining to governments, industry, academia, the public and the professions. For more information visit www.iom3.org
• The Worshipful Company of Horners is one of the oldest liverycompanies in the City of London and was formed to regulate the horn-working trade. In 1943 it adopted its modern equivalent, the plastics industry. For more information visit www.horners.org.uk

Dr. Christopher Stillings, Head of Covestro Global Color & Design CMF in Engineering Plastics segment, said, “With the ambition to bring together materials functionality and aesthetics, we’ve partnered with top designers and CMF experts to present the new CMF trend reports. Covestro intends to be more than just a material manufacturer and become an inspirational partner of choice for designers and CMF experts when it comes to the realization of their concepts or strategies into our materials. We are able to add value by enabling functional, aesthetic, and circular design elements.”

Exploring global trends from a Chinese perspective

Covestro, in collaboration with Tongji University, Shanghai Jiao Tong University, and Goodmatter studio, sourced research with a Chinese perspective for the 2022-2023 CMF Design Trend Reports. The impact of globalization is prevalent in industrial design, particularly reflected in the convergence of consumer lifestyles and commercial activities worldwide. Despite the universal design themes, diverse cultural expressions are still needed to resonate with local consumer groups. Covestro aims to smartly identify global trends of industrial design while capturing culture relevance. In the 2022-2023 reports, Covestro hopes to inspire global customers with design with Chinese flavors as the country is on track to transform from “Made in China” to “Designed in China.” Wenqing Yang, professor at Shanghai International College of Design and Innovation at Tongji University, noted, “By exploring global trends from a Chinese perspective, Covestro’s innovative aesthetic design has brought new color trends to life for the industry in a new era.”

By collecting customer insights and holding expert seminars, Covestro and its partners developed trend stories for the automotive, electronics, electrical and healthcare industries, driving more opportunities in CMF industry-wide. “I am honored to be involved in this color research project. Despite all the challenges, Covestro has always remained true to its innovation principles. I hope this report will lead industry customers to new successes,” said John Fu, associate professor and head of the Design Trend Institute, School of Design, Shanghai Jiao Tong University.

CMF Aesthetic Toolkits inspire designers in unique ways

For designers, Covestro’s polycarbonate CMF Aesthetic Toolkits are key to understanding the potential of this high-performance plastic and other materials such as TPU and composites. With different shapes, textures and surfaces, the design possibilities of the material are ideally showcased. This allows designers to discover more performance possibilities of polycarbonates and gain inspiration for design. Covestro’s CMF Aesthetic Toolkits were awarded the German Design Award 2022 in the category “Excellent Product Design – Material and Surfaces,” one of the most prestigious design awards in the industry.

Covestro believes that new trends bring challenges and require new CMF solutions to address them. The company’s material solutions and CMF Aesthetic Toolkits empower designers to contribute to aesthetics, functionality and sustainability, creating added value for their customers. Through its CMF activities, Covestro aims to inspire designers to discover more application opportunities for polycarbonate in the consumer market.

Covestro is using the trade show to target designers and CMF professionals and make its developments tangible. "Together with these important target groups, we are also developing scalable design solutions with a focus on circularity and higher volume production," says Dr. Christopher Stillings, Head of Color & Design in the Engineering Plastics segment. "For inspiration and to start the dialogue, we offer them various aesthetics toolkits that explain the visual and tactile properties of our polycarbonates and other materials, and also introduce 24 trendy colors." The six Color & Design Centers that the company operates worldwide are also located close to customers.

On the road to a circular economy

The vision of Covestro is to become fully circular, and to this end it offers its customers climate-neutral¹ polycarbonates and polyurethane raw materials, but also develops innovative recycling technologies and engages in the reuse of recycled post-consumer plastics.

New polycarbonate grades are carbon-neutral from cradle to factory gate¹, thanks to the use of renewable electricity for production processes at Covestro and the introduction of raw materials derived from mass-balanced biowaste and residual materials. The plastics offer equally good quality as their fossil-based counterparts and can be seamlessly integrated into customers' existing production processes without compromising on quality.

Thermoplastic polyurethanes (TPUs) have proven to be versatile materials in a variety of applications, from electronic devices to sporting goods. Covestro aims to make the products more circular and is working with partners in the value chain to achieve this. The current range includes partially bio-based raw materials, mass-balanced as well as recycled TPUs.

Due to the good recyclability of TPU, Covestro is expanding its portfolio of recycled grades. Together with Dutch customer Fairphone, the company developed circular material solutions for its Fairphone 3 and 4 models based on fully and partially recycled TPU and polycarbonate grades. 

New trend reports for color, material and finish

On June 10, Covestro will unveil the second edition of its CMF (Color, Material, Finish) trend reports in collaboration with the renowned Shanghai Tongji University, Shanghai Jiaotong University and the Good Matter Design agency. The three trend reports for the automotive, electrical and electronics as well as healthcare industries look at global trends in consumer lifestyles. The trend studies show how the key themes for 2022 and 2023 can be translated into targeted CMF strategies and designs using Covestro products.

¹ The "climate neutral" rating is the result of an assessment of a subsection of the entire product life cycle. The section from resource extraction (cradle) to Covestro's factory gate was considered. The assessment is based on ISO standard 14040 and was critically reviewed for plausibility by TÜV Rheinland.

Wearable patch sensors (smart patches) are rising in popularity, as they offer a wide range of options for medical diagnosis. Current trends include enhanced convenience, even more functions, and ongoing miniaturization. What's more, the public is demanding more sustainable solutions and a move away from disposable products. Together with its partner accensors, Covestro has developed a smart patch consisting of two elements: The disposable patch, which contains the sensors, and the ReUse patch, which contains the electronics. This makes it possible to reuse the valuable electronic parts.

Efficient production of wound dressings

The production of wound dressings and plasters, as well as medical wearables, involves a multi-stage process. The combination of a polypropylene (PP) backing with blown films from the Platilon^® range made of thermoplastic polyurethane (TPU), in particular, is now proving to be well suited to satisfying today's high demands for process efficiency and ease of use in wound care. In comparison to the production of paper backings, the generation of dust in the production process is significantly reduced.

Breathable wound dressings to prevent bedsores

In the case of prolonged disease progression, it is important to prevent bedsores (pressure ulcers). Covestro has developed a concept for a prevention dressing that addresses the three most important factors for bedsores: Pressure, friction and shear. A highly breathable prototype is made exclusively from Covestro polyurethane materials.

The key features of this prototype wound care dressing made from Baymedix^® and Platilon^® materials are:

• Optimized friction, shear and pressure management
• Excellent moisture management to support a healthy microclimate
• Application- and skin-friendly polyurethane adhesive
• Efficient and sustainable manufacturing technology

Extra matte films for increased wear comfort

The PP backings can also be combined with multilayer Platilon^® TPU films, for example, to achieve individual properties such as a specific surface finish. TPU blown films offer a wide range of surface qualities from silky to extra matte. In particular, Platilon^®XM films offer an extra matte, skin-like surface and a soft feel that offers increased comfort for patients. Medical products made with the low-friction Platilon^® XM films adhere to the skin longer because friction against textiles is minimized. This, in turn, prevents premature changes of dressings and plasters. Owing to its soft surface feel, the film feels like a second skin. It is used in wound dressings, plasters and other medical products that require high breathability.

The new capacity is intended to meet the growing global demand for multilayer TPU Films. They are used in automotive interiors and construction, among other applications. Breathable, water-impermeable specialty films have also proven their worth in wound care and outdoor clothing. The new facilities are scheduled for completion as early as the end of 2023.

"With this capacity expansion, we are strengthening our Bomlitz site and our position as a leading supplier of technical specialty films," said Dr. Klaus Schäfer, Chief Technology Officer of Covestro, at the groundbreaking ceremony. "At the same time, we are investing in promising technologies and applications and creating new jobs."

