“It’s nice to be thinking about how we grow and expand, instead of how we survive,” Stacey said. “It’s comforting to know we were able to pick up the ball from Dad and keep it moving.”

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

Other challenges are those more typical to any similar business, such as workforce development. “A big challenge is finding the perfect recipe to attract and keep employees,” said Stacey. “There’s no metal plating school, so there’s no pool of experienced people to choose from. Even through the pandemic, it’s been hard to pull people in.”

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.

What were you doing in your mid- to late twenties? It may have been challenging, whatever it was–but it probably wasn’t as challenging as mourning an unexpected and devastating personal loss while simultaneously trying to keep a family business alive, like the Bales sisters did.

“As companies increase cavitation, balance decreases and part quality, dimensional stability, and repeatability degrade,” Alexander says. Because of this limitation, he adds, medical molders often are not running at optimal cavitation, from a business perspective. At a certain level of market demand, a 32-cavity mold might make the most sense, Alexander explains, but the best parts can only run on eight-cavity tools, so a molder might have to use multiple eight-cavity molds.

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

In 1999, Mike Bales retired. Things moved along smoothly in the early 2000s, with the company adding proprietary metal coatings to their offerings, and purchasing land adjacent to the Downers Grove shop for expansion. In 2009, the company had some struggles from the added debt burden combined with the difficulties so many businesses experienced from the recession. Still, any concerns were lessened by having Steve still at the helm. “My dad was 53, so we figured he’d be around for another 20 years,” said Stacey.

It was, and still is, a family business. “For me, that was the best part,” said Stacey Bales, one of Steve’s two daughters, along with her younger sister Sara Mortensen. “We grew up in a house about a mile from the shop, and we stopped in all the time. Dad would show us things like how you could sandblast glass to get frosted glass. When I was 13, I started working there, cleaning the offices. Eventually I got a full-time job and never left–I worked as a receptionist and in shipping and sales, then as Office Manager and eventually CFO.” Sara started by cleaning the offices as well, and was similarly exposed to the business, working with accounts and legal.

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.

“In 2007, Dad purchased the last house next door to the plant, and completed an expansion right before he passed away,” Stacey added. “Now we’ve been the owners for eleven years, and we’re moving forward with new, larger plating lines to expand capacity.”

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.

Among multiple advantages, Alexander says one of the biggest is the overall impact on pressure. In a standard press, a molder might set the pressure to 35,000 psi in front of screw, but once the melt travels through the nozzle, sprue, manifold and hot runner, pressure loss can be up to 50%.

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.

They did anything but. Stacey stepped in as President and Sara as Vice President of Sales and Marketing, and they got to work. “A nice thing about our industry, since we focus on plastic injection molding, is that it’s very diversified–plastic is in everything. So sales stay consistent.” That gave them time to grow into their roles. “I was thrust into the young leaders’ community,” said Stacey. “We’re part of industry groups like the Technology & Manufacturers Association and the National Association of Surface Finishing. Those were helpful in being able to network with, and be friends with, other business owners, especially in family businesses.”

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

In another example, Alexander says one of the UltraShot systems Husky currently has in the field is for a medical catheter—a two-component device composed of a long tube made from a harder material, with a soft tip at the end. Normally, such an application would be created in a multi-step process where tube is extruded and cut; the tip is injection molded; and then the two are joined together. With the UltraShot, Husky was able to combine all those steps into one machine, merging molding and assembly into one work cell.

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

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

As the original melt-delivery system, cold runners still have their place in injection molding, but when demand for a plastic part—and required production—rise, the move to a hot runner can unlock myriad benefits.

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.

Husky says its new UltraShot injection system miniaturizes the shooting-pot concept of a traditional two-stage injection system—putting it within the mold—to create proximity to the gate that all but eliminates pressure drop.

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

They’ve focused on progressing in other ways as well. “I think from a different perspective, we made a big change in 2015,” Sara said. “We rebranded and unveiled a new logo. It honors the past, but also made a significant visual change. It’s another piece of us really owning the business.” The company name was shortened to Bales, and the rebranding included a new website and customer communication strategy as well.

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.

In 1978, Steve and Mike Bales founded a company called Bales Mold Service in Lombard, Illinois. They actually started out in Mike’s garage, before eventually buying land and building a factory in Downers Grove, just outside Chicago. The company originally provided metal polishing services to plastic injection molding companies around the region to help maintain the molds those manufacturers used to produce finished parts. The company grew rapidly, adding welding, stainless steel passivation, and chrome, nickel and composite coating services to their offerings. In 2001, the Bales brothers added a second location in Harlingen, Texas, near the Mexican border.

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

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).

Five industry pros with more than 200 years of combined molding experience provide step-by-step best practices on mounting a mold in a horizontal injection molding machine.

