Small-Scale Injection Molding - plastic casting

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.

To date, SolidWorks remains one of the few CAD companies offering a sustainable design development tool, built right into the modeling environment. If you’re on the latest release of SolidWorks (2010), you can use Sustainability Xpress, the app under the Evaluation tab, to calculate your design’s environmental impact. But the free Xpress version works only on parts. To work on assemblies, you need SolidWorks Sustainability, the full license that costs roughly $3,000.

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.

“Ownership” of problems and their potential solutions also contributes to success at these companies. Isaac Trevino of Best Tool & Engineering, Clinton Township, Mich., says that’s key for continuous improvement at his business. “When you have ownership in the solution, you’re more likely to take action,” Trevino says. “Our employees understand this and have been creating processes and documenting and organizing internally.”

The advantage of the full version is the ability to visualize how each individual part contributes to the entire assembly’s environmental impact. The color-coded visualization makes it easy to identify parts that cause the greatest harm, prompting you to switch material, production method, or something else to bring down the carbon count, energy use, and pollution levels. Furthermore, the ability to perform stress analysis and environmental assessment in the same window goes along way to ensure that you don’t inadvertently compromise your design’s structural integrity while you’re exploring ways reduce its carbon footprint.

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.

Kenneth Wong is Digital Engineering’s resident blogger and senior editor. Email him at [email protected] or share your thoughts on this article at digitaleng.news/facebook.

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.

Five industry pros with more than 200 years of combined molding experience provide step-by-step best practices on mounting a mold in a horizontal injection molding machine.

Looking at machine fleets for survey participants, all entries showed roughly the same age, orientation (proportion of horizontal vs. vertical) and styles (relative proportions of hydraulic, all electric and hybrid), for their machines; but Top Shops actually had 43% fewer machines on average than the rest (16 vs. 28), and those machines were mostly smaller, with a majority under 500 tons of clamping force or less. In terms of secondary operations, Top Shops provided far more assembly and decoration than other survey entrants.

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.

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

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

All survey participants showed the average age of their shop-floor workers skewing older—40 and 46 for Tops Shops and others, respectively. The overall headcount grew much more at Top Shops, with 43% reporting expanded staff in 2019 vs. 11% for the rest of the survey. Top Shops also paid their employees more, with an average hourly wage for non-management shop-floor workers of $16.73, vs. $14.80 for other shops.

The results can be exported as a PDF report, a good way to present your findings or justify your engineering change orders to those who might not have SolidWorks. If you’d like to learn more about the results, you may visit SolidWorks’ Sustainability portal, which has a free carbon footprint calculator. The browser-based app lets you compare your design’s impact (measured in kg of CO2) to the effects of driving an average U.S., European, or hybrid car for a number of miles, adding more weight to your understanding of the assessment.

In terms of total employees—manufacturing and front office—Top Shops averaged 87 staff, 42% more than other entrants; but Top Shops averaged 40 manufacturing employees, just above the 31 employed by the rest of the survey group (on average), indicating more of their staff were on the administrative side or in part and mold design and quality assurance.

“We have always asked employees to be open with their comments and suggestions for making work better for customers and themselves,” says Paul German, director of quality at Bender Products Inc., Mishawaka, Ind. Eric Seebeck, operations manager at Modern Molding, Delano, Minn., says his company also seeks employee feedback—and accountability. “Our employees are first trained to know that they are part of making us a stronger company,” Seebeck says. Modern maintains a continuous-improvement board, and when suggestions are added to it, they are assigned to a departmental manager. “The employee that made the suggestion is kept informed of the progress towards that suggestion.”

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

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.

Coverage of single-use plastics can be both misleading and demoralizing. Here are 10 tips for changing the perception of the plastics industry at your company and in your community.

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

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.

“Our largest costs are indirect and direct labor,” says Maple Mold’s Bachan, noting that continuous improvement typically reduces labor input. “People enjoy improving things, and the company reduces costs—win-win!”

With Sustainability Xpress, you can use your material specifications, manufacturing methods (injection molding, machining, etc.), raw material locations, and deployment destinations (where the end products will be used) to tally up your parts’ environmental impact in four areas: carbon emission, energy use, air pollution, and water pollution. In the full version, in addition to the parameters listed above, you can also specify transportation mode (air, train, truck, and so on) and lifetime energy use (say, the anticipated energy used by a washing machine’s average lifespan).

