machines and robotic integration - injection mold manufacturing companies

The company operates Class 7 cleanrooms on site for the production of infusion, transfusion, and hemodialysis kits. It runs Krauss Maffei and Negri Bossi molding systems in its 4500-sq-m production space. Muroplás also has developed an IT system to help maximize the production of precision parts for medical applications. One investment that has contributed to its success is the purchase early on of PowerMILL CAM software from Delcam plc (Birmingham, UK), which it has used to develop its own range of medical devices. Muroplás carries on a tradition, in fact: Back in 1983, a Portuguese company was the first European moldmaker to install CAD/CAM technology, according to industry association Cefamol.

Powder bed fusion 3D printer manufacturer Xact Metal has announced an initiative named, “Breaking the Mold: The Xact Solution to Better Tooling.”

With a background in journalism, Ada has a keen interest in frontier technology and its application in the wider world. Ada reports on aspects of 3D printing ranging from aerospace and automotive to medical and dental.

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Unlike many molding companies in Portugal, which historically have tended to specialize in specific activities—tooling design, polishing, the fabrication of precision molds, and so forth—Muroplás chose to invest in its own machining department and build molds as well as provide injection molding services.

On another note, binder jet 3D printing company ExOne provides a comprehensive suite of 3D printed tooling solutions under the X1 Tooling brand. Launched in 2021, X1 Tooling boasts a vast selection of industrial-grade options for various manufacturing processes, including plastic molding, forming, composite work, and metal casting.

Featured image shows Xact Metal printed automotive connector insert on a tool with the corresponding plastic injection molded final part. Image via JST.

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"We believe that combining the conception and manufacture of molds with injection molding of precision plastic parts offers our customers unique benefits," Dinis Baptista, International Sales/Information Systems, told PlasticsToday. "The use of high-speed machining technology and a dedication to improving the form, function, and manufacturability of molds has allowed us to provide medical device manufacturers with the best of both worlds: accuracy and precision at less cost," adds Baptista.

Moreover, Xact Metal has broadened its offerings through collaborations with Oqton and Dlyte Polishing Solutions (GPAINNOVA). Oqton’s advanced software, including automated conformal cooling channel design, streamlines the integration of 3D printing (additive manufacturing) into the tooling and molding process. Additionally, the partnership with Dlyte Polishing Solutions provides a complete workflow solution for achieving high-quality surface finishes on additively manufactured tooling components.

Contrary to common belief, the major reason suppliers of injection molding services incorporate moldmaking and mold repair into their portfolio typically is not a matter of economics but delivery time, according to Delcam. Time and reputation is lost when a company has to wait for a mold to be repaired or parts shipment is delayed because molds have not been delivered within the planned timeframe. Being able to implement small changes or improvements to the mold on site also improves customer service, and intellectual property ceases to be an issue when molds are built in house, says the company.

Portugal has a storied moldmaking tradition that dates back to the beginning of the 20th century, when companies in the town of Marinha Grande, about 95 miles north of Lisbon, started manufacturing molds for glassware rather than importing them. After World War II, plastic injection molds gained a foothold and, with the inevitable ups and downs, that has continued ever since. Automotive OEMs have been reliable customers; medical device manufacturers, not so much. Muroplás, located in Muro-Trofa, about 130 miles north of Marinha Grande, is the exception that proves the rule.

Xact Metal is growing its presence in the tooling industry with over 140 machines installed globally, says the company. Its approach combines metal choices, refined printing methods, and partnerships with software and polishing businesses. This creates a full solution for moldmakers, encompassing design to final part production.

“Actco has nearly six decades in close tolerance tool and die work, and we’re actively looking to the future by adding more close tolerance equipment to our toolbox,” said Dana Gruber, President of Actco. “The Xact Metal XM200G fits that bill. The 20-micron build layer and compact machine design allows us to meet our customer’s needs.”

