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

Although the stiffness of the thermoset polymer is only a quarter of that of aluminum, design measures enabled the research team to adhere to the maximum allowable deformation. After 600 hours of testing on the engine test stand, the lightweight design element demonstrated flawless functionality in a state-of-the-art internal combustion engine. With the aid of the planned fuel injection tests, the project partners now want to prove the functionality and the NVH characteristics taking the gas forces of the combustion process into account.

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 camshaft module features a monolithic design with integrated bearings — in other words, it is manufactured in one piece, thus reducing assembly time in the engine manufacturing plant. Car manufacturers receive a pre-assembled module from their supplier and can mount it on the engine with just a few simple mounting operations. This eliminates the need for separate, time-consuming installation of the camshaft. This innovative solution boasts an additional advantage: aluminum inserts in highly stressed areas of the camshaft bearings absorb the direct forces.

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

Castings made from aluminum require extensive reworking after casting, resulting in high costs. In contrast, fiber-reinforced thermoset polymers allows a near-net-shape manufacturing, thus requiring comparatively little reworking and which again leads to reduced production cost.

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.

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.

KraussMaffei’s ColorForm process — where coloring of parts is done directly in the injection mold via introduction of a polyurethane or polyurea layer (PUR/PUA) coating — has a new large lab line for product and process development at the company’s site in Parsdorf, Germany. In this new setup, an MXW 4500 injection molding machine (with more than 5,000 tons of clamping force) has been paired with two RimStar metering systems and three different mixing heads, with a maximum PUR discharge of up to 500 g/sec. (17.6 oz./sec.) possible.

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

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

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

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.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

In 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

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

Camshaft modules, which are a key component of powertrains, are still being made from aluminum. Now a research team from the Fraunhofer Institute for Chemical Technology ICT, in collaboration with their partners, has succeeded in manufacturing a camshaft module from fiber-reinforced thermoset polymers using the injection molding process. This lightweight design element helps lower engine weight and reduces assembly costs. It is currently available as a functional demonstrator.

Further, at up to 500,000 molding cycles, the service life of a thermoset polymer injection mold is significantly higher than that of aluminum high-pressure die cast molds. Furthermore, plastics reinforced with a high fiber content have a much lower CO2 footprint compared with aluminum, since this light metal is very energy-intensive to manufacture.

KraussMaffei says it designed the lab line to mimic a complete all-in-one production process, including injection molding, PUR flooding, parts handling, postprocessing and surface treatment, with the ability to run medium and very large components. The production of sample plates is also possible.

And there is another advantage: automotive manufacturers are eager to minimize noise emissions. Rattling cars are not only annoying, they are also a clear competitive disadvantage, so noise, vibration and harshness (NVH) characteristics are high up on the list of factors used to assess vehicle quality. Polymers have good damping characteristics. “This makes it very easy to optimize the acoustic performance of the camshaft module,” says Sorg.

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.

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.

Weight reduction is one of the most effective methods for reducing CO2 emissions. Researchers at Fraunhofer ICT in Pfinztal are supporting the automotive industry in its efforts with a newly developed camshaft module made of thermosetting composite materials. This lightweight camshaft module was realized in cooperation with the MAHLE Group and associated partners Daimler AG, SBHPP/Vyncolit NV and Georges Pernoud.

When determining the best ejection option for a tool, molders must consider the ejector’s surface area, location and style.

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.

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.

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.

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.

KraussMaffei has paired an MXW 4500 injection molding machine featuring more than 5,000 tons of clamp force with two RimStar polyurethane (PUR) metering systems and three different mixing heads in a new ColorForm lab line at its facility in Parsdorf, Germany.

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

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

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

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

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

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

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.

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.

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

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.

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

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

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

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

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).

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.

“The camshaft module is located in the cylinder head, so normally in the upper installation space of the powertrain. Here, it makes particular sense to reduce weight, since doing so also contributes to lowering the vehicle’s center of gravity.”

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.

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.

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.

The German Federal Ministry for Economic Affairs and Energy (BMWi) has been funding the project. When it comes to the choice of the right polymer, the project partners opted for high strength, fiber-reinforced thermoset polymers, as they are able to withstand high temperatures and mechanical and chemical stresses such as those caused by synthetic motor oils and coolants, for instance. “We contribute the know-how regarding how to design the component geometries to suit the material and the process so that they satisfy all requirements,” says Thomas Sorg, a researcher at Fraunhofer ICT.

To support this, the MXW 4500 machine features a swivel plate and widened clamping plates. A RimStar Flex 8/8 metering system with MK5/MK8 mixing heads handles quantities of up to 50 and 250 g/sec., respectively. A RimStar Compact 16/29 with the newly developed MK10-3K mixing head is also available, providing output rates of up to 500 g/sec. Depending on the component weight, the paint is added via a modular dye module, with the 2K mixing pots, or directly, as with the MK10-3K.

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.

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

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

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.

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.

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

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

Camshafts ensure that the charge-cycle valves in internal combustion engines are opened and closed reliably and precisely. These valves are located in the camshaft module, the standard material for which is still aluminum metal. But automotive manufacturers and suppliers are putting great effort into producing powertrains and their components in lightweight design.

KraussMaffei has installed an MXW 4500 injection molding machine that supports its PUR overmolding Colorform process in a lab in Parsdorf, Germany. Source: KraussMaffei

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.

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.

In terms of handling, the automation was also designed with practicality in mind. Because nonconductive plastics like PP, PA and PE need to be “activated” to ensure adhesion between the thermoplastic and polyurethane, a flame treatment station is integrated into the lab system. Postmolding, the system also includes a trimming cell, which can be used to remove sprues or perform other secondary functions.

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