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

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

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.

Open house at 116,000-square-foot applications center in Moncks Corner, SC, featured more than 100 electric and servo-hydraulic plastic injection molding systems.

Absolute Haitian held an open house and luncheon September 28 for customers and industry members at its 116,000-square-foot applications center in Moncks Corner, SC, which opened in 2019. The event gave industry professionals the opportunity to view new technology, product introductions and more than 100 electric and servo-hydraulic stock machines and large-tonnage subassemblies ready for quick delivery.

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

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

Treated like a clean room, Allegheny ultrasonically cleans, packs and ships parts, which can have no contamination. The final element of this room is dubbed the “supermarket.” Racks hold labeled blue bins full of parts that require some additional processing, typically machining, that workers pull from and refill based on a kanban system to track work in progress.

In satellites, in jets, in automotive transmissions — the parts that Allegheny Performance Plastics molds for the roads, skies and outer space operate at the boundary of the harshest environments that plastics can inhabit. The list of materials that can survive in these environs is short, as is the list of molders that can successfully run them.  Allegheny gladly, intentionally calls this rarefied air home. “We don’t like easy; we want difficult,” explains Robert Stutzman, Allegheny CEO. “We want something no one else does.”

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.

Using high-temperature materials means that Allegheny runs oil through the molds instead of water, with longer cycles required and more expansion and contraction of the molds over time, demanding vigilance in preventive maintenance. How hot do these resins run? As we pass a hot runner temperature control unit in front of a press, the display’s set point reads 750°F.

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.

Drones and unmanned aerial vehicles (UAV) are approaching an inflection point where their production volumes — and functionality — will increasingly point to injection molding.

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.

As an example, Allegheny points to a thrust washer it molds from Torlon that’s part of a hydrodynamic bearing for automotive transmissions. This part replaced a metal roller bearing and, to date, the company has made more than 100 million polymer thrust washers. In addition to lower weight and more design freedom (including possible part integration), polymers in applications like this offer lower NVH (noise vibration harshness) than metals, while resistance wise, the coefficient of friction is the same. In terms of wear, Allegheny says that, with proper hydrodynamic lift, polymers can provide unbeatable durability.

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.

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

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

Running three shifts, Monday to Friday, with the occasional Saturday, Allegheny has roughly 50 employees, with the goal to be at 57 by the end of the year. Thanks to automation and process monitoring, Stutzman notes that in Team #2, two  employees can keep tabs on 19 machines. All the workers on the floor are cross trained such that they can take on all the production roles: mold setup, process technician, inspection and more.

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.

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

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.

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.

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

Allegheny also recently converted a used piece of equipment into a friction and wear test stand, enabling it to perform lubricated and dry tribology testing. These capabilities and Allegheny’s extensive research database make it a sought-after partner of resin suppliers as they test new materials and applications. Its collaborations with Solvay over the years on the processing and functionality of Torlon have helped create best manufacturing practices for the specialized material.

With it acquisition of DuPont’s engineering resins, Celanese’s resin solutions for automotive electrification, e-mobility and consumer electronics are plentiful.

The Polimotor 2 all-plastic engine project for competitive auto racing is moving right along with Solvay's materials playing a key role.

Since Stutzman’s hiring, Allegheny has added a network of 17 external sales agents, and laid out a 5-year plan with four key pillars: people, where/how will the company grow, operational excellence and continuous improvement. To support this plan, the company is seeking to update its ERP program, and add other operations and manufacturing software, including MES, this year.

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.

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

In the eight months he’s been on the job, Stutzman walks the floor every day, and virtually every day he has seen a new part in production as the company maintains several  hundred active molds. When Plastics Technology visited, the manufacturing floor — which features 30 injection molding machines (mostly Nissei, ranging from 20 to 500 tons), seven CNC machining work cells for post-mold processing, and 40 ovens for post-curing parts molded from Solvay’s Torlon PAI resin — was humming with production of an array of parts. Seal rings; a satellite bound insert- and over-molded part; nylon gears and brake pistons; an Ultem transmission component; and an elastomer pad whose surface texture, imparted by the mold, imitates the grip of a gecko’s feet, were among just a few of the jobs in production.

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

Allegheny’s expertise in high-temperature materials has placed it at the forefront of metal-to-plastic conversion in the automotive and aerospace industries. Shoup — who’s been with Allegheny for 28 years, including the last 18 in the Performance Plastics molding division — has seen these plastics wins firsthand, and the impact they’ve had on Allegheny’s portfolio, with the 2009 recession and subsequent “transmission wars” in auto as an inflection point. Shoup estimates that, prior to the recession, Allegheny’s business broke 70/30 aerospace to automotive, while today those figures are flipped, as both markets grew overall with auto outpacing aero.

