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.

Supporting software is crucial to the successful and efficient development of all AM applications; however, this is especially true when it comes to the design of a conformal cooling mould. Rauch explained, “3D Systems’ Cimatron and 3DXpert packages have been phenomenal at giving me the tools needed for quickly navigating the process of designing an entire mould or just a single part for production by AM. I feel that, to be truly successful with additive, a designer has to completely change how they design – it is not a cliché that you have to design for additive. As tool designers we have all been taught to design a certain way. We had to design for how a tool would be manufactured but, with AM, all of the limitations put upon you by subtractive methods of manufacturing are almost completely removed. Cimatron and 3DXpert are very powerful modelling programs that give me the design freedom to quickly make that transition to designing for additive. The complexity of geometry I design with Cimatron and 3DXpert would be inconceivable using anything else. Tailored design tools assist me in the construction of the parts themselves and a complete suite of conformal cooling design tools automates much of the design process, allowing me to focus more on designing a part for its function rather than its ease of manufacturing. 3DXpert then takes it a step further. Once I move into build preparation I again have full freedom to design my support structures with ease because of the huge number of options I have for deciding which type of support structure will work best.”

A pre-hardened stainless-steel mold base is an even better solution. The thermal conductivity of stainless isn’t as good, but it usually doesn’t matter for a mold base. I always wondered about moldmakers who prefer steel types that have good weldability. While that is a good property to have, it shouldn’t be a guiding factor. Some steel preferences are based on years of experience. Some are based on how easy they are to machine, or how much they change size or warp during heat treatment. Usually, the commonly used steels are more than adequate for most parts. But occasionally the properties of the steel should be given greater consideration.

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.

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.

Just like an airplane, car, boat or motorcycle, a mold can potentially last forever if it is maintained properly and repaired when necessary. The only time a mold is considered unusable or has reached the end of its lifespan is when the repair cost exceeds its worth. In addition to the part and mold complexity, the mold’s longevity is based on many other factors, including (but not limited to) the mold design, steel selection, quality of the mold components and construction, the molding machine it runs in, molding material type and molding process used to make the parts, as well as the mold installation, removal, maintenance and storage.

4.  Is there a dimensioned 2D drawing of the part? I have seen too many jobs quoted strictly based on a 3D CAD model. CAD models do not specify the tolerances for critical dimensions. Nor do they specify the surface finish, aesthetic areas that cannot have gate or ejector-pin marks, secondary operations, mating parts, etc. 2D drawings almost always help the moldmaker decide the best way to design and build a mold—or if the part is even moldable to the stated specifications.

As with any technology, conformal cooling can be applied well or applied poorly. Commenting on what sets a great solution apart from a poor solution, Rauch explained, “Not all conformally cooled tooling solutions are created equal. When you are designing a conformal cooling passage you are trying to achieve several different things. The number one goal when wanting to be successful with conformal cooling is figuring out how you can rapidly and uniformly dissipate the heat over the entire surface of the moulding geometry. One of the most important factors that comes into play when achieving this goal is confirming that the conformal circuit itself produces turbulent flow inside the water passage. The best way to achieve this is by using CFD analytical software that simulates the fluid’s flow through the line. The Reynolds Scale helps us determine if we are obtaining turbulent flow inside our additively manufactured waterline geometry. The Reynolds number scale is a scientific way to measure flow patterns in different situations. Fluid travels in three different ways; laminar, transitional and turbulent. Laminar flow is when the molecules are following a smooth and steady path in a parallel fashion. An example would be when you open a tap to the slowest flow you can get and the water comes crystal clear.”

Lindemann cautioned, however, that,“there is still a resistance to embracing conformal cooling and this likely will remain for some time. Not all moulded parts are suited for conformal cooling. I once heard an AM representative tell of how he felt mistakes were made at the beginning when metal AM began taking on popularity. He explained about how mould makers especially were being told that this technology would replace them and what they were doing. That has proven far from the case. Good mould making and mould design practice remain essential to the industry and, if anything, AM has proved to be another tool in the tool kit to getting the overall job done well, and not a replacement for everything.”

