How to Follow a Smart Flexible Material Sourcing Path

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Material sourcing is a challenging and time-consuming exercise. This is especially true in the flexible materials segment, as there are a number of new materials meeting rapidly growing Internet of Things (IoT) applications.

There are many aspects of flexible materials sourcing that are unique. For example, in this segment, while the application is important, the specs are even more so. A good place to begin this process, therefore, is to list what you want to accomplish based on the desired characteristics and properties that will meet all of your important specifications. Once the list is made, prioritize it. Your first inclination will be to jump online and search. Fight the urge. When searching for flexible materials, depending on online searches is problematic mostly based on the interchangeability of industry definitions. It is easy, in fact predictable, that you will be taken down the wrong path quickly.

Whether you’re a large company or a startup, begin your search by adhering to best practices, including:

• Obtain three competitive bids for every material. You’ll thank yourself later when your first source falls off, or you find an option that fits better because you didn’t stop looking.
• Material sourcing projects typically takes four months on average. Start early.
• Understand not only your purchasing requirements but also limiting factors.
• Discuss volume up front with suppliers—Minimum order quantities are very important in the flexible-materials arena, as some applications are typically very low-volume.
• Budgetary, environmental, regulatory and logistical considerations must also be identified and planned for early in the process and revisited throughout the selection timeframe.

Narrowing Down Potential Materials

The first three things that you will establish along the way are the type, subtype and composition of the sourced material. The type can be, for example, film or non-woven material.

Even at the outset, it is critical to not choose the wrong path with incorrect terminology. Settling on the type of material needed might seem simplistic, but it is common that a user will ask for a membrane with particular characteristics when, in fact, they are looking for a non-woven solution with those characteristics. A search just for membranes (especially online) will lead the user down multiple paths, with none of them being correct. The first step, therefore, is to narrow down the material type.

Material subtype takes into account subcategories of broad material types. For example, there are multiple manufacturing processes for film. When you indicate you want a blown film, therefore, you’re pretty far along in narrowing down the search. Third, the ingredient/material composition—what’s it made of—can be of natural or synthetic origin, further narrowing the search criteria.

Figure 1. In Sourcebook’s Material Finder, once at Composition, the materials search is narrowed considerably.

By reviewing the types of flexible materials, it is easy to see how they are different and also how easily one might mistake one for another without assistance. Here is an oversimplified glossary of the nine flexible materials under consideration:

The Nine Materials―An Oversimplified Glossary

Composites are a combination of two or more distinct materials with a recognizable interface between the materials. The three main types include coated materials, laminates and tapes. Multiple components enable functions that could not have been attained singularly by one part of the composite. This represents the most diverse material type, and there are as many uses as there are materials.

Extruded Nets are a strong mesh material created by extruding thermoplastic polymer pellets in a melting and pressurizing process. A die is then used to form the extruded material into its desired structure. The formed netting is cooled and hardens into its final shape. Common patterns are diamonds or squares. Although there are several uses, they are often used as containment materials.

Films generally describe a thin plastic material no more than 76 micrometers (0.003 inches) thick. Typically, films are a semi-permeable barrier layer between two different environments, or a support layer for materials with less structural stability. There is a large range of finishes that can be used to further customize the function of the material, including structural and surface changes.

Foams represent a porous material composed of polymers and masses of gaseous air pockets within them. The pockets can be closed, forming closed-cell foam, or open for open-celled or reticulated foam. The desired polymers and additives are mixed together, poured and allowed to cure and rise into the final shape.

Foils are an unsupported thin metal sheet less than 152 micrometers (0.006 inch) thick. Foils are commonly used as an impermeable barrier layer between two environments.

Membranes include a permeable or semi-permeable matrix made of metal, polymer or other materials capable of separating micron and sub-micron size particles from liquids and gases by retaining particles larger than the pores on the membrane’s surface. The three main forms of filtration include microfiltration (MF), ultrafiltration (UF) and nanofiltration (NF), or Reverse Osmosis (RO), referring to the size of the particles able to pass through the membrane material.

