Despite all of the optimism about AM, there are still major challenges to be overcome before the technology enjoys truly widespread adoption (Exhibit 3).

Meanwhile, various stakeholders are accelerating the overall market development for AM. Large OEMs are investing significantly in R&D and building internal centers of competence, while other large corporations—such as HP, from the traditional printing business—are entering the market. Major governments are setting up R&D funds, including the European Union’s Horizon 2020 program, or are starting capability-building programs for their workforces, as in Korea.

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

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

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

And just as making tooling need not cut into production, making prototypes can be kept isolated from production resources as well. Desktop polymer printers often can be effective not just for look-and-feel prototypes but for functional prototypes as well. Stanley Black & Decker recently introduced a simple 3D desktop printer with a 200 mm square build area. With a resource such as this, the engineer might be able to make a prototype at his or her desk without enlisting the attention of manufacturing staff.

AM machine manufacturers are working on better in-process control, advanced quality diagnostics, and data storage along the entire production process for certification purposes. Large AM manufacturers, including Materialise and Stratasys, suggest that AM can achieve material properties in both plastics and metals comparable to those from traditional production techniques.

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

3D printing of metal molds makes possible conformal cooling channels that can improve both the quality of the molded part and the molding cycle time. This rendering from Conformal Cooling Solutions shows a cavity with conventional cooling channels and a 3D printed core that has conformal cooling channels built in.

The AM landscape is diverse. In the plastics printing market, larger, integrated players cover the entire value chain from supplying materials to manufacturing printers to providing printing services. Several have added services by making targeted acquisitions. The larger players are also very active in creating new use cases in particular industries, driving sector-wide adoption and sale of equipment. In the metal printing market, by contrast, relatively small players focus more on certain parts of the value chain, such as in printing equipment or in printing services.

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.

Can a manufacturing plant locate in the heart of a city? Manufacturers today tend to locate in suburban industrial parks with easy access to major highways. But because of its reliance on 3D printing, Voodoo Manufacturing is able to locate in Brooklyn. The company uses 160 desktop printers working simultaneously to achieve a part production rate that makes the company cost-competitive with injection molding—and faster in delivery—for quantities up to 10,000 pieces.

Additive manufacturing (AM)—the process of making a product layer by layer instead of using traditional molding or subtractive methods—has become one of the most revolutionary technology applications in manufacturing. Often referred to as 3-D printing, the best-known forms of AM today depend on the material: SLS (selective laser sintering), SLA (stereolithography), and FDM (fused deposition modeling) in plastics, and DMLS (direct metal laser sintering) and LMD (laser metal deposition) in metals. Once employed purely for prototyping, AM is now increasingly used for spare parts, small series production, and tooling. For manufacturing with metals, the ability to use existing materials such as steel, aluminum, or superalloys such as Inconel has significantly eased the process of adopting AM.

As companies adopt industrial 3D printers to accelerate product development by prototyping in-house, it becomes only a short leap to manufacturing production parts in-house as well. Arizona Home Floors, a developer of tools for installing and removing flooring, never intended to become a manufacturer. It had previously outsourced manufacturing. But for a new chipping hammer it recently developed, making some of the components on the same 3D printer that had prototyped the parts proved to be the most efficient approach. As more companies choose this route, 3D printing is expanding not only the application of plastics, but also who is doing plastics manufacturing.

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

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.

With these changes in production capabilities will come equally dramatic shifts in company functions and their relative importance on the value chain. The ability to make completely customizable products will shift the traditional manufacturing mind-set of “What is feasible?” to one of “What is possible?” Design capabilities will therefore become an even more important strategic asset.

Meanwhile, in addition to the traditional material, printing, and service businesses, fast-growing niche players are starting to arise. These companies ground their entire business models on AM, ideally combined with digital sales and service models. Align Technology, with its product Invisalign, provides an alternative to metal dental braces; there are similar examples from Sonova for in-ear hearing aids, Mykita with eyeglasses, and Shapeways with crowd design of consumer products.

Meanwhile, the number of materials that AM can handle is constantly expanding. A wide range of new plastics has been developed, along with processes and machines for printing with ceramics, glass, paper, wood, cement, graphene, and even living cells. Applications are now available in industries ranging from aerospace to automobiles, from consumer goods (including food) to health care (where artificial human tissue can be produced using AM) (Exhibit 1).

3D printing plays multiple roles at the company’s Knoxville microfactory, from prototyping to the production of parts for autonomous vehicles.