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

Some of the common causes for a mold’s decreased longevity are due to accidents on the production floor. The folks in the trenches describe such events as “crashes.” One of the most common crashes involves a cam that is out of position—usually after cleaning the parting line or removing a part, or simply because the cam retention device was too weak, and the cam slid out of position. When a cam is out of position, the angle pin does not line up with the hole in the cam and then—crash—it snaps like a twig. If the angle pin hits the top of the cam, it’s usually not a big deal. Simply replace the pin. But if it hits any cavity impression, that’s going to end the production run and cost a lot more to repair. Another common type of crash is handling a mold with one eyebolt and no safety strap. An unsecured mold half can easily hit the ground well before you can yell “Look out!”

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

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.

I have a 1982 edition of the Classifications of Injection Molds for Thermoplastic Materials by the Society of the Plastics Industry (now the Plastics Industry Association, or PLASTICS). My edition defines the construction requirements for various types of molds for machines up to 400 tons and labels them type 101 through 105. It also has three types of quick-change mold inserts, which are labeled type I through III. It specifies similar classifications for molds that require machines with 400 tons or more of clamp pressure. Each type has a specific number of cycles a mold is capable of producing. Table 1 summarizes these classifications and lifespan quantities.

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.

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.

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).

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

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

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.

Rauch is also confident that we are just seeing the start of what conformal cooling using AM can do for the plastic injection moulding industry. “Right now, the technology is constantly evolving as new materials and better machines become available. But I think we are still scratching the surface of what AM can truly do for the moulding industry. The big changes won’t begin to happen until the people accept change. Designers must learn to think differently and design differently. Applying system level thinking into the engineering process has the power to change everything. Engineers with an open mind will become innovators overnight, and tooling companies willing to use AM in the production environment will become pioneers in what I believe is going to be the next industrial revolution.”

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.

2.  What is the part used for? If it’s a medical, optical or automotive part, there’s a very good chance that the mold is required to be made of ESR (electroslag reduction) stainless steel for cleanroom conditions and optical polishing or mold texturing.

Additive Manufacturing conferences rarely attract as many industry CEOs as New York's Additive Manufacturing Strategies event, let alone persuade t...»

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.

Drivers for the use of conformal cooling are often application-specific, he continued, “What we see are production needs relating to the requirements of a specific product driving the decision to use conformal cooling. In some cases, moulds that have AM components with conformal cooling strategies are delivering a 30-50% increase in production at the moulding machine making the plastic parts. This dramatic increase in productivity alone will end up returning 100% or more of the entire mould’s cost over the life cycle of the tool.”

Whilst conformal cooling opens up a world of new possibilties for tool designers and plastic injection moulders, it brings a new level of complexity and its own unique requirements. Rauch explained, “If a designer has good design skills and a good understanding of fluid dynamics, additively manufacturing conformal cooling passages can dramatically improve cycle times and also improve part quality. However, it’s not that simple. People tend to have tunnel vision and focus solely on designing an optimised conformal circuit, but one thing that will cause AM tooling with conformal passages to fail – and fail rather quickly – is the quality of water that is circulating inside. Most people don’t initially think about this being an issue, but you have to remember that most moulding facilities’ water systems consist of open-loop systems, with large cooling towers outside that carry the water through pipes to each moulding machine. Large amounts of debris and deposits build up which end up inside the mould waterlines. Eventually these build-ups cause catastrophic issues during the moulding process and you have to remove deposits.”

In addition to providing extensive industry news coverage, Metal AM magazine is known for exclusive, in-depth articles and technical reports.

