of NETSTAL - krauss maffei injection molding

MHI also extended the size range of its direct-drive, all-electric MEII toggle series with a new 720-tonner that replaces a 610-ton model. It has two servomotors directly coupled to the injection screw. An on-board hydraulic power supply is used for nozzle-touch, core-pull, and valve-gate functions.

In-mold technologies for labeling, decorating, painting, and assembly were another major theme at NPE. Another was the integration of long-fiber compounding and injection into a single machine as a way to combat rising materials costs. Other timely market needs were addressed by the latest developments in automotive glazing, multi-component presses, and higher-volume PET preform systems.

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.

Sumitomo introduced its SE-DU line of U.S.-built direct-drive all-electrics from 20 to 198 tons. They use four direct-drive Sumitomo AC servo motors with closed-loop control and digital sensors for plasticating, injection, toggle clamping, and ejection. New PC-based N-9 control provides faster response, full SPC/SQC, and machine-optimization functions.

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.

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

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

Ningbo Haitian Group of China, known in the U.S. now as Absolute Haitian, also introduced its first all-electric line—HTD machines from 64 to 396 tons. Injection speed is 150 mm/sec standard, 300 mm/sec optional.

New electric vertical presses and models for LSR, multi-component, and micro-molding also made debuts. And even hydraulic systems followed the trend with servo-driven pumps.

A still more elaborate demonstration by moldmaker Electroform showed off its brand-new twin-turret tooling technology by combining two-shot molding, IMD, and in-mold assembly of a toy race car. Using a 200-ton Engel tiebarless machine, the process starts with robotic insertion of a preprinted, preformed ABS film from Serigraph into the mold cavity. That film is backed up with injection of white ABS to form the top of the car. Black ABS is injected separately to mold the bottom chassis and four wheels. Then all six parts are snap-fitted together in the mold. Moving slides are used to snap on the wheels perpendicular to the direction of joining the car’s top and bottom halves. Cycle time at the show was 22 sec, but Electroform president Wade Clark hopes to get that down to 15-16 sec.

Krauss-Maffei showed its all-electric EX series for the first time in the U.S. The direct-drive injection unit provides up to 300 mm/sec speeds, and its three-platen, modified toggle clamp has just eight pivot points—half those of a conventional five-point toggle—bringing compactness and precision. The water-cooled motors reportedly can handle long holding pressure.

Cincinnati Milacron rolled out the sixth generation of its Magna hydraulic toggle machine. The Magna MTg comes in four sizes from 170 to 450 tons and has a new injection unit, new hydraulics that are easy to service, new Mosaic control, and a compact footprint with fast-lockover clamp. It is designed for fast set-up and changeover. Proportional hydraulics yield a positioning accuracy of ±0.0014 in.

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

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.

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

The glass-filled, high-flow PBT/ASA carrier is shot first, and then the mold is rotated for injection of the second material in a “negative coining” (mold expansion) step with Engel’s Coinmelt process. The mold-opening stroke determines the thickness of foaming and hardness of the surface.

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.

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

• TPE melt temperature: The relationship between temperature of the TPE melt and adhesion strength is reflected in the example of a 65 Shore A TPE overmolded on a PC substrate (Fig. 2). As the melt temperature increases from 370 F to 400 F, a notable improvement in adhesion strength is evident. But a further increase to 430 F actually reduces adhesion strength. In this instance, the optimum melt temperature is somewhat less than 400 F. Molders must balance desired adhesion strength against the possible adverse effects of elevated melt temperature, e.g., thermal degradation and ejection difficulty.

Milacron publicly demonstrated molding of automotive glazing for the first time, using a standard Maxima MG 1100 two-platen press. It injection-compression molded a fixed sidelight from clear polycarbonate overmolded with a black PC frame. The second injector was mounted on an angled sled affixed to the stationary platen above the primary unit. The system was done in partnership with Exatec, LLC, Wixom, Mich., which provided the mold with a retractable core. Shot weights were 2.15 lb for the clear PC and 8.4 oz for the black frame.

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.

Exhibits in Chicago testified not only to the growing popularity of liquid silicone (LSR) injection molding but also to multi-shot molding of LSR with thermoplastics. Arburg molded ice scrapers from a self-adhesive LSR and PC on an 88-ton Allrounder A electric machine.

