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.

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

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

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

The plastic industry seeks sustainability opportunities throughout the breadth of the market from automotive to medical to packaging. It’s in the latter market where the depth of that commitment was exemplified in the plastic pail category at NPE2024 where Milacron exhibited an M-Series Model 1070 injection molding system capable of adding a core layer of recycled content.

This specially-formulated, high-temperature, high-voltage PVC insulator is used to injection mold various terminal caps and barriers. Safety is increased during thermal runaway because the material maintains high dielectric strength, reducing arcing risk and ignition of gases, and forms a structured char barrier, helping reduce spread of fire from one module to another.

Since 1970, this globally oldest and largest competition of its kind has highlighted the positive changes that polymeric materials have brought to automotive and ground transportation industries, such as weight and cost reduction, parts consolidation, increased safety, and enhanced aesthetics and design freedom.

The seat cables produced by Tier 2 supplier Hi-Lex Controls are delivered to Tier 1 supplier Toyota Boshoku pre-routed on the module plate and injection molded with Washington Penn’s 40% glass-reinforced PP. This eliminates the brackets, cable ties and clips typically used to control seat cables, and greatly reduces labor for an assembly operator. The module also reduces rework and scrap due to cable misalignments. In addition, lever pull effort for consumers is reduced because direct cable routing enables use of shorter cables.

With many benefits for numerous potential applications, including in the burgeoning electric vehicle market, Celanese’s Zytel Bonding Technology achieves stronger bonds than overmolding or welding.

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.

Produced with Celanese’s Celstran PP-GF40 by Cascade Engineering, this conversion resulted in a 48% mass reduction and a 37% cycle time reduction, while eliminating the cost and environmental burden of paint. Also, seal interfaces were improved, secondary routering of holes is no longer needed and the frunk is fully recyclable at end of life. A 4,000-ton injection press and a tool equipped with a 16-drop hot runner system are used to mold parts.

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.

SyBridge’s Matt Little, business development manager, life sciences and consumer, sees plastic handles replacing metal to simplify and maximize plastic pail recyclability.

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.

Baystar's Borstar technology is helping customers deliver better, more reliable production methods to greenhouse agriculture.

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.

Rick Lingle is Senior Technical Editor, Packaging Digest and PlasticsToday. He’s been a packaging media journalist since 1985 specializing in food, beverage and plastic markets. He has a chemistry degree from Clarke College and has worked in food industry R&D for Standard Brands/Nabisco and the R.T. French Co. Reach him at [email protected] or 630-481-1426.

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.

Said to be the world’s first all-thermoplastic splitgate rear closure system, which is delivered to the assembly line as a ready-to-install module, it is featured in Rivian’s 2023 Rivian R1S all-electic SUV.

The high-modulus, creep-resistant, flame-retardant polymer eliminated the need for compression limiters and electrical isolation films, yet withstands extreme pressures from cell expansion and met all mechanical requirements. In addition, four components were reduced to one and many functional features were incorporated in the patented side plates that would not have been possible in metals. Mass was reduced by 37% and cost by 55%.

The 2023 Rivian R1S won the 2023 SPE Automotive Innovations Award for its thermoplastics splitgate. Photo Credit: SPE Automotive Division

Injection molded by Magna International with Advanced Composites’ 40% glass-reinforced LGF-PP and TPO, it features a complex, deep draw (>80 mm) design, which is said to offer improved perceived quality at lower mass, NVH, and cost vs. metals, and is offered in a two-tone execution. By commonizing grades between the liftgate and the benchgate and focusing on sustainability, parts were reduced from nine to three and with just two materials  — a 40% glass-reinforced LFT-PP and a TPO. The CHMSL (center high-mounted stop lamp) and taillamps were carried over from Rivian’s pickup model.

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

Participating in the demonstration this year were a collaboration of NPE partner companies Beck Automation, KW Plastics, LyondellBasell, MCC Verstraete, Mold Masters, Shell Polymers, and SyBridge Technologies.