Proper steel selection plays a critical role in the longevity of a mold. Most moldmakers have their “go-to” types, such as 1030 or 4130 for the mold base and P-20, 420 or H-13 for the cavities and cores. 1030 and 4130 are good steel types for mold bases, but if the project needs to last for several years, or if the water quality in the molding facility is prone to calcium deposits, the mold base should be electroless nickel plated.

Reach a truly international audience that includes component manufacturers, end-users, industry suppliers, analysts, researchers and more.

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

Personally, I have a passion for using thermally conductive materials, especially in hard-to-cool areas. Not because they are great at reducing cycle time, but because they are great at achieving uniform cooling. Non-uniform part cooling invites part warpage, and warped parts are often a rejectable condition. Table 2  gives approximate thermal-conductivity values for various mold materials. These values can vary widely depending on the manufacturer, heat treatment and operating temperature.

Supposedly, the classifications were updated back in 1996. More recently, there was an article in the August 19, 2021, edition of Plastics News mentioning that these standards are once again in the process of being updated by a team of industry leaders, association members and select members of the American Mold Builders Association. We should applaud their efforts to further improve this important document.

Commenting on what attracted B&J Specialty to 3D Systems’ technology offer, Rauch explained, “When we decided to invest in Additive Manufacturing, we looked at several different machine manufacturers, but when we considered what 3D Systems had to offer we were drawn to the fact that they not only focused on the printers themselves but also a complete line of design software that streamlines the conformal cooling development process. Having a good workflow simply makes good business and 3D Systems provides that with its end-to-end solutions for the tooling industry. From the start I can transition from design to build preparation and manufacturing, all from within the same piece of software. This is a huge time saver. We all talk about how AM can affect the supply chain because we can now take a digital design file and, in a matter of hours, have a finished product. 3D Systems seems to understand this, having the same mindset when developing its products. Other companies that we looked at had good machines but fell short when it came to having that smooth flow from the digital to the physical.”

“We see the most resistance to AM with customers that know nothing about it. It’s a major change and people will normally fear change. I believe they dig their heels in because we are disrupting the status quo. The moulding industry is mostly based around a set of standards that have been in place for decades and now, when you tell a customer we are throwing most of the manufacturing limitations out the window because of what AM brings to the table, they find it very hard to believe. Education is the key. You need to educate your customers on what they can gain through AM – and also help them realise that if you want major improvements things just have to change. Once a customer can accept this, you will then be heading down the path of success with Additive Manufacturing,” explained Rauch.

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.

Metal AM magazine, published quarterly in digital and print formats, is read by a rapidly expanding international audience.

Figure 1 shows a cavity set for a toy soldier. It was made in 1955 by hobbing blocks of copper. Hobbing is a manufacturing method rarely used today. Non-alloyed copper is also rarely used today because it is extremely soft. The figurine in Fig. 2 (left) was originally molded out of PS. The figurine in Fig. 2 (right) was cast out of liquid silicone material a few weeks ago on my desk. There’s a little flash on the cast part, but the “clamp pressure” was only about 10 lb—generated by a few rubber bands. The point is that part geometry is where it all begins, and oftentimes, defines when it all ends.

Lindemann concurs with Rauch in that there are two drivers behind the growth of AM for conformal cooling, stating, “Right now the momentum is coming from end-users who want better quality parts at reduced cycle times. The end cost may be such that it is an economical advantage even if the mould with conformal costs more to make initially. In some cases we see mould makers wanting to have the option of offering this technology to their customers, the end-users, as they see a need to be more competitive. With this they can, in some cases, also offer a quicker turnaround time in mould repair. Now they can print replacement cores overnight or in a few days, harden and finish them and have the mould back up and running quicker than with a traditional process. I have to again use the disclaimer ‘in some cases’ – wisdom dictates that each part or mould be considered on a case by case basis and it is not a fair statement to suggest this is a blanket statement for everything.”

