•  Avoid using sub-gates if the molding material is abrasive, or if the cavity is made of a soft metal, such as aluminum or copper. They will wear out quickly.

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.

•  Shortened ejector pins with a conical tip are used to stabilize a runner from shifting or rolling over during ejection, as shown in Fig. 11.

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

​​​​​​​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

•  Consider the location of any runner undercuts. They should be at or near an ejector pin to prevent the runner from bending or cracking during ejection.

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

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.

Approximations of the general parameters of each process are detailed on WayKen.com in the company’s Technology Selection Guide, and a supporting Materials Selection Guide.

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

•  Specify the vent locations, depths and widths on the mold drawing. Do not leave venting up to the toolmaker’s discretion.

Addressing hot-runner benefits, improvements, and everyday issues from the perspective of decades of experience with probably every brand on the market. Part 1 of 2.

Luckily, the company’s quoting system quickly responds to enquiries within 24 hours by our allowing “On-time delivery — every time, no exceptions.” Request a quote from WayKen Rapid online now at WayKen.com.

The question is – which technology should you choose? As a WayKen spokesperson states, “it is very difficult to get a standard answer to the cost comparison between 3D printing and CNC machining.” Instead, technology should be selected based on application.

3D printing services at WayKen are primarily laser-powered, offering a high level of speed and accuracy. WayKen stereolithography (SLA) is a UV based curing process, and selective laser sintering (SLS) uses a carbon dioxide laser.

•  “Breaking” or blending the sharp edges of the runner system will help reduce stress on the material and help prevent the runner from cracking upon ejection. Sharp edges are typically located where the sprue meets the runner, where the cold well meets the runner, where the gate meets the runner, and at every runner intersection.

•  One reason you want all of the parts in a family mold to finish filling at the same time is so they all receive the same amount of packing pressure. If they don’t, you waste material by over-packing some cavities, which makes them heavier. Another reason is that cavities that are under-packed or over-packed will have dimensional issues because they will have a different shrinkage rate than what was used to machine the mold.

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 automotive, WayKen applies a plethora of CNC prototyping and rapid tooling methods to the production of spare parts. The services are useful to car manufacturers running limited trials of a car/motorcycle, and allow volume customization. WayKen automotive rapid prototyping is delivered as a complete service, guiding customers through proof of concept design reviews and mechanical component engineering tests, to show car projects and exterior/interior prototypes.

Established in Hong Kong and located in Shenzhen, WayKen is a contender for China’s most experienced prototype manufacturer. The WayKen Prototype shop operates across two sites, one for plastic and one for metal. In total, the facilities span 20,000 square feet, employing over 60 dedicated personnel. WayKen’s specialist prototyping services include 3D printing (particularly SLA and SLS), CNC milling and rapid tooling technology.As a service bureau operating within high value automotive, medical, and aerospace industries, WayKen Rapid’s expertise is in selecting the right technology for the specific application, and delivering results at a cost competitive with the west.

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

•  For high-volume molds (about 500,000 cycles or more), consider incorporating replaceable gate inserts, especially for abrasive materials.

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

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.

3. In the event of parting-line flash, the runner inserts can be skim ground and shimmed up This eliminates the need to make any other height adjustments to the cavities, interlocks, cams or shutoffs.

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.

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

CNC operation is determined by computer aided design (CAD) or computer aided manufacturing (CAM) data translated into Gcode – as used by 3D printers. The precision tool path in a CNC system creates an excellent surface finish, and parts can be sanded and finished on the same machine.

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.

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

SLS and SLA 3D printing are useful for fast response solutions. With digital operational tools like slicer software, the process does not require as much specialized training as CNC machining. With little labour involved, the manufacturing cost of 3D printing is priced based on the amount of materials. As larger parts cost more 3D printing is advantageous for small volumes and lightweight parts. Realtively simple structures, wth less demand for surface quality and precision parts, also benefit the most from WayKen’s 3D printing services. The technology is ideal for protoyping small medical devices, industrial tooling, and outer covering of electrical tools.

•  The goal in balancing a family mold is to have all of the parts finish filling at the same time—not start to fill at the same time. Keep that in mind when you are making progressive short shots.

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

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

The primary SLA material used by WayKen is an ABS-like photopolymer, suitable for use in the lost-wax method of casting favoured in jewelry making and dental industries. SLS uses powdered Nylon feedstock, which acts like a support material throughout 3D printing, cutting down post-processing times. Parts made using SLS also benefit from the potential of nesting meaning that more designs can be 3D printed within the same build.

•  Some moldmakers and molders do not like to add vents until after the first sampling. This can lead to an erroneous fill pattern. At the very least, add vents at the last place to fill.

•  An edge gate or sub-gate that intentionally feeds a part on an angle is referred to as tangential gate, as shown in Fig. 5. It is often used to prevent core shifting, relocate a weld line, or improve weld strength. However, it can cause jetting inside the cavity.

•  Designing the mold with a separate runner bar or runner block will cost a little more but has multiple benefits—especially for long running molds.

•  If a full-round runner sticks on the cavity side of the mold, instead of using pullers, you can add undercuts on the ejection side. A teardrop-shaped undercut is best for preventing flakes or shavings, as shown in Fig. 12.

•  Sub-gates do not necessarily have to be machined parallel or perpendicular to the runner. They can be machined on almost any angle. This is helpful when gating into a part with a radius or a steep angle, or when you want to shift a weld-line location.

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

•  Some runner layouts can have a heavy mass at branch intersections. These can often be cored out without affecting the material flow or pressure, as shown in Fig. 1.

•  The trick to adjusting a family mold is to adjust the flow rate of the material in the runners feeding each cavity. Changing the gate depth or width only changes the fill speed (mph). It does not change the flow rate (in.3/sec). Changing the gate depth will also create different gate-seal times, which leads to parts having different packing pressures. Therefore, to correctly balance family molds, change the runner diameters to each cavity, as shown in Fig. 7.