For Aleta Richards, global head of the Specialty Films segment, the expansion offers opportunities to respond even better to individual customer needs and offer more sustainable products. "For some time now, we have also been developing customer-specific solutions with films made from alternative raw materials, as we are also seeing increasing demand in this area. The development and production of partially bio-based products is therefore to become a new focus at the Bomlitz site."

Covestro is fully geared toward the circular economy and aims to become climate-neutral by 2035. To this end, the Bomlitz site plans to switch its energy supply completely to green electricity starting this year.

Epurex Films is one of three Covestro competence centers for specialty films in Germany. The other two centers in Leverkusen and Dormagen are focused on research, production and application of polycarbonate films.

At MD&M West Conference and Exposition, April 12-14, 2022 in Anaheim, California, Covestro will showcase its materials for healthcare applications in booth #2221, including Makrolon^® RE for Healthcare. Makrolon^® RE polycarbonate grades have a low carbon footprint thanks to the use of renewable electricity for their manufacture, as well as raw materials produced from mass-balanced bio-waste and residues.

This new offering further expands the company’s portfolio of proven materials for diverse healthcare uses:

• Polycarbonate resins and blends: Covestro’s broad portfolio including Makrolon^® and Makroblend^® deliver strength and durability for drug delivery devices, dental applications, advanced injection devices, medical device housings, and more – to withstand everyday use and chemical interaction.
• Polyurethane raw materials and adhesives: Baymedix^® polyurethane adhesive and foam components provide excellent breathability and low trauma removal to wound care products, in addition to excellent absorption. In wearables applications, skin-friendly adhesive systems and thermoformable foams for electronic embedding are also available.
• Thermoplastic Polyurethane (TPU) films and resins: Platilon^® TPU films offer breathable applications for wound dressing and prevention, as well as wearable patches. Texin® Rx TPU resins provide flexibility and strength for applications such as medical tubing and dental applications, all while remaining resistant to cleaning agents and bacteria.

Several applications of these materials will be on display, including:

• Makrolon® RE for Healthcare: Covestro showcases the expansion of its product portfolio into the medical and healthcare space with Makrolon^® RE – a drop-in, low carbon footprint, medical-grade polycarbonate solution.
• Drug Delivery demonstrator: Materials from Covestro’s line of medical-grade polycarbonates come together to form an innovative and sustainable drug delivery device.
• PharmaJet: Covestro and PharmaJet team up to advance needle-free injection. Makrolon^® from Covestro stands up to gamma and ethylene oxide sterilization in a device that eliminates needle-stick injuries, and can be used for COVID-19 vaccinations.
• SmartGuard^®: Covestro and SmartGuard work together to provide restful sleep for those who involuntarily grind their teeth. Makrolon^® 2858 from Covestro provides the strength, softness and biocompatibility needed for this application.
• Medical Device Housings and Hardware: Durable Makrolon^® and Makroblend^® materials feature improved disinfectant resistance and next-generation flame retardancy with skin contact biocompatibility. 

Attendees can visit the Covestro booth (#2221) to learn more about the company’s impressive combination of material solutions and technical expertise for the healthcare market.
 

More comfortable and sustainable wearables

Wearable patch sensors (smart patches) are enjoying increasing popularity, as they offer a wide range of options for medical diagnosis. Current trends include enhanced convenience, even more functions, and ongoing miniaturization. What's more, the public is demanding more sustainable solutions and a move away from disposable products. Together with its partner accensors, Covestro has developed a smart patch consisting of two elements: The disposable patch, which contains the sensors, and the ReUse patch, which contains the electronics. This makes it possible to reuse the valuable electronic parts.

Efficient production of wound dressings

The production of wound dressings and plasters, as well as medical wearables, involves a multi-stage process. The combination of a polypropylene (PP) backing with blown films from the Platilon® range made of thermoplastic polyurethane (TPU), in particular, is now proving to be well suited to satisfying today's high demands for process efficiency and ease of use in wound care. In comparison to the production of paper backings, the generation of dust in the production process is significantly reduced.

Breathable wound dressings to prevent bedsores

In the case of prolonged disease progression, it is important to prevent bedsores (pressure ulcers). Covestro has developed a concept for a prevention dressing that addresses the three most important factors for bedsores: Pressure, friction and shear. A highly breathable prototype is made exclusively from Covestro polyurethane materials.

The key features of this prototype wound care dressing made from Baymedix® and Platilon® materials are:

• Optimized friction, shear and pressure management
• Excellent moisture management to support a healthy microclimate
• Application- and skin-friendly polyurethane adhesive
• Efficient and sustainable manufacturing technology

Extra matte films for increased wear comfort

The PP backings can also be combined with multilayer Platilon® TPU films, for example, to achieve individual properties such as a specific surface finish. TPU blown films offer a wide range of surface qualities from silky to extra matte. In particular, Platilon® XM films offer an extra matte, skin-like surface and a soft feel that offers increased comfort for patients. Medical products made with the low-friction Platilon® XM films adhere to the skin longer because friction against textiles is minimized. This, in turn, prevents premature changes of dressings and plasters. Owing to its soft surface feel, the film feels like a second skin. It is used in wound dressings, plasters and other medical products that require high breathability.

High-quality breast implants require high packaging standards

Breast implants must be treated with the utmost care, from manufacture and transport to visual inspection before surgery. The packaging must be particularly shock-resistant, transparent, and highly sterile. Makrofol® MA507 and MA336 polycarbonate films are able to achieve the necessary impact resistance and transparency. They also withstand superheated steam sterilization at 120 and more degrees Celsius without damage. Covestro also offers films for packaging orthopedic implants.

Producing wound dressings and plasters, as well as medical wearables, involves a multi-stage process. Various coating and cutting processes can be employed to convert the products to achieve different desired functions. For instance, the liner material is often given a wavy cut (S-cutting) to allow clinicians to quickly remove the carrier when applying the dressing. In other cases, the outer edge of the carrier is not coated with adhesive and can therefore be easily lifted to remove it (finger lift).

Advantages of films with rigid PP liners

PP liners are relatively stiff and therefore offer sufficient strength, for example when gently creating windows without damaging the underlying layer, or when transferring the adhesive layer to the product. At the same time, they are flexible enough to optimally cover curved body parts such as hands, ankles and shoulders. PP carriers can also be combined with multilayer TPU films, for example to produce individual properties.

The blown film technology enables high speed production and enhanced efficiency. Blown TPU film on PP liner feature a wide range of surface qualities from silky to extra matt. In addition, various colors are offered in different skin tones for more discretion. Covestro has a range of TPU films with polyethylene (PE) liner and is developing paper carriers to offer a large choice of solutions to its customers.

The Platilon^® XM range of TPU extra matt blown films from Covestro is ideally suited for use in wound management as well as other medical applications: They are breathable and feel like a second skin with their soft texture. These types also have an extra matte surface. This offers lower friction with textiles and they also do not reflect much light. This allows them to be used as incision drapes in brightly lit operating rooms to eliminate distraction of surgeons as little as possible from their work.

"With this expansion in capacity, we are strengthening our Dormagen site as a production and competence center for specialty films," says Dr. Klaus Schäfer, Chief Technology Officer at Covestro. "At the same time, we are investing in future-oriented technologies and applications."

The new lines will mainly produce multilayer flat films. These products, for example, play an important role in identity documents in order to embed security features and ensure the best possible protection against counterfeiting. They are also used in medical technology and car interiors.

Equipped for the future

Michael Friede, Global Head of the Coatings, Adhesives, Specialties segment: "These high-quality products and applications represent an important future business for Covestro. With the new capacities and their integration into our film center, we are emphasizing our proximity to the customer and our service."