“We have seen some injection moulders and mould makers experiment with conformal cooling in that they will take an existing job that they know well and then create a version for conformal cooled inserts to use as a comparison. In some cases the difference was dramatic and the practice of conformal cooling was adopted. That is not to say it is the best or only solution for every job. It is being investigated on a subjective basis. This trend has grown in recent years and seems to be continuing to grow,” added Lindemann.

If the material is highly abrasive, such as those with glass fillers, all the surfaces in contact with the plastic need to be through-hardened—the harder the better. That includes the sprue bushing and runner inserts, not just the cavities and cores. Abrasive materials can also dictate that the gate(s) be inserted because they will be the first thing(s) to wear out. Steels with high concentrations of carbon and chrome typically have good wear resistance. If the material is extremely abrasive, such as a thermally conductive material with silicon carbide filler, then one of the powdered-metal tool steels with a typical hardness value of about 60 Rockwell C could be best suited.

Toughness, which is basically a combination of strength and ductility, is important for tall, free-standing cores, as well as cavities with sharp inside corners where cracking from molding pressures is a concern. H-13 has very good toughness properties. S-7 is also good.

5.  Is there a target price for the molded part? This is a common question for thin-walled and commodity parts, such as caps and closures, where cycle time is critical and the need for a hot-runner system is paramount. High-thermal-conductivity materials such as copper alloys may be required. Unfortunately, too few moldmakers ask this question—unless they are also going to be the molder.

The only time a mold is considered unusable or has reached the end of its lifespan is when the repair cost exceeds its worth.

While it’s true that heat-treated tool steels with high compressive strength can delay the amount or severity of flash damage, it cannot make the mold impervious to damage. Figure 4 shows a severely hobbed parting line of a pre-hardened 28-32 Rockwell C mold caused by nozzle strings. Generally speaking, the harder the tool steel is, the more brittle it is. Obviously, there is a tradeoff when it comes to the physical properties of metals. Depending on several factors, you might need to consider using a more ductile material, or making a spare cavity set as insurance.

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

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

ABOUT THE AUTHOR: Jim Fattori is a third-generation molder with more than 40 years of experience in engineering and project management for custom and captive molders. He is the founder of Injection Mold Consulting LLC in Pennsylvania. Contact: jim@injectionmoldconsulting.com; injectionmoldconsulting.com

Rauch stated, “Most customers are eager to listen but very hesitant to make the decision to use AM. Mostly because you are telling them you will be changing both the established processes and the materials used to make the AM parts. Customers like to hear about new technologies but don’t seem to like it when they hear they will have to change. My best tools to convince them that this change is for the best are our own case studies, mould flow simulations and CFD analytical tools. These allow us to show things in black and white for them, so they can see first-hand what could be achieved if they decide to go down the path of change. After seeing the results, customers often think it’s too good to be true.”

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.

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.

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.

Acknowledgement: I want to thank Brenda Clark of Hasco America; Patricia Miller of Uddeholm; Roy Glenn, retired mold builder and designer; and Rick DeBeer, retired from LyondellBasell, for their knowledge and insight, which helped me compose this article.

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.

“Roughly 20% of the tools we are currently producing have some type of AM component. So far, all tooling we make with AM has conformal cooling. The other 80% of our conventionally manufactured moulds would all benefit from the use of conformal cooling in certain areas due to the shape of the geometry and the inability to get a cooling passage into the location needed. AM is slowly gaining traction in the moulding industry and it’s just a matter of time before all of the moulds that B&J Specialty builds will have AM parts with conformal cooling passages.”

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 correct software, believes Lindemann, is fundamental to achieving success in this sector and the designer needs support in ensuring both functionality and manufacturability. “Not all conformal cooling lines are good waterlines for their intended function or even good to be printed. There are design standards associated with all of this and having the right CAD software that works with these standards is invaluable. We recommend using Cimatron software for the mould design software that has dedicated functionality for conformal cooling that allows for consistent use of ‘printable’ waterlines and waterlines that are checked for consistent distance from the mould surfaces to hold the conformal effect.”

