Avenue Mould - medical molding

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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.

I could give many examples where tools were designed with hydraulic cylinders that were not able to withhold the plastic pressures they would experience. The formula to determine this is not complex. First, you need to know the maximum plastic pressure the cylinder would see. You never design at a 1:1 ratio (that is the opposite of robust), so I would recommend at the very least a 1.5:1 ratio, or designing for 150% of the maximum plastic pressure anticipated.

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.

My main focus is to have a robust process window, and this typically relies heavily on the tooling. I’ve been successful in focusing on the tool to address root causes to help achieve a broad processing window. While I agree that processing is the number-one tool for eliminating molding problems, every time you “process around” a root cause, your overall window becomes smaller. But when a change is made to the tool to address an issue, it provides a more robust solution. There are so many variables in plastics materials, processes, and machinery—all of which can easily change over time—that if your processing window is narrow, you will certainly run into problems.

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

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.

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.

It’s necessary to understand the importance of support pillars and the surface area of support they create, not just the number of them or the way we’ve designed them for years. Just by going from a 1-in. to a 2-in. support pillar, you will gain over 400% more surface area. And going from a 2-in. to a 3-in. support pillar will gain you another 200% of surface area.

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.

It’s important to understand these concepts. If you have two mating surfaces perfectly matched, the tool is robust enough to prevent any deflection from cavity pressure, and if clamp force exceeds any amount of cavity pressure, absolutely nothing can penetrate the mating surfaces. Venting is often raised as a question here—it’s an important topic that

I have been living and breathing injection molding for 26 years. I’m excited about this column as an opportunity to share lessons learned in that time and to assist the industry with troubleshooting problems. Over the years, I’ve questioned everything I’ve been taught, and I strongly believe in facts versus opinions or assumptions. Thanks to this,

How can flash occur perpendicular to clamp force? Three areas come to mind from experience—mold components that sometimes cannot withhold the plastic pressure they see: laminated inserts, inadequate slide locks, and hydraulic cylinders for cores, slides, etc. I’ve been amazed by how much steel can deflect when it sees thousands of pounds of plastic pressure. You really need to focus on the mold design and the components that will see cavity pressure perpendicular to clamp force. This requires knowing the square inches of cavity surface, the material being used, part design, the process, flow lengths, and the possible pressures per square inch that they can create.

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

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.

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).

I have seen many cases when inadequate slide locks contributed to flash issues. Again, it comes down to understanding the amount of plastic pressure they see based on the square inches of cavity perpendicular to clamp force. When lock angles are inserted they are weaker than solid steel. Nothing wrong with them, but keep in mind that you need a robust tool if the cavity surface area they are forming is large. They can also be interlocked into the opposite mold half to make them more robust.

Mold maintenance is critical, and with this collection of content we’ve bundled some of the very best advice we’ve published on repairing, maintaining, evaluating and even hanging molds on injection molding machines.

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

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.

Get a better understanding of their use, proper sizing, and how the tool design and setup in the machine can impact failures in manufacturing.

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

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

I’ve accomplished many improvements after being told something wouldn’t work or is not achievable. I take a logical approach to every issue or problem. Nothing is allowed off the list of possible root causes unless proven otherwise. No assumptions or opinions should block a potential solution from being investigated.

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

Even if the lock angle is in the solid cavity steel (not a bolted insert), that does not mean it is robust enough to withhold cavity pressure. I was amazed some years back when working with a glass-filled nylon part that had a flash issue with the slides on a 650-ton tool. I would have bet everything I owned that it was not deflection and was a preload issue on the lock angle because of how robust it appeared.  I was wrong. I ended up putting an indicator on the side of the tool during the injection process, and the side of the tool was deflecting 0.012 in. We ended up having to fasten a thick plate to the side of the tool with large bolts to prevent flash from deflection.

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.

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.

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.

I’ve found that many tool designers underestimate the maximum plastic pressures. Once you know the cavity pressures base on the square inches of cavity surface perpendicular to clamp force, you need to determine the surface area of the bore size of the cylinder (3.14 × radius2) and the hydraulic PSI that will be used. Make sure you understand the operating hydraulic pressure—some machines will use system pressure based on the injection process.