There are certain applications 3D printing cannot touch, and might never be able to. For a production run of hundreds of thousands of parts, for example, the option to 3D print plastic components cannot come close to competing with the speed and efficiency of an established process such as injection molding. However, in many other applications and in many different uses, 3D printing is both improving plastics manufacturing and expanding the options for plastic parts. Here are just 10 of the ways 3D printing is advancing:

Company functions of today will also change when, for example, operators skilled for one production line will need to operate new AM production lines that produce a large variety of products. Traditional engineers will need to be trained in AM design. Marketing and sales, meanwhile, will need to learn how to market individualized products that can be produced anywhere in the world.

This 21-article compendium gives practical insights for manufacturing leaders looking to keep a step ahead of today’s disruptions.

3D printing thrives on one-off parts, and perhaps the most common type of one-off part in any manufacturing facility is its own internal tooling. That is, not just mold tooling but jigs, fixtures and all manner of industrial tools. Much of this tooling can be made from polymer instead of metal components, and when it is made on a 3D printer, it need not consume production capacity or even take up much of the production personnel’s time. With 3D printing, Volkswagen Autoeuropa reduced its tool development time by 95 percent while improving tools’ ergonomics and simplifying tool repair and modification.

Medical and dental products are now routinely tailored to the individual via 3D printing, so how far are we from consumer products following suit? The work of various footwear providers suggests shoes will soon be widely available that optimally fit the wearer’s feet. Footprint 3D is an example of a company advancing this idea; the firm uses 3D scans of an individual’s feet to 3D print shoes with custom midsoles that use lattices for precise support and cushioning.

Manufacturers of AM machines, however, are addressing these limitations with significant results. Specialized AM service companies, along with engineering and consulting firms, are now bridging the design-skills gap. In addition, regional governments are funding AM-focused production clusters for applied R&D. Several analysts predict that next-generation machines will cut current AM production costs dramatically because of factors such as patent expiration and reduced postprocessing needs. Manufacturers will also benefit from increasing economies of scale and sourcing opportunities in low-cost countries.

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 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

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.

3D printing provides a short-lead-time option for directly making a few parts, but it also provides a short-lead-time option for making an injection mold. The right choice of polymer can reliably produce mold tooling for low to medium quantities. Wyoming-based Avante Technology 3D prints injection molds from carbon-fiber-reinforced polymer that have consistently lasted beyond 100 cycles, and the company says could last to 500 cycles.

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).

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.

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

Meanwhile, 3D printing in steel can make improved mold tooling for high-volume production. With printed-in conformal cooling channels replacing straight drilled holes, the mold’s cooling is more effective, likely improving molded part quality and reducing cycle time. Mold supplier Conformal Cooling Solutions uses robotic deposition technology to 3D print large injection molds with conformal channels.

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

In many cases, metal is the material of choice for a given part only because it offers the easiest way to get a rugged functional component in a low quantity. Machining the part from aluminum is a practical option. But with 3D printing now able to efficiently deliver polymer parts in low quantities, metal will not be the material of choice so frequently. Carbon-fiber-filled 3D-printed polymer can replace even a hard or strong metal.

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.

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

Universities are partnering with manufacturers’ research centers to create innovation centers for applied R&D, with examples including Advanced Remanufacturing and Technology Centre in Singapore and RWTH Aachen University/Fraunhofer Institute for Production Technology. Finally, a vibrant start-up scene has arisen as most patents on existing AM technologies have run out, leaving space for new (as well as established) players from various industries to enter at all points on the value chain. New design and service companies are being set up and new technologies developed, such as by BigRep and Carbon3D.

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

We are also seeing an increasing availability of materials with properties comparable or even superior to those of existing ones. These materials include polymers such as nylon, PEEK, and ULTEM that are becoming more heat resistant and lending themselves to more applications, and metals and alloys within the standard range of available materials: industrial metals such as steel, aluminum, titanium, and Inconel; precious metals such as gold and silver; and new materials including amorphous, noncrystalline metals.

Plastics processors are finding applications for 3D printing around the plant and across the supply chain. Here are 8 examples to look for at NPE2024.

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

Compared with traditional production methods, AM offers enormous benefits, including less hard tooling and assembly. In the long run, AM can completely change the way products are designed and built, as well as distributed, sold, and serviced (Exhibit 2).

This prototype from Footprint 3D exposes the lattices of the midsole to show how they provide cushioning and support that are customized to the shape of the wearer’s feet.

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.

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

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.

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

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.

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

The earlier version of part of a tool from Arizona Home Floors is made of metal (center). For a new version of the tool, the company made a prototype of the part on its own 3D printer (left), then proceeded to run the production part this way as well (right) as an alternative to outsourcing manufacturing.

