Even as polymer 3D printing is increasingly being used for production, tooling remains a major application for 3D printing in the plastics industry. Exhibitors at the 2022 Plastics Technology Expo (PTXPO) were showcasing several examples of 3D printed tooling for injection molding. For mold inserts, 3D printing can aid in rapid prototyping, production molds with conformal cooling channels and mold repair. 3D printing can also be used to produce mold components, such as ejector pins with a porous structure that enables gas to escape a mold while containing the material inside. And 3D printed end of arm tooling can be lighter than traditionally produced versions with faster turnaround times.

So that's great. I want to hear about PTXPO, Plastics Technology Expo. New show that our employer has begun Gardner Business Media. Plastics has been on my mind to there are some pretty fundamental advances happening in plastics 3D printed I've gotten interested in I want to talk about. So PTXPO, what was it like?

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

Winther Mould brings 56 years of experience in design for manufacturing (DFM), mold design and manufacturing, and testing and validation to the MGS portfolio. In partnering with Winther Mould, MGS said it will add complex, premium-quality tooling and moldmaking capacity and expertise to its international network of tooling, automation, and manufacturing capabilities. MGS currently operates from 12 locations in the United States, Mexico, Ireland, Sweden, Germany and Denmark.

The Plastics Technology Expo took place March 29-31, 2022 at the Donald E. Stephens Convention Center in Rosemont, Illinois.

Next Chapter Manufacturing 3D printed these porous metal parts using DMLS. The company uses this technology to produce porous ejector pins that can vent out gases during the molding process.

Driven by brand owner demands and new worldwide legislation, the entire supply chain is working toward the shift to circularity, with some evidence the circular economy has already begun.

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.

And so the subject matter of the show is broad, it's plastics manufacturing, it's not by any means exclusively about 3D printing. And 3D printing was just kind of like a small element of it. But additive had a presence there. What did you encounter that kind of struck you as far as 3D printing taking its place in plastics production?

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.

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.

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.

Exactly. And I have one more tooling example to talk about from the show. Alright, 3D printed end-of-arm tooling for automating injection molding, I talked to Savage Automation. And all they do is 3D printed end-of-arm tooling. They showed me an example of what this typical end-of-arm tooling looks like. And it's usually made out of metal, and it has all these tubes coming out for the vacuum gripping mechanism. So this company designs end-of-arm tooling that has internal channels for the airlines instead of needing the hoses and tubes. And they can make it faster than traditional end-of-arm tooling. And it's also lighter than metal, which means that the robot can move faster and there's less wear on it.

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 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.

Yeah, so like you said, this is the first time the show has ever been held. So I don't have a direct comparison. But compared to other events that we've been to since the pandemic started, this one felt the most like a pre-COVID event, it felt a little more normal. I was there at the end of the first day, and most of the second day and foot traffic seemed really good, especially on day two, all of the Tech Talks I went to, the theaters were full, and just the general atmosphere felt really positive.

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.’

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

“We celebrate this new growth milestone for MGS, which further strengthens our offer of unparalleled tooling capacity to ensure the seamless launch of large-scale programs. Our expanding global footprint continues to provide healthcare innovators with end-to-end support for new product introductions and ongoing production,” said Paul Manley, president and CEO of MGS. “MGS and Winther Mould share a strong customer focus and commitment to agility and reliability. Together, we are poised to deliver unmatched value, precision, and dedication to our global customers to accelerate the development of innovations that improve lives,” said Manley.

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.

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

Yeah, so I have pictures and videos of I think everything that I talked about on Twitter and Instagram, we can post links to them in the show notes as well.

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

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

So a composite mold tool. That's interesting. We've been talking about 3D printed metal tooling. You see also in some of the more temperature-resistant polymers, sometimes there's short run bridge mold tooling that are 3D printed that way, this kind of sounds like something in between. So the ceramic reinforcement, ceramic, we tend to think of that as heat resistant material toughness to stand up to the pressures of the molding process. Like where does this land in terms of the quantities? Did they give you any sense of the shots you can get out of out of a composite mold tool before it wears out?