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

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

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

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.

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.

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.

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

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

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.

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.

“The fact that Diversified is owned by the employees helps drive a strong culture and company success,” Hogan says. “We communicate the financial benefits of continuous improvement and benefits to our customers.”

This work-handling tray molded by Precision Tool Technologies  is used to hold prescription eyewear components, frames and lenses for automation processing in digital wholesale laboratories.

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

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.

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.

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.

Improvements in nozzle design in recent years overcome some of the limitations of previous filter, mixing, and shut-off nozzles.

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

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.

Given that respondents were completing a benchmarking survey, it’s obvious that they regularly monitor various metrics around their operations. Some of these are familiar to molders, but other key performance indicators they shared were unique to their operations. At Precision Tool, Georges says the company asks itself whether a project is “168able.” That derives from one shift a day, 7 days/week multiplied by 24 hr in a day to equal 168 revenue hr/week. “Conventional manufacturing-think and new technology just don’t work well together,” Georges says. “Owners and managers must adopt 168-manufacturing thinking to drive profit into business.”

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

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.

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

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.

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.

Both Sustainability and Sustainability Xpress are designed as a comparison tool—that is, to set up one scenario as your baseline, then compare it against other iterations. This method lets you pick the best materials, production methods, and acquisition regions to make your product greener.

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).

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.

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

From A (Accurate Plastics) to Z (Zircon); heading west to California and east to New York; tracking north to Michigan and down south to Texas: Plastics Technology’ 2020 Top Shops survey represents a wide swath of the United States’ injection molding community. But despite the broad diversity of the group, the best performers share some key similarities.

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

For Jim Georges, president of Precision Tool Technologies Inc. in Brainerd, Minn., “100%” of the company’s success can be tied to its culture. He adds, “Having best fit our people for our needs leads to success,” Georges says, adding that goal-setting keeps the company focused on continuous improvement. “Thinking beyond today—we will take long-term over short-term every time.”

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.

Despite their status as a Top Shops, all the companies Plastics Technology contacted acknowledged they still face challenges, especially in the midst of the coronavirus crisis. “Like many small businesses during this time, there are ebbs and flows,” Trevino says. “One minute you think you don’t have enough work to keep everyone on, and the next minute there’s too much work but not enough to justify hiring someone full-time.”

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

Despite the difficulty of running a business in a pandemic, Top Shops have shown resiliency. When the company set out to establish its 2021 business goals, Precision Tool had to account for customer industries hit hard by the virus. “Our 2021 goal is 50% growth over 2020,” Georges says, adding, “2020 is a record-breaking sales year in spite of COVID-19.”

This benchmarking survey of injection molders asked participants to share demographic data, performance indicators and business and process strategies from 2019. A portion of those performance metrics was then scored, with the resulting 23 companies named Top Shops for 2020.

Morton brings one metric to molding that was broadly used in his contract-manufacturing days: value-added margin (VAM). VAM essentially means sale price minus purchased goods. “So if I sell something for a dollar and 30% of what I’m selling I purchased—whether it be a box of raw material or an insert—the other 70% is the value I’ve created from the raw material to when I sell the item for a dollar,” Morton says, noting that his company “lives and dies” with that metric. “There’s nothing more important than knowing what that adds to the absorption rate of your organization.”

For more on SolidWorks Sustainability Xpress, read the previous blog post “A Look at SolidWorks Sustainability Xpress (Or How Green is Homer Simpson’s Beer Can?).”

Perhaps the best example of a gap in performance beween the two groups is in the revenue generated relative to a molder’s size. Sales per employee and per machine for Top Shops were nearly double those for the others; and Top Shops also enjoyed profit margins more than six times higher than the rest of the survey group.

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.

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

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.

Life Cycle Assessment, or LCA, is an emerging science, still in its infancy. Currently, several prominent LCA methodologies compete for legitimacy and recognition. This is reflected in SolidWorks Sustainability FAQ, which states, “The values in SolidWorks Sustainability are useful to within +/- 20% and should be used as an estimate. The more accurate way of using the product is to track the relative changes from one version of a design to the next.”