"Our new production lines are equipped with state-of-the-art technology," emphasizes Dr. Thorsten Dreier, Global Head of Covestro’s Specialty Films and Thermoplastic Polyurethanes business. "That’s why we can now supply our customers faster and with higher quality. We also want to improve our development work and bring new products to market even faster."

Competence centers close to customers

The competence center in Dormagen houses production, a technical center for film processing, as well as a showroom and research laboratories. Covestro operates two other German competence centers for semi-finished products in Leverkusen and Bomlitz, as well as several competence centers worldwide.

As a further measure of the global investment program, Covestro started up a new production facility for polycarbonate films in Map Ta Phut, Thailand, last year. Previously, a coextrusion film plant in Guangzhou, China, was converted for the future and the efficiency and quality of production in South Deerfield, USA, were improved.

"Our new TPU plastic and a printer developed specifically for this application make it possible to print very soft structures. The material and printer were harmonized during development to achieve a perfect result," explains Lukas Breuers, 3D printing expert at Covestro. "With the help of the automated software solution, soft and hard structures can be combined in a shoe insole, achieving a level of customization that was previously virtually impossible." The TPU also meets the requirements for medical devices with regard to cytotoxicity and skin sensitization in accordance with the DIN EN ISO 10993-5 and 10993-10 standards.

In addition to functionality, the development of the material also focused on its ecological footprint, as Marcel Domenghino, Managing Director of GeBioM, points out: "It was important to us that the new solution also allows for improved sustainability. Currently, the production of insoles also generates large amounts of waste. Moreover, the insoles themselves are hazardous waste after use. With 3D printing, we now enable our customers to produce in a waste-free manner by using only the material that is needed for the insoles."

Aiming for recyclable material

Covestro is currently working on a recyclable TPU for this application and is developing opportunities with GeBioM and value chain partners to recover used insoles for recycling. Already, the spools on which the filament is wound are reused. The development is part of a global strategic program to fully align the company with the Circular Economy. Components of the program include innovative recycling technologies and the increased use of alternative raw materials such as biomass, CO₂ and plastic waste, as well as renewable energy.

Covestro has been committed to developing innovative material solutions for additive manufacturing products for years and offers a versatile product range under the Addigy^® brand, including for orthopedic shoe insoles. Just recently, the company also significantly strengthened its 3D-printing portfolio with the acquisition of the Resins & Functional Materials business of the Dutch DSM Group.

Meanwhile, the materials manufacturer unveiled plans to start offering the world’s first climate-neutral polycarbonates later this year, in a major step towards its vision to become fully circular while better supporting its customers to reach their sustainability goals.

"This is another milestone in pursuing our sustainability vision. We are committed to supporting our customers in mobility, electronics, electrical, healthcare and appliances industries to meet their challenges by providing products and solutions that provide excellent performance, cost efficiencies and sustainability," says Michelle Jou, President of the Polycarbonates segment at Covestro. "We are accompanying our clients in accelerating the transition to the Circular Economy, as well as helping to build an industrial ecology that favors circularity."

World’s first climate-neutral polycarbonate resin

These polycarbonate grades are climate neutral from cradle to gate¹, thanks to the introduction of raw materials coming from mass-balanced bio-waste and residues² and renewable energy into the production process. Covestro is already supplying ISCC PLUS certified polycarbonates based on renewable feedstock attributed via the mass balance approach, with a significant carbon footprint reduction. Mass balance is a chain of custody method to track materials through the value chains and allows allocation of renewable feedstock to selected end products.

"With the use of renewable energy, Covestro is expected to cut carbon emissions completely for these selected products from cradle to gate. These products have the same good quality and performance as fossil-based polycarbonates, and are a drop-in replacement without the need to modify existing processes or workflows," says Jimena Ruesta, Venture Manager, Sustainability Solutions at Covestro’s Polycarbonates segment. The first climate-neutral products are going to be delivered from the company’s European sites later this year, to be followed by sites in other regions including China, in agreement with market requirements.

Meanwhile, Covestro announced that it is now offering post-consumer recycled (PCR) polycarbonates on its flagship store at 1688.com, China’s leading B2B trading platform under the Alibaba Group, to better support its customers in reaching their sustainability targets with this digital approach. With 75 percent recycled content, the PCR grade offered on 1688.com reduces the carbon footprint by 50 percent compared to the virgin grade.

Advanced solutions for multiple industries

In the electrical, electronics and appliances industry, Covestro helps electrical and electronics brands obtain the EPEAT (Electronic Product Environmental Assessment Tool) ecolabel, resonate with global consumers in caring for the environment, and fulfill their commitments to low carbon and recycling with a diversified sustainable solution portfolio, together with rigorous supply chain and quality control processes. At CHINAPLAS, Covestro will also present a series of high-performance materials solutions that enable intelligent functions, connectivity, aesthetics, and circular design. Thin-wall, flame-retardant Makrolon^® and Bayblend^® polycarbonates cater to the design trends in the consumer electronics and smart home appliances sectors, while the thermal conductivity of Makrolon^® leads to enhanced heat dissipation in high-performance smart interconnected devices.

Themobility industry also has increasing requirements for materials. In response to the personalization and functionality trends, especially in the passenger vehicle market, Covestro provides integrated front grille materials solutions for distinctive exterior styling, while enabling effective combination with autonomous functions. The company’s DirectCoating process and transparent glass-fiber polycarbonates enable interior trims with visual aesthetics and processing efficiency. In addition, Covestro will present battery pack materials solutions for electric vehicles that cater to various battery module materials, reduce energy consumption by lowering vehicle weight, and guarantee vehicle safety.

As healthcare patients increasingly self-administer medicines, they rely on drug delivery devices using low-friction components for accurate dosing. To enable faster recovery, patients demand minimally invasive surgeries, where strong and reliable surgical tools are needed. Therefore, Covestro introduces a new glass-fiber reinforced medical polycarbonate portfolio for surgical and drug delivery applications, such as internal components for delivery devices and handles for surgical tools. It also introduces a new low-friction medical polycarbonate portfolio used in moving components for delivery devices, eliminating the need for external lubricants. Both scenarios will be displayed at CHINAPLAS 2021 to showcase how Covestro leverages these new materials and beyond to meet healthcare needs of today and the future.

Design aesthetics increase value

Also on display is Covestro’s CMF (color, material, finish) expertise. Covestro’s CMF Team aims to provide clients with unique solutions by considering aesthetic value, design trends, and composition materials. The artwork ´garden´ to be exhibited at the booth consists of recycled Nongfu Spring water barrels in combination with Covestro’s latest CMF trend colors, forming the "Beautiful Recycling Flower".

Additionally, Covestro will present the Circular Design Guidebook for the electrical, electronics and home appliance industries. The guide, jointly authored with consultancy REnato lab, is designed to help designers, developers and other players in the value chain to consider the Circular Economy from an early stage of product design, as well as providing instructions on how to select materials.

Visitors can visit Covestro’s booth at 17P71-1, Hall 17, Shenzhen World Exhibition & Convention Center. Covestro’s CHINAPLAS digital showroom will be launched simultaneously.

¹ Cradle-to-gate is an assessment of a partial product life cycle from resource extraction (cradle) to the factory gate. Based on Covestro internal calculation, external review is ongoing.
² Biogenic carbon uptake is considered in the carbon footprint calculation.

Smoother movement without lubricants

The new low-friction polycarbonates Makrolon® M204 LF, Makrolon® M402 LF and Makrolon® M404 LF ensure that injections proceed smoothly and reliably – also without additional lubricants. Any place where plastic parts slide against one another, primarily in injectors, in the operating room and in patient care, the low-friction and wear-resistant plastics help facilitate the handling of devices. Covestro will showcase the new products in a customer webinar (Update 2021: Link expired and removed) on March 30, 2021, from 3 to 4 pm CEST.