This is illustrated by adhesion data for a 55 Shore A TPE containing a color concentrate and overmolded on a PC/ABS substrate (Fig. 3). In this case, a PP concentrate carrier exhibits adverse effects on adhesion, apparently because of a conflict between the carrier and the TPE. In contrast, data show that with this particular TPE, EVA and TPU carriers provide superior adhesion.

JSW Plastics Machinery showed two models in its new J-AD Advantage series of electric toggle presses. It will range from 40 to 1800 metric tons (44 to 1980 U.S. tons). The new line will eventually replace JSW’s ELIII series and has controls with response times as short as 62 millisec vs. 250 millisec for the ELIII. The controller also has a new 15-in. touchscreen. Injection rate up to 350 mm/sec is standard, 550 or 800 mm/sec optional. The new clamp design accommodates larger molds while also reducing platen deflection. Clamp and ejector speeds also have been increased. A 121-ton model at the show produced a 1.25-in.-diam. helical gear with 28 teeth using injection-compression molding.

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

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

NPE was also the North American debut for Krauss-Maffei’s Injection Molding Compounder (IMC) with a twin-screw extruder mounted over the injection press, which was first introduced at K 2001 in Germany. The 1000-ton system produced an automotive front-end carrier using 30% long-glass PP. Krauss-Maffei has sold more than 30 units globally, 10 of them for North American plants. Most systems are of 2700 to 3200 tons, though K-M is working on a 4000-tonner. Major applications are structural auto parts and shipping pallets.

Sumitomo also introduced the iii-System, its new real-time production and quality monitoring system. Up to 50 machines can be connected, and the unit can store up to 60,000 shots of data and burn it onto a CD or DVD.

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.

Moreover, thickness of the TPE layer also affects adhesion strength. Thin TPE layers tend to surrender heat rapidly in the cold cavity, and the drop in temperature tends to reduce bonding strength. The challenge for the designer is to strike a balance between the durometer and thickness of the TPE to achieve the cushioning level desired.

PBT polyester was molded with a new self-adhesive LSR material on a 110-ton Engel electric E-motion Combi US. Integrated robotics transferred the part from the first to the second cavity.

A 110-ton model at the show molded polycarbonate light guides 0.4-mm thick x 2.7 in. long using its optional 400-mm/sec injection speed with injection response time under 38 millisec. A 180-ton ECNII-4A showed a new LAP feature for overlapping molding functions to shorten cycle times. It produced PP coasters in a four-cavity mold in under 5.5 sec. A 20-tonner molded thin-wall (0.4-mm) PC parts using optional 550-mm/sec injection speed.

Where the TPE layer is less than 0.060 in. thick, the feel of a soft elastomer can easily be negated by the hardness of the underlying substrate. The degree of cushioning provided by a TPE layer is also greatly influenced by the substrate’s inherent hardness.

Another problem is the broad array of available nylons, which differ by resin class (e.g., nylon 6, 66, and 12), reinforcement type and loading, and additives used. In the case of a first-generation TPE, test data show that a dramatic loss of adhesion strength occurs when it is bonded to impact-modified and heat-stabilized nylon 6 (Fig. 4). But progress is being made: Data show that a second-generation, improved-adhesion grade of the same TPE class yields significantly improved adhesion performance, even with heat-stabilized products.

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.

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.

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

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).

Nissei upgraded its FN series of fully hydraulic presses with a longer screw and barrel, optimized hydraulics, reduced sliding resistance, and the TACT controller for high-speed injection control and repeatability. There is also a new oil heat-up function to ensure quick starts. The upgrade results in one-third shorter set-up time, 50% less part-weight deviation, and 30% energy savings. Eight models range from 89 to 501 tons.

NPE2024: Coinjection of postconsumer resin, in-mold decoration, LSR micromolding and bioplastics processing are just some of the machine displays at Milacron's booth.

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.

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

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.

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.

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

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

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.

Additional considerations also make nylon adhesion more difficult. One is their propensity for high moisture pick-up, which makes careful drying imperative. And the melt temperatures of nylons are higher than for most other substrates, so the TPE melt temperature has to be increased accordingly to ensure good bonding. Preheating of nylon inserts is also generally advised.

Toshiba’s new ECNII line of all-electric machines have a new low-inertia injection motor and mechanism for quick response. Like the ECN series the size range is from 5 to 950 tons, but the toggle clamp has been improved for “shockless” opening/closing and the new Injectvisor-V30 controller has touchscreen data entry and expanded memory to store data on up to 300 molds and 1000 shots.

