Material - ultem injection molding

3.  The overall length of the nozzle tips varies in order to vary the land lengths: The larger the orifice, the longer the land to increase thermal conductivity. If the land lengths were all the same, tips with small orifices would be more susceptible to generating cold slugs, and tips with large orifices could string under almost any condition.

As Fattori explains, stringing results when the center of the slug of plastic inside the machine nozzle-tip orifice has not sufficiently solidified when the mold opens. When the part is ejected, it drags thin strings of still-molten plastic after it. Those strings tend to be static charged and therefore stick to the mold. If they hang over the parting line, those thin strings of plastic will hob the mold—even a heat-treated steel tool—eventually leading to flashing. Fattori says that can’t be fixed properly by simply grinding the parting line—it requires an extensive mold rebuild, “all because of a $20 nozzle tip.” He adds, “I know of one molder that spends thousands of dollars a year on mold repairs due to stringing.”

“Additive manufacturing is becoming increasingly valuable for low production volumes in the manufacturing sector,” said Ryan Martin, Senior Research Director at ABI Research. “Manufacturers are using 3D printing for low-volume and custom parts, which helps reduce lead times and waste. This allows for greater flexibility and cost efficiency, supporting both prototyping and on-demand production. As a result, additive manufacturing is proving to be a practical solution for companies looking to adapt quickly to market needs and reduce inventory costs.”

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

According to Fattori, “A nozzle tip undergoes both a constant and cyclical thermal battle. It is heated in the back half by the machine’s nozzle body. It is cooled in the front half by contact with the sprue-bushing seat and by convection into the atmosphere.” These opposing thermal forces are fairly constant and come into equilibrium over time. But, he notes, that equilibrium is upset by the substantial heat generated during each injection cycle from frictional shear of the material.

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

Real-world testing (here with ABS) confirms that the IMC nozzle tip (top) eliminates stringing, regardless of the orifice size or material type.

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

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

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.

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.

1,346 polymer and metal AM companies and 143 end-users. Consumer products AM generated $2.6 billion in 2023. Segment expected to grow to $28 billion by 2033 at 26.8% CAGR. This new market study fro...

The IMC nozzle tips are available with a ½-in. spherical radius, in eight different orifice sizes of 5/32 in. through 3/8 in. in 1/32-in. increments. Fattori says the bore diameters of the IMC nozzle tips are slightly smaller than their nominal size. But even with the internal fins, the resulting flow area is comparable to most “full-flow” style nozzle tips. He also says that his tips’ large internal transition radius “virtually eliminates ‘dead spots’ where material can stagnate.”

The IMC nozzle tips cost more than other tips, because they cost more to make. “But the ROI on any mold that has an extended cycle time to overcome or reduce a stringing problem is typically just a few days,” Fattori asserts. “And the money saved from not having to repair just one mold due to string damage can probably pay for a year’s supply of IMC nozzle tips.”

According to Fattori, most nozzle tips are made of H-13 steel with a Rockwell hardness of 46 to 48 Rc. IMC tips are made of 420 stainless steel with a vacuum bright hardness of 48 to 52 Rc for greater durability.

After four years in development, an injection machine nozzle tip has been commercialized that is said to eliminate problems of stringing and all the compromises that molders make to avoid it. Jim Fattori, inventor of the IMC nozzle tip, has 40 years’ experience as a plastics tooling engineer and consultant. He heads up his own firm, Injection Mold Consulting LLC, in the Philadelphia area, and writes frequently for this magazine (see his monthly Tooling Know-How columns). His newly patented invention is now available from Progressive Components.

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.

Your very costly mold in that very expensive press is relying on the performance of a $20 nozzle tip that no one ever checks, and has a high probability of not doing its job. Stop learning from your mistakes and start learning how not to make them.

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.

