The team has already tested some of their molds at an injection-mold factory near Linz. “The factory employees were surprised at how easy it was to extract the finished objects, as well as how durable the 3D-printed molds were. Even after creating a hundred objects, the molds were still working,” says Auzinger. The team already has further improvements in mind. One idea is the inclusion of connectors that snap together to ease the final assembly of the object.

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

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

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

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.

OUR EXPERIMENTAL SETUP We started with a 12 in.2, 1.5-in.-thick sheet of acrylic and drilled two cooling circuits. One was a 7/16-in. diam. “U” shape and the other a 7/16-in. diam. blind circuit for experiments with baffles and bubblers. All exterior and interior surfaces were polished to be clear as glass, so we could easily observe flow patterns in the circuits.

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.

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 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.

Over the years there has been lots of thought, talk, lab work, and articles written about the topic of coolant flow in molds, heat transfer, turbulence, Reynolds number, and good cooling practices. But what if you could actually observe and study coolant flow in a clear simulated cooling channel? About a year ago, Burger & Brown Engineering Inc. made that happen. This article chronicles the construction, operation, and interesting results from our clear mold.

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.

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

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).

The units of kv and flow are admittedly inconvenient. To make the calculation easier we suggest using our online Turbulent Flow Calculator. Use it for calculating Reynolds numbers or determining flow and temperature conditions required to produce a desired Reynolds number. Simply enter circuit size, coolant temperature, and flow rate or desired Reynolds number. The calculator also allows for solutions of water and ethylene glycol.

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.

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.

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

Molding is a popular method for the mass production of objects. Essentially, two (or more) mold pieces are fit together, leaving the shape of the desired object as a hole. During fabrication, a fluid is introduced into this cavity and is allowed to harden. Once the fluid has solidified, the pieces of the mold are removed, leaving behind the molded object. While the process is fairly simple, creating the mold to produce an object is extremely difficult, and a multitude of considerations go into its creation. How should the object be oriented and divided to ensure that the pieces of the mold can be removed? If the object should be hollow, how should it be decomposed into pieces? Figures with loops or holes add further complications, as do aesthetic considerations, such as avoiding a parting line through a face. In mass fabrication, the high costs of the initial mold design are offset by the low per-unit cost of production. For a small-scale designer, however, or a novice interested in experimenting with injection molds, hiring a professional mold designer is impractical, and creating the molds unaided infeasible. Similarly, 3D-printing the desired number of objects would be far too time- and resource-intensive.

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.

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.

The video shows how the varying flow conditions look, but it is useful to relate the visual experience to cooling results. Accordingly, we designed a new study with a fixed heat input and with Reynolds numbers covering the full range of those in the video. We recorded coolant ∆T and mold temperature for each Reynolds number and then plotted the data, shown in the accompanying chart.

•  We talk a lot about our L-shaped curve of Reynolds number vs. cooling efficiency. It tells us that up to the turbulent transition and perhaps a little beyond, more coolant flow is changing things for the better. But is it also reminding us that going far beyond the transition to turbulent flow results in a diminishing cost-benefit ratio.

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

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.

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.

Burger & Brown Engineering created a clear mold from a 12.5 in2, 1.5-in. thick sheet of acrylic to observe and study coolant flow.

•  Actually seeing the dramatic change in flow behavior as the Reynolds number increases provides a great intuitive grasp of how turbulence improves cooling. Vigorous mixing is the key to quickly moving the heat from the inside wall of the cooling surface into the interior water. Seeing both the video and the data is even better.

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

With this setup we could pump a thin stream of dye right into the center of the pipe in the direction of flow. We believed we would need to match the velocity of the dye trace to the water velocity. This meant we needed a variable-speed pump—a really tiny one! We found a miniature peristaltic pump that we could control with a variable power supply. We used diluted black ink to create the trace.  Our water supply came from city water and we found it necessary to regulate the pressure down to about 15 psi to prevent water from backing up into the dye-pumping system. We controlled the water flow rate with a precision flow regulator. We were now ready to make a test run.

