WATSON's Arrest - injection part

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

Collaboration partner BNP Brinkmann, a specialist for multifaceted types of fleece that are used for semi-finished products by the automotive industry, supported the production of the component. “When we develop innovative technical fleece fabrics, we are, as far as mobility is concerned, apart from light-weight, absorption and insulation solutions, particularly focusing on products made from renewable raw materials. Our experience and the particular characteristics of the Acrodur binder enabled us to produce the highly effective composite required by the German Aerospace Center by almost exclusively using natural fibers”, says Thomas Güthe, Managing Director of BNP Brinkmann.

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.

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

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

•  An edge gate or sub-gate that intentionally feeds a part on an angle is referred to as tangential gate, as shown in Fig. 5. It is often used to prevent core shifting, relocate a weld line, or improve weld strength. However, it can cause jetting inside the cavity.

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.

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

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.

•  If a full-round runner sticks on the cavity side of the mold, instead of using pullers, you can add undercuts on the ejection side. A teardrop-shaped undercut is best for preventing flakes or shavings, as shown in Fig. 12.

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.

​​​​​​​About the Author:  Jim Fattori is a third-generation molder with more than 40 years of experience in engineering and project management for custom and captive molders. He is the founder of Injection Mold Consulting LLC  in Pennsylvania. Contact:  jim@injectionmoldconsulting.com; injectionmoldconsulting.com

•  Always use geometrically (or “naturally”) balanced multi-cavity runner layouts. Multi-cavity molds inherently have balancing issues. Don’t compound the problem with fishbone, ladder, or other types of unbalanced runner designs.

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 trick to adjusting a family mold is to adjust the flow rate of the material in the runners feeding each cavity. Changing the gate depth or width only changes the fill speed (mph). It does not change the flow rate (in.3/sec). Changing the gate depth will also create different gate-seal times, which leads to parts having different packing pressures. Therefore, to correctly balance family molds, change the runner diameters to each cavity, as shown in Fig. 7.

•  Adding redundant runner sections, as shown in Fig. 9, has only a minor effect on cavity balance. They will also narrow the processing window and increase the amount of runner scrap or regrind.

•  One clever engineer engraved text on a family-mold runner to help the operators identify similar-looking parts for sorting and assembly, as shown in Fig. 2. Engraving the cavity number on the runner is also helpful when the parts are very small or the aesthetic requirements do not allow a cavity number on the part.

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.

•  An inexpensive way to delay the ejection of a runner (or a part), without having to incorporate a two-stage ejection system is shown in Fig. 13. The pins are well supported and have positive return. This design can help reduce flaking from sub-gated parts.

•  For high-volume molds (about 500,000 cycles or more), consider incorporating replaceable gate inserts, especially for abrasive materials.

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.

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

Performing fundamental maintenance inspections frequently assures press longevity and process stability. Here’s a checklist to help you stay on top of seven key systems.

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.

•  Never machine a runner on a split line of two or more mold inserts. The injection pressure will try to push the components apart, resulting in “down-flash” that could cause the runner to stick.

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.

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

BASF helped produce the component by providing its experience with fiber bonding products. In the past, this expertise and the use of the Acrodur binder for natural fiber composites led to several high-performance light-weight components that were serially produced for the automotive industry.

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.

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

The goal of the German Aerospace Center’s NGC project is to promote the development of quiet, low-emission road vehicles with a high degree of automation and a wide range. It uses state-of-the-art technologies, among other things, for vehicle structure, engine, and energy management. Light-weight construction is key when it comes to the development of innovative vehicle concepts: About two-thirds of fuel consumption depends directly on the weight of the vehicle.

•  The goal in balancing a family mold is to have all of the parts finish filling at the same time—not start to fill at the same time. Keep that in mind when you are making progressive short shots.

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

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

As the second-largest, institutionally funded transport research institution in Europe, the German Aerospace Center (Deutsches Zentrum für Luft- and Raumfahrt/DLR) uses its transport program to address the big questions involving the future of mobility. BASF and its partner BNP Brinkmann are supporting the current research project — Next Generation Car (NGC) — with a tailormade, light-weight composite based on natural fiber. “By using our Acrodur binder we were able, together with our partner BNP Brinkmann, to produce a composite material from renewable resources that meets the German Aerospace Center’s particularly high requirements for stability and weight”, explains Thorsten Habeck, Head of Business Management Fiber Bonding – Europe, Middle East & Africa at BASF.

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

BASF and partner BNP Brinkmann participate in German Aerospace Center’s transport program to address the big questions involving the future of mobility.

•  One reason you want all of the parts in a family mold to finish filling at the same time is so they all receive the same amount of packing pressure. If they don’t, you waste material by over-packing some cavities, which makes them heavier. Another reason is that cavities that are under-packed or over-packed will have dimensional issues because they will have a different shrinkage rate than what was used to machine the mold.

•  Keep in mind what effect the gate location and runner pattern will have on the mold. The gate and runner in Fig. 6 may be a balanced design, but it caused the cavity and core halves of the mold to rotate in opposite directions, resulting in parts that had a core-shift problem.