“With the new polycarbonates, we are helping medical device companies develop instruments for new trends in drug delivery devices,” says Irving Paz Chagoya, healthcare segment manager for polycarbonates in the Europe, Middle East, Africa region at Covestro. “In addition to the product advantages, they can also benefit from our more than 50 years of experience in the healthcare industry.” All new products are available worldwide.

The low-friction plastics also feature high dimensional stability and are superior in this respect to the competing material polyoxymethylene (POM). They also meet requirements in terms of durability, comply with ISO 10993-1 biocompatibility standards and can be sterilized using different methods, such as gamma radiation.

High and lasting strength

The new glass-filled polycarbonates are in demand when it comes to maximum strength and durability; for example, in surgical instruments and in drug delivery devices. The load-bearing interior parts of self medication devices are one example, particularly those with viscous or high-volume medicines. Single-use sterile instruments are a current trend in surgery for reducing the risk of infection. In addition, a solid thermoplastic polymer can be more efficient than a metal material.

These products are divided into two series with different strength levels. The high performance series includes the polycarbonates Makrolon® M810 GF, Makrolon® M820 GF and Makrolon® M830 GF. The high flow series includes the polycarbonates Makrolon® M410 GF, Makrolon® M420 GF and Makrolon® M430 GF. The latter are used for filling larger or thinner parts with improved productivity. All types are dimensionally stable and biocompatible according to ISO 10993-1.

Compared to the competitive product glass fiber reinforced polyamide, glass fiber filled polycarbonates exhibit a better combination of different properties when used for drug delivery devices and surgical instruments. This improves their resistance to humidity and temperature fluctuations as well as their mechanical properties. Aided by a special process called Rapid Heat Cycle Molding (RHCM), parts which require particularly glossy or smooth surfaces can be produced from these Makrolon® GF types.

Smart patches should be as small, flexible, and unnoticeable as possible in order to offer patients a high level of comfort. The newly developed solution consists of two elements: a non-reusable element (the Disposable Patch) including sensors that is applied to the skin with an adhesive and used only once, and a reusable element, the ReUse Patch, which houses all the electronics, for example the measurement technology, power supply, data processing, radio transmission and if desired an optical camera.

High comfort, ease of use, efficient manufacturing

Thanks to Covestro materials and to integrated film sensors, the wearable patches are very lightweight, thin and flexible, and fit well to the surface of your body – you can hardly feel them. Polyurethane adhesives made from Baymedix® raw materials are skin-friendly and offer low trauma when removed from the skin. Various sensors are integrated in the patch to determine vital signs, for example pulse, pressure or temperature. Here, sensor integration is achieved by using special Platilon® films in combination with a thermoformable foam based on Baymedix®. All these materials are breathable and can be efficiently processed with roll-to-roll technology.

Removing and inserting the ReUse Patch into the Disposable Patch couldn’t be easier – thanks to an ideal combination of materials and function. accensors particularly developed a film sensor that forms the interface between the smart patch and the patient and can be equipped with varied sensors.

Smart patches are already widely used for medical diagnosis, for example, to measure a patient’s blood sugar levels, body temperature, or heart rate. The observation of disease patterns such as skin cancer or chronic wounds is also possible. Many other applications are emerging in sports and recreation. Covestro is contributing to the further dissemination of these innovative products through customer-oriented developments.

“With this additional production line using state-of-the-art technology, we are investing in future growth in the Asia-Pacific markets, which are very important to us," says Sucheta Govil, Chief Commercial Officer (CCO) at Covestro. "At the same time, we are responding to the rapidly growing demand for specialty films in this region and are supporting the expansion of promising technologies and industries.”

More intensive customer service

Dr. Thorsten Dreier, Global Head of Specialty Films, sees advantages in customer service: "The new production line is important to us because it enables faster market launches and at the same time expands our market access in Asia-Pacific. Our most important goal is to intensify our cooperation with customers in the region and to increase our efficiency. We intend to drive growth in the plastic film business with innovations and a stronger customer focus.”

Covestro has been operating a production facility for specialty films in Thailand since 2007. The range comprises polycarbonate films from the Makrofol® range and Bayfol® products made from polycarbonate blends. The new line is equipped with the latest technology and operates very efficiently.

As a further measure in the investment program to expand film production, Covestro has already converted a coextrusion film plant in Guangzhou, China, for the future. At the South Deerfield site in the USA, the efficiency and quality of film production was also improved. The next milestone will be the expansion of films production in Dormagen, where the company is currently building up new coextrusion capacities. This project is scheduled for completion by the end of 2020.

Now, a breakthrough in drug delivery is changing how veterinarians deliver pain medication to dogs and cats. The Mini-Infuser™ Subcutaneous Constant Rate Infusion (SQ-CRI) pump is the first wearable drug delivery device designed for small companion animals, according to RxActuator. By eliminating the possibility of tangled or disconnected IV lines, this device enhances comfort while reducing staff oversight. Additionally, the manufacturer designed this easy-to-use wearable to improve treatment by:

• reducing the risk of medication errors
• allowing animals to maintain mobility during drug delivery
• enabling owners to take their pet home

Polycarbonates meet special requirements

The Mini-Infuser™ pump case features white Bayblend^® T85 XF PC+ABS blend from Covestro. Additionally, clear Makrolon^® Rx1805 polycarbonate in a blue tint is used for the device’s trim. According to Roy Ince, global account manager, healthcare commercial operations – Polycarbonates, Americas, Covestro LLC, these polycarbonate materials are easy to mold and offer good chemical and impact resistance – important attributes for this application.

“With its wealth of materials and technical knowledge, Covestro was able to recommend the right polycarbonate grades to help us create an innovative and dog-proof drug delivery device for the veterinary industry,” said Doug Nutter, chief marketing officer, RxActuator.

Simple and cost-effective solution

According to RxActuator, the Mini-Infuser™ is unique in that it achieves constant and reliable infusion without any electronics. Additionally, it is more cost-effective than a regular infusion pump. The device is distributed by REM Systems in Australia and New Zealand, and sold directly in North America and worldwide by RxActuator.

“We think of our four-legged companions as members of our families, so naturally we want them to be as comfortable as possible when medicine must be administered,” said Lauren Zetts, Americas segment manager, Healthcare – Polycarbonates, Covestro LLC. “We appreciate the opportunity to collaborate with RxActuator on an innovative device that does just that.”

Attendees at MD&M West, February 11-13 in Anaheim, California, can visit the Covestro booth (#2221) to learn how the company’s materials are pushing boundaries in healthcare applications.

Attendees at Pharmapack, February 5-6, in Paris, can visit the Covestro booth (K46) to learn more about the company’s polycarbonate materials for the healthcare industry. Covestro will also highlight its materials at booth #2221 during MD&M West Conference and Exposition, February 11-13, in Anaheim, California.

Smooth delivery with low-friction polycarbonate

More and more, patients are using autoinjectors and injection pens to self-administer therapeutics from the comfort of their own home or on the go. These devices are expected to operate consistently every time, and utilize low-friction components to ensure injections are reliable and smooth.

To meet challenging low-friction requirements, Covestro is launching three new medical-grade polycarbonates: Makrolon^® M204 LF, Makrolon^® M402 LF and Makrolon^® M404 LF. Featuring reduced coefficients of friction, these grades deliver the excellent dimensional and mechanical properties of polycarbonate while eliminating the need for external lubricants.

The new low-friction Makrolon^® polycarbonates offer the following benefits to drug delivery devices:

• • Lower deployment forces
  • Durability and biocompatibility according to ISO 10993-1
  • Sterilizable with various methods, including autoclave, ethylene oxide and radiation (e-Beam, gamma)

“We built on the superior performance of polycarbonate to formulate low-friction grades that offer consistency and versatility which, in turn, help OEMs design devices that address emerging drug delivery trends,” said Doug Hamilton, global healthcare marketing leader, Covestro LLC.