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

Yeah. So it's just like, control of the positioning of the laser as it's hard to get hardening the material to leave some microscopic channels through the part, I guess, here's what this reminds me of kind of ejector pins, you have written about additive manufacturing, making cutting tools for machining, like cutting tools, basic fundamental component of CNC machining, so ejector pin basic fundamental component of molding, so here's, like, additive serving conventional processes.

3D printed tooling for injection molding, including mold inserts, components and end of arm tooling, were on display at the Plastics Technology Expo.

Okay, so they're prototyping them on a Markforged, they send them out. So what 3D printing process makes the final production tooling?

Hey, Pete. So I just got back from PTXPO. That's why we did our little Graduate intro. PTXPO is a trade show that's put on by our parent company, Gardner Business Media, and it's a plastics processing show. So it's not an additive-focused show, but there is an additive presence. So we're going to talk about plastics today.

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.

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

MGS Mfg. Group Inc., a global supplier of end-to-end manufacturing services to the healthcare industry, has acquired Danish tooling manufacturer Winther Mould Technology A/S. The investment in additional tooling capacity and expertise continues its strategic growth as a leading provider of high-precision plastic solutions for pharmaceutical, diagnostic, and medtech applications, said MGS in the announcement dated Oct. 2, 2023.

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.

Peter Zelinski and I talked about all this on the latest episode of the AM Radio podcast. For more details on how 3D printing complements injection molding, listen to the episode above or read on for the transcript.

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

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

Yeah, so we've covered this before, but they have done some testing on the material itself. And they're finding that they can integrate the, you know, Mantle material into their already existing mold, machining processes really easily.

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.

Okay, controlled porosity. I love that. It's another one of these design possibilities you can get from 3D printing, way, way, way back. When 3D printing was first entering production like that was one of the raps on it. Sometimes there was porosity. We're long past that. We get fully dense parts and we've controlled it to such an extent that there are some kinds of parts where you want to build in the porosity for the the useful effect you get out of it. Did an episode of The Cool Parts Show about these air filters that were made with controlled porosity. That was an idea, a prototype, but now here, it seems like these Innovent pins, real production components made with controlled porosity built in. Did you learn more about that? Like, like, how did they get exactly the porosity they want? How did they achieve that?

So Xact Metal, we like them. Laser powder bed fusion machine, and they make these really little machines that are pretty cost effective, in part because the size is so small, but a lot of the metal parts you want to 3D print precise components, they fit within a smaller build envelope and but laser powder bed fusion, like we always think about starting with a build plate, starting with a flat surface, you're describing starting with an existing tool and building on top of that, I guess, like the most basic question that comes to my mind is, do the metal properties come out the same as the the mold tool you're starting with?

Yeah, so for plastics production, I visited the RE3DTECH booth. They're a 3D printing service provider. And they use a whole bunch of different processes, including HP Multi Jet Fusion, and they're starting to see production applications for plastic AM using MJF. And they showed me this like perfect part, that was the perfect example of AM moving into production with plastics, it was a part that was formerly machined from aluminum. And they're now making it from PA12. And they're doing more of a manufacturing on demand type model, and ultimately saving the customer a bunch of money. And it was just sort of the perfect example of that.

Yeah, so it depends on a lot of factors, like you know, the how detailed the design of the mold is, and how tough the material that they're molding is, but they said it can be anywhere from 25 to a 1,000 shots with 25 to 200 as sort of being their sweet spot.

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

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.

So you said you saw a lot of tooling for plastics and even saw a lot of injection molded tooling. So like, let's keep going. What's another example?

Yeah. So I think that's a good place to wrap up this part of the conversation. And when we come back from the break, we will talk some more about polymer additive manufacturing.

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

Yeah, so I also talked to Xact Metal, and they have a DMLS system. And one of the really interesting applications that they talked about was their VP of commercial operations, Dave Jankowski, gave a Tech Talk. And he mentioned a case where a customer used the metal 3D printer to repair a mold. So they cut off the damaged part, fixed it in the machine and added new material directly onto the cut surface. And I just thought that was a really interesting application that I hadn't heard of before.

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.

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

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

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.

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.

So yeah, another example of 3D printed tooling that I saw that wasn't injection molded tooling is 3D printed molded components. So Next Chapter Manufacturing was at the show, and they were showcasing these 3D printed ejector pins. They also do 3D printed injection molded tooling, but they started making these ejector pins that can vent gases out of a mold, and they call them Innovent pins. Get it?