Fattori realized that the solution to the problem was to get more cooling into the center of the flow channel in the nozzle tip. He came up with the idea of adding inwardly protruding, heat-conducting metal fins inside the bore of the nozzle tip. These fins are angled, with their maximum height 70% into the melt stream, with their peak at a location Fattori calls the “transition plane” inside the nozzle tip, which is where the molten material will separate on part ejection from the semi-solidified plastic. From this plane, the fins taper down to blend with the front orifice diameter. This taper concentrates the cooling at the transition plane, which flow simulation shows is the area where the greatest concentration of thermal gradients occurs inside the nozzle. The temperature differential between the sprue-bushing nozzle seat and the transition plane was found to be as high as 135° F in the simulations. Using fins to concentrate the cooling at the transition plane ensures the separation point is consistently in the same location, which results in repeatable shot sizes, Fattori adds.

Cross-section of IMC nozzle tip shows tapered internal heat-sink fins, which start at the “transition plane,” which is where the solidified material separates from semi-solidified melt on part ejection. Also shown is the novel profile of the tip, which reduces thermal mass for improved temperature control.

The new tips have eliminated stringing in tests with PS, HDPE, LDPE, PP, PVC, ABS, ASA, acrylic, nylon, acetal, PC and PPS (filled and unfilled). However, Fattori cautions that “these new IMC nozzle tips are only to be used on molds with a stringing problem, or molds for which you cannot reduce the cycle time without having a stringing problem. The new nozzle tips are so efficient at removing heat that they can cause a freeze-off condition, particularly on the smaller orifice sizes.”

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.

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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.

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

The ‘DryerGenie’ marries drying technology and input moisture measurement with a goal to putting an end to drying based on time.

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.

Traditional high-volume manufacturing is under pressure due to a myriad of challenges, such as supply chain disruptions, material shortages, and changing consumer preferences, and there is a growing demand for low-volume production solutions to offset the costs of mass production. AM with the new Origin Two is designed to eliminate the high setup and tooling costs typical for low to medium-volume production.

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

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

1.  The thick mass in the front was replaced with a contoured outer shape that corresponds to the internal geometry, with the smallest diameter at the transition plane.

One more innovation is very simple, but nonetheless valuable to molders. Fattori explains, “For some reason, you have to physically measure the orifice of most nozzle tips with some kind of tool in order to know their size.” He solves that by engraving the orifice size of each IMC nozzle tip on a wrench flat.

IMC nozzle tips are made of 420 stainless steel, which is harder than the typical H-13 steel. A simple but helpful added feature is the orifice diameter engraved on the wrench flat, unlike most nozzle tips, so no measuring tool is required.

Nozzle tips with large orifices are more prone to stringing because they take considerably longer to become semi-solid—usually longer than the best possible cycle time. Molders have tried various methods to reduce string formation, each of which has its own drawbacks:

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

Strings originate at the molten center of the melt channel in a machine nozzle tip, which often does not solidify within a desirable cycle time.

•  Using sprue break, which adds to cycle time (a little or a lot, depending on how far the barrel is retracted) and can lead to nozzle drool, leakage between the nozzle and sprue bushing (when drooled material obstructs close contact), and deformation of the nozzle tip and/or sprue bushing from repeated banging together—leading to even more material leakage.

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

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.

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.

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.

Stratasys’ new Origin Two, with Origin Cure, aims to address the key pain points by enabling manufacturers to ensure that end parts meet required properties by maintaining stringent quality controls; bring production in-house – reducing reliance on third parties; improve inventory management and lower warehousing costs with on-demand delivery of spare parts; and consolidate part manufacturing into a single process with better consistency.

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

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

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

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.

IMC’s novel injection nozzle tip (available from Progressive Components) has internal heat-sink fins to cool the center of the melt channel and prevent strings. Sand-blasted finish reportedly ensures a better seal against the sprue bushing.

•  Using a smaller nozzle orifice diameter, which increases the pressure drop through the nozzle tip. That increases shear and often requires a slower injection rate to avoid shear burns—adding to cycle time. What’s more, slow injection through a restrictive bore requires higher injection pressure—risking trouble if the machine is close to being pressure-limited;

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.