Superior strength with glass-filled polycarbonate

Covestro also developed new glass-filled polycarbonates for surgical and drug delivery applications that demand stiffness and strength, such as load-bearing internal components for drug delivery devices and handles for minimally invasive or laparoscopic surgical tools.

These grades are divided into two series with varying levels of reinforcement. The high-performance series includes Makrolon^® M810 GF, Makrolon^® M820 GF and Makrolon^® M830 GF polycarbonate. In the high-flow series, Makrolon^® M410 GF, Makrolon^® M420 GF and Makrolon^® M430 GF polycarbonate are used for filling larger or thinner parts with improved productivity.

Additional advantages of Makrolon^® GF polycarbonates include:

• Biocompatibility according to ISO 10993-1 for applications less than 30 days
• Superior rigidity and strength
• High-gloss surface achievable with rapid heat cycle molding
• Higher tensile modulus and tensile strength, and improved dimensional stability under stress when compared to unfilled polycarbonate

“Our expanded materials offering gives healthcare OEMs access to a wide range of glass-filled polycarbonate products that deliver performance tailored to fit their applications,” said Hamilton.

Breast implants are sensitive products that should arrive undamaged at the treating doctor or hospital after manufacture, sterilization and transport. Covestro's Makrofol^® MA507 polycarbonate film is well suitable for their packaging because it is highly transparent and allows the physician to reliably visually inspect the implant before unpacking it. It also provides stable protection for the valuable medical device. The comparable product Makrofol^® MA336 offers the same advantages, but also features a laminating film on it.

Both films are characterized by high tear and impact resistance. They can be easily thermoformed and are fully compatible with the demanding autoclave sterilization process, where they need to withstand temperatures of up to 163 degrees Celsius. Both materials meet the ISO 9001:2015 quality management standard and two ASTM standard specifications for implantable breast prosthesis certification.

The Invisalign system from Align Technology is a clear aligner system for straightening teeth, and the most advanced clear aligner treatment available. It is available through Invisalign trained dentists and orthodontists.

Align Technology pioneered the clear aligner orthodontic segment 22 years ago with the launch of the Invisalign system. Through continuous innovation, the Invisalign system is a leading solution in the field of clear aligner orthodontics.

At the Covestro booth (Stand A 75 in Hall 6), visitors will have the opportunity to learn more about Align Technology’s cutting-edge innovations, as well as view interactive videos, see and touch sample aligners.

On October 18, 2019 at 12:00-12:30 pm at the Covestro booth, Markus Sebastian, Senior Vice President & Managing Director at Align Technology EMEA, will deliver a keynote address, followed by a discussion about the Invisalign system.

The Invisalign System with SmartTrack material

The patented SmartTrack material, used to produce Invisalign clear aligners is a multilayer, highly elastic, transparent material, jointly developed with Covestro, designed specifically for the Invisalign system to achieve more predictable orthodontic treatments*.

The multi-layer, transparent material, engineered over a span of eight years with more than 260 material variations developed and evaluated, exerts gentle, constant force that enables doctors to better control tooth movements.

Orthodontic treatment with clear aligners is preceded by a patient assessment by the treating doctor who takes a digital scan or manual impression of a patient’s teeth. A digital treatment plan is then created and – once approved by the doctor – the individual aligners are produced and shipped. The treatment plan is digitally staged, and custom-made digital aligners are manufactured so that the patient's malpositioned teeth are corrected in small steps to a better smile. The patient is required to change the aligners at regular intervals as directed by the doctor, and take them out for eating and drinking.

Comfort and functionality

“The Invisalign system with SmartTrack material, SmartForce^® features and SmartStage^® technology enables tooth misalignments to be corrected with greater than 75 percent improvement** in overall tooth movement predictability,” said Zelko Relic, Chief Technology Officer and Senior Vice President, Global R&D at Align Technology. “This clear, highly elastic material makes Invisalign aligners easily inserted and removed by patients of all ages, from growing patients who have a mixture of primary and permanent teeth, to teens and adults.”

“The Invisalign system with patented SmartTrack material is a combination of an individual, digitally planned treatment and individually customized aligners by thermoforming films, which are manufactured by Covestro,” said Dr. Thorsten Dreier, Global Head of Specialty Films at Covestro, the SmartTrack supplier to the Invisalign system. “Thanks to our joint materials research with Align Technology, we're providing foundation for a new, bright smile for millions of new patients across Europe and worldwide.”

Align Technology Senior Vice President and Managing Director, EMEA, Markus Sebastian, adds: “I would like to thank Covestro for inviting us to be part of this exciting showcase here at the K 2019 Trade Show in Düsseldorf. I am looking forward to sharing our cutting-edge technology that has enabled Invisalign trained doctors to create beautiful smiles for over 7 million people worldwide, including over 1 million patients in the EMEA region.”

*/** Data on file, Align Technology.

In addition to digitalization, the UN goals for sustainable development will especially influence the economy and society in the coming years. Covestro is determined to realize these sustainability goals at many levels. Meeting them is not only a prerequisite for a better, cleaner and healthier world, but also has great long-term economic potential

Change to circular economy indispensable

“Megatrends such as climate protection and population growth require a fundamental rethink in lifestyle and consumer behavior, not to mention in global production,” CEO Dr. Markus Steilemann said to journalists. “We need a complete transition from a throwaway to a circular economy in order to handle limited resources more responsibly and protect the climate.”

Covestro is committed to establishing new material cycles throughout the entire process chain with a view to making a tangible contribution to achieving this major goal. “We have set up a comprehensive and long-term program which will also open up new opportunities for value creation,” Steilemann explained. “High-quality plastics are and will remain drivers for sustainability and for overcoming global challenges. However, it is crucial to decouple the economic growth achieved from the consumption of fossil resources such as crude oil.”

Turning away from crude oil

A key aspect for developing a circular economy in the plastics and chemical industry is the closure of the carbon cycle through the recycling of raw materials. “In the long term, we want to do as much as possible without fossil resources and use alternative sources such as waste, plants and CO₂ instead,” said Steilemann. “In particular, used plastics are a valuable resource. That's why we want to work with partners to intensively develop innovative recycling methods,” said the Covestro CEO. Under no circumstances should plastic waste be allowed to enter the environment uncontrolled for longer. The industry is working intensively worldwide for better waste management – for example in the Alliance to End Plastic Waste, of which Covestro is a member.

Given its importance, the company is dedicating a special Theme Day to Circular Economy at its booth on Wednesday, October 23. External and in-house experts present practical examples and discuss with visitors. At the Covestro booth, these will also find many examples of products and technologies that can help close material cycles in various industries.

Covestro is one of the pioneers in the use of the exhaust gas CO₂ as a new raw material. A team from Covestro and RWTH Aachen University is now in the final round of the German President´s Award for the development of a corresponding process. Exhibits based on this technology will be specially featured at the booth. With modern materials and technologies, the company also supports the supply of energy from renewable sources.

Digitalization as a growth driver

Another driving force for the development of the economy and society in the coming years is the ongoing digitalization. Covestro wants to take advantage of the resulting opportunities and has started a comprehensive strategic program, which focuses on the customer. To this end, the company is anchoring digital technologies and processes along the value chain – from the supply chain through production, research and all interfaces to customers to the development of new business models. Various developments and exhibits at K 2019 as well as a separate Theme Day on Tuesday, October 22, underscore the great importance of digitalization for Covestro and its customers.