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.

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.

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

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.

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

Allegheny’s expertise in high-temperature materials has placed it at the forefront of metal-to-plastic conversion in the automotive and aerospace industries.

Haitian Die Casting was established in 2016 and has quickly become of the largest suppliers of die-casting machines in the world. Haitian Die Casting offers standard machines sizes from 180 to 4,500 tons and is one of the few suppliers in the world with the manufacturing capability for die casting machines up to 9,000 tons.  On display was an HDC550 with tonnage of 618 tons/560 tonnes.

Study shows the plastic compounding process is being used to boost electrical properties and UV resistance while custom compounding is increasingly being used to achieve high-performance in plastic-based goods.

BlueHalo’s Intense Eye UAS has replaced a machined aerospace-grade aluminum chassis with one molded from Alpine Advanced Materials’ HX5 multi-scale reinforced polymer for a stronger, lighter craft.

On display were three operating injection molding machine cells and a static display of the electric Zeres III molding machine equipped with Haitian’s Medical Package introduced at K 2022. Injection molding machine cells in operation included:

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.

Stutzman notes that on the floor and throughout the company, there is a culture of genuine teamwork, with no cliques. Over his 25-plus years in molding, he says he’s managed other production floors that operated socially more like a high school, making him feel like the principal.

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.

Eliminating the need to contact each supplier for every individual quote, a new CRM for automotive supplier Axiom Group tracks past quotes as well as industry history to generate fast, reliable RFQs and more.

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.

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

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

The Haitian Group introduced their Haitian Precision and Haitian Die Casting product lines to US and Canadian markets at the open house. Both business units’ products are now sold in Asia, Europe, Mexico, and South America. Distribution in the US and Canada will be handled by the Absolute Group with full-scale distribution in 2024.

Allegheny Performance Plastics CEO Robert Stutzman and CTO Greg Shoup on the company’s molding floor, which applies lean and scientific molding principles. Photos: Allegheny Performance Plastics

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.

Allegheny Performance Plastics specializes in molding parts from high-temperature resins for demanding applications as part of its mission to take on jobs ‘no one else does.’

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

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.

Haitian Precision was established in 2002 and offers a wide range of CNC machinery including vertical and horizontal machining centers, lathes, and dual-column machining centers. A preview of the new Haitian Precision product line at the open house included a TC25 II CNC lathe and a VMC850 II vertical machining center. Four vertical machining centers are currently in stock in South Carolina.

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.

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

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).

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.

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.

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

Mars III servo-hydraulic molding machine – MA 6500 / 6300h (730 U.S. tons) running a two-cavity flowerpot mold; cycle time of 18 seconds

“We’re at the point now in our business that we need to be able to have some things integrated,” Stutzman says. “Not just ERP and MRP to handle our purchasing — we’re tight on space so we don’t want to have a warehouse full of stuff — but an MES system. I want data off the manufacturing floor and I want it all tied together. The business is going to grow and for us to maintain what we have — our performance financially but also for our customers — we can’t get bogged down doing stuff manually.”

Zeres III electric molding machine – ZE 1500 / 210 III (169 U.S. tons) running a 4-cavity, thin-wall cup mold; cycle time of 10 seconds

“The key is that we can’t be everything to everyone,” Stutzman says. “So you focus on a certain type of material offering. The reason being that if you mold PP and PE, thousands of people in the country can do that. You use a commodity material, and you’re one of many — you become a commodity yourself.”

Attendees heard from industry experts in a series of quick-hitting “Tech Talks” geared towards providing high-value takeaways. Presenters included:

Established in 1936, Allegheny Plastics Inc.’s initial focus was using plastics to print and laminate reusable charts. Based in Leetsdale, Penn., the Allegheny Performance Plastics division has been in injection molding since the 1960s. In 2016, Allegheny executives Greg Shoup and Shevey Westbrook, with the backing of two investment firms, completed a management buyout of the molding unit. Shoup and Westbrook remain at Allegheny, serving as chief technology officer and director of operations, respectively, with Stutzman hired on in October 2022 to act as CEO.

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.

