As evidence of the Tri-State’s continuing success in high-tech manufacturing, Jasper Rubber recently became the exclusive producer of ElectriPlast, a patented, electrically conductive plastic.
The product, which is produced at the facility in Jasper, Ind., comes from a relationship with Integral Technologies, Inc., based in Bellingham, Wash.
ElectriPlast, recognized by Popular Science with a “Best of What’s New Award” in 2004, combines the conductivity of the base metal with the lighter weight of plastic.
AT TOP: Wire embedded in plastic pellets at Jasper Rubber is molded to plastic parts used to shield electronics. ABOVE: A variety of parts can be molded using the metal embedded pellets.
BOB GWALTNEY / Courier & Press Ryan Lawrence works at one of the molds making plastic parts at Jasper Rubber in Jasper, Ind.
BOB GWALTNEY / Courier & Press Wire embedded in plastic pellets at Jasper Rubber is molded to plastic parts used to shield electronics.
The product can be sold as pellets or a component part. The pellets can be molded and shaped in a company’s existing plastic machinery.
No special equipment or processes are required.
That means the material can save companies money, said Doug Bathauer, director of public communications at Integral, because production costs, especially in retooling, are significantly lower for plastic components than metal ones.
Turnaround time, especially important for suppliers in just-in-time manufacturing chains, is significantly reduced also, he said.
“Right now, over 40 companies have tested the material,” Bathauer said.
The benefits over traditional metal components are not exclusively economic either.
“In some cases, its a greener technology,” Bathauer said.
As an example, he said the material can be used in battery components in hybrid-electric cars. Making just the battery housing out of ElectriPlast rather than metal would save 10 to 18 pounds, improving vehicle performance and fuel efficiency.
Replacing metals in various applications, rather than just dominating the market for conductive plastics, is the end goal, Bathauer said.
“Engineering teams are able to replace metals through ingenuity in design,” he said. “It’s a totally different way of thinking.”
The product traces its roots to the late 1990s.
At the time, Integral was working on an antenna application and needed a conductive material that would not rust like existing components.
Early research led them toward conductive plastics, but none of the products on the market performed at a satisfactory level.
Development soon began in earnest, and the company’s first patent was awarded in 2003.
The company now holds 45 patents for the product.
Jasper Rubber’s role with ElectriPlast began in late 2006.
At the time, there was no significant production capability for the compound. Bathauer said Integral considered having a larger company such as GE Plastics or DuPont handle production, but eventually chose to work with Jasper Rubber.
“We were more comfortable working with a smaller company,” Bathauer said.
He said the levels of trust and collaboration are both higher.
Staff at Jasper Rubber are enthusiastic about the relationship, too.
ElectriPlast is not the only conductive plastic on the market, but representatives believe they produce the most advanced and effective one.
“There are conductive plastics out there,” said Adam Auffart, sales manager at Jasper Rubber. “None of them have the properties of ours.”
Bathauer said the pellets contain more metal fiber than competing materials, making them 40 percent more effective in shielding applications in some cases, close to the performance level of aluminum.
The formula still is flexible, though.
“We’re able to use different fibers and plastics to address different parts of the market,” Auffart said.
Because of this, he said, various shielding levels can be achieved in rigid or pliable plastic components, creating a wide range of applications.
Auffart said the biggest challenge in the marketplace has been a lack of independent test data.
“Early on, there were some significant challenges in getting people to talk to us, to think outside the box,” he said.
Now that a series of lab tests have been published, he said, clients are beginning to pay attention.
The benefits to Jasper Rubber go beyond ElectriPlast itself.
“Customers don’t want huge supply bases. We can give plastics, rubber and molding work,” he said.
Thus, between ElectriPlast and the ancilliary benefits, Auffart said, the product could be transformative for Jasper Rubber and its workforce.
“Long term, if a few of these products take off it could mean doubling or tripling the size of the company in a short time,” he said.
The business has about 650 employees who own 100 percent of the company.
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