A stage for visitors

“We cordially invite all visitors to K 2019 to our booth in hall 6,” says Booth Manager Dr. Ulrich Liman. “We will be providing them a stage for discussions on their themes and wishes. They will also find products and technologies for important key industries.”

“A special experience awaits visitors in our ‘Sample Parcours’,” explains Liman. “There they can get to know materials and patterns through their senses, through seeing, feeling and hearing, but also in a playful manner. For example, join our Life Cycle Wheel and learn more about the circular economy! Or test your knowledge of plastics on our Quiz Machine.”

Theme Days from Automotive to Science

On each of the eight days of the fair, visitors can experience how Covestro is pushing boundaries on a different main theme. Lectures and discussions with experts from industry and academia will serve to deepen the topic and promote personal exchange.

All journalists are cordially invited to visit Covestro's press center at the A 75 exhibition booth gallery in Hall 6. You will have the opportunity to talk about the innovations and topics on display and receive the Covestro press kit for K 2019. On request, we would also be happy to give tours of the booth or arrange interviews.

Automotive (October 16)

The highlight of Covestro's trade fair appearance is a comprehensive interior concept for future mobility: trends such as autonomous driving, electric drive and car sharing make the automobile a multifunctional, mobile living and working space. It's all about functionality, comfort and design, not least also about efficiency. Covestro has developed the concept together with important partners along the automotive value chain. The main features are newly designed surfaces, the integration of ambient lighting, the latest infotainment systems and forward-looking seating concepts. On Wednesday, 16 October, the company will dedicate a special Theme Day to the automotive industry.

Science Celebration (October 17)

The second day of K 2019 is dedicated to current and outstanding research findings in polymer science. The highlight will be the presentation of the Covestro Science Award to a professor in the presence of invited guests from the world of science. The prize consists of a three-year doctoral fellowship to promote young scientists in materials research at universities. In addition, a researcher from Covestro will be awarded the Covestro Science Medal for outstanding scientific developments.

Start-up Challenge (October 20)

With the Start-up Challenge, Covestro aims to promote the creativity and entrepreneurial thinking of its employees and find the best business idea of 2019. The winners of the first competition will be chosen at the trade fair: they will be able to work as founders, implement their ideas and test their marketability. In return, they will receive start-up financing of up to one million euros, be released from their jobs for up to one year and can work within the company as start-ups. The ideas of the six finalist teams are focused on the development of the circular economy.

Local talent search

At K 2019, Covestro also will be presenting itself as an attractive employer to students, junior employees and experienced professionals. Curious jobseekers will find the right person to answer all their questions at the Career Bar.

At Booth D46 in Hall 13, material solutions for flexible medical electronic patches based on Platilon^® and Baymedix^® polyurethane materials will be presented, as well as new solutions for on-body drug delivery devices made of Makrolon^® polycarbonate and Bayblend^® blends.

A growth market: electronic patches

Electronic patches are already being used in many areas such as patient monitoring, and with the increasing digitization of healthcare, market demand for such products is growing rapidly.

In the field of flexible materials, applications such as electroencephalograms (EEG), maternity belts, blood pressure measuring tapes and individual electrocardiograms (ECG) are at the heart of the markets that Covestro is targeting. Covestro will therefore show prototypes made of its flexible integrated materials:

• Soft, breathable and stretchable Platilon^® films for outstanding patient comfort
• Printable substrates for printed electronics
• Skin- and application-friendly adhesive systems based on Baymedix^® materials
• Weldable foams based on Baymedix^® for safe use of electronics

Plastics for on-body equipment

In addition to flexible materials, Covestro also offers the ideal materials for wearables with hard covers that are required for mobile drug delivery devices or sensitive diagnostic devices, for example. Makrolon^® polycarbonate medical grades meet the requirements for excellent dimensional stability and outstanding mechanical properties and enable the development of safe, patient-friendly devices. Thanks to its high degree of transparency and good surface texture, Makrolon^® also provides a wide range of design options such as the integration of LED light guides. Polycarbonate blends such as Bayblend^® (PC+ABS blends) and Makroblend^® (PC+PBT blends) meet additional customer requirements.

Covestro expert Dr. Ulrike Lützow will give a lecture on "Wearable Housings: Material solutions between medicine and electronics" on November 19, 2019.

Innovative concept for wound prevention

Covestro will be presenting innovations in the field of wound management at Booth H30 in Hall 8b. The company has developed a design study for wound prevention that deals with the three most important factors for bedsore (decubitus): Pressure, friction and shear. A highly breathable prototype is being manufactured exclusively from polyurethane materials from Covestro.

The main features of this prototype wound prevention dressing made of Baymedix^® and Platilon^® materials are:

• Optimized friction, shear and pressure management
• Excellent moisture management to support a healthy microclimate
• Application- and skin-friendly polyurethane adhesive
• Efficient and sustainable manufacturing technology

Components based on these products help increase both cost and manufacturing efficiency by allowing roll-to-roll processing and inline production of all layers. During processing, thermoplastic welding of the edges is possible. Moreover, the process is energy-saving and environmentally compatible because production steps are reduced.

In the course of the Compamed Suppliers Forum Covestro expert Dr. Marc-Stephan Weiser will present the design study for focused wound prevention on November 20, 2019, at 3.30 pm in Hall 8b.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

For more information please see www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

The results of the DIP competition, which is industry headline sponsored by Covestro, were announced at a ceremony in London on Friday.

Daniella Kaligorsky, a third year Product Design student from Technological University Dublin, came up with CHECKKIT, a kit which shows how to conduct a self-examination for breast cancer. It includes models that simulate the breast and the physical symptoms of breast cancer and it also has a brochure to explain what to do and how to recognize 12 possible symptoms, along with a notebook to log results.

The longest running student plastics design competition of its type, DIP is held every year to encourage university students to come up with brand new products made primarily of plastic.

Competition organisers, the Institute of Materials, Minerals and Mining and the Worshipful Company of Horners, this year set the challenging brief of ‘Healthy body – healthy world’ inviting ideas for improving health, wellbeing or encouraging exercise, with a product which could demonstrate longevity and sustainability.

Commenting on the winner, chairman of judges, Richard Brown, said the panel was extremely impressed with Daniella’s thorough research into the medical and practical need; her comprehensive review of materials to get the right texture and touch for her product, along with her analysis of manufacturing methods, costs, end user experience and sustainability. She had also given due consideration to competitor products. “We felt very strongly that this was a product that would enhance wellbeing and was market-ready to meet Daniella’s vision for it,” he added.

Another member of the panel, technical engineer, Mike Stuart, formerly of Covestro, said the well thought through manufacturing and practical presentation would help de-stigmatise the subject of breast examination and make it useable even in schools. “This product could be put into production fairly quickly, and we feel a possible future application could be a similar kit for testicular cancer,” he explained.

Daniella Kaligorsky said losing a member of her family to breast cancer had inspired her to look deeper into this subject and try to address the problem. “It is a great opportunity to be able to pursue product design and be recognized and acknowledged by such a great competition and I am proud that the significance of the problem with cancer is recognized,” she said.

“I’ve learned a substantial amount about plastics and the manufacturing process. There is still so much to learn, and I am excited to take a step further to discover more about the world of plastics and the benefits that it can provide.” In second place came Kai Wang – 4th year integrated product design student from Brunel University. His product, POTLUCK, is a clever combined cooking and storage device that encourages and simplifies the production of stock cubes using food waste.

Christopher Kay, a 4th year product design student from De Montfort University came third with EnviroJect – a re-usable syringe system, providing a safe and sustainable method of administering medications.

Highly commended awards went to:

Louis Farnsworth, 3rd year product design student from De Montfort University, whose product, Air, is a smart breathing aid for asthmatics to reduce asthma flare up and irritation to the lungs and airway when exercising

Namgyun Ryu, 1st year MSc Integrated Product Design student from Brunel University, with ‘Tri Walker’ – a walking aid for the elderly providing enhanced mobility improved functionality over conventional walking aids.