THREE RULES OF FLASH PREVENTION In this two-part series, I’ll cover flash. Remember this essential principle: Flash is avoidable if three conditions are met, no matter what process or material is being used. I’ve had many people challenge this statement, but I’ve never been beaten by flash if these three conditions are met:

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

•  Clamp pressure must exceed cavity pressure.  •  The tool must be robust enough to prevent deflection both in line with clamp force and perpendicular to clamp force.  •  All shutoffs or parting lines must be “true net,” meaning they are tight with no gaps, damage, or anything holding the mold open.

Baystar's Borstar technology is helping customers deliver better, more reliable production methods to greenhouse agriculture.

The tool must be designed to withstand more than the amount of plastic force against it. Over the years, I’ve been amazed at how easily plastic pressure can deflect or move what appears to be a robust mold. One area of focus should be where the plastic is injected into the mold via the runner system and gates. I’m sure everyone reading this article has seen flash in a new tool at the runner or gate area. These areas see extreme amounts of plastics pressure and are typically at the weakest area of the tool, in the center.

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.

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.

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.

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

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.

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.

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.

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.

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

Laminated cavity inserts can also be an issue if the cavity block is not robust enough to prevent deflection. This is probably a rare case with mold design, but I had my hands full some years back with the side of a tool deflecting under pressure. We ended up doweling the cavity block to the support plate with many large dowels to help prevent the deflection.

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

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.

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.

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

I’ll cover in the future. For now, I’ll cover the first two rules of flash prevention, and the third rule in Part 2 next month.

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Warpage was found to be the same whether the part was gated on the end or the middle of the part. The pressure results were telling. If gated on the end of the part, the fill pressures exceeded 12,000 psi. If gated in the middle, the pressure was only 5500 psi. The difference in machine size needed to ensure the clamp force exceeded the cavity pressure was a 120-ton machine vs. a 300-ton press.

I have also witnessed a tool being deflected 0.060 in. from the surface area of cavity on the slide, and it bent the cavity block from the tool not being designed with enough support on the slide locks to withhold maximum cavity pressures.

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

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

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

There are many things to consider, and paying attention to the details can help avoid machine downtime and higher maintenance costs, and keep the customer happy.

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.

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

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.

The time gained by laser polishing and the cost saving achieved are enormous. Whereas a skilled polisher needs about 10 to 30 minutes for each square centimeter, the laser polishes the same area in about a minute. A prototype of the laser polishing machine developed by the scientists in cooperation with mechanical engineering firm Maschinenfabrik Arnold has already been built. Willenborg estimates that the system will be ready for industrial use in one to two years’ time. At the Euromold trade show, to be held from December 2 to 5 in Frankfurt, the researchers will be presenting examples of three-dimensional surfaces polished by laser.

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

Now you’re wondering about how much preload should be on the support pillars. That’s not a standard spec, as many will tell you. First, I want you to understand why. If you have a solid block of steel, zero preload would be needed. So, the more surface area you have with support, the less preload is needed. Everyone has their own opinion on what is adequate, especially tool makers. The most likely answer would probably be around 0.003-0.005 in. of preload. But I’ve had tools that needed to be preloaded as much as 0.015 in. in the center and gradually reduced until the pillars meet the rails. I call this crowning the preload — heaviest in the center and tapering off toward the edges.

Researchers at the Fraunhofer Institute for Laser Technology ILT in Aachen have developed a way of automating the polishing work: “We do not polish the surface by hand with grinding and polishing media. Instead we use a laser,” explains Dr.-Ing. Edgar Willenborg, group leader at the ILT. “The laser beam melts the surface to a depth of about 50 to 100 micrometers. Surface tension ensures that the liquid metal flows evenly and solidifies smoothly.” Like in conventional grinding and polishing, the process is repeated with increasing degrees of fineness. In the first stage the researchers melt the surface to a depth of about 100 micrometers, in further steps they gradually reduce the depth.