Driven by brand owner demands and new worldwide legislation, the entire supply chain is working toward the shift to circularity, with some evidence the circular economy has already begun.

•  Inferior mold design  •  Inferior mold construction  •  Insufficient mold-plate thicknesses  •  Insufficient support-pillar area  •  Lack of parting-line relief  •  Improper mold setup  •  Insufficient clamp pressure  •  Excessive clamp pressure  •  Cavity imbalance  •  Poor processing parameters  •  Excessive injection or pack pressures  •  Low material viscosity  •  Insufficient venting  •  Excessive vent depth  •  Using adhesive labels as vents  •  Machine bushing wear  •  Machine platen wear  •  Lack of alignment  •  Worn shutoffs  •  Abrasive molding material  •  Abrasive material fillers  •  Nozzle stringing  •  Sub-gate flaking  •  Sticking parts or runners  •  Rust or corrosion  •  Lack of preventive maintenance

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.

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.

I have already mentioned polishability, thermal conductivity, hardness and corrosion resistance. But what about toughness, compressive strength, wear and abrasion resistance? These are important properties to consider as well, especially when two pieces of steel slide against each other, like a cam, lifter or shutoff. The old rule of thumb says that if different steel types are used and there is a 10-point Rockwell C differential between them, everything will be fine. That rule of thumb doesn’t always hold true—especially if the forces are high and the contact area is large. O-6 and A-10 steels are good for sliding applications because these two steels have high concentrations of graphitic particles in their microstructure. O-1, O-2, D-2 and S-1 are also good steel types for sliding applications.

When it comes to presenting a review of the world's largest international exhibition for AM, one can go about it in two ways: very broad generalisa...»

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.

The real mold killer—for any mold, of any complexity—is parting-line flash.  When plastic or other debris adheres to the parting line of a mold, it can deform the mold by leaving an impression or indentation. If you think about it, when debris is sandwiched between two flat surfaces and is exposed to a few hundred tons of clamp pressure, it has nowhere to go but in.

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

Discover suppliers of these and more in our comprehensive advertisers’ index and buyer’s guide, available in the back of Metal AM magazine.

Rauch continued, “When other forces such as change in direction and obstructions disrupt the flow, it starts to change into what is known as transitional flow. Once the flow has become fully disrupted and a mixing and stirring action happens, turbulent flow has been achieved. This is the goal when I design conformal geometry, because once the fluid travelling inside the conformal passage becomes turbulent I know trapped heat within the steel AM part will start to rapidly dissipate. The mixing action from turbulent flow transfers heat away from the geometry it is travelling through more effectively because you are mixing the warmer fluid near the walls of the cooling passage with the relatively cooler interior fluid. It’s just like a hot cup of coffee – if you stir it with a spoon it will cool faster than just letting it sit still. If a designer takes all of these things into his thought process when designing a conformal cooling solution, they will be able to capitalise on the capabilities of what conformal cooling can do in the moulding industry.”

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.

1.  What is the expected annual quantity? This helps the moldmaker decide the mold classification and the number of cavities required to meet those annual quantities.

In-mould part cooling is the most time-consuming part of the plastic injection moulding process – reduce the time for part cooling and you will increase production speed whilst achieving higher quality moulded parts with less scrap. A variety of techniques have been used to maintain even temperatures over the years, using methods such as bubblers, heat pipes and complex drilling operations using laminated blocks. These, however, are cumbersome, time consuming and can limit the useful life of a mould. Drilled cooling channels are also limited to straight lines, no matter what the part geometry.

There are many factors that determine the longevity of a mold. Part complexity, which dictates mold complexity, is probably the biggest factor. A mold that produces a flowerpot, 5-gal bucket or a Frisbee can last a very long time. But more complex molds, such as those with cam action, unscrewing mechanisms, collapsible cores, contoured parting lines, sliding shutoffs, etc., will not last nearly as long because there are more component parts that can wear, break, gall, or seize. Just because a mold is made of heat-treated tool steel doesn’t mean it’s going to pump out hundreds of thousands of parts.