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.

Yeah, that's all they do. They don't even do the printing for the production parts in house. They have a Markforged machine that they use for prototyping, but they ultimately send their work out to a service bureau for printing. And so they can just focus on the design of the part.

Yeah, so the first big example this is sort of the bulk of what I saw was 3D printed injection molded tooling. And I have several sub-examples of this. The first one is Mantle. We've covered them before, but they make a system that's specifically designed for 3D printed mold tooling that uses a flowable metal paste, and a hybrid machine tool. They were at the show presenting a case study with another exhibitor Westminster Tool, which is a mold shop in Connecticut. And they were talking about a project they worked on together, making a mold for a pair of medical tweezers, and Westminster was designing the mold for this part. And it needed to be made out of this 65% glass filled polyamide which is tough to work with. It's abrasive it doesn't flow well and it has narrow molding parameters. So they designed a mold with a conformal cooling channel that would help them mold this material. They designed the mold and mantle printed it, sent over the inserts to Westminster where they did a little bit of postprocessing and then they were able to run thousands of these parts. It was more of a prototyping-type application. And they were able to go from design to part in like three weeks.

Okay, 3D printed end-of-arm tooling. So Savage Automation like is that their whole gig people come to them for 3D printed solutions and end-of-arm tooling?

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

So yeah, the Mantle process we've written about that before. We'll put a link in the in the show description to our coverage of this but it's like a 3D printing with this like mud-type material that partially solidifies, can then be machined right in the same process as 3D printed, and then it's baked to a harder state later and becomes production ready mold tooling. It's a) a type of 3D printing process that is different from everything else out there and b) this alternative to get full scale, full production quantity, mold tooling. And now here, Westminster, they’re a mold shop, their business is machining molds, and they're, they're evaluating this other way of making mold tooling, has some new freedoms, like you say, the ease of putting conformal cooling in there. I wonder in your conversation with them any like little nuances that have come out either positive or challenges about like what they're discovering about this process?

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.

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

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.

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.

And you told me a little bit about it. And it's a part where like, they showed it to you, but you couldn't photograph it because there's still some confidentiality around their customer. But like, like, what, what industry did it have to do with?

When compared to the traditional end of arm tooling on the left, the 3D printed EOAT section from Savage Automation on the right is lighter and faster to produce.

I have one more example for you. This one was at the Fortify booth. And they have a DLP system and a resin that's reinforced with ceramic fibers for added toughness. It's really good for making rapid prototype molds. Because you can have a mold that's ready to use it in three days, and you can get a couple hundred shots out of it.

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.

Okay, so um, you saw a lot of tooling at PTXPO molds, molded components, end-of-arm tooling. Like I think that is just about all the tooling that goes into injection molding, pretty comprehensive.

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

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 AM Radio podcast is brought to you by the Additive Manufacturing Conference at IMTS, the leading industry event focused on 3D printing for production. We're currently open to speaker submissions for the 2022 event. Learn more and submit your proposal at AdditiveConference.com.

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

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

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

And it's a case of plastics, replacing metal. And we talk about that from time to time. Sometimes things are made of metal, not because you need the metal, but just because machining something out of aluminum is the quickest way to get it. And yeah, now 3D printing in some cases is an even quicker way.

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.

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

Westminster Tool designed this mold with a conformal cooling channel for a pair of medical tweezers, and Mantle 3D printed it using its TrueShape process.

Time is running out to enter Plastics Technology’s Hot Shot’s Injection Molded Parts Competition — share your company’s capabilities via its greatest molding challenges.

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.

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.

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

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.

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

It’s the second acquisition of a Danish company by MGS this year. In June, it brought Technolution under its wing, a consultancy that provides R&D, regulatory compliance, quality, and project management assistance to companies in the pharma and medtech sectors.

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.

But yeah, they're made out of steel using DMLS. And they kind of have what they described as a porous structure on the inside that can let gases out without letting any of the material out. And they had this cool demo at their booth with some 3D printed parts that they were submerged in a tank of water and then they had air going up through the parts and you can see the air bubbles coming up through the water to show the porosity.

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

Yeah, he said it was it's like a physical thing. It's not a chemical thing. And they said it was sort of a combination of design and manipulation of process parameters.