For Chris Morton, CEO of Medical Components of America in Sequin, Texas, operational efficiency extends to benchmarking itself. “I don’t measure anything I don’t have to, and I don’t add any complexity to the business that isn’t needed for end results,” Morton says.

Ascribing a company’s success to its “culture” can seem a cliché, but Top Shops contacted by Plastics Technology said it’s a shared—and communicated—philosophy that contributes greatly to their operational success. “I believe all of our success is attributed to our company culture,” says Matt Bachan, operations manager at Maple Mold Technologies. This molder and moldmaker, with operations in Rochester Hills and Auburn Hills, Mich., is family owned and operated, with many of its employees “beyond dedicated,” according to Bachan. “This dedication flows through our company—we all have the same goals,” he says.

The two quickest ways to reduce your design’s impact are (1) reducing your design’s overall mass and (2) switching to less harmful materials. For the latter, you can use SolidWorks Sustainability’s Find Similar tool to single out alternative materials with comparable tensile strength, yield strength, and heat conductivity.

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.

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’s 2020 Top Shops benchmarking survey reveals that the most effective molders are, not surprisingly, the most efficient, accomplishing more than their peers from a smaller manufacturing footprint.

•  Accurate Plastics and Mold Co., Auburn, Ga.  •  AquaCal, St. Petersburg, Fla.  •  Bender Products, Mishawaka, Ind.  •  Best Tool & Engineering Co., Inc., Clinton Township, Mich.  •  Certainteed, McPherson, Kans.  •  Diversified Plastics, Inc., Minneapolis  •  Foreman Tool and Mold, St. Charles, Ill.  •  Janler Corp., Chicago   •  Manufacturing Services Inc., Bessemer City, N.C.  •  Maple Mold Technologies, Auburn Hills, Mich.  •  Medical Components of America, Seguin, Texas  •  Modern Molding Inc., Delano, Minn.  •  Mold Precision Engineering Inc., Simi Valley, Calif.  •  Nortic Inc., Oriskany, N.Y.  •  Pioneer Plastics Inc., Marinette, Wis.  •  PlastiCert Inc., Lewiston, Minn.  •  Plastikos Inc., Erie, Pa.  •  Polyfab Corp., Sheboygan, Wis.  •  Precision Tool Technologies Inc., Brainerd, Minn.  •  Primera Plastics, Zeeland, Mich.  •  Stenner Pump Co. Inc., Jacksonville, Fla.  •  Winzeler Gear, Harwood Heights, Ill.  •  Zircon Corp., Hulmeville, Pa.

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

Top Shops also shared frequent and open communication as a common trait. Kevin Hogan, CEO of Diversified Plastics Inc., Minneapolis, says that’s part of the program at this 100% employee-owned company, which has monthly meetings where key metrics and financial results are shared with “employee owners.”

Regarding markets served, Top Shops and other survey participants hewed closely to each other, except in three instances: automotive, military/defense, and packaging. Only 35% of Top Shops served automotive, compared with 57% of others; while 43% of other entrants generated defense and military business, compared with 22% of Top Shops. While 22% of Top Shops generated revenue in packaging, only 7% of other survey participants did.

Compared with other survey respondents, Top Shops molded almost double the amount of individual parts from nearly the same amount of resin (2.4 million lb for Top Shops vs. 2.9 million lb for the rest), indicating smaller parts; and they ran an average of 32 different resins—34% more than other shops. The total part discrepancy can also be explained by the percentage of high cavitation tools—16-plus cavities—run by Top Shops (30%), compared with only 3% for others.

At Diversified Plastics, in addition to hiring, Hogan says winning new business in a pandemic can be difficult. “One of the biggest business challenges we face is currently in COVID-19—re-energizing business development in a virtual world,” Hogan says.

Determining the source of streaking or contamination in your molded parts is a critical step in perfecting your purging procedures ultimately saving you time and money.

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.

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

The top performers and the remaining pool of participants have more in common than not, but where there are discrepancies they are often pronounced and impactful in terms of business success.

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.