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When you think of sheet extrusion, the frst things that likely come to mind are thin structures for packaging applications like cups and trays, or thicker structures for industrial applications. But ice skates, orthopedics, sneakers? Those are among the more curious end markets served by Bixby International of Newburyport, Mass., whose roots go deeper than some trees. Bixby was founded in 1874 and is now in its ffth generation of family ownership. That in itself is unique: Most family-business management experts will tell you that by the third generation, a company usually has either been sold or gone out of business. But this one has persevered while adapting. It originally operated in Haverhill, Mass., as a footwear manufacturer, supplying multi-material structures used for shoe heels and toes. But much of that business migrated to Asia over the years, and Bixby (bixbyintl.com) opted not to chase it. Instead, it evolved and diversifed into a highly engineered, project-oriented sheet extruder whose focus is to generate solutions, not pounds. "Footwear is still part of our business, but far less than what it used to be," states Dan Rocconi, Bixby's president and CEO. "We think our heritage is in engineering. We developed cutting-edge technologies in footwear. In fact, we were the frst to use plastic in toe supports and heel counters. Fact is, many shoe manufac- turers have built their production process around 'Bixby's.' But as demand and technology changed, we had to change with it to become a top-of-the-line sheet extruder." Footwear currently comprises about 18% of Bixby's business, which is projected to reach $20 million this year. It also partici- pates in a wide range of other markets, where it extrudes a gamut of materials and adhesives onto a variety of fabrics for applica- tions in dental retainers and alignment devices, orthopedic foamed-back braces, conveyor belting, solar EVA encapsulants, protective fooring, and recreational and sporting goods. "We end up in markets that a lot of other companies try to avoid because of the extent of engineering that's involved up front," says Marc Gagnon, v.p. of R&D; and product development. "Each project is diferent, so each solution is diferent," Gagnon continues. "As a company, we look at ourselves as the hub of the wheel in any project. The spokes are the scientists and engineers we interact with every day—at resin companies, fabric mills, compounders, adhesive companies, and the like. We work with 16 diferent compounders, for example, and with companies that specialize in slitting, winding, and sewing all kinds of fabrics. We bring together the intellectual frepower of all of the companies in order to develop highly tailored solutions." Adds Dennis Lauzon, v.p. of sales, "Our business is not based on responding to RFQs. In fact, most of the leads we get are from our suppliers asking us if this or that is possible." Among its more unusual products is one tradenamed BixCure. This is an optically transparent, UV- and weather-stable, fast- curing EVA solar encapsulant. It was developed to optimize adhesion to a broad spectrum of substrates used in manufacturing photovoltaic modules, both rigid and thin-flm constructions. Its balance of properties enables end users to realize greater power retention after accelerated UV and weathering exposure. BixCure can be extruded onto customer-specifed substrates such as glass scrim or other flms to reduce manufacturing steps. Another product, called BixTherm, is an optically trans- parent, highly UV- and weather-stable TPO solar encapsulant. It also adheres to a broad range of substrates used for photovoltaic modules, primarily for thin-flm applications where the encapsu- lant must bond in a continuous, roll-to-roll process. As a thermoplastic, BixTherm requires only heat and pressure, with no curing, to encapsulate photovoltaic cells and bond to substrates. It does not require long cycle times to build crosslink density. No curing reaction means fewer by-products generated during lamination, and no bubbles formed when using aggressive lamination temperatures and rates. Since it is not based on EVA, there is no corrosive acetic acid generation, which can decrease "We regularly pull screws, dies, and rolls. In a lot of ways, our manufacturing setup is more akin to an injection molder than an extruder." Visit the Sheet Extrusion Zone at PTonline.com. Learn more at PTonline.com QUESTIONS ABOUT SHEET EXTRUSION? A pilot extrusion line in Bixby's lab allows it to quickly prove concepts and generate prototypes that solve specifc problems. Left to right: Dennis Lauzon, v.p. sales; Marc Gagnon, v.p. R&D; and product development; Dan Rocconi, president and CEO. @plastechmag 47 Plastics Technology On-Site Bixby International