•  Adding a short flow restrictor, as shown in Fig. 8, is not as effective as reducing the diameter of the entire runner branch.

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

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.

Performing fundamental maintenance inspections frequently assures press longevity and process stability. Here’s a checklist to help you stay on top of seven key systems.

•  A shortened ejector pin is required for ejecting a runner puller near a sub-gate machined into the cavity side. A good puller design is shown in Fig. 10. Note how the ejector pin has a smaller diameter than the puller and how the puller has a radius and small pad on the bottom. This design will minimize the risk of getting flakes or shavings on the parting line.

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.

4. The inserts can affordably be made of a different material, such as a high-hardness tool steel for abrasive materials, or thermally conductive materials for faster cycles.

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

In some cases, it may even be beneficial to combine both additive and subtractive manufacturing process to complete an end goal. As an example, SLA and SLS could be used as a preliminary stage before moving the CNC machining.

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.

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

Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.

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

WayKen specializes in an ability to machine a range of plastics (opaque and optically clear) and aluminum. In the CNC process, a toolhead gradually subtracts material from a solid block. As such, molecular stability of the base material remains constant producing a part with unparalleled tensile strength.

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.

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.

•   Figure 4 shows two different runner designs. Both runners have sub-gates machined into the injection half of a two-cavity mold. The runner on the left is far superior to the one on the right because:

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.

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.

•  An inexpensive way to delay the ejection of a runner (or a part), without having to incorporate a two-stage ejection system is shown in Fig. 13. The pins are well supported and have positive return. This design can help reduce flaking from sub-gated parts.

•  Always use geometrically (or “naturally”) balanced multi-cavity runner layouts. Multi-cavity molds inherently have balancing issues. Don’t compound the problem with fishbone, ladder, or other types of unbalanced runner designs.

•  Keep in mind what effect the gate location and runner pattern will have on the mold. The gate and runner in Fig. 6 may be a balanced design, but it caused the cavity and core halves of the mold to rotate in opposite directions, resulting in parts that had a core-shift problem.

•  Never machine a runner on a split line of two or more mold inserts. The injection pressure will try to push the components apart, resulting in “down-flash” that could cause the runner to stick.

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

Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.

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

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.

•  Ideally, an ejector pin should be located at each runner intersection, because as the massive runner shrinks, it will try to stick on the inside corners.

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.

•  Add a runner overflow at each runner intersection. This is particularly important for stripper-plate molds when there is no cold well opposite the sprue. The length of the overflow should be 1.0 to 1.5 times the runner diameter or width. Overflows work very well, as shown in Fig. 3.

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.

•  Adding redundant runner sections, as shown in Fig. 9, has only a minor effect on cavity balance. They will also narrow the processing window and increase the amount of runner scrap or regrind.

This month I sifted through four decades of Post-It notes, hand sketches and photographs to uncover a number of worthwhile tips and tricks related to this five-part series on gates, runners and sprues. Therefore, this month’s conclusion to the series will simply be a bullet-point list of helpful information.

•  One clever engineer engraved text on a family-mold runner to help the operators identify similar-looking parts for sorting and assembly, as shown in Fig. 2. Engraving the cavity number on the runner is also helpful when the parts are very small or the aesthetic requirements do not allow a cavity number on the part.

The competitive price point for all services, according to the company’s website, is “normally 30%-50% less than the US/European prices, due to lower labor costs. Moreover allowing a quick project start compares to other rapid prototype companies.”

“Traditional” processes at WayKen cover CNC plastic/metal parts machining, vacuum injection molding and rapid injection molding. In the case of CNC machining, a solid block of raw material can be used.

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 rapid production time of 3D printing means it is finding increased uses throughout the medical industry. WayKen SLA & SLS 3D printing for medicine can be used to make hand held appliances, concept models, and new devices in low volume, e.g. diagnostic equipment, surgical instruments, electronic apparatus and ultrasonic systems. These devices are valuable for surgical planning, simulation and also to map dental correction procedures.

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.

One of the main advantages of this process is material availability as virtually any material can be CNC machined. For this reason, and its use in industry since the 1940s, CNC machining remains the most common means of prototyping to date

As far as resolution is concerned, the accuracy of CNC machining at WayKen is typically higher than 3D printing, between 0.02mm and 0.05mm – 0.10mm depending on geometry. Turnaround time for 3D printing is typically faster at just 2-5 days versus 3 – 8 days for CNC. This does however come at a tradeoff with the volume of products than can be produced. A typical SLA/SLS run can create 1 – 10 parts, whereas CNC has a range of 1 – 50.

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

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.

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

Start by picking a target melt temperature, and double-check data sheets for the resin supplier’s recommendations. Now for the rest...

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).

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.

•  If you want to increase the size of the gates, runner or sprue by some percentage, you need to run the numbers. For example, if you feel a 0.050-in. gate should be about 20% larger, don’t multiply the gate size by 1.2 and get 0.060 in. That’s not 20% larger. In terms of flow area, that’s 44% larger. An easy and correct way to determine the new gate is size is to use the following formula: DNEW = DEXISTING × √ (1 + percentage increase). In this case, it would be 0.050 × √ 1.2 = 0.055.

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.

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

CNC machined parts at WayKen on the other hand can be used to make functional prototypes which are suitable for engineering evaluation and testing. In contrast to the SLA and SLS services offered, CNC machining requires specially trained engineers to pre-program the processing parameters and toolpaths, then machine according to the programs. Manufacturing costs are therefore quoted taking the extra labor into account. CNC’s advantage is for machining parts with special requirements such as dimensional tolerances and surface qualities.

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.

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.