The use of metal AM is impacting the tooling industry by enabling the creation of complex tools with unique features. While cost-effective for low-volume applications, this technology offers advantages in design freedom and lead times compared to traditional methods.

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Recently, Xact Metal collaborated with Uddeholm to provide Corrax powder for its 3D printers. Corrax is a new material with two key properties: it lacks cobalt and resists corrosion. Additionally, it can be polished to a very smooth (A1) surface finish. This collaboration allows moldmakers to create improved mold inserts and tooling components, resulting in faster production and higher quality.

As per Xact Metal, its technology is making inroads within the tooling and molding industry. Companies across various sectors, like Actco Tool and Mfg, DuPont’s subsidiary Spectrum Plastics Group, JST, and plastics packaging company The Plastek Group, have strategically invested in Xact Metal. All these companies utilize the technology for a specific purpose: creating complex tool inserts used in injection molding processes.

Muroplás is always attuned to the needs of its customers and continues to invest in the necessary resources to produce complex molds and optimize production, says Baptista, and that is the simple secret of its ongoing success. "R&D is an obsession at Muroplás," says Baptista. "We exist for our customers, and we are proud to have forged a relationship based on quality."

By offering economical solutions for intricate parts, Xact Metal’s 3D printers seamlessly integrate with conventional manufacturing. Its focus on affordability aims to break down cost barriers in powder-bed fusion technology. Additionally, on-site production capabilities with Xact Metal minimize downtime, allowing for a more agile production process.

This expansion highlights the significant time and cost reductions Mantle’s technology offers in tooling production. Additionally, Mantle shared an example wherein Westminster Tool leveraged Mantle’s 3D printers for tooling applications. In doing so, the company was able to rapidly produce complex mold inserts, slashing traditional lead times by 50%.

Founded in 1989, Muroplás initially produced precision parts for the automotive industry. Shortly after setting up shop, however, "domestic companies that needed components for infusion systems challenged us to produce parts," says Dinis Baptista, International Sales/Information Systems. The company never looked back, and has been a national pioneer in plastic injection molding for medical device OEMs since the 1990s. Medical technology applications now represent 90% of the company's business, and it has cemented its reputation by investing in R&D and new technologies, and embracing change.

Through this move, Xact Metal is making its metal 3D printing technology more accessible to moldmakers, aiming for faster and cheaper parts production. This approach focuses on affordability compared to other metal 3D printing methods. Xact Metal has customers who are successfully using this technology, suggesting it can be profitable for mold and tool businesses.

Portugal has a storied moldmaking tradition that dates back to the beginning of the 20th century, when companies in the town of Marinha Grande, about 95 miles north of Lisbon, started manufacturing molds for glassware rather than importing them. After World War II, plastic injection molds gained a foothold and, with the inevitable ups and downs, that has continued ever since. Automotive OEMs have been reliable customers; medical device manufacturers, not so much. Muroplás, located in Muro-Trofa, about 130 miles north of Marinha Grande, is the exception that proves the rule.

“We are excited about the new possibilities direct metal 3D printing brings to our rapid prototyping capabilities and engineering labs,” said Tyler Stark, Innovation Hub leader at Spectrum Plastics Group. “Adding stainless steel printing to our current lineup of 3D thermoplastic printers not only bridges the gap for fixtures and tooling but also speeds up significantly the prototyping process, enabling us to meet our customers’ most complex device development needs and in rapid fashion.”

Much recently, Mantle announced its expansion in the tooling sector with 3 new customers signing on to utilize its metal 3D printing technology. DuPont’s subsidiary Spectrum Plastics Group, Heyco Products, a Penn Engineering company, and General Pattern are the latest to join Mantle’s growing client base.

French 3D printing company AddUp launched AISI 420 steel for tooling manufacturers compatible with FormUp 350 machines. This material enables complex mold creation with minimal post-processing thanks to AISI 420’s strength, corrosion resistance, and use in injection molding. Its collaboration with Aachener Werkzeubau Akademie has demonstrably produced high-durability, low-porosity molds.