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 catheter application is a particularly apt example of UltraShot’s potential, according to Alexander. Typically in the medical field, new applications are ramped up slowly. A new device might be initially molded from a four-cavity prototype mold, moving up to eight, 12, 16 cavities or more, as it gains market acceptance. As molders boost cavitation, they often struggle to maintain quality.

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

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.

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

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

Another possible use would be in a family mold where the individual parts are very different in geometry and filling pattern. “Since we’re essentially using mini injection units, you can add many as you like,” Alexander says. For a 16-cavity family mold with four different parts, UltraShot would provide four individual internal injection units with independent control.

Simply stepping into leadership roles was a challenge. “We grew up here,” said Sara. “Some employees had watched us grow up. Now we were trying to run meetings, and tell people what to do.”

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.

He says Husky is most excited about the design freedom UltraShot can bring to molders, shifting away from today’s dynamic where the process dictates the part. “We’re at a point in the industry where part designers are more concerned with whether or not a part can be molded rather than the best design for the functionality of the part.” UltraShot, says Alexander, frees the designer from this limitation.

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

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

When determining the best ejection option for a tool, molders must consider the ejector’s surface area, location and style.

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.

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.

“We can mold parts that were considered unmoldable,” Alexander says. “Whether it’s from an L/T standpoint, part complexity, heat-sensitive resins, shear-sensitive resins, or from a cavitation standpoint.”

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.

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

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

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

Continuing to develop the right products and services remains a priority. “Sara has stayed close to our customers, and really understands what their challenges are,” Stacey explained. “We focus on helping them resolve their problems. Regulatory challenges also drive things–there’s a stigma around chrome plating, for example, so we’re offering alternatives.”

The new UltraShot technology from Husky is described as a completely standalone technology that is independent of the mold and the machine.  UltraShot incorporates a series of small injection plungers in close proximity to one or a group of hot-runner valve-gate nozzles. According to Sheldon Alexander, business support manager for hot runners and controllers, this technology simplifies the role of the molding machine’s injection unit, limiting it to melting and metering resin and then handing off to the UltraShot, which builds pressure as close to the gate as possible and injects with more precision, higher pressure and greater repeatability, according to Alexander.

“With UltraShot technology, whatever quality results you get from a four-cavity mold,” states Alexander, “we can scale up in multiples of four and give the customer confidence that the quality will be on same as they ramp up to 16, 32 or more cavities.”

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.

By better controlling injection pressure and moving it closer to the gate, Husky’s UltraShot injection system achieves greater L/T flow ratios for shear- and temperature-sensitive resins.

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

Husky’s UltraShot moves plasticated resin as close as possible to the gate so that resin can be held under lower pressures and temperatures prior to injection through adjacent valve gates, preserving the material’s properties.

Alexander notes that two areas where the UltraShot really shines are in molding resins that are shear and temperature sensitive and in molding small parts below 10 g that require precision injection control.

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.

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

With the UltraShot moving the prepared resin as close as possible to the gate, the resin can be held under lower pressure and temperature prior to injection, preserving the material’s properties. “That gives you more control and better melt quality,” Alexander says. “You get control as close as possible to the gate.” By doing so, any issues with melt compressibility and shear generation are minimized, if not completely eliminated, according to Husky.

There were two things that worked in their favor, though: their commitment to the people and their past experience. “We don’t know everything, and we don’t act like we do,” said Stacey. “We weren’t bossing people around. We really wanted their help.”

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

In 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.

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.

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.

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

In November of that year, however, tragedy struck. Steve Bales passed away suddenly. The sisters were faced with the incredible challenge of dealing with their own grief while jumping in to lead their dad’s company. “Dad didn’t leave a succession plan, and we had other family members working here,” Stacey explained. “Initially we didn’t know who should take over. Emotionally, that was my biggest struggle.”

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.

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.

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

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.

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

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.

“What we’ve done,” Alexander says, “is take the shooting-pot idea, miniaturize it, and put it into UltraShot system.” UltraShot effectively replaces the injection unit from the standpoint of delivering melt into the cavities. “The injection unit is simply a way to melt and meter the resin and hand it off to us,” Alexander explains, adding that there are no special requirements from machine, like a high-performance injection unit. “We actually take control of the injection unit and turn it essentially into an extruder,” Alexander says.

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

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.

UltraShot adapts the concept of two-stage injection, which splits the functions of the injection unit—melting/metering resin and injecting it into the mold—into two steps. In conventional two-stage injection, melted resin is metered into a plunger or shooting pot, which then injects material into 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.

That’s not to say it was all easy. Not everyone believed the sisters could pull it off. One of the company’s bankers in particular not only didn’t offer any condolences, but wanted to know how quickly the sisters would liquidate the company and pay off his loan.

“I’d already had experience with the bankers and the customers,” added Stacey. “That made the transition go easier.” Sara agreed. “It was helpful when it all hit the fan, and comforting to know we had access to the books and all. And we got lucky–nobody left.”

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.