Boy introduced its 60.5-ton 55 Ae model with servo-electric plastication and hydraulic injection and clamping. Its dual hydraulic pumps permit ejection on the fly for 10% faster cycles.

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

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

Ferromatik Milacron, for example, molded two-color PP flip-up dispensing closures on a 275-ton K-Tec machine with a 48-cavity Foboha “Twin-Cube” turning-stack mold that was jointly developed with Milacron and introduced at NPE. It has two four-face center turrets that rotate 90° on each cycle. The two parts of the closure were snapped together in the mold.

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.

Sumitomo rolled out a 7.7-ton all-electric unit for micro-molding. The SE7M has direct drive on the toggle clamp, plasticating, and ejection. New control software reportedly delivers 25-millisec response. New synchro-plast control mode for screw position and backpressure can be used with low-viscosity resins or uneven pellet sizes. At the show, the machine molded 0.035-g connectors from LCP in four cavities with a 3.3-sec cycle.

Milacron rolled out vertical/vertical Magna V machines from 15 to 130 tons. Offered in stationary, shuttle, or rotary-table designs, they have a C-frame clamp, digital positioning, and overlapping functions for maximum speed and precision.

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.

As reported in April, Negri Bossi USA launched its new Canbel VE all-electric machine series of 77 to 935 tons, redesigned and upgraded from its previous Elma line for faster injection, more precise and repeatable movements, and reduced maintenance. Negri Bossi now also uses direct drive on the toggle clamp and injection unit of all sizes (previously only on smaller models). Direct drive provides higher clamp speeds than before on the larger presses.

Swedish compounders HEXPOL TPE AB and Polykemi AB have collaborated on a 2K sustainable development project for consumer products.

Toshiba’s new ED series of two-platen hybrid presses ranges from 720 to 1950 tons and combines electric plasticating and injection with hydraulic clamping.

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.

The medical device contract manufacturing company with eight facilities globally has purchased the Riverside, California-based micromolder.

A new factor in direct in-line long-fiber compounding and molding is Engel, which is now working with PlastiComp to offer PlastiComp’s patented Pushtrusion technology on Engel’s Combi press (licenses are included in the purchase).

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.

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.

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.

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.

The Pushtrusion Direct In-Line Compounding unit is a small extruder unit and glass-roving feed system that is mounted atop the feed throat of the primary injection press. The system melts the resin and forces it through the Pushtrusion die, where it wets out continuous glass rovings. The melt pressure coming through the die pushes the glass into the system, where an internal knife chops the material to desired lengths of 2 to 10 mm. The chopped material is fed into the throat of the Engel press fitted with a special screw designed for low shear and little mixing.

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

A critical challenge for designers and producers of these parts is poor adhesion of TPE to substrate, which reveals itself in peeling, curling, fraying, or delamination of the material layers. Initially, this was a fairly straightforward issue since the most common approach was to combine an olefin-based TPE with a compatible rigid PP substrate.

Engel and a group of partners developed the new “Dolphin” multi-component process to produce auto interior trim such as instrument panels with integral thermoplastic foam skins. This avoids secondary operations such as slush molding and post-trimming, as well as non-thermoplastic urethane foam. Recyclability is thus enhanced.

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.

Engel also demonstrated integration of RJG’s eDart process monitor with the CC200 controller—the first such move by an injection machine OEM. This allows users to program separate profiles for the three phases of filling, packing, and holding and to use cavity-pressure monitoring as the changeover between the phases. RJG eDart screens appear on the CC 200 display.

Plasticomp offers a portable Pushtrusion unit as a separate device, but Engel’s integrated system is said to have advantages: integrated control from the Engel operator panel and lower cost and smaller footprint since no separate power supply is needed for the Pushtrusion device.

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 insert molding, the rigid substrate is molded first and transferred to a second mold, where a TPE is shot around the insert to create the finished part. The process uses standard injection molding machines and relatively simple, low-cost tools. Insert molding is best suited to applications involving relatively low volumes and manufacturing locations where labor costs are low.

Netstal’s new Elion all-electric press made its U.S. debut. The new line will be offered initially in four models from 55 to about 200 tons. They feature a new toggle-clamp design that makes the ma chine considerably shorter and has closed-circuit, oil-free lubrication. A new “combi” gearbox integrates plastication and injection functions into a single transmission. Three different plasticating systems are offered: high-speed, high-torque, or a blend of the two. The unit can deliver injection speeds of 250 to 450 mm/sec, depending on which option is selected. The moving platen rests on a new linear guide system rather than the tiebars. Netstal says the machine achieves a dry-cycle time of 1.2 to 1.4 sec. Elion also uses Netstal’s DSP/3 and Sycap closed-loop control with 15-in. flat-screen touch panel.