The five finalists, who were praised for their concepts and their very high level of professionalism, will all receive cash prizes and short work placements with one of the competition sponsors: Brightworks; Innovate Product Design; PDD and RJG Technologies.

The winner will take a trip to Germany to visit Covestro, and will be joined by Christopher Kay, who was given special recognition by Covestro for his innovation.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

Find more information at www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

About Design Innovation in Plastics:

Established in 1985, Design Innovation in Plastics is the longest running student plastics design award in Europe. For more information visit www.designinnovationplastics.org

The Institute of Materials, Minerals and Mining (IOM3) is a major UK engineering institution and is the professional body for the advancement of materials, minerals and mining to governments, industry, academia, the public and the professions. For more information visit www.iom3.org

The Worshipful Company of Horners is one of the oldest livery companies in the City of London and was formed to regulate the horn-working trade. In 1943 it adopted its modern equivalent, the plastics industry. For more information visit www.horners.org.uk

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

Covestro offers material solutions for improved design compared to marketable products. The range is a response to the growing customer demand for materials with increased wearing comfort. Covestro offers the right combination of materials for the perfect lightweight, flexible and hardly visible patch that provides a comfortable feel. There is no comparable offer on the market so far.

Complete solution for modern wearable patches

For this purpose, Covestro has developed special breathable thermoplastic polyurethane (TPU) films from the Platilon^® range. The materials are perfectly suited and designed for customers using a roll-to-roll manufacturing process that allows wearables to be efficiently produced. The electronics can be printed on the film and embedded in thermoformable polyurethane foam covered with a second film layer for better wearing comfort. The patch is then fixed with a special skin-compatible adhesive, which adheres firmly to the skin but allows painless removal of the patch. The adhesive system and the thermoformable foam are based on Baymedix^® polyurethane raw materials. Covestro thus offers a complete solution for modern and high-quality wearable patches.

A prototype was produced in collaboration with the Holst Centre, which is known for its expertise in printed electronics and wearables. The materials being used are already ready for the market. In addition to the wearable patch, Covestro will present a design study at K 2019 to present different wearable designs depending on their medical use.

Covestro is providing convincing design and material alternatives to currently available wearable raw materials. The company is considering advances in printed electronics to demonstrate that its materials can contribute to a design with a stronger patient focus that takes into account patient comfort and skin sensitivity.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

Find more information at www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

Visitors to the world’s premier fair for the plastics and rubber industry will find many examples of this presented by Covestro at Booth A75 in Hall 6. From October 16–23, 2019, products and technologies for the automotive, construction and electronics industries will be on display, but also innovative and functional applications in the health, furniture, sports and leisure sectors.

“In addition to the advancing digitalization, the United Nations Sustainable Development Goals will be a driving force in society and the economy for the coming years,” said CEO Dr. Markus Steilemann to journalists. “Their fulfillment is not only imperative for a better, cleaner and healthier world, but also holds great economic potential in the long term,” explained the CEO. “Covestro is determined to realize the UN sustainability goals at many levels.”

Industry pioneer

Steilemann named the development of a functioning circular economy and improved management of limited fossil resources, primarily crude oil, as central points for increased sustainability. “These are goals that will impact society as a whole and Covestro wants to contribute to this. Within our company, we want to establish material cycles along the entire value chain, from suppliers, to production and logistics, to the use of our products and their reuse,” explained Steilemann.

When recycling used plastics, it will be important to be able to exhaust all technical possibilities. “The relatively new method of chemical recycling is also an option, which requires additional support,” said the CEO.

A key aspect for developing a circular economy in the plastics and chemical industry is closing the carbon cycle with recycled resources. Here, plant waste and increasingly CO₂ are worth considering as alternatives to fossil resources. Covestro has already achieved numerous successes in these areas. “We want to become a pioneer on the path toward a future without fossil-based resources and emphasize our claim to leadership in the industry,” stressed Steilemann.

Digitalization creates added value

Another driving force is the advancing digitalization. Covestro wants to take advantage of the resulting opportunities and has started a comprehensive program, which focuses on the customer. To accomplish this, the company is incorporating digital technologies and processes into production, the supply chain, research and development, at all customer contact points and in new business model development. Various topics and exhibits at K 2019 underline how important digitalization is for the company, which hopes to set standards in this field in the plastics and chemical industry.

The examples below give an impression of the wide range of developments that Covestro will present at K 2019.

Completely networked society

One important requirement for future mobility and the digitalization of all areas of life and business is the new transmission technology 5G. To build the infrastructure for it, Covestro is working together with Deutsche Telekom and the Umeå Institute of Design to develop innovative material solutions for base stations, antennas and other system components. Covestro is also working on a multi-layered film solution in conjunction with a new manufacturing process for the backs of smartphone bodies. Unlike conventional metal elements, these polycarbonate films are permeable to high-frequency radiation.

Auto interior of the future

The highlight of the trade show exhibit is a comprehensive interior concept for future mobility. In line with the latest trend, it intends to turn car interiors into multi-functional, mobile living and working spaces. “We developed the concept together with key industrial and academic partners,” explained Jochen Hardt, marketing expert at Covestro and head of the project. “It involves functionality, comfort and design in equal measure, as well as efficiency.” The car of the future is fully networked and is seamlessly integrated into everyday life. Key design features are surfaces with a decorative look and feel, integrated ambient lighting, the latest infotainment systems and cutting-edge seating concepts.

Textiles with CO₂

Together with partners such as RWTH Aachen University and various textile manufacturers, Covestro succeeded in producing elastic textile fibers from thermoplastic polyurethane with CO₂, and as a result partially replaced crude oil as the raw material. The starting point is an intermediate product called cardyon®, which is already used for the soft foam found in mattresses and the base layers of sports fields. The partners are currently working on developing production to industrial scale and want to introduce a material cycle that is based on sustainable resources to the textile and garment industry.

Renewable energies on the rise

In addition to promoting an efficient circular economy, Covestro is also committed to further expanding renewable energies, such as wind power. Cooperation with partners has led to the development of a polyurethane resin as well as a process technology, which makes it possible to manufacture wind turbine rotor blades efficiently and cost-effectively. The company just recently processed its first commercial order for this from China.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

For more information please see www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports. These reports are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to make them conform to future events or developments.

Headline sponsored by Covestro, and the longest running student plastics design competition of its type,it is held every year to encourage university students to come up with brand new products made primarily of plastic.

Organisers, the Institute of Materials, Minerals and Mining and the Worshipful Company of Horners, this year set the challenging brief of improving health, wellbeing or encouraging exercise, with a product which has the qualities of longevity and sustainability.

The panel of renowned industry judges carefully examined 149 entries at the preliminary judging stage before selecting five finalists, whose entries most closely matched the brief and satisfied the competition criteria.

Chairman of judges, Richard Brown (RJG Technologies), commented: “The brief this year was quite wide-ranging and was clearly open to different interpretations – but also provided the opportunity for more original thought.

“Whilst many fell short, due to insufficient investigation into intellectual property, materials and manufacturability of the product ideas, a hard core of students came up with some interesting product ideas.

“There was much debate among the judges, and it was eventually decided to pick five finalists rather than the usual six, as these were the candidates whose entries met the criteria. Having progressed to the final, we will be looking for these students to further develop their concepts taking into account the judges’ guidance.”

Commenting on their design and ingenuity, technical service engineer, Mike Stuart (formerly Covestro) said: “This year’s finalists have clearly spent a great deal of time and effort putting detail into their designs, giving thought to materials and production methods, including costings.

