Plastic enclosures have many advantages over metal enclosures: They are lighter, more sustainable, cheaper to produce, and have better electrical insulation. In the event of a damaged cell, the battery housing can be exposed to enormous thermal loads if thermal runaway of individual cells occurs. In the worst case, this reaction can spread to adjoining cells, known as thermal propagation. The battery housing has a high safety-relevant function in this case, as it can contain spread of the resulting hot gases and particles. One challenge, however, is proving its safety, which is complex and expensive.

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.

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.

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

Since the first public demonstration at the 2018 National Plastics Expo, Canon Virginia has seen interest in its system grow. “At first, we sometimes see resistance to the idea, as it runs counter to the philosophy most molders work by,” Daniel says. “But shaving a few seconds off of cooling, or even cutting cooling time in half just isn’t as efficient as working straight through the cooling cycle.”

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

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

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.

Every injection molding machine knows cooling time is lost productivity. They spend hours of engineering time and thousands of dollars just to shave a few seconds off a cycle. Unfortunately, improvements to cooling time necessarily bottom out. There is simply no way around the fact that plastic must cool down before it can come out of the mold, and you can only reduce cooling time so much before you run into issues affecting part dimensions and physical properties.

Additionally, the cost savings the Shuttle Mold System provides are exceptional. Compared to the cost of buying two separate machines, including dryers and other auxiliary equipment, purchasing a single machine with the capacity of two provides excellent savings. “You can double your production speed for one part,” Daniel says, “or you can produce two different parts with a single machine. Both options save you a lot of money in the long run.”

The Shuttle Mold system enables users to inject parts in two molds with a single injector, turning cooling time for one part into productive time for another.

Canon Virginia is actively involved in supporting its customers, working with them to develop processes and providing support. “We developed this system to improve the cost and efficiency of producing inkjet printer parts in-house,” Daniel says. “It started out with an end-user focus because we are end users.”

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

Depending on the process, the Shuttle Mold can improve efficiency as much as 200%. “It’s not a fit for every process,” Daniel says, “as it relies on a cooling time long enough to accommodate an additional injection.” Smaller injection molding machines and parts with short cooling times simply do not see as much benefit as parts more suited to the process. “Once you get to 30-second cycle times, the Shuttle Mold can start showing productivity improvements over a single-mold process,” says Daniel. “Once we can effectively double the production over a single mold, we can hit 200% efficiency.”

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.

According to Daniel, injection molding machines are not limited to always using the Shuttle Mold system on machines equipped with it. If, for example, a company needs to run other molds on the machine and does not wish to use the shuttle function, it is perfectly capable of operating as a standard single-mold machine. “It does not hold your machine captive,” he says.

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.

The Shuttle Mold System from Canon Virginia relies on a simple premise: Rather than waiting for the part to cool before beginning a new cycle, the system runs two separate molds in a single press simultaneously. The process begins with the system injecting plastic into the first mold, which the system then unclamps and moves the mold out of position as it shuttles the second mold into place. As the part in the first mold cools outside the machine, the system clamps the second mold into place and injects the plastic into it. Finally, the system unclamps and moves the second mold out of position, bringing the first mold back into place where it can eject its part and restart the cycle.

While the tooling is quite like a standard injection mold, the mold base needs to meet certain conditions to work with the rollers that shuttle the molds into position. “This is not a problem for new molds,” Daniel says, “as this can be incorporated in the tool design. It does mean reworking existing molds, however.” Other modifications are relatively minor such as relocating existing water and electrical connections.

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

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

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

The SiKuBa project aims to develop simulation methodologies for “safe and sustainable plastic-based battery housings.” Image courtesy of Kautex Textron.

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.

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

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

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.

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

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.

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

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.

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.

Farasis Energy, a developer and producer of high-performance lithium-ion battery technology and pouch cells for electromobility, is leading the method development of the simulation model for mapping thermal runaway of individual cells and propagation in the module. The company is also providing support on all battery-related topics within the project. The three-year project started in July 2023.

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.

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.

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.

Fundamental effects are being investigated at the laboratory level, including thermomechanical material behavior and cell degassing. The knowledge gained is being integrated into simulation models and validated by physical tests on a demonstrator housing that closely resembles the planned product. The simulation methods developed not only enable significant time and cost savings during the development phase, but also support comprehensive assessment of battery safety under a variety of load case scenarios, materials, and component 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.

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.

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.

The Shuttle Mold System from Canon Virginia allows a molder to turn cooling time into productive time. The system enables the injector to make parts in a second mold while the part in the first mold cools.

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.

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

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

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

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.

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

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

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

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.

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

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).

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.

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.

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

As you can see here, the two molds used in the Shuttle Mold System do not have to be identical. You can have two molds making the same part, or you can have completely separate parts in production.

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.

While the concept is simple, the engineering that went into making the Shuttle Mold is advanced. “It requires integration with the machine maker, including both the physical shuttle and the software,” Daniel says. “However, it can work with any molding machine that can be easily upgraded.”

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and a proud dachshund owner.

Farasis Energy, together with its partners, will develop a detailed model for simulating thermal runaway or enhance existing models within the company. In future development processes for module and pack projects, the insights gained from the developed simulation model will be utilized to expedite development and save on costly testing. Additionally, these simulation models enable the company to achieve a quicker and safer integration of plastic-based module and pack enclosures.

When cooling times are around 30 seconds, the Shuttle Mold can start showing productivity improvements over a single-mold process. Under the right conditions, Canon Virginia can effectively double the production rate, as this chart shows.

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

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

Faced with this reality, one company decided that instead of making cooling time shorter, it would turn this lost time into production time. To do this, Canon Virginia uses a shuttle system to switch between two molds using a single injection molding machine. Because they can simultaneously mold two parts at the same time, total part cycle time can be dramatically reduced which the available capacity of the molding machine goes up significantly. Here’s how they do it.

According to Canon Virginia Director of Business Development Wayne Daniel, this process came about after Canon started changing how they thought of cooling time. While common practice treats any time spent cooling as time wasted, the company recognized that there were diminishing returns with that approach. “It’s a known fact that molded parts have to have cooling time, whether it’s short or long,” he says. “Instead of reducing it, we asked ourselves how we can utilize it.”

Farasis Energy is part of the research consortium, along with Kautex Textron and the Fraunhofer Institute for High-Speed Dynamics, Ernst-Mach-Institut (EMI). Their efforts are aimed at making plastic-based battery housings safer by means of virtual design and, thus, increasing the safety of electric vehicles (EVs).

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

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.

To this end, Germany’s Federal Ministry for Economic Affairs and Climate Action has invested €2.6 million ($2.8 million) in funding for Project SiKuBa. This research initiative will study formation and propagation of hot gas and particle flows and their interaction with structural elements experimentally as well as via simulation models, which will lead to increased cost- and time-efficiency in the development phase. It will also be possible to assess battery safety regarding load case scenarios, materials, and component design. SiKuBa is an acronym for “safe and sustainable plastic-based battery housings.”

Instead of letting cooling time be wasted time, the Shuttle Mold System from Canon Virginia enables molders to inject a second mold while the part in the first mold cools.