manufacturer Daiwa for Japanese schools - ppsu injection molding

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

The solution? Use one of Formlabs’ 3D printers and a high-temp resin to build a temporary mold, thus “bridging the gap between prototype and production, reducing turnaround time for a crucial component by 85 percent while saving over $100,000,” said Edman.

Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.

This month’s resin pricing report includes PT’s quarterly check-in on select engineering resins, including nylon 6 and 66.

Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.

“One of the biggest issues with plastic tools is their higher coefficient of thermal expansion,” he said. “This causes them to grow and shrink during use, leading to dimensional variations of the finished part. We also find that plastic molds are unpredictable. You might get 20 or 30 shots out of one, but then again, it might break on the first part. So even though the mold itself might be less expensive to produce than one made of metal, it can end up costing far more in the long run.”

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

While the melting process does not provide perfect mixing, this study shows that mixing is indeed initiated during melting.

In a time where sustainability is no longer just a buzzword, the food and beverage packaging industry is required to be at the forefront of this innovation. By adopting circular packaging processes and solutions, producers can meet regulatory requirements while also satisfying consumer demand and enhancing brand reputation. Join Husky to learn more about the broader implications of the circular economy — as well as how leading brands are leveraging this opportunity to reduce costs, increase design flexibility and boost product differentiation. Agenda: The cost and operational benefits of embracing circularity Key materials in circular packaging — including rPET and emerging bioplastics How to design a circular food and beverage package Strategies for selecting sustainable closures to future-proof packaging solutions Optimization and streamlining of production processes for enhanced efficiency How Husky Technologies can enable your sustainable success

Across all process types, sustainability was a big theme at NPE2024. But there was plenty to see in automation and artificial intelligence as well.

Varotsis said that 3D Hubs continually works to expand its injection molding offerings to accommodate “a whole range of new possibilities that serve the needs of its engineering customer base.”

NPE2024: Live demos of updated RGS controller are among the highlights at its Wisconsin facility that will house the ‘new’ color R&D lab.

But before you run off to your computer, gung-ho to upload your latest product design, please remember the “hundred parts or so” caveat. That’s a reasonable quantity expectation for most 3D-printed molds, and it might be far less if you want parts molded from a high-temp polymer such as ULTEM or a glass-filled nylon. Around the 100-part threshold, your mold will be kaput and you’ll heading back to the 3D-printer to build a new one.

The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda:  Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

3D Hubs, an online service provider, works with a network of manufacturing partners to determine the most cost-effective and streamlined way to bring product designs to fruition. As such, it often recommends traditional steel molds as the best solution for its clients, especially for injection-molding end-use parts.

“The majority of cases I see are for manufacturing validation,” he said. “A customer might have a part that’s quite finicky to mold, for example, or looking at pulling the trigger on an expensive multicavity tool. Perhaps they’re making a consumer product with a Class A surface finish on all sides of the part, or they want to do mechanical or chemical testing. There are a lot of good reasons for getting your hands on a few dozen parts so you can make sure they’ll perform as planned before you commit to hard tooling.”

The mold design itself, however, is also different, requiring larger draft angles and greater care with the placement of ejector pins and gates. This must be done to avoid undue stress on the mold. None of this is meant to imply that 3D-printed molds don’t have their place—they do—only that they need a little extra TLC during and after the design process.

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.

After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.

Depending on part complexity and the number of shutoffs and side-actions, molds often can be turned around in a few days, straddling the “gotta have it tomorrow” crowd and those willing or able to wait a month or so.

Exhibitors and presenters at the plastics show emphasized 3D printing as a complement and aid to more traditional production processes.

In his experience, customers that can wait three to five weeks for a steel mold will see better results. A manufacturer of sports equipment in Norway, for example, recently turned to 3D Hubs to machine a whopping 29 molds in just 17 weeks for a series of polyoxymethylene and glass-filled nylon components. By waiting for steel molds, the Norwegian company took delivery of tools it could use for years instead of weeks or even days.

That’s a big wad of cash, for sure, but few companies are the size of Google, nor do they have to validate a mold that might cost more than a yacht. In some cases, Edman pointed out, it might be simpler to just print the parts, as suggested at the beginning of this article.

The other caveat is part design. As Varotsis noted, parts produced with 3D-printed, two-part molds are limited to less complex geometries. Undercuts and similar features, which are common with production mold tooling, must be generated through the use of hand-loaded inserts. The reason is that the automatically sliding side-action cores used in metal molds are not an option because of their cost and design complexity. Again, no big deal unless you’re planning on making several hundred parts, in which case the manual labor might become burdensome.

Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.

Of course, you can always use 3D Hubs’ printing service to produce your own mold if you do not have access to an industrial printer, he added. That is what researchers at Eindhoven’s University of Technology, Netherlands, recently did to create patient-specific models of neonatal organs using PolyJet-printed molds.

This is why most of Protolabs’ molds are made of aluminum, although, Utley said, steel might be used when molding high-temperature resins such as PEEK.

“It’s all a question of your reasons for building a mold and what you’re willing to put up with,” he said. “These are pretty low-cost tools made of relatively inexpensive material, so if you have any sort of production quantities, you could just plan on burning through a handful of printed molds. That said, an increasing number of companies are choosing to go the direct-print route, especially in light of increasingly faster print speeds and the availability of robust, end-use materials.