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

•  Some runner layouts can have a heavy mass at branch intersections. These can often be cored out without affecting the material flow or pressure, as shown in Fig. 1.

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

3. In the event of parting-line flash, the runner inserts can be skim ground and shimmed up This eliminates the need to make any other height adjustments to the cavities, interlocks, cams or shutoffs.

•  If you want to increase the size of the gates, runner or sprue by some percentage, you need to run the numbers. For example, if you feel a 0.050-in. gate should be about 20% larger, don’t multiply the gate size by 1.2 and get 0.060 in. That’s not 20% larger. In terms of flow area, that’s 44% larger. An easy and correct way to determine the new gate is size is to use the following formula: DNEW = DEXISTING × √ (1 + percentage increase). In this case, it would be 0.050 × √ 1.2 = 0.055.

•   Figure 4 shows two different runner designs. Both runners have sub-gates machined into the injection half of a two-cavity mold. The runner on the left is far superior to the one on the right because:

•  Avoid using sub-gates if the molding material is abrasive, or if the cavity is made of a soft metal, such as aluminum or copper. They will wear out quickly.

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

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

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.

Water-based binder can create stable, sustainable and environmental-friendly car components that weigh up to 50% less than traditional metal parts.

Acrodur is a water-based binder containing no added formaldehyde that transforms renewables such as hemp, kenaf, flax and wood into light-weight, stable and durable functional composites. Due to its high-flexibility, easy-processing features, and superior thermomechanical stability, low-emission Acrodur can create stable, sustainable and environmental-friendly car components that weigh up to 50% less than traditional metal parts.

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.

•  Shortened ejector pins with a conical tip are used to stabilize a runner from shifting or rolling over during ejection, as shown in Fig. 11.

•  Adding a short flow restrictor, as shown in Fig. 8, is not as effective as reducing the diameter of the entire runner branch.

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.

This month I sifted through four decades of Post-It notes, hand sketches and photographs to uncover a number of worthwhile tips and tricks related to this five-part series on gates, runners and sprues. Therefore, this month’s conclusion to the series will simply be a bullet-point list of helpful information.

Start by picking a target melt temperature, and double-check data sheets for the resin supplier’s recommendations. Now for the rest...

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.

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.

•  Designing the mold with a separate runner bar or runner block will cost a little more but has multiple benefits—especially for long running molds.

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.

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 contribution to the project made by BASF and its partner BNP Brinkmann was related to the Safe Light Regional Vehicle (SLRV), the smallest and lightest of the vehicle concepts developed as part of the NGC project. It combines a novel, metal sandwich type of construction with an innovative entry concept, a highly efficient hydrogen fuel cell engine and a novel car body to meet the demanding safety and weight (450 kg) requirements of the light-weight L7 vehicle category.

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

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.

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

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

•  Add a runner overflow at each runner intersection. This is particularly important for stripper-plate molds when there is no cold well opposite the sprue. The length of the overflow should be 1.0 to 1.5 times the runner diameter or width. Overflows work very well, as shown in Fig. 3.

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.

•  A shortened ejector pin is required for ejecting a runner puller near a sub-gate machined into the cavity side. A good puller design is shown in Fig. 10. Note how the ejector pin has a smaller diameter than the puller and how the puller has a radius and small pad on the bottom. This design will minimize the risk of getting flakes or shavings on the parting line.

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.

•  Sub-gates do not necessarily have to be machined parallel or perpendicular to the runner. They can be machined on almost any angle. This is helpful when gating into a part with a radius or a steep angle, or when you want to shift a weld-line location.

•  Ideally, an ejector pin should be located at each runner intersection, because as the massive runner shrinks, it will try to stick on the inside corners.

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.

•  Some moldmakers and molders do not like to add vents until after the first sampling. This can lead to an erroneous fill pattern. At the very least, add vents at the last place to fill.

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.

•  Consider the location of any runner undercuts. They should be at or near an ejector pin to prevent the runner from bending or cracking during ejection.

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.

•  “Breaking” or blending the sharp edges of the runner system will help reduce stress on the material and help prevent the runner from cracking upon ejection. Sharp edges are typically located where the sprue meets the runner, where the cold well meets the runner, where the gate meets the runner, and at every runner intersection.

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and is a proud dachshund owner.

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.

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.

4. The inserts can affordably be made of a different material, such as a high-hardness tool steel for abrasive materials, or thermally conductive materials for faster cycles.

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).

The interior floor of the NGC SLRV features light-weight composites made from natural fiber to protect the car body against mechanical deformation. “BASF and BNP Brinkmann were able to help us meet a difficult requirement and supplied us with tailormade molded parts that combine extremely low weight with high stability. This was essential for our NGC SLRV because, as the hood opens upward, people get into the car in an upright position, which leads to a particularly high point load on the car body in the footwell”, explains Michael Kriescher, responsible project leader at the Institute for Vehicle Concepts of the German Aerospace Center.

•  Specify the vent locations, depths and widths on the mold drawing. Do not leave venting up to the toolmaker’s discretion.

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

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.