Blending Amorphous PHA into PLA - pla plastic injection molding

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

ABOUT THE AUTHOR: Michael Sepe is an independent materials and processing consultant based in Sedona, Ariz., with clients throughout North America, Europe, and Asia. He has more than 45 years of experience in the plastics industry and assists clients with material selection, designing for manufacturability, process optimization, troubleshooting, and failure analysis. Contact: (928) 203-0408 •mike@thematerialanalyst.com

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.

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 1978, DuPont solved the problem of slow crystallization through nucleation using a combination of additives and fillers to introduce a line of products known commercially as Rynite. But almost a decade earlier, another type of polyester had been introduced that did not exhibit the problems with slow crystallization and had already made inroads into the engineering thermoplastics market. This was PBT, a material with a structure similar to PET. The ability to achieve faster crystallization was due to a small change in the molecular structure that brought with it some compromises. PBT also revealed the potential for a remarkable level of versatility in polyesters, a topic we will cover in our next installment.

SPT Vilecon said it has begun expanding the range of injection mold prototyping with silicone, metal, and ceramic materials to provide medical device manufacturers with an even wider selection of product development and verification services.

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

A supplier of development and manufacturing services to medical device OEMs used Freeform Injection Molding from Nexa3D to accelerate time-to-market and slash prototyping costs for a complex silicone-based IV device. SPT Vilecon explained the process in a recent press release.

Previously we have discussed the effects of temperature and time on the long-term behavior of polymers. Now let's take a look at stress.

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.

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.

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

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.

Injection-molded silicone parts were produced within two days, allowing early verification of key design and performance aspects.

Today amorphous PET accounts for the majority of PET resin consumed, due to over half a trillion bottles produced annually.

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 the amorphous state, PET polyester was relegated to applications that could accommodate the limited mechanical performance of a material with a glass-transition temperature of 80-85 C (176-185 F). Parts are injection molded in amorphous PET, but the application temperature is limited to about 65-70 C (149-158 F). The properties of amorphous PET present another challenge that can limit the maximum use temperature to an even greater degree. Because amorphous PET has one of the lowest glass-transition temperatures of any commercial amorphous polymer, it is susceptible to a phenomenon known as physical aging.

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

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.

Incorporating the aromatic ring into the backbone structure of the polymer created a mixture of advantages and disadvantages. While the melting point of PET is slightly lower than that of nylon 66, the glass-transition temperature is 20° C (36° F) higher. In addition, the ester group, while polar, is much less hygroscopic than the amide group in nylon due to the absence of the hydrogen bond. And the aromatic structure reduces the susceptibility of the polymer to hydrolytic degradation, an important consideration in a material targeting fibers for clothing. Polyester exhibited less dimensional change with water absorption, which translated to a fabric that did not wrinkle when washed.

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.

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.

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

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

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.

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.

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.

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.

Today amorphous PET accounts for the majority of PET resin consumed, due to over half a trillion bottles produced annually. The ability of the polymer to be either amorphous or semi-crystalline is illustrated by the fact that much of the recycled PET from bottles is converted to fiber for clothing and other fabrics. But for applications that require heat resistance, such as under-the-hood environments, PET must be semi-crystalline. And most of these types of parts are produced by injection molding. This created problems for those wishing to use PET since the slow crystallization rate of the polymer resulted in long cycle times and the need for very high mold temperatures.

Last month’s column recounted a vital step in the commercialization of PET polyester. The accompanying figure shows one of several chemical processes used to create PET. This breakthrough involved using an organic acid containing an aromatic ring, terephthalic acid, to replace the aliphatic acids that were part of the original chemistry investigated by the Carothers’ team at DuPont. The aromatic ring boosted the performance of the resulting polymer, yielding a material with a melting point just 10° C (18° F) below that of nylon 66.

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.

SPT implemented Nexa3D’s Freeform Injection Molding (FIM) technology to help customers shorten time-to-market on complex medical devices in demanding medical-grade materials and to expand on the range of materials that can be quickly and reliably used in prototyping and early device test manufacturing.

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.

Freeform Injection Molding technology from Nexa3D compresses design, iteration, and validation cycle times into a matter of hours rather than weeks.

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

The industry has learned a lot about the advantages and disadvantages of polycarbonate during its more than 60-year history, and it would be difficult to imagine a world in which it did not exist.

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.

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).

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

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.

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

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.

In this three-part collection, veteran molder and moldmaker Jim Fattori brings to bear his 40+ years of on-the-job experience and provides molders his “from the trenches” perspective on on the why, where and how of venting injection molds. Take the trial-and-error out of the molding venting process.

In 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.

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

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.

Last month we briefly discussed the influence of temperature on the mechanical properties of polymers and reviewed some of the structural considerations that govern these effects.

Design input collected from the first tests was integrated in a second iteration that took only a couple of hours to complete. By contrast, conventional metal tooling would have taken more than six weeks to design and procure, and the adjustments needed for the second iteration would have taken an in-house tool-shop a week to complete.

Based on input collected from the first two iterations, the design of the silicone part was approved and manufacturing of a metal tool was initiated with full confidence of part moldability and performance. The in-house tool shop built the final metal tooling in four weeks without iterations.

This is one of several chemical processes used to create PET polyester. This breakthrough involved using an organic acid containing an aromatic ring, terephthalic acid, to replace the aliphatic acids that were part of the original chemistry investigated by the Carothers team.

But while the material was losing market share in the world of fibers and fabrics, a new opportunity was on the horizon that capitalized on the amorphous form of the material. This was as an alternative to glass for water and carbonated beverage bottles. Here was a situation where crystallinity was not needed nor was it desired. The selling points were transparency and toughness, both of which required an amorphous polymer. Nathaniel Wyeth, a DuPont engineer, patented the technology for blow molding bottles from PET in 1973. The material proved to not only have the desired appearance and toughness needed for the application, it also possessed the strength and barrier properties needed for carbonated beverages.