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.

Rail width should be another consideration, along with the distance between the rails and the unsupported area that creates. Here is a mental picture of how the area between the rails affects required support: For the sake of an example, if the support rails are only 1 in. apart (that’s one thin ejector plate!) you would probably need zero support. And if your support rails were 36 in. apart, how much support would you need? I have seen many 120-ton tools with 2-in. rails and 500-ton tools with 2-in. rails, so why wouldn’t the width ratio have changed with the tool size? Just food for thought. Take it into consideration in the mold design that the rails should never be too wide, and the distance between them should never be too small when considering the surface area of support.

Jobs are in short supply, and yet some sectors have difficulty in finding suitable trainees for specialist tasks, such as polishing injection molds. The work is time-consuming and monotonous but requires highest levels of concentration, because any blemish in the mold can render it useless. A skilled worker may often need a whole week to polish a single metal mold. Up to now it has not been possible to use machines for this dreary work because they cannot get into the curved shapes.

Wall thickness can have the same impact. I like to bring up these two factors when the question of required clamp force arises, because they throw the standard industry formulas right out the window.

Support pillars become a very important component to resolve this issue, and many do not understand the importance of adequate surface area and preload. (I didn’t myself for years.) You can never have too much surface area of support. Two important areas of support to consider are the area between the rails on the ejector (moving half) having adequate support with pillars, and any areas on the stationary half that would need support where steel has been removed for hot runners or mechanics.

There are many things to consider, and paying attention to the details can help avoid machine downtime and higher maintenance costs. In this installment, the focus is on design and placement of sucker/puller pins.

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.

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PREVENTING TOOL DEFLECTION Now let’s look at how parting lines and tool deflection can contribute to flashing. An inadequate tool design can contribute to flash by allowing deflection in line with clamp force and perpendicular to clamp force. Also, improper spotting, timing of components, and fitting of components can contribute to flash.

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

Next month I will follow up with shutoff angles and wear issues causing flash, along with how the machine itself can be the root cause of flash.

I reviewed a tool design a while back that had the runner length increased to gate at the end of a huge part. It was a glass-filled material and the concern was with warpage. The part had many contours and holes, so the orientation of the glass was going to get mixed up anyway. My first concern was with the runner size and no regrind being allowed. I suggested gating in the middle of the part to drastically reduce the runner scrap. (I know some of you are thinking “hot runner” right now. That’s another topic.) We had a warpage and pressure study performed before deciding on the tool design.

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

“We can set the melting depth by means of various parameters: the laser output, the speed at which the laser beam travels along the surface and the length of the laser pulses,” states Willenborg. Laser polishing does not achieve the same surface smoothness as perfect hand polishing - hand polishers can achieve a roughness Ra of 5 nanometers, the laser at present can only manage 50 nanometers - but Willenborg still sees considerable market potential for the system. “We will concentrate on automating the medium grades: a roughness of 50 nanometers is adequate for many applications, including the molds used for making standard plastic parts.” The high-end levels of smoothness will therefore remain the domain of skilled hand polishers.

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

Randy Kerkstra has been in the plastics industry for more than 26 years, occupied frequently with troubleshooting injection molding. He is currently a tooling manager for a large, multi-plant molding and manufacturing company.

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(PhysOrg.com) -- Polishing metal surfaces is a demanding but monotonous task, and it is difficult to find qualified young specialists. Polishing machines do not represent an adequate alternative because they cannot get to difficult parts of the surface. A new solution is provided by laser polishers.

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.

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.

HOW MUCH TONNAGE DO YOU NEED? The industry has standard formulas for clamp tonnage per square inch, based on the particular plastic being used. These are typically good standards to go by, but they don’t even come close to what pressures you can encounter when wall thickness and flow length come into the picture. Flow length and wall thickness can drastically increase the pressure needed to fill the part.

A robust process window relies a lot on tooling. So it stands to reason that making a tool change to address issues provides a more robust solution

With advocacy, communication and sustainability as three main pillars, Seaholm leads a trade association to NPE that ‘is more active today than we have ever been.’