German chemicals company Evonik and Swiss plastics processor Samaplast have collaborated in the development of an osteo-conductive PEEK-based material compatible with injection molding. Spinal implant prototypes have been molded to illustrate the processing properties of the new high-performance polymer, VESTAKEEP Fusion.

Machined contacts can reduce the occurrence of pin-push out and are more durable than stamped or formed contacts. Since machined contacts are solid, they provide improved electrical characteristics due to greater contact surface and tend to stay fixed in the connector more reliably. Female machined contacts have more “wall” material than stamped or formed contacts. This improves pin holding forces between male and female contacts. They can also withstand greater amounts of abuse. Additional benefits of machined contacts are:

Pin burn-out is a catastrophic connector failure caused by current overload or a short circuit. Using a 10-amp connector for a 15A circuit is a major contributing factor. The typical 25-pin crimp connector used in hot-runner power cable assemblies is rated for 10A.

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.

Thanks to the design freedom afforded by injection molding, VESTAKEEP Fusion–based cages can be tailored to patient-specific anatomies and different surgical techniques. The cage models show the design diversity in the interlocks and in the cavities for ossification. In addition, the design facilitates instrument guidance during surgery and enables minimally invasive, patient-friendly surgical techniques.

Other causes include cable failures, broken pins, and pin push-out. Reducing costs associated with pin burn-out is simple: Use UL-listed connectors and cables rated for at least 15 amps.

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

To demonstrate the medical potential of the technology, Evonik and Samaplast have produced prototypes of intervertebral implants, known as cages or spacers, which are used to fill the disc space in the spine following its removal due to disc degeneration. "We have produced a cage that contains all the details, such as serrations, threads, and apertures, that are relevant for spinal implants," explained Okle.

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

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

Jacket materials on hot-runner cables can be degraded by chemicals, heat, ozone, and UV exposure. Make sure that you select the appropriate jacket material for your manufacturing environment. Two common jacket materials are PVC and TPE.

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.

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

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

Here’s a view from the trenches of a tooling manager who, over 30 years, has experienced the joys and pains of using virtually every type of hot runner on the market. Part 2.

Failures on the production floor are simple to understand. Uncovering their root causes and  solutions takes a bit more research and insight into cable assembly construction and use over their life cycles. Common failure modes and remedies are summarized below. In reviewing them, keep in mind the following key principles:

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

Excessive mechanical loading and improper strain-relief selection are the primary causes of cable pull-out, allowing the cable to work itself out of the backside of the connector. This increases the likelihood of cable failure, pin push-out, and short circuits. Some contributing factors are:

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

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.

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.

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).

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.

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

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

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

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

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.

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

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.

Lastly, standardize on screw terminal connectors or upgrade to overmolded cable assemblies. These “encapsulate” or “capture” the pins so push-out is not possible. Broken pins can be drastically reduced. The 24-pin screw-terminal connector used on hot-runner thermocouple cable assemblies is an excellent example. By adding “coding pins,” it is possible to standardize on this connector for power and thermocouple cable assemblies.

Until now, it has been virtually impossible to manufacture implants from polymer compounds with bioactive particles by injection molding, because a thin polymer layer usually forms on the surface, preventing the implant from growing in, explained Evonik in a press release. VESTAKEEP Fusion's specially configured microparticles and their homogeneous distribution, however, allow the formation of functional biphasic calcium phosphate (BCP) additives on the surface of injection-molded components. The additives allow bone cells to adhere to the implant more quickly and promote osteo-integration between the bone and implant.

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.

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

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

Mechanical damage can be a more difficult issue. Connectors get dropped, caught in the tools, run over by forklifts, and subjected to other abuses. Broken latches, damaged latch “bails,” cracked or smashed hoods, and broken mounts are just a few examples of connector damage found on plastic injection presses.

Flex-rated cable, such as the Alpha XM Series (Flex Control) or Alpha F Series (Continuous Flex) from Alpha Wire & Cable, Elizabeth, N.J. (alphawire.com), reduce failures caused by repeated flexing. Running individual wires through a flex-rated conduit also reduces failures. Flexible power cable solutions are fairly simple. Flexible thermocouple cable solutions are more challenging. Sourcing flex-rated thermocouple wire and cable can be difficult and costly. Typical thermocouple wire uses a solid conductor, which does not accommodate flexing and will fail. Thermocouple cable assemblies should use stranded thermocouple cable or single-pair stranded thermocouple wire in flex-rated conduit. The reduced failure rates will offset the added cost.

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

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

Pin push-out decreases or eliminates contact with the mating pin. The simplest solution is to use high-quality components from a respected manufacturer, and avoid mixing brands unless you have verified that there are no tolerance issues.

Initially offered in granule form and as semi-finished products, VESTAKEEP Fusion can be milled, compression molded, extruded, and injection molded, said Evonik. The compound was optimized for injection molding in close cooperation with Samaplast AG.

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.

The simplest solution to reduce or eliminate pin push-out or breakage is to use high-quality components from a respected manufacturer. Avoid using multiple brands of connectors unless you have verified that there are no tolerance issues.