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.

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.

Husky also developed a new split sprue-bar (SSB) system that keeps the mold area clear for free-drop parts or robot access and eliminates drool and stringing when running stack molds. The split sprue bar is offered in an in-line or offset configuration. A HyPac unit produced a 19.5-g deli container in a 24-cavity tool in 3.8 sec.

The best antidote is a shut-off design that creates a sharp transition between TPE and substrate. Ideally, a uniform TPE layer thickness of around 0.04 in. is desirable for good adhesion, but that is not always feasible.

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.

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.’

Nissei also unveiled the AN1 series prototype hybrid press based on its NEX all-electric toggle press but using the hydraulic X-Pump for plasticating. It is designed for high-speed plasticating and fast-cycle molding of PP and PE. Sizes will be 300 to 500 tons. A 397-ton AN1 model at the show molded thin-walled PP lids in a 16-cavity tool in 4.9 sec. The X-Pump raised the plasticating rate to 794 lb/hr, 70% higher than a standard NEX unit.

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.’

Since prying fingers tend to challenge adhesion in soft-touch infant products, molding technique and tool design are especially critical.

To ensure that the TPE melt adequately fills the mold cavity, a key consideration is the ratio between flow length and part thickness. The minimum ratio should be around 150:1. Another proven approach is to locate the gate at the thickest area of the part and to keep flow length as short as possible.

Husky introduced other HyPET improvements that reportedly trim cycle times up to 25% compared with three years ago. These include improved in-mold and post-mold cooling (through the addition of a fourth stage of cooling) plus faster dry cycling and hot-runner refinements. For example, a HyPET 300 system produced a 14.5-g preform for a 500-cc water bottle in a 72-cavity mold in 6.5 sec, while a HyPET 500 molded a 20-oz carbonated soft-drink bottle in a 144-cavity mold in 10.5 sec.

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

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.

Niigata upgraded its MDVs-IV and MDVRs-IV lines of vertical all-electric presses (55 to 110 tons) with new software that enhances speed, responsiveness, and precision. Shuttle or rotary table response is improved 20% and table oscillation is down 20%. For lens molding, the presses can maintain injection speeds as low as 0.01 mm/sec and resin pressures down to 14.5 psi. A new nozzle-temperature control reportedly eliminates “cobwebs,” drool, and plugged nozzles. The operator panel is now a larger touchscreen with new screen layouts. The new injection unit features a wear-resistant screw tip.

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.

Netstal pushed the limits in PET preform molding with its Pet-Line 660-ton machine running the first 192-cavity tool capable of a 7.3-sec cycle—90,000 preforms/hr. The tool comes from MHT in Germany and employs a narrow-pitch technology that reduces cavity spacing. Netstal has sold one 192-cavity system.

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.

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.

• Ejection efficiency: Part ejection can be facilitated by designing 0.5° to 1° of draft into each side of the mold. With more ejection-resistant materials like TPUs, a 5° to 6° draft is sometimes required. Texturing the tool surface frequently improves ejection, whereas a more polished surface tends to impair it.

In recent years, however, the range of materials used in overmolding has expanded significantly to include more TPE classes (e.g, TPU, TPV, SEBS) and a broader range of substrates (ABS, PC, and nylon). While the broader materials spectrum for overmolding expands opportunities for soft-touch design, it also adds new levels of complexity and poses new challenges in adhesion.

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.

As we reported in June, at least 20 machinery suppliers exhibited systems for in-mold labeling and decorating (IML and IMD), anticipating growth of those technologies in North America. (IML, in particular, is already widespread in Europe.) A number of exhibits went for maximum visual impact in IML with lenticular films (in many cases supplied by Xtreme Graphics) that give a 3D animated effect. However, the most dramatic demonstrations were combinations of multi-shot molding with in-mold assembly and, in one case, IMD too. These applications showed off the multi-functional flexibility of stack-type molds with one or more rotating turrets between the fixed and moving platens.

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.

Toshiba used two new 45-ton ECNII electric models to produce a golf-green repair tool of PBT overmolded with a soft-touch skin of self-adhesive LSR. A Toshiba SCARA robot transferred the part from machine to machine.

Molders found more new choices in hybrid machines at the show. Toshiba announced its