Injection Machines Use Novel Two-Stage Molding System - double shot molding/Injection Machines Use Novel Two-Stage Molding System

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Injection Machines Use Novel Two-Stage Molding System - double shot molding

Author：gly Date: 2024-09-30

A collaboration between show organizer PLASTICS, recycler CPR and size reduction experts WEIMA and Conair recovered and recycled all production scrap at NPE2024.

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

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

Other speakers at this event emphasized the speed at which 3D printing can deliver end-use polymer parts, not necessarily as a competitor to injection molding but to support applications that would be time-consuming or expensive to mold. Daniel Baker, program manager for plastics at Endeavor 3D, shared a case study in which his company delivered a short run of about 500 parts for a new high-end gaming controller still in development, which would have suffered a long lead time waiting for injection molding. Andrew Roderick, senior applications and sales engineer for Extol, described how his company 3D printed 53,000 automotive parts over three months in a bridge production application to prevent the shutdown of the customer’s assembly line. Spencer Loveless, founder and CEO of Merit3D, described how his company manufactured 62,000 binocular case tether components in just 7 hours, delivering the parts more quickly than injection molding and saving the customer about $300,000 in potential tooling costs.

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.

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.

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

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

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.

The prevalence of 3D printing technology in the mainstream may also help with recruiting the next generation of toolmakers. Xact Metal, which showcased the tooling production capabilities of its laser powder bed fusion platform (described in more detail below), sees 3D printing as an aid to reshoring manufacturing as well as meeting workforce challenges. “Kids today know 3D printing,” says Scott Kraemer, application engineer, “and bringing this technology into this space could entice them into a career in toolmaking.”

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.

“There’s a solution for everything out there, from software to polishing to auxiliary equipment,” Kraemer says. Xact now has relationships with a number of other companies whose products it can recommend to customers — including materials. The company recently announced a new partnership with Uddeholm to supply the latter’s Corrax tool steel in powder form.

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

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.

Mantle says tooling is “just the beginning” for TrueShape. Additional solutions are on the company’s “roadmap” for jigs and fixtures, low-volume industrial machinery and spare parts, and high-volume precision part production.

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

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.

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

The foundation of the TrueShape process is Mantle’s flowable metal paste, which incorporates metal particles within a liquid carrier of solvents and polymers. Different metal particle types and sizes within the paste are said to minimize dimensional change during sintering. Mantle currently offers two FMP materials. One is P2X, which reportedly acts like popular P20 stool steel but boasts improved corrosion and abrasion resistance and is formulated to come out of the process in the hardened state without requiring additional heat treatment. The other is H13, which is chemically equivalent to standard H13 tool steel and can be hardened to greater than 50 Rockwell C, according to Mantle. Both grades can be machined, welded and ground, DiLaura says. A stainless grade may be next in line, he adds.

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.

A new 3D printing process that shapes extruded metal paste before sintering can produce fine detail and surface finish suitable for injection mold cores and cavities with limited or no additional postprocessing.

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.

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.

Unusually high-precision details and very low shrinkage distinguish TrueShape inserts like this one for a medical device mold.

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.

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

Stephanie Hendrixson reports on 3D printing technology and applications as executive editor for Additive Manufacturing. She is also co-host of The Cool Parts Show, a video series that highlights unique, unusual and weird 3D printed parts, and co-host and creator of the AM Radio podcast. SUBSCRIBE HERE

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

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

Contract manufacturers and OEMs are seeing additive manufacturing “win” when it can provide the fastest route to a part or tool. Material supplier BASF showed several sets of mold inserts in its booth printed with a ceramic material called Ultracur3D RG3280 intended for SLA and DLP-style printers. The chemistry of the slurry makes it possible to achieve a usable injection mold tool with just a short 10- to 15-minute UV cure to crosslink and densify the material, says David Constant, sales and business development manager for BASF 3D Printing Solutions North America. A longer heat treat can be done as a secondary step, if necessary, but avoiding this lengthy procedure (often 7 hours or more) helps to accelerate mold creation such that turnaround time on a new molded part can be as little as 24 hours.

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

A new company called Mantle offers 3D printing equipment and materials that boast unique suitability for producing injection mold components, overcoming limitations of other printing methods.