“It was interesting to see the variety of approaches, from re-thinking existing products; to using innovative material choices making them attractive as well as versatile; and addressing a particular day-to-day issue in a novel way, with a product anyone would be happy to try.

“Some have come up with very interesting new concepts, which could have tangible value in real world situations, depending on whether they can be further refined. We will look forward to seeing how the products have progressed when the finalists present them in person in a few weeks’ time!”

The finalists go through to a final judging round on May 24, and the overall results will be announced at a ceremony in London on July 5. The winner will receive a trip to Germany to visit Covestro, along with a cash prize. A key feature of the competition is that every finalist also receives short industry placement with one of the competition sponsors: Brightworks, HellermannTyton, Innovate Product Design, PDD and RJG Technologies.

The five finalists are:

Louis Farnsworth – 3rd year product design student, De Montfort UniversityProduct Name: Air – A smart breathing aide for asthmatics to reduce asthma flare up and irritation to the lungs and airway when exercising.

Daniella Kalligorsky – 3rd year product design student, Technological University DublinProduct name: Checkkit – A new way to raise breast cancer awareness by promoting self-examination.

Christopher Kay – 4th year product design student, De Montfort University.Product name: EnviroJect – A re-usable syringe system, providing a 97.8 per cent reduction in plastic syringe wastage per year within the NHS.

Namgyun Ryu – 1st year MSc Integrated Product Design student, Brunel University.Product name: Tri Walker – A walking assistant product for enhanced mobility and health for the elderly, adding improved functionality to conventional walking aids.

Kai Wang – 4th year integrated product design student, Brunel University.Product: Pot luck – A combined cooking and storage device that encourages and simplifies the production of stock cubes using avoidable food waste.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

About Design Innovation in Plastics:

Established in 1985, Design Innovation in Plastics is the longest running student plastics design award in Europe. For more information visit www.designinnovationplastics.org/.

The Institute of Materials, Minerals and Mining (IOM3) is a major UK engineering institution and is the professional body for the advancement of materials, minerals and mining to governments, industry, academia, the public and the professions. For more information visit www.iom3.org.

The Worshipful Company of Horners is one of the oldest livery companies in the City of London and was formed to regulate the horn-working trade. In 1943 it adopted its modern equivalent, the plastics industry. For more information visit www.horners.org.uk.

Find more information at www.covestro.com.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

One of the highlights this time is breathable yet waterproof outdoor clothing. It is intended to protect joggers or hikers from rain, but at the same time let sweat escape from their skin. With the INSQIN^® technology, textiles are coated with waterbased polyurethane (PU) dispersions without the use of solvents.

The breathable textiles impart a pleasantly comfortable feeling. This is ensured by an adhesive coating based on Impraperm^® DL 5310 dispersion and a top coat based on Impraperm^® DL 5249. Both products also give backpacks, shoes and gloves their desired functionality.

Biodegradable textile coating

When assessing the sustainability of textiles, it is becoming increasingly important to consider the entire product cycle – including the behavior at the end of its useful life. With Impranil^® DLN-SD, Covestro offers a waterbased PU dispersion that is biologically degradable by microorganisms at the end of the product life cycle. The initial internal tests performed on pure polymer films without additives confirm this. The raw materials enable biodegradable coatings and composite solutions, which in turn contribute to a modern recycling economy. Under the conditions of OECD Standard 301, more than half of the dispersion is degraded within 28 days. The percentage is significantly higher than with acrylate film formers.

The aliphatic PU dispersion Impranil^® DLN-SD can be used to formulate very light-resistant coatings for adhesive, intermediate and top coats. They are also suitable for other product applications, such as latex gloves and packaging.

New TPU fiber for fabrics

At Techtextil 2019, Covestro will also showcase a new fiber made from thermoplastic polyurethane (TPU). Compared to conventional polyethylene terephthalate fibers, it is characterized by an improved abrasion resistance and can be heat pressed at lower temperatures. Tear resistance and a good haptic feeling are further advantages.The fiber can be used in footwear, functional textiles, sports accessories and casual wear.

Innovative film solutions for smart textiles

The use of printed electronics is becoming increasingly important in the course of increasing digitalization in the medical and health sector and also in leisure time. Covestro has developed a range of skin-friendly film solutions to meet the requirements for lightweight and very comfortable smart textile design. Smart textiles are an important application, for example for biomonitoring, diagnostics and drug administration.

Platilon^® thermoplastic polyurethane (TPU) films are used, for example, in the continuous monitoring of vital functions and exact performance measurement. A conductive ink can be safely applied to the films to achieve this. Housed inside a shoe sole, patient data can be directly recorded and evaluated in real time by electronic devices.

Sustainable textile coatings for medicine

Recently, Covestro has also been developing textile coatings for medical applications. These include surgical clothing, bed pads for hospitals, coatings for medical furniture and even bandages. At Techtextil 2019, the company will present raw materials for sustainable, water-based textile coatings with good haptics and resistance to disinfectants, as well as cohesive bandages without latex for compression therapy and secondary fixation.

About Covestro:

With 2018 sales of EUR 14.6 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,800 people (calculated as full-time equivalents) at the end of 2018.

Find more information at www.covestro.com, https://solutions.covestro.com/en/materials/coatings, https://solutions.covestro.com/en/materials/films and https://solutions.covestro.com/en/materials/thermoplastic-polyurethane.
Follow us on Twitter: https://twitter.com/covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.

To meet the toughest device design challenges, Covestro developed Makrolon^® Rx2235 polycarbonate. This new medical grade features high-flow properties for a variety of healthcare applications, such as on-body devices, surgical instruments, pen injectors and IV components.

“Makrolon® Rx2235 polycarbonate sets a new benchmark for flow length and brings the expected transparency and toughness of polycarbonate to help manufacturers fill very thin walls and accurately replicate intricate features with lower pressures,” said Pierre Moulinié, global healthcare technology lead, Polycarbonates Covestro LLC. Furthermore, Moulinié points out that material savings with thin walls could be pushed even further with increased cavitation to reduce production costs.

Formulated specifically to meet rigorous healthcare industry requirements, Makrolon^® Rx2235 polycarbonate is biocompatible according to ISO 10993-1 test requirements and designed to be sterilized using gamma or e-Beam methods. It is complementary to Makrolon® 2258 polycarbonate, another ideal material for medical devices. This grade is suitable for ETO and steam sterilization, biocompatible according to many ISO 10993-1 test requirements, and offers low viscosity and easy release.

“Makrolon® Rx2235 polycarbonate is a significant addition to our broad range of medical polycarbonates,” said Doug Hamilton, global healthcare segment leader, Polycarbonates Covestro LLC. “This is just the latest example of how we continue to innovate and expand our polycarbonate portfolio, giving healthcare OEMs access to the advanced materials they need to design, develop and produce their next breakthrough.”

Attendees at Pharmapack 2019, Feb. 6 and 7, in Paris, France, can visit the Covestro booth (#C94) to learn more about the company’s materials for the healthcare industry.

About Covestro:

With 2017 sales of EUR 14.1 billion, Covestro is among the world’s largest polymer companies. Business activities are focused on the manufacture of high-tech polymer materials and the development of innovative solutions for products used in many areas of daily life. The main segments served are the automotive, construction, wood processing and furniture, and electrical and electronics industries. Other sectors include sports and leisure, cosmetics, health and the chemical industry itself. Covestro has 30 production sites worldwide and employs approximately 16,200 people (calculated as full-time equivalents) at the end of 2017.

For more information please see www.covestro.com.
Follow us on Twitter: www.twitter.com/Covestro

Forward-looking statements

This news release may contain forward-looking statements based on current assumptions and forecasts made by Covestro AG. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. These factors include those discussed in Covestro’s public reports which are available at www.covestro.com. The company assumes no liability whatsoever to update these forward-looking statements or to conform them to future events or developments.