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

These humble but essential fasteners used in injection molds are known by various names and used for a number of purposes.

For example, if a part design has sharp outside corners (meaning sharp inside corners in the mold) and is subjected to high injection pressures, it’s longevity could be very short due to the potential of fracturing. I’ve seen well-built, class 101 hot-runner molds fail after the first five minutes because the manifold filled up with plastic—snapping bolts and splitting plates apart. I have also seen dead-soft aluminum molds run trouble-free for well over a decade.

The PLASTICS document is meant to be a guideline for purchasers of injection molds, and it should be renamed accordingly—guideline. The problem is that many people consider the stated minimum cycle counts to be factual, if not contractual. And that can lead to problems down the road. What happens to a class 101 mold at a million and one cycles? The customer pays for all the maintenance and repairs to the mold—regardless of how small or how large the cost? What happens at 999,000 cycles if a cavity cracks? Does the moldmaker have to replace it at his cost? As unpleasant as this topic is, it may be worth setting some initial ground rules with your customers.

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

Metal AM offers the jewellery industry significant creative and commercial opportunities. One such opportunity is the production of platinum and ti...»

A moldmaker’s objective is to maximize the performance of a mold to achieve the lowest possible total cost per part based on the intended lifespan of the project. That analysis should include the goal of minimizing the cost to maintain the mold. Therefore, when reviewing a new project, moldmakers will wisely ask:

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

Every customer I’ve ever had always asked how many parts their mold could make. Most moldmakers will respond to that question by saying something like, “Well, you paid for a Class 101 mold, so it should produce up to 1 million cycles.” Obviously, that answer is based on the PLASTICS mold classifications. While the classifications and the requirements for those classifications are excellent, I don’t agree with specifying the number of cycles each type of mold should be able to produce.

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

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.

B&J Specialty uses a portfolio of dedicated software solutions from 3D Systems to develop its conformal cooling solutions, including Geomagic® Design X™, Cimatron® and 3DXpertTM. The tool parts are then built on a 3D Systems ProX® DMP 300 Laser Powder Bed Fusion system.

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.

Providing 3D Systems’ perspective on the broader industrial use of conformal cooling, David Lindemann, Cimatron Application Engineer at 3D Systems, told Metal AM magazine, “The driving forces seem to be coming from automotive, aerospace, and medical. The reason is mostly to improve overall part quality and reduce warpage, this in turn improves part fit and functionality. As previously stated, another crucial reason is to reduce the cooling cycle time and thus reduce overall part cost.”

3.  What is the molding material? If it’s a corrosive resin, such as rigid PVC, the only good option is to make the mold out of stainless steel. I say the only good option because nickel and other coatings do not protect carbon steels from PVC gases for very long. If you think that stainless is too expensive, consider the cost to remove the worn or flaking plating, re-polishing the cores and cavities and then re-plating the mold.

Despite the limitations of the early technology, tooling became one of the most important markets for the fledgling metal AM industry and the sector is regarded as one of the first real commercial applications of the technology. Whilst this success continues today, the use of Additive Manufacturing in the mould and die industry remains relatively niche compared to conventional toolmaking technologies.

Let’s do some simple math. Assume a sub-gated part leaves 1/16-in. diam. flakes on the parting line. A 1/16-in. diam. flake has an area of 0.0031 in.2.  The mold is in a 500-ton press. Pressure = Force ÷ Area so in this case:

“Up until now, most waterline passages were machined with some type of a drill bit – as all water circuits travelled in a straight line. So a blocked waterline just meant you had to run a drill bit back through the straight drilled hole to clear it out and everything’s good to go. With conformal cooling, it’s not so easy. The conforming line that follows the three-dimensional shape of the geometry makes it impossible to clean out in this way. I therefore urge all of our customers to invest in a closed-loop system so you have filtration options and much better control of the quality of water you are using. Once you have water quality in check you can then view conformal cooling as a perfect technological solution for injection moulding.”