As it turns out, there are some very valid reasons to 3D-print a mold. There’s the aforementioned need for speed, for example. That might be all the justification necessary for a person who needs a hundred or so parts in a few days.

“I like to think of it more like good medicine in that it is dosed at low loadings but is highly functional. This, without the brute force lubricity seen in the traditional lubricants. So, like medicine, it is effective with minimal adverse effects, such as loss of mechanical properties along with no risk of waxy residues,” said Marshall. Flowability of PLA with dosage of 1-2% of ST-PA210 has been shown to dramatically increase, according to Marshall.

Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.

In terms of customer-use cases, Edman said most of his are hush-hush, but he did discuss the Google Advanced Technology and Projects lab wanting to validate a product’s design before moving into large-scale production of a wearable, over-molded electronics device.

Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.

Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.

“That last part isn’t all that important because of the lower production quantities involved with 3D-printed molds, but what is important is mold longevity. With abrasive or less-moldable materials, you might only get 10 pieces before the mold chips or breaks or wears to the point that part quality becomes unacceptable,” said Varotsis.

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

Produced by China’s Starbetter Chemical Materials, for which CAI Additives is the sole distributor in North America, this flow agent is based on a unique polymeric chemistry, versus traditional wax or ‘oily’ lubricants, and has been shown to be highly compatible with PLA, according to CAI Additives CEO Richard Marshall.

Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics:  Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.

Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Tim and Caleb discuss the challenges of hiring and retaining employees in the metal fabrication industry, particularly at...

While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

To someone needing molded parts pronto, a week is an eternity. This is one reason why 3D-printer manufacturer Formlabs Inc., Somerville, Mass., continues to see a strong call for molds made using stereolithography (SL) technology.

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.

Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES

Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.

When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.

“They’re fast and inexpensive to make. Just remember that they’re limited. But if you need a reliable tool, one that’s able to handle most engineering-grade resins, and you don’t have thousands and thousands of parts to make, I’d go with aluminum,” said Utley.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution

“Here’s where I think it makes sense to make a 3D-printed tool for injection molding,” Utley said. “If you’re in a hurry, and you already own an Objet or comparable high-end printer, and you have access to an injection molding press, and you have an injection molding technician on-site who knows how to set that press up, and you have some experience in mold design, then by all means go ahead and print your own molds.

August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

That’s great, you’re thinking, but really? A plastic mold? Why not just print the parts themselves and cut out the middleman, so to speak?

Online manufacturing service provider 3D Hubs often recommends traditional steel molds for end-use part applications. 3D Hubs

Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.

For your patience, you get a tool able to mold perhaps 10,000 parts or more, depending on the workpiece material, that has a price tag probably not a whole lot higher than a 3D-printed tool.

Join KraussMaffei for an insightful webinar designed for industry professionals, engineers and anyone interested in the manufacturing processes of PVC pipes. This session will provide a comprehensive understanding of the technology behind the production of high-quality PVC pipes: from raw material preparation to final product testing. Agenda: Introduction to PVC extrusion: overview of the basic principles of PVC pipe extrusion — including the process of melting and shaping PVC resin into pipe forms Equipment and machinery: detailed explanation of the key equipment involved — such as extruders, dies and cooling systems — and their roles in the extrusion process Process parameters: insight into the critical process parameters like temperature, pressure and cooling rates that influence the quality and consistency of the final PVC pipes Energy efficiency: examination of ways to save material and energy use when extruding PVC pipe products

Across the show, sustainability ruled in new materials technology, from polyolefins and engineering resins to biobased materials.

Plastics Technology covers technical and business Information for Plastics Processors in Injection Molding, Extrusion, Blow Molding, Plastic Additives, Compounding, Plastic Materials, and Resin Pricing. About Us

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

Plastic injection molds can’t be made in a minute, or even in an hour. But they can be 3D-printed in a day or so, which is far faster than the weeks or even months most in the industry have come to expect.

In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.

“As a rule, manufacturers have two options for rapid injection mold tooling: traditional metal molds, or very-low-run, typically 3D-printed, plastic molds,” said Alkaios Bournias Varotsis, technical marketing engineer for Amsterdam-based 3D Hubs. “With the latter, you’re generally limited to a basic, two-piece mold with no side actions; relatively simple part geometries; and, because their cooling capabilities are less robust than with metal molds, much longer cycle times.

The new additive is being targeted to both unfilled and filled PLA resins, where improved performance is needed. CAI sells the additive in solid powder form to compounders and processors who can add it at the extruder throat. Typical end-use application include single use cups, spoons, forks, coatings on coffee cups, transparent cold cups, deli containers and clamshell salad boxes.

Eric Utley, additive manufacturing applications engineer at Protolabs Inc., Maple Plain, Minn., would like to point out that the choice of plastic injection mold tooling isn’t an either/or choice between steel and polymer. There’s also aluminum.

This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

Boston-based CAI Performance Additives is now marketing here what is said to be a unique flow improver for use with biodegradable PLA and other biobased polyester resins. Flow Improver ST-PA210 has been shown to increase melt flow index, enhance dispersion, and improve compatibility.

Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.

Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

According to Andrew Edman, industry manager for product design, engineering, and manufacturing at Formlabs, SL produces the fine detail and smooth surface finishes needed for plastic injection molding. It’s also known for its ability to produce patterns for investment casting, one of the first uses of the technology.