New system automatically cleans mold-cooling lines—including conformal channels—removing rust and calcium, among other deposits, while simultaneously testing for leaks, measuring flow rate and applying rust inhibitor.

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.

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.

The new solution is designed to achieve a consistently high accuracy of +/-50 µm – critical for industries such as connectors, aerospace, and automotive. For applications such as seals and gaskets, housings, and window parts, it provides additional essential features including achieving repeatability of more than 93% within +/-50µm across Origin Two printers, and surface finish smoothness of up to RA 3µm, while maintaining high-print speeds up to 20 mm/hour. The heated chamber of the Origin Two enables reliable printing of materials with a Heat Deflection Temperature (HDT) of up to 300°C – making it suitable for a wide range of high-performance applications; and running on a 385-nanometer wavelength, the Origin Two system supports a broad range of high-performance materials – from high-temperature resins to high-viscosity formulations.

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

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

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).

•  Using a nozzle-tip insulator, which Fattori says can be “a royal pain out on the production floor—and most of them don’t work”;

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

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.

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

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.

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

The new IMC nozzle tip incorporates four features to greatly increase the rate of heat transfer to compensate for momentary temperature rises:

“Additive manufacturing has grown to be a critical component of production at any scale on the manufacturing floor,” said Rani Hagag, Chief Healthcare and Consumer Business Officer at Stratasys. “With the new Origin solution, manufacturers in need of low-volume, high-precision parts now have an alternative to mass production that can meet their most stringent requirements, something which was not possible with additive before.”

As a result, Fattori states, “A nozzle tip must be able to react quickly to temperature changes, so as to prevent formation of strings within the best cycle time.” That requires efficient heat conduction to remove excess heat from the nozzle tip. But rate of heat conduction is affected by the mass of the object: Greater mass slows heat transfer. In Fattori’s view, “Every standard nozzle tip today has a very large mass. It begins at the back side of the wrench flats and extends all the way to the front face of the tip.”

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.

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

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.

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.

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

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.

4.  Diameter of the nozzle-tip face is reduced to decrease the amount of contact area between the face of the tip and the sprue-bushing seat. Other nozzle tips, with their large contact area, are greatly affected by how well, or how poorly, the sprue bushing is cooled. Since every mold is different, these nozzle tips can behave inconsistently from one mold to another. Fattori points out that the reduced contact area also results in greater sealing pressure for the same nozzle touch force, preventing carriage blowback and nozzle leakage.

•  Lowering the nozzle-tip temperature, which can increase the risk of cold slugs and nozzle freeze-off, leading to cosmetic flaws in parts and/or to costly downtime;

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.

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

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

One more thing: Fattori says, “In case you were wondering, the internal heat-sinking fins have also proven to work well in hot sprue bushings and in hot-runner systems.”

Fattori concedes that the thin fins inside the IMC nozzle will tend to wear, especially with filled materials and/or high injection speeds. Wear will gradually reduce the fins’ effectiveness at heat transfer. “Some tips have been running for over a year now with minimal wear,” Fattori comments. “But let’s say you’re running 33% long-glass filled nylon and you have to replace the tip once a month—that’s still a lot cheaper than having to literally rebuild the mold.”

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.

Stratasys, a leading 3D printing technology developer, has officially launched the Origin Two DLP printer in tandem with its own post-processing system, the Origin Cure. This solution addresses the growing demand among manufacturers for injection molding quality for short production runs – delivering a level of accuracy, repeatability, and surface finish previously unattainable with AM.

Oak Ridge National Laboratory's Sustainable Manufacturing Technologies Group helps industrial partners tackle the sustainability challenges presented by fiber-reinforced composite materials.

Fattori also notes that as plastic cools inside the nozzle tip, it shrinks away from the inner bore surface, which reduces the rate of heat transfer. But the fins are always in contact with the melt and are in close proximity to the center of the melt stream, increasing the effective cooling rate.

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.

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.

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.