To properly understand the differences in performance between PET and PBT we need to compare apples to apples—the semi-crystalline forms of each polymer.

Whilst conformal cooling solutions can significantly reduce the total cost of production by lowering mould cycle times, they also require sophisticated mould designs. A well-designed conformal cooling mould typically has a wide variety of unconventional curves, twists and shapes that must be precisely placed. Once designed, these complicated moulds must be manufactured to the same standards as any other mould.

A very common cause of mold damage is due to galling. When two pieces of steel rub or slide against each other, there is a risk of them metallurgically bonding together. You can usually hear the components squeaking shortly before they seize up. Galling can occur at any time—from the initial mold sampling up to 1 million cycles later. Everyone from the machine operator to the plant manager should be aware of what this sound means. Recognizing a galling situation early can reduce the amount of mold damage.

The free to access Metal Additive Manufacturing magazine archive offers unparalleled insight into the world of metal Additive Manufacturing from a commercial and technological perspective through:

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

Additive Manufacturing has been used to build moulds incorporating conformal cooling channels since  the 1990s when the first metal powder-based AM systems came to market. The AM process in those early days used CO2 lasers and required metal powders coated with polymer binder, which would evaporate out after the part was built. The part would then be infiltrated with a second metal to remove the porosity. Today, the technology has moved on considerably, and the new generation of AM systems uses significantly more precise fibre lasers, high purity metal powders and an oxygen-free manufacturing environment.

The thickness of the molded part is important when it comes to selecting the best material out of which to make the cavities and cores. If the part is thin-walled, selecting a material with extremely high thermal conductivity may not be the best choice. The material can solidify too quickly during injection, and you can end up with a lot of short shots or injection pressures that exceed the machine’s capabilities. Conversely, if the part is extremely thick, the thermal conductivity of the cavity and core material is not nearly as important because the molded part forms an exterior skin, which acts as an insulating barrier. That’s why a graph of cooling time vs. wall thickness is not a straight line. It is an upwardly projecting curve.

An uncommon, but very serious crash can occur when a large mold is hung in the machine in two halves. If one of the halves is accidentally oriented 180° out of position and the setup man overrides the low-pressure setup mode because the mold won’t close, really bad things happen. On a couple of occasions, I have seen a molding machine with a bad hydraulic valve. The mold closed at full velocity and shook the entire building. But accidental mold crashes are thankfully infrequent and one-time events.

B&J Specialty, Inc., based in Wawaka, Indiana, USA, offers precision machining, engineering and mould and die services to customers in the US Midwest. With the support of technology from AM technology provider 3D Systems, headquartered in Rock Hill, South Carolina, USA, the company works to offer high performance plastic injection moulding tooling for customers through the implementation of additively manufactured conformal cooling solutions.

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.

According to Jarod Rauch, B&J Specialty’s Information Technology and 3D Printing Manager, whilst the demand for tooling with conformal cooling is seeing strong growth, there is also some resistance to such a transformative technology in what can be seen as a very traditional industry.

Rauch believes that the sector’s growth is coming from both a combination of customers who are demanding faster process times and from innovative toolmakers looking to gain a competitive advantage in terms of their technology offering. “At this point it has been almost a 50/50 split between these drivers, however I am starting to see a change as AM has become a real game changer in the moulding industry. Now I am seeing larger companies wanting to ‘go additive’ without a company such as ours trying to sell the technology. The door has opened and we are beginning an industry-wide transition.”

Commenting on the increasing demand for injection moulding tooling with conformal cooling, and expectations of growth in the near term, Rauch stated, “Seeing the demand increase for AM with conformal cooling in the moulding industry has really been exciting. As with all disruptive technologies it takes some time for a new solution to become the new ‘norm’ and I believe we are still just scratching the surface of what Additive Manufacturing can do for the moulding world. B&J Specialty has seen the results and we know that conformal cooling is a huge game changer. I would say in the next five years almost all of the moulds we build will have some type of AM components with conformal cooling in them.”