Sustainably speaking, other pails pale in comparison. But that’s not the ultimate solution because there’s more pail sustainability ahead.

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.

Toyota’s 2024 Grand Highlander’s seat module received SPE Automotive’s 2023 Innovation Award for the process/assembly/enabling technologies category. Photo Credit: SPE Automotive Division

The GMC Hummer EV received the 2023 SPE Automotive award for the electric and autonomous vehicle systems category. Photo Credit: SPE Automotive Div.

Coverage of single-use plastics can be both misleading and demoralizing. Here are 10 tips for changing the perception of the plastics industry at your company and in your community.

The 20% GF/PA6 grade, which is also heat stabilized and flame retardant, was selected for its ability to offer high levels of functional integration in limited space plus be compatible with snapfits, heat staking, ultrasonic welding and adhesive bonding.  Laminated core-block inserts are used in rotary injection tooling for venting and to control stampings during overmolding.

Milacron and partners perfect the injection molding of a precise layer of recycled content — mechanical or advanced processes — to sustainably boost the eco-footprint of 5-gal plastic pails.

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

The grand award winner which appears in the battery-electric Ford Motor’s 2024 F-150 Lightning is a first in that it entailed converting from compression-molded painted SMC to mold-in-color, injection-molded PP-LFT (40% glass) to produce the industry’s largest Class A composite frunk.

The at-show encapsulated post-consumer recycle (PCR) layer was 46%, according to Stirn, “but we go up to 50% with complete control of where the recycle layer is located, whether inner, middle, or outer layer.”

A collaboration between show organizer PLASTICS, recycler CPR and size reduction experts WEIMA and Conair recovered and recycled all production scrap at NPE2024.

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).

Versus virgin TPO, the more sustainable grade lowered density slightly and offered better impact at 5°F (-15°C). Concurrent redesign reduced component count from six to one, including eliminating two metal brackets, saving 6.6 lbs of mass, increasing cargo volume and functionality, improving water management, reducing labor and reducing greenhouse emissions by 67%. Cost savings of $26.26 per vehicle are achieved.

The breakthrough is gaining traction. Stirn informs us that tests and trials are already lined up in North and South America with more to follow.

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

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

This patented injection-molded seat module in Toyota Motor’s 2024 Toyota Grand Highlander hybrid SUV incorporates both temporary and permanent holding features to control cables and dramatically reduce both components and labor at the seat manufacturer.

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

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.

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.

A metal-to-plastic innovation, which appears in General Motors’ electric GMC Hummer EV, is the two BDUs (battery disconnect units) which have been integrated into a single system supporting two 400-volt systems. It is injection molded by Lear Corp. using BASF’s 25% glass-reinforced nylon 66  Ultramid 66 H2 G25 V0KB1 and hydrolytically-resistant PBT Ultradur B4450G5 HR.

Another first is a patented hybrid battery interconnect board that appears in General Motors’ Chevrolet Corvette E-Ray. Produced by Sun Microstamping Technologies using BASF’s Ultramid B3UG4 nylon 6, it features small and delicate metal current collectors, bus bars and sensing lines in a very compact design to fit in limited packaging space.

This integrated system is said to enable fast and safe recharging of EVs, and disconnects power in an overcurrent situation to protect passengers. The meter-long parts feature a complex design that offers improved thermal management and reduced component mass. The two UL94 V0 halogen-free materials — one, the PBT, with very-high CTI (comparative tracking index, which measures the electrical breakdown of an insulating material) replaced die-cast aluminum while maintaining superior physical properties and ease of processing. Complex simulation and process optimization were also key to success.

The 52nd annual Society of Plastics Engineers (SPE) Automotive Division’s Blue Ribbon Automotive Innovation Awards once again celebrated several “firsts” among eight categories, which included innovations in last year’s added categories of Electric & Autonomous Vehicle Systems and Aftermarket & Limited Edition/Specialty Vehicles, as well as an expanded and renamed Sustainability category. As has been the case for the last several years, thermoplastics and thermoplastic composites led by far in all categories.