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

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

NPE: The Plastics Show returned for the first time in six years, bringing plastics manufacturing technology to Orlando, Florida, May 6-10, 2024. In the interim since the previous edition of this trade show, additive manufacturing’s adoption in plastics has advanced and expanded. While AM technology lacked a centralized footprint within NPE’s two exhibit halls, its presence was felt throughout the show — from the 3D Printing for Plastics Processors Workshop held on Wednesday to material- and technology-focused exhibits scattered throughout the exhibit floor.

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

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

This insert for a high-volume dishwasher component took 71% less time to produce and cost 67% less than conventionally manufactured insert.

This mold insert for an automotive suspension ring is 3D printed from BASF’s Ultracur3D RG3280. The tool was produced in about 12 hours with 3D printing versus about 6 weeks to source a conventional tool cut from aluminum.

What is TrueShape? It is a process based on a proprietary machine that combines both additive manufacturing and subtractive finishing into a single hybrid process for superior accuracy and surface finish. It uses unique Flowable Metal Pastes (FMP) that produce high-hardness steels that meet or exceed tooling industry requirements. The accompanying diagram shows the basics of the process. First, the flowable metal paste is extruded in layers from a vertical printhead to form a part. After depositing each layer, a heating step drives off solvents and other organic carrier liquids from the metal paste. Next, a milling tool in the TrueShape machine cuts precise dimensions and details into the relatively soft “green” material. This can occur either at the end of the build or at intervals throughout the build, depending on the part geometry. The whole process takes one to two days, depending on the part size and shape. Finally, the green part is transferred to a custom furnace for high-temperature sintering, which typically takes about a day.

A global medical-device manufacturer sought to significantly cut the time to make prototype parts with a high-temperature plastic. Using TrueShape and P2X material, cavity and core inserts were printed from a CAD file in just over 2.5 days, and the tool was ready for molding after another 5.5 days of mold and insert preparation. That compared with a conventional fabrication time of seven weeks, for a time savings of more than 80%. Cost was reduced by more than 60%. Actual printing and shaping of the inserts took 40 hr, followed by sintering for 24 hr. The finished inserts achieved tight dimensional tolerances and had a smooth matte finish similar to parts after EDM. About 40 hr of additional time was used to add ejector-pin holes, tap mounting holes, and install the inserts in the mold base. No surface finishing of the molding surfaces was required prior to use.

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.

To solve the latter challenge, UR often works with and recommends EMI’s services. The company, which supports automation through many services, has been applying Multi Jet Fusion (MJF) 3D printing primarily in nylon to supply automation peripherals such as cable management brackets, part nests and vacuum grippers. According to George Baker, EMI regional sales manager, the 3D printing technology from HP is cost-effective, helps to reduce the weight of peripherals and enables accelerated lead times.

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.

One of just a few 3D printing machines physically present on the show floor was Xact Metal’s XM200G2, a laser powder bed fusion printer which is positioned for accessibility. The machine is small enough to fit through a standard doorway, runs on 110-V electricity and offers a compact build volume that keeps operating costs down by limiting how much powder is needed to fill the bed and how much argon is required to keep the environment inert. But, just to the right of this 3D printer was a postprocessing machine, a DLyte electropolisher from GPAInnova, one of Xact Metal’s equipment partners. The company has found that, while some buyers want to research and choose their own auxiliary equipment, 3D printer adoption (and sales) can be eased by offering customers a more complete package of equipment.

Scott Kraemer is a senior application engineer at Mantle. He spent years as a mold designer and tooling engineer at a custom injection molder where he experimented with a variety of 3D printing methods for making mold inserts, including direct metal laser sintering (DMLS) and hybrid DMLS, in which milling is incorporated into the printing machine. Despite a number of successes with 3D printed tooling (reported previously in this magazine), Kraemer is enthusiastic about the superior performance of TrueShape in terms of precision details, crisp edges, and drastic reduction of the shrinkage and warpage issues that plagued other technologies:

The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda: Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

In 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

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.

Xact Metal highlighted other potential benefits of 3D printed metal tooling with this insert. Leaving areas open enables printing this tool faster and with less material; supports cooling in injection molding; and also enables faster press operation due to lighter weight.

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

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.