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

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

While DuPont may have passed on the initial development of polyester in favor of nylon, it obviously recognized the advantages of the new aromatic chemistry and in 1946 DuPont bought the rights to PET and developed its own product by 1950, trade named Dacron. In 1952 DuPont developed a thin-film form of the material that was trade-named Mylar. Eastman Chemical entered the market in 1958 with its own commercial offering, trade named Kodel.

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.

Robust and valid prototyping and verification are key to minimizing cost, time, and risk factors in developing medical devices, said SPI Vilecon. FIM is a new toolbox for medical device companies seeking to accelerate their innovation and obtain early verification of part performance and moldability, added the company.

One of the consequences of the presence of the aromatic ring in the PET polymer backbone was a slower rate of crystallization than was typical in nylons. Because PET was used primarily in fibers, processing the material allowed for the achievement of an appropriate level of crystallization with all the associated beneficial properties. But the crystallization process was slow for the growing world of injection molded products. So, while nylon became an increasingly popular material for injection molded articles in the 1950s to the 1970s, PET remained a material for fibers and film, where the process of crystallization was slower but could be controlled through the manufacturing process.

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.

Editor in chief of PlasticsToday since 2015, Norbert Sparrow has more than 30 years of editorial experience in business-to-business media. He studied journalism at the Centre Universitaire d'Etudes du Journalisme in Strasbourg, France, where he earned a master's degree.

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

The 3D-printed molds for the first and second iterations cost less than €2,000 combined. And the technology enabled a two-day design cycle, which is more than 90% faster than conventional metal tooling.

Medical device manufacturers are tasked with developing elaborate test protocols to ensure that the product in development is safe and meets essential requirements. If these tests are conducted late in the development process, the more onerous and risky they become. SPT Vilecon often works with silicone, a material that is extensively used in medical applications because of its chemical resistance, mechanical performance, and biocompatibility. However, silicone parts are notoriously difficult to prototype and test, since most grades need to be injection molded to achieve their full performance potential, said the company. FIM enabled SPT Vilecon to offer an alternative to a customer developing an intravenous (IV) silicone product — the use of 3D-printed tooling to perform early design and material verification at a fraction of the cost of conventional methods.

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

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 behavior of PET was still being learned in the early 1970s ,and while crystallization was necessary for use of the material in fabric, it was not at all desired in bottles.

This was discovered in the early days of the plastic bottle industry when bottles stored at elevated temperatures exhibited a substantial decline in ductility in a matter of weeks. At the time there were only two mechanisms that were known to contribute to a decline in toughness—crystallization and polymer degradation. Neither of these could explain the loss in impact resistance of the PET bottles. But in 1978, L.C.E. Struik published a landmark paper outlining the mechanism of physical aging, a process in amorphous polymers that involves the collapse of the polymer chains into the free volume that exists between the chains. This creates stronger intermolecular forces that result in an increase in strength and stiffness but a decline in ductility over time.

Certified to ISO 13485, Denmark-based SPT Vilecon describes itself as a fully integrated provider of development and manufacturing services to the medical device industry. It offers in-house tool making and injection molding along with other manufacturing services to companies in northern Europe.

The rate at which physical aging occurs is dependent upon temperature, and studies by Eastman have shown that with each increase of 10° C the rate of physical aging in amorphous PET increases by a factor of nearly 10 (9.8 to be precise). My own experiments using accelerated aging techniques have confirmed this. And since the relationship is exponential, an increase of 30° C will increase the rate of physical aging by 9.83 or 941. So, a change in mechanical properties that might take a few years at room temperature can occur in a matter of days in a hot warehouse.

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

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 this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

The patented FIM process uses high-speed Nexa3D printers and xMOLD resin to print injection molding tools that are compatible with thousands of off-the-shelf injection molding materials, including reinforced high-performance feedstocks. The process reduces design, iteration, and validation cycles using end-product materials to a matter of hours rather than weeks.

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.

Throughout the remainder of the 1950s and well into the 1960s, polyester became a dominant synthetic fiber before it fell out of favor due to complaints about comfort. Few polymers have as much of an association with changing societal tastes as polyester. The convenience of polyester fibers relative to natural fibers such as cotton and wool created a huge market in the 1950s and 1960s. This was followed by a period where polyester became associated with societal trends that made it appear out of step and obsolete (the disco scene comes to mind).

A story regarding Wyeth’s early experiments in blow molding the polymer illustrates the difference between the properties of crystallized PET and amorphous PET. When Wyeth first attempted to blow mold a bottle from the material, the bottle shattered into small shards because the polymer had crystallized during the reheat process, making it very brittle. The importance of heating the material only slightly above the glass transition before blowing a bottle is well understood today, but the behavior of PET was still being learned in the early 1970s, and while crystallization was necessary for use of the material in fabric, it was not at all desired in bottles. Today, the systems that preheat molded preforms carefully control the temperature in order to avoid crystallization. A walk through a bottle blow molding plant will usually reveal a gaylord of scrap preforms that exhibit a cloudy appearance, a sign that the undesirable crystallization has started.

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.

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.

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

Ironically, DuPont did not benefit from Wyeth’s invention when it came to sales of raw material. DuPont lacked the ability to produce a polymer with a sufficiently high molecular weight for the bottle market. Both impact performance and barrier properties required this high molecular weight, and competitors such as Goodyear and Eastman brought on the capacity needed to satisfy demand.

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

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.