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.

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.

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.

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.

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.

GM’s 2024 Chevrolet Corvette E-Ray won the 2023 SPE Automotive’s Innovation Award in the materials category. Photo Credit: SPE Automotive Division

The Safety category award for the 2023 SPE Automotive Innovation Awards went to GMC’s Cadillac Lyriq and Hummer for its intumescent terminal covers. Photo Credit: SPE Automotive Div.

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.

Resin supplier Celanese turned to startup Rafinex and its Möbius software to optimize the design for an engine bracket, ultimately reducing weight by 25% while maintaining mechanical performance and function.

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

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.

Automotive molder ITW Deltar Fasteners found new life for the battered bolt holes on its machine platens with a solution that’s designed to last.

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.

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.

The encapsulating concept was introduced at NPE2015 for a single-cavity model, but the 2024 difference is that there is a higher output “double-cavity processing with precise control of the layer,” explains Andy Stirn, general manager advanced systems. “And that is now applicable for chemically recycled content along with mechanically recycled content.”

The inner and outer layers are made of high-density polyethylene. The advanced recycling material demonstrated on May 6 was provided by LyondellBasell. Shell Polymers provides the virgin HDPE.

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

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.

Dozens of teams made up of OEMs, tier suppliers and polymer producers submit nominations describing their part, system or complete vehicle and why it merits the claim as the ‘year’s most innovative use of plastics.’ The annual event typically draws approximately 700 OEM engineers, automotive and plastics industry executives, and media.

The 2024 Ford Mustang Mach E trunk with a PCR-content TPO won the 2023 SPE Automotive Innovation Award for sustainability. Photo Credit: SPE Automotive Div.

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

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.

The 2024 Ford F-150 Lighting’s injection-molded LFT-PP frunk was the grand winner of the 52nd SPE Automotive’s Innovation Awards. Photo Credit: SPE Automotive Division

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

Yet, another metal-to-plastic innovation is the patented battery module side plate in General Motors’ 2024 electric Chevrolet Corvette E-Ray. Injection molded by the Novares Group using RTP Co.’s RTP-299 K X 138337 black PARA (polyarylamide) material, it results in extremely flat side plates for this battery module. The parts boast high dimensional accuracy, stiffness and strength in a complex geometry.

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

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.

The development supports legislation that sets single-use plastic targets and recycled content goals for brand owners, which stateside is most notably forthcoming CA SB 54.

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

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

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

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

Yet another industry first is a 20% postconsumer-recycle (PCR) content, mold-in-color, Class A structural frunk for Ford Motor’s 2024 Ford Mustang Mach E. It is injection molded by IAC Group using Advanced Composites’ ADX-8327 Recycled Grade TPO, which will also be used in the 2025 model year vehicle. PCR content is sourced from yogurt cups and packaging materials.

Said to be the first ever use of a flame-retardant intumescent flexible PVC as an insulator for thermal runaway mitigation in high-voltage batteries for electrical vehicles, this terminal cover appears in General Motors’ 2023 Cadillac Lyriq and GMC Hummer. Injection molded by Molded Precision Components (MPC) for Tier 1 Auto-Kabel (AK) using Pyrophobic Systems’ Lithium Prevent 200 PVC, it replaces ‘traditional’ plastics (PP/PE/nylon) which melt and burn in thermal runaway conditions.

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

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.

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

Sybridge’s Matt Little and Milacron’s Andy Stirn pause at NPE2024 with the innovative pail and the injection molding system in the background. RICK LINGLE

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.

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.

The 2024 GM Chevy Corvette E-Ray won the Aftermarket & Limited Edition/Specialty Vehicles Award for its hybrid battery interconnect board. Photo Credit: SPE Automotive Division

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