“Peripherals are the challenge,” says Travis Langford, channel and business development manager at Universal Robots (UR). “It’s the interface between the robot and the machine, the safety measures, the end-of-arm tooling.”

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.

He notes that although Mantle continues to produce mold components for market development, the company’s ultimate goal is to supply technology, not printed parts. It offers the TrueShape printer and custom sintering furnace, as well as associated software and the FMP materials. The current printer model has a bed size of 8 × 8 × 6 in. It can print four to six small parts at once, all with equal tolerances, DiLaura says.

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).

In recent years, it has become apparent that additive manufacturing—aka 3D printing—is destined to have a role in plastics moldmaking, owing to cost and lead-time advantages over conventional subtractive manufacturing—CNC machining—and unique abilities to produce complex internal tooling geometries such as conformal cooling channels. But, according to Mantle, existing 3D printing technology have been to imprecise or too expensive to be successful on a large scale. Mantle claims its TrueShape process is the first 3D printing technology that meets the tooling industry’s requirements.

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.

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

In each case, additive manufacturing was presented less as an industry disruptor and much more as an aid to toolmakers, molders and OEMs, and a means to augment what these companies are already doing. Here are a few takeaways from the show:

Mantle co-founder Stephen Connor developed a printable liquid-metal electronics material for solar panels. He wondered if a similar material could be layered to produce solid metal parts. He joined forces with a Silicon Valley entrepreneur, Ted Sorom, who had a tooling and manufacturing background as a product-design engineer. The two formed Mantle, with Sorom as CEO and Connor as chief science officer, and spent the last five years developing the TrueShape technology with a small number of “Frontier Partners.” One of those is Westminster Tool, a plastics moldmaker in Plainfield, Conn. “We have worked closely with them as we developed our technology,” says Paul DiLaura, Mantle’s chief commercial officer. “We have printed many materials samples and tool inserts for them, which they have evaluated and, in some cases, used. We are also working together on select joint customer projects.” A statement from Westminster Tool on the Mantle website says, “Mantle achieves a level of quality and speed that is revolutionizing how tools are made.”

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

The target price for a TrueShape system is in the six figures, in the same range as a high-end CNC system, but less than a DMLS or hybrid DMLS system.

The break-even point between direct polymer 3D printing and injection molding depends on a number of factors, including the part’s design, dimensions and ability to be nested within a build volume, as Greg Paulsen illustrated through several examples. Slide source: Xometry

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.

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.

Of all the trends you can see at NPE2024, this one is BIG. Not only is the auto industry transitioning to electrification but there are concerted efforts to modify the materials used, especially polymers, for interior applications.

Metal 3D printing offers a faster way to obtain injection mold inserts, such as this mold slide for an automotive trim tool 3D printed with Mantle’s technology. Printing this slide required only 4 hours of active labor from the customer’s toolmakers versus several hundred hours to produce it conventionally.

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.

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

Kraemer notes that binder jetting processes are not capable of printing clean conformal cooling lines because the lines get filled with powder. Also, he notes that 3D printing systems based on binder-encapsulated metal particles (similar to metal-powder injection molding, or MIM) are not suited to tooling wall thicknesses greater than 0.25 in., while with TrueShape, “We’re doing metal thicknesses greater than 3 in.” He adds that thicker walls in DMLS are more prone to warpage. The overall shrinkage rate for TrueShape is claimed to be 9% to 11%, vs. 17% to 25% for binder jetting, for example. The accompanying table summarizes Mantle’s comparison of TrueShape with other 3D printing processes.

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.

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.

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

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

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.

Mantle describes TrueShape as requiring four steps that typically require two to four weeks (including the time to fit the printed inserts into the mold base): Quoting > Print & Shape > Sinter > Final Finishing.

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

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

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

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

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.

Additive manufacturing also has a role to play in aiding the adoption of other technologies. This demo in the Universal Robots booth combines a UR cobot with a vacuum gripper, part nests and other 3D printed integration elements produced by EMI Corp.

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

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.

For contract manufacturers such as Xometry, additive manufacturing enables faster on-demand manufacturing and product development. New designs can be iterated in a “shotgun approach” in which multiple designs are 3D printed at once to quickly arrive at the best choice, says Greg Paulsen, director of applications engineering and marketing, in his presentation during NPE’s 3D Printing for Plastics Processors Workshop.