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.

Wear and galling explain why there has been a lot of attention given to various surface coatings and surface treatments, as well as the metallurgical compatibility of different types of mating steels.

Commenting on how 3D Systems is helping toolmakers embrace AM in order to develop their conformal cooling capabilities, Lindemann stated, “We have the software to assist and can work with the customers on a job by job basis and prove out the design. The customer may naturally hesitate to jump in with both feet and buy a metal AM system that he knows little about. We have services where we can print the mould core and prove out its viability and best case situation for printing. Once it is seen as a success, then the customer can move forward using this proven process on their own. They will be trained to use the software and the machine and start manufacturing their own cores per the proven process.”

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

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

The yield strength of P-20 steel is about 125,000 psi.  The yield strength of 1030 and 4130 steel is about 64,000 psi.  This equation doesn’t even include the added force applied to the debris due to the closing speed and momentum of the moving platen.  Figure 3 shows what gate flakes can do to a mold when the applied pressure is considerably greater than the yield strength of the steel.

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

Conformal cooling moulds have curved cooling channels that conform closely to part geometry and their use for an injection mould can reduce cycle time by anywhere from 10% to 40%. The low range gains are possible with little to no engineering analysis; the higher estimates reflect the use of flow analysis, computational fluid dynamics and finite element analysis.

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Compounders face a number of processing challenges when incorporating a high loading of low-bulk-density mineral filler into polyolefins. Here are some possible solutions.

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.

If the injection or packing pressure is excessive, or if the clamp pressure is insufficient, the plastic will try to ooze out of the cavity. This usually results in the sharp-edged perimeter of the cavity starting to look like someone added a small radius to it. Over time, the cavity will have more and more flash growing around it. The problem with flash is that once the surface of a mold is indented, it never gets better. It can only get worse. It needs to be repaired and the root cause determined and corrected when it’s first noticed. Giving an operator a razor blade or some other tool to remove the flash is not an appropriate corrective action.

Our audience includes component manufacturers, end-users, materials and equipment suppliers, analysts, researchers and more.

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

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

Concluding, Lindemann believes that increases in the production speed of AM systems, combined with a move towards increased automation, will accelerate the adoption of AM conformal cooling solutions. He stated, “Right now the direction is to make AM systems capable of manufacturing larger parts, using multiple lasers during the build process, and developing a greater degree of automation. Imagine a production floor environment dedicated just for metal AM. Conformal tooling can certainly benefit from these factors. From there, honestly, who knows where it can go? The future promises to be exciting in the least.”

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.

The hardness of the plastic, as well as the hardness of the mold can dictate how quickly and how severely the mold will get damaged. If a hot bushing is drooling Ultem PEI in a P-20 mold, it won’t be long before you are grinding a few thousandths off the parting line to clean it up. I know moldmakers that intentionally make the mold cores 0.005 in. taller because they believe they will be grinding the parting line a couple of times over the life of the mold. But the hardnesses of the plastic and the steel are not the only factors that promote flash. The list of potential causes is exhaustingly long. Here are some of the more common ones:

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

Lindemann believes that it is crucial to understand the limits of the technology and to apply it only as appropriate. He stated, “There certainly are many ‘upsides’ but this is when the conditions are right. There has to be a realistic expectation. Mould builders making extremely large muolds look at the additive process and say that it is not for them. Their moulds are simply to large. There is however a trend in applying additive in a limited degree by creating mould inserts that are of printable size for key areas of the mould where conformal cooling would be beneficial. This requires some creative engineering but many are getting good results.”

The frenzy of media attention surrounding Artificial Intelligence (AI) dwarfs the past hype surrounding Additive Manufacturing (AM). Whether you lo...»