Nonwovens are a fabric made directly from a web of fiber without yarn for weaving and knitting. With nonwovens, the assembly of textile fibers is held together by:

• Mechanical interlocking in a random web or mat.
• Fusing of the fibers, as in the case of thermoplastic fibers.
• Bonding with a cementing medium such as starch, casein, rubber latex, a cellulose derivative or synthetic resin.

Fibers may be oriented in one direction or deposited in a random manner. This web is then bonded together. Fiber lengths can range from 0.25 inches to 6 inches for crimped fibers up to continuous filament in spun-bonded fabrics.

Technical Papers are a material manufactured in thin sheets from wood pulp or other fibrous substances. Unlike traditional paper, they are manufactured for non-aesthetic purposes, where function is the primary criterion. Technical paper is typically constructed using the traditional wetlaid process.

Technical Textiles, in comparison, are woven or knitted material with extremely precise dimensions. Technical textiles are constructed from mono- and multi-filament polymer or fabric based yarns. Similar to extruded net, greater precision can be reached through the weaving process. The highly accurate dimensions of technical textiles make precise filtration a common application for this material.

Why Is This All So Complex?

There are several competing trends at work where flexible materials are concerned. There is a move, for example, toward massive customization. People want to customize and design their own products, while manufacturers still want the efficiency and all the good things that come out of mass production and its lower cost.

The number of single-use disposable products continues to grow so that small-batch production runs are common. This means that ordering is not in the same bulk/volumes that were true in the past, necessitating that a company be particularly adept at supply chain management―and getting what they need.

Another underlying trend is that for both consumers and businesses, the level of patience that we have is exponentially decreasing. We want resolutions in minutes, not months. Amazon is delivering products within the hour. Is it necessary? Maybe not, but will it be adopted? Probably.

Sourcebook: Your Vast Experience Meets Ours

On the path to establish smart flexible material sourcing, Boyd Technologies’ Sourcebook brings together developers, engineers and sourcing departments directly with material manufacturers. Not only does Sourcebook go far in reducing the time and cost inherent in material sourcing, it also enables product development and advances improved innovation.

While the average sourcing of materials takes approximately four months, Sourcebook enables you to search, compare materials and order samples—all in one day. Samples can be delivered overnight to ensure that you stay on track to rapidly include or eliminate materials as a possibility for your design.

Sourcebook has several elements, including:

Material Finder

The Material Finder is a customized tool that takes users through the beginning steps of the material selection process. With an emphasis on material specifications rather than the application it will be used in, it is designed to enable users to rapidly and accurately narrow down material possibilities. It will not, however, eliminate a potentially promising option just outside the established scope. Finder results can be narrowed easily through the use of range filters compared and samples requested for next-day delivery.

The Knowledge Center

Knowledge Center content spans technical briefs, best practices, glossary of terms, additional resources and tutorials. Guest-contributed content is penned by industry experts and includes additional resources within the industry.

Sample Library

Physically located at Boyd Technologies, the Sample Library houses material samples (U.S. letter or A4 size) of all of the materials available in the Sourcebook database, including composites, extruded nets, films, foams, foils, membranes, nonwovens, technical papers and technical textiles. Sample requests are always fulfilled overnight and in your hands the next day.

Sourcebook Engineers

Representing the heart of Sourcebook’s material sourcing efforts, Sourcebook engineers qualify and maintain ongoing relationships with all Sourcebook suppliers, as well as support material for sourcing and development projects. Sourcebook supplements your sourcing team with access to a full-time assigned engineer at a fraction of what you would pay to add this expertise directly to your staff.

When you perform material-sourcing activities well, there are immediate and long-lasting benefits. If not, you will instead experience a high degree of risk and costs.

Sourcebook represents an opportunity to not only move your materials sourcing projects along efficiently, but also to find alternative materials, develop new materials, solve supply chain issues, manage risk and cost and find the answers you need—fast.