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.

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.

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

A Boston recycler invested in a turnkey shredding, granulation and elutriation system to expand its plastics reclaim business.

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.

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.

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

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.

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

These inserts were used with two difficult materials—Radel polyphenylsulfone (PPSU) and acetal. Radel requires a high melt temperature of 680 F, a mold temperature of 320 F, and high molding pressure of 38,000 psi. Acetal is challenging because of its highly corrosive gas emissions and ease of flashing. Parts molded with the TrueShape inserts in both materials passed all visual and dimensional requirements.

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.

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.

Beyond Plastic and partners have created a certified biodegradable PHA compound that can be injection molded into 38-mm closures in a sub 6-second cycle from a multicavity hot runner tool.

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

The costs of injection molding had Dustless Technologies making tooling and many parts offshore. Additive manufacturing promises an alternative, as in the case of the company's newest product, which is entirely U.S.-made.

Oak Ridge National Laboratory's Sustainable Manufacturing Technologies Group helps industrial partners tackle the sustainability challenges presented by fiber-reinforced composite materials.

A global manufacturer of consumer appliances replaced a plastic injection mold insert for a high-volume dishwasher part with a mold component printed with TrueShape in P2X material. The part took 46 hr to make—22 hr for printing and 24 hr for sintering—compared with a lead time of a week with conventional toolmaking, a 71% time savings. The TrueShape insert had a tolerance within 0.001 in. and smooth finish of less than 2 μm as printed. It was ready for use without additional finishing. It was used in a full nine-month production run of 200,000 parts. Showing only minor wear, it was reinstalled in the mold for an additional 200,000-part production run. Cost of the insert was 67% less than one manufactured conventionally.

In another meeting, I talked with team members from automation technology company Universal Robots and its partner EMI Corp. about the ways in which 3D printing is enabling the adoption of collaborative robots (cobots).

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.

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.

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

What if all the current limitations of metal 3D-printing technologies for making plastics mold tooling were overcome with a new approach that offers improved precision and surface finish, as well as shorter lead times and reduced cost? And that technology has already been proven in prototyping and full-scale production of hundreds of thousands of medical, appliance and other products with companies such as L’Oréal (cosmetics), Delta Systems (electronics), Hypertherm (industrial plasma, laser and water-jet cutting systems), Diversified Plastics and Westminster Tool. All that is precisely what is promised by the new TrueShape process from a San Francisco startup called Mantle.

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.

While mold inserts and directly 3D printed polymer parts were the primary areas of emphasis for AM at NPE2024, the technology is also helping manufacturers achieve other benefits in their operations. In one conversation at the show, I spoke with a member of a new additive manufacturing services company which is specifically targeting the jigs and fixtures market for clients with large factories and assembly lines, seeing this as an underserved market.

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.

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.

While 3D printing was scattered across the show, most AM-focused exhibitors could be found in the Advanced Manufacturing Zone. Xact Metal’s booth included both support equipment, in the form of the polishing machine seen in the foreground, and its 3D printer, located just beyond.

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

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.

“Having run laser powder bed fusion and also having many parts made with the various other metal AM technologies over the last eight-plus years, I realized there were limitations. It seems like I was always having to do more work to the parts after they were printed. TrueShape technology has the ability to meet those tight tolerances without compromising the design or having to do a lot of work on those parts after they are printed. So, to me, this is the first metal AM technology that is focused on the tooling world. And to me, that will have a much greater impact on the injection molding world, which is my passion.”

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.

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.

Many experienced toolmakers are retiring or near to it, and “There’s no second bench,” as Mantle co-founder and CEO Ted Sorom puts it. Additive manufacturing technologies like Mantle’s TrueShape process (a technique that builds tooling by extruding, milling and then sintering metal paste) are gaining traction because they can consolidate workflow steps to produce mold inserts. Mantle’s process, for example, often reduces or eliminates the need for sinker EDM operations (and the associated tooling). Avoiding or reducing the time spent on process steps like this enables toolmakers to be more efficient in their work and shortens the time line from insert design to use.

Uniloy is revising its machinery lines across the board and strengthening after-sales services in tooling maintenance, spare parts and tech service.