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

1)  The slow, lazy laminar flow is very interesting to watch. At Reynolds 250-450 there is separation and rotating flow induced by the first turn in the cooling channel. This causes a minor disturbance in the flow that moves downstream as its energy is dissipated into the placid laminar flow. You can also see the dye trace dividing as the flow splits and passes some small air bubbles trapped in the passage. Of course, these conditions would not provide good cooling performance. When the flow is laminar it moves as a connected “chunk” of water with little mixing to promote good heat transfer.

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.

Phil Burger, P.E., founded Burger & Brown Engineering, Inc. in 1978 and served as president until 2005. Based in Grandview, Mo., Burger & Brown manufactures products related to mold cooling and in-mold sensing and holds 10 patents. Burger currently works part-time for the firm and has most recently developed an educational program called Scientific Cooling that was launched in October 2013. Contact: (816) 878-6675; pburger44@gmail.com; smartflow-usa.com.

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.

According to the book, Marks’ Standard Handbook for Mechanical Engineers, flow inside a pipe will generally be fully turbulent when the Reynolds number reaches 4000. The completed video shows the interesting progression of coolant behavior from very slow laminar conditions transitioning to well-developed turbulent flow.

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.

Implementing a production monitoring system as the foundation of a ‘smart factory’ is about integrating people with new technology as much as it is about integrating machines and computers. Here are tips from a company that has gone through the process.

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.

Next, consider Reynolds numbers in the range of 2500-4000. Notice that the slope of the graph changes to a nearly horizontal shape. Above 4000, increases in coolant flow rate have a minimal effect on mold temperature. We would consider this a stable cooling process, providing a measure of security.

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

A common technique in liquid flow studies is to inject a dark dye trace into the flow stream. Burger & Brown Engineering built this dye injection pipe and screwed it into the mold inlet, allowing it to pump a thin stream of dye right into the center of the pipe in the direction of the flow.

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

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

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

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

2)  At Reynolds 640-900, the corner circulation and induced downstream turbulence are more pronounced, but the flow leading to the first turn is still totally laminar. The induced turbulence is weak and insufficient to create good cooling performance.

•  Watching the transition to turbulent flow might also give rise to the idea that there is an energy cost associated with pumping water fast enough to achieve turbulence.

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.

This graph has a steep slope in the laminar flow range (Reynolds number 250 to 2500), revealing that a relatively small change in Reynolds number causes a more pronounced change in mold temperature. This range should be considered a potentially unstable cooling process. Increases in coolant flow rate above 4000 have a minimal effect on mold temperature and are considered a stable process.

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.

Assuming a fixed pipe size, the two variables in the Reynolds number calculation are flow rate and viscosity. Water temperature makes a big difference in the viscosity and, thus, the Reynolds number. Surprisingly, kinematic viscosity values for water vary by a factor of 5 between 40 F and 200 F.

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.

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

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.

Next let’s examine the relationship between Reynolds number and coolant ∆T/in. of circuit length. High values of ∆T/in. are associated with low Reynolds numbers and laminar flow. As Reynolds number increases and flow becomes turbulent, the curve bends and flattens out. Values of ∆T/in. decrease dramatically in this transition.

Most of the plastic objects we see are created using injection molding, but designing such molds is a difficult task, usually requiring experts. Now, computer scientists from the Institute of Science and Technology Austria (IST Austria), the University of Tokyo, and CONICET have created an interactive design tool that allows non-experts to create molds for an object of their choice. The software will be presented at this year’s prestigious SIGGRAPH conference, one of IST Austria’s five successful submissions.

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.

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.

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

WHAT IT ALL MEANS First, consider the relationship between Reynolds number and mold temperature shown on the right vertical axis. Note how the graph has a steep slope in the laminar-flow range (Reynolds numbers 250-2500). This means that a relatively small change in Reynolds number causes a more pronounced change in mold temperature. This range should be considered a potentially unstable cooling process. Variations in coolant supply pressure or a slight flow blockage could trigger enough mold-temperature change to cause defective parts.

Years of talk about observing and studying coolant flow in a clear simulated cooling channel finally becomes a reality. Here’s how it all came together, and what it all means.

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.

Driven by brand owner demands and new worldwide legislation, the entire supply chain is working toward the shift to circularity, with some evidence the circular economy has already begun.

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.

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

CoreCavity, a new interactive design tool, solves this problem, and allows users to quickly and easily design molds for creating hollow, free-form objects. Created by Kazutaka Nakashima, a PhD student from the University of Tokyo visiting IST Austria, Thomas Auzinger (IST Austria), Emmanuel Iarussi (CONICET, IST Austria), Ran Zhang (IST Austria), Takeo Igarashi (University of Tokyo), and Bernd Bickel (IST Austria), this software tool opens up opportunities for small businesses and enthusiasts. Given a 3D-scan of an object, the software analyzes the object, and creates a “thin shell”, essentially a hollow version of the object, where particularly small gaps are considered solid–another of the team’s innovations. The software then proposes a decomposition of the object into pieces; each piece will be created by one mold, then joined together at the end. Moreover, the program is able to suggest slight modifications to the original design, for instance to eliminate tiny hooks that might complicate unmolding. “Previous tools were unable to suggest such changes,” says Thomas Auzinger, a postdoc at IST Austria. The user can adjust the decomposition simply by clicking, and choose to accept or reject any proposed modifications. When the user is satisfied, the software automatically produces the mold templates, which can then be 3D-printed and used for molding.

The decompositions suggested by the design tool are often surprising: “The computer is able to find solutions that are very unintuitive,” says Bernd Bickel, professor at IST Austria. “The two halves of the rabbit, for instance, have a curving, complicated connection–it would have been extremely difficult for a human to come up with that.” Industry designers, as well as previous design programs, generally rely on straight cuts through the object. In practice, this often leads to a larger number of pieces, as well as “unnatural” divisions. “The software tool could also be extremely useful in industry–it would fit seamlessly into the production process,” adds Bickel.

Next, we needed to decide what observations to make and how to present them. We decided to record video segments of the flow at several different Reynolds numbers. Also, we wanted to display the Reynolds number for each corresponding flow condition. This meant we needed to accurately measure the water flow rate and temperature for each segment and calculate each Reynolds number. We ended up with nine useable video segments with Reynolds numbers ranging from 250-3970. We organized the segments in increasing order of Reynolds number and edited them into a 3-min. video.

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.

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

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

TEST RUNS Our first attempt at injecting dye and creating a nice trace failed. Our syringe tip was too small, which made the dye velocity so fast that we could only create ink clouds in the flowing water, like from a squid. So we made a second dye-injection pipe with a slightly larger syringe tip to slow the dye injection velocity. This setup worked much better, and with some practice we could match the dye and water speeds and get a nice stream of dye right in the center of the flowing water.

4)  Observing the change from Reynolds 1840 to 3970, one can see the gradual migration of the turbulent water to the walls of the passage, reducing the non-turbulent layer to a thin film inside the channel. This condition provides effective heat transfer and good cooling performance.

The next step was to devise a means of making the flowing water visible. A common technique in liquid flow studies is to inject a dark dye trace into the flow stream. The visible trace makes it easy to observe the flow behavior. We weren’t certain how to get the dye into the flow, but we thought we could use a tiny 90° syringe tip, commonly used for industrial dispensing of adhesives and the like. We built our first dye injection pipe from a 6-in.-long, ¼-in. NPT brass pipe nipple. We drilled a tiny hole in the side, and inserted the syringe tip through the hole, carefully positioning it to be concentric with the pipe. We epoxied the syringe tip to the pipe. The dye injection pipe could then be screwed into the mold inlet.

There has been lots of thought, talk, lab work, and articles written about the topic of coolant flow in molds, heat transfer, turbulence, Reynolds number, and good cooling practices. Now, thanks to Burger & Brown Engineering, you can see it.

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.

Browse the most current issue of R&D World and back issues in an easy to use high quality format. Clip, share and download with the leading R& magazine today.

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.

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In its mold-cooling simulation, Burger & Brown used this miniature peristaltic pump with a variable power supply to match the velocity of the dye trace to the water velocity.

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.

3)  At Reynolds number 1190, the dye trace shows the start of transition to turbulent flow but there remains a sheath of laminar flow around the turbulent center. The laminar layer provides resistance to heat transfer and degrades cooling performance.