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

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

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

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.

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

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.

Evonik is also developing a 3D-printable VESTAKEEP Fusion filament that can be processed via additive manufacturing using fused filament fabrication technology.

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.

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

With VESTAKEEP Fusion, Evonik is introducing a new product line of next-generation PEEK-based implant materials that accelerate bone fusion and convalescence. In vitro studies document a more than 30% increase in cell attachment and cell proliferation, according to Evonik. In preclinical tests, histological examination reveals a dense network of newly formed osteoblasts at the bone-implant interface. Bone histo-morphometry shows an approximately twofold increase in bone apposition. Moreover, pull-out tests demonstrate a more than twofold increase in implant fixation, said the company.

"We tested VESTAKEEP Fusion on injection molding machines in the cleanroom and found that it was very easy to process," said Samaplast CEO Stefan Okle in a prepared statement. "Thanks to the excellent exchange with Evonik, we were able to produce a prototype within 10 days." Previously, tool development alone had taken eight to 10 weeks. With rapid prototyping, this process can be shortened considerably.

In the challenging environment of the last several years, manufacturers are looking inward to improve their manufacturing processes, streamline their supply chains, lower maintenance costs, and improve their bottom lines. Injection molders are frustrated with the costs associated with failing power and thermocouple cable assemblies in hot-runner systems. These costs include tool or controller damage, cable repair or replacement, loss of production, strained customer relations, overtime expenses, and much more.

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.

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.

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.

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.

"Implant manufacturers were missing a PEEK material that fuses with bone cells and, thus, accelerates healing," said Marc Knebel, Head of the Medical Systems Market Segment at Evonik. "We are closing this gap in the market with VESTAKEEP Fusion and offering an alternative to titanium, stainless steel, or cobalt-chromium implants."

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.

In the challenging environment of the last several years, manufacturers are looking inward to improve their manufacturing processes, streamline their supply chains, lower maintenance costs, andimprove their bottom lines.

Proper wire sizing is the most effective way to minimize costs associated with short circuits or burnt-up cables. Do not use a connector rated for 10A for a 15A application. Cables intended for 15A should be 16 Awg or more depending on the cable length.

A collaboration between show organizer PLASTICS, recycler CPR and size reduction experts WEIMA and Conair recovered and recycled all production scrap at NPE2024.

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.

Cable failure is costly. The most effective way to avoid it is proper wire sizing and using flex-rated cables and conduit, where appropriate.

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.

Connector misalignment can cause pin push-outs and breakage. Guide pins and bushings are very inexpensive, easy to install, and reduce the chances of connector misalignment. Guide pins simply replace the connector-insert mounting screws.

After field testing, validation and refinement with customer feedback, Husky announced the introduction of a cold-deck system for direct gate molding of LSR.

Latches are damaged by excessive physical loading on the latch while it is plugged in, by being latched while there is a misalignment issue, or by random physical abuse. Switching from top-entry (straight) to side-entry (90°) hoods may help reduce mechanical loading on the latch assemblies. This may not be possible in all cases, due to physical constraints of the system. Most standard  hoods and housings come in both single-lever and dual-lever designs. Dual-lever designs distribute the physical load better. Guide pins and bushings also can be installed to prevent connector misalignment.

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.

Proper strain-relief design is the solution. Select cable glands based on the cable OD and installation environment to ensure a tight fit and to maximize holding force. Do not use plastic  compression nuts. These can loosen due to thermal expansion and contraction, vibration, or gland-nut failure. Plastic strain-relief nuts will degrade over time from exposure to heat, ozone, or UV light and should therefore be checked often. Metal strain-relief nuts can be tightened more securely than plastic and will not degrade over time.

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.

A collaboration between Evonik and Swiss plastics processor Samaplast results in an alternative to titanium, stainless steel, and cobalt-chromium implants.

Power and thermocouple assemblies come in a variety of configurations, many of which are based on rectangular connectors similar to those made by Harting, Inc., Elgin, Ill. (hartingusa.com). Unfortunately, in many cases components from different suppliers are mixed and matched in the same assembly and/or application. This contributes to increased failure rates. Key factors are connector manufacturing quality, design tolerances, cable types, cable gauges and strain-relief selection. To minimize this, you need properly sized, UL-listed connector and cable components.

Jody Williquette is national business development manager for Electrivert, Inc., Fraser Mich., a leading producer of industrial control panels and cable assemblies. Williquette has more than 21 years’ experience in plastics injection molding equipment, material-handling systems, automated assembly lines, and quality inspection stations. Besides two years with Electrivert, his career includes five years with connector manufacturer Harting Inc., and 11 years with Omron Electronics. Contact: (586) 285-0720; email: jw@electrivert.com; web: electrivert.com.

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.

Upgrade your connectors to a newer design. A common older standard for hot-runner power cables is a 25-pin connector with crimped pins. This can be switched out for a newer 32-pin crimp connector that fits a 16B sized hood and housing. This conversion offers three very important benefits:

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.

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.

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.