One common means for organizing polymers that’s familiar to those in the industry is the “plastics pyramid.” From a large base of commodity resins, the pyramid builds upward, getting smaller as it goes with engineering plastics in the middle and high-temperature plastics — those with melt temperatures typically above 300°C (572°F) — occupying the smallest space at the pinnacle. Within this capstone, you find resins like PEEK, PEI, PPS, PI, PBI and PAI with familiar trade names such as Ultem, Ryton and Torlon. For these materials, Allegheny offers its customers assistance in selection, design optimization, sample production/testing and cost-competitive production.

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

“We developed experience in these high-temperature materials,” Stutzman says, “and aerospace presented the opportunity. Then in the ‘90s, automotive started to embrace polymers, especially in these critical wear opportunities. That business was slightly different — same materials and same technical challenges, but the scale was different.”

All that those capabilities and in-house expertise are also reflected in Allegheny’s approach to new product and process development. “I use the phrase ‘geek out,’” Stutzman says. “There’s a technology there that created the excitement — the impetus to want to do something different — that’s really sort of the catalyst that drives (geeking out).”

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.

Allegheny is IATF 1649, AS9100, ISO 9001 and ITAR (International Traffic in Arms Regulation) certified, in addition to earning Supplier Gold and Quality Clinic accreditation from United Technologies Corp. Aerospace Systems. These acknowledgments of capabilities will help lead the company’s next stage of growth as it pursues and wins jobs in electric vehicle charging, drones, UAVs and advanced missile systems. The company estimates that it currently has nearly 50,000 molded parts in space, with the number growing all the time.

That inspection also happens on the floor simultaneous to production. In the middle of the molding cells, an inspection station (including a CMM), moisture analysis and more, resides. “It’s more about quality assurance than quality control,” Stutzman says. A lean manufacturing concept, this cell ensures good parts as they’re molded. Allegheny also operates a full quality control lab in a climate-controlled space off the molding floor.

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.

Allegheny has invested in testing technologies to fully vet these materials and applications, including adding a differential scanning calorimetry (DSC) unit. Used in troubleshooting, the DSC can determine if a resin is contaminated or not what the supplier said it was. In particular, the DSC can be used to determine the polymer’s crystallization, melt and glass-transition temperatures.

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

Based in Worcester, MA, Absolute Haitian is the exclusive sales and service partner in the US and Canada for Ningbo Haitian Machinery Co., Ltd. based in Ningbo, China. Ningbo Haitian Machinery Co., Ltd. is the world’s largest supplier of plastics injection molding machinery, shipping an average of 43,000 machines each year. Haitian products are sold in more than 130 countries with machine sizes ranging from 44 to 7,425 tons of clamp force.

Adjacent to the molding floor, Allegheny operates a full tool room with a handful of in-house mold builds each year. The molds that do come in, don’t leave, Stutzman says, with all the maintenance and tuning handled internally. In addition to three full-time toolmakers, the toolroom has an employee focused on preventive maintenance, with two younger employees — including an apprentice and a college student studying mechanical engineering — as Allegheny builds a bridge to the next generation of moldmakers.

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.

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 manufacturing floor is divided into three “teams,” with all 19 presses in Team #2 utilizing RJG’s eDART process monitoring technology, with molds featuring temperature and pressure sensors. This team focuses on high-volume jobs, while Team #3 targets low-volume/high-mix jobs. Team #1 handles lower volume aerospace work. The Haas CNC machining centers are utilized to machine in part features post injection, where molding them in would have required more expensive tooling with longer lead times.

When Stutzman was recruited to lead Allegheny, that curiosity and drive to try something new lent the company a highly appealing atmosphere. “There was this vibe to just get stuff done, move forward,” Stutzman says. “There was excitement, and it wasn’t like, ‘Oh my god, we won this job, and now we have to do it.’ There was this infectious desire to want to move forward.”

Allegheny’s toolroom has the capability to build new tools and maintain existing molds. Photo Credit: Allegheny Performance Plastics

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.

Jupiter III servo-hydraulic, two-platen molding machine – JU 5500 / 4630 (618 U.S. tons) running a thick-wall electrical junction box mold

Just off the plastics machining area, Allegheny houses its “skunk works,” a space for experimentation as well as validation. All new projects are scaled up here, ensuring a repeatable process is introduced to the molding floor once a tool goes into production. The company houses a polymer 3D printer here. For the materials and markets Allegheny works in, Stutzman says 3D printing for production isn’t currently viable, but it does use the machine to trial test fixtures, for instance, before creating final designs. This room also houses certified secondary cleaning processes for parts destined for outer space.

Working in collaboration with Solvay and Alpine Advanced Materials, Allegheny developed this test application dubbed TPC-IOM (thermoplastic composite injection overmolding) combining composite tape materials with an injection molded backing.