How will the traditional way of serving markets change, and what are the implications for traditional plant setups and value chains? As far as production and distribution are concerned, a few things seem clear. Advantages from production in low-cost countries will likely diminish. New, customer-centric plants will emerge, allowing the finishing of products according to local demand and significantly reducing the need for long-distance transport of finished goods. We may also see new production-network models—for example, production of half-finished products in low-cost countries, with finishing done close to customers to adjust for local taste, seasonality, and similar factors.

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.

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.

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.

Adoption of AM has been highest in industries where its higher production costs are outweighed by the additional value AM can generate: improved product functionality, higher production efficiency, greater customization, shorter time to market (that is, improved service levels), and reduced obsolescence, particularly in asset-heavy industries. Engineering-intensive businesses such as aerospace, automotive, and medical can accelerate prototyping, allowing them to explore completely new design features or create fully individualized products at no extra cost. High-value/lower-volume businesses see faster, more flexible manufacturing processes, with fewer parts involved, less material wasted, reduced assembly time for complex components, and even materials with completely new properties created. And spare-parts-intensive businesses in fields such as maintenance, repair, and overhaul get freedom from obsolete parts, faster time to market, more local and on-demand production opportunities, and independence from traditional suppliers.

3D printing expands possibilities for plastic parts, short-run molds and production mold tooling. Here are just 10 of the ways 3D printing is advancing:

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

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.

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.

People tend to overestimate the short-term impact of technologies and significantly underestimate the long-term impact. Yet there is currently a lot of uncertainty about the long-term impact of AM on traditional value chains. Understandably, the issue is being raised by traditional players such as logistics companies that will be directly affected, and by governments that aim to prepare their manufacturing ecosystems and workforces for changes that may be coming soon.

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.

At certain scales, 3D printing is indeed an option for production, and the scale is increasing. Some 3D printers engineered for production today generate parts at rates an order of magnitude faster than what has previously been accepted. 3D Systems, for example, says its Figure 4 production 3D printing system increases speed by a factor of 15 over previous industrial 3D printers, reducing the unit cost of a 3D printed part by 20 percent, thanks in part to the cycle time reduction.

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.

Plastic molds can make plastic parts. This mold, which was 3D printed in carbon-reinforced polymer by Avante Technology, offers a cost- and time-effective option for molding a short run of parts. A mold such as this can last for hundreds of cycles.

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

New competitors are also entering the OEM market. Large players such as Stratasys and 3D Systems are certifying an end-to-end process for producing medical parts with newly developed materials, using their own printing technology and offering printing services to customers such as hospitals, which formerly purchased from OEMs.

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.

A very large polymer 3D printer such as the Cincinnati Incorporated BAAM machine might offer a build volume of 180 cubic meters. This is huge, and machine models such as this capture a lot of attention. But just as notable is the range of machine models now available at sizes that are much smaller, yet still large. Various machine builders have introduced cost-effective industrial 3D printers making parts the size of a large molded component. A representative example, the 3DMonstr Super-Rex 3D printer, offers a build volume of 3 cubic meters.

Several analyst reports expect that the direct market for AM will grow to at least $20 billion by 2020—a figure that represents just a fraction of the entire tooling market today.1 1.Nancy Eigel-Miller, Joe Jablonowski, and Steven Kline Jr., 2014 World machine-tool output and consumption survey, Gardner, February 27, 2014, gardnerweb.com. However, we believe that the overall economic impact created by AM could be much higher, reaching $100 billion to 250 billion by 2025, if adoption across industries continues at today’s rate. Most of that potential will come from the aerospace and defense, automotive, medical, and consumer-goods industries.

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

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.

9T Labs continues to enhance the efficiency of its technology, which produces composite parts with intentionally oriented fibers.

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

Implementing a production monitoring system as the foundation of a ‘smart factory’ is about integrating people with new technology as much as it is about integrating machines and computers. Here are tips from a company that has gone through the process.

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.

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.

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.

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.

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

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.

We see little evidence of a race toward a single technology, since—because of factors including variations in cost, available materials, and surface finish—the existing technologies serve different purposes. To explore the potential of AM, manufacturers therefore often need access to more than one technology, which they can get via specialized service providers that offer all the key ones. This picture may change, however, if new entrants dramatically increase performance by improving an existing technology or creating a completely new one.

There are things you may have put off when you were occupied with shipping parts to customers. Maybe it’s time to put some of them on the front burner.

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

Given the investments necessary for developing the next-generation machines, many of these smaller players are looking for capital. Consolidation in the market has therefore begun. Uncertainty about which manufacturers will survive will change the face of the industry, creating risk for manufacturers investing in equipment even as improving technology holds out the promise of surmounting current barriers to the adoption of AM.

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

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.

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.

There are a lot of 3D printing technologies out there, and it’s not uncommon for processors new to additive manufacturing to get tripped up. Here are some typical snafus, along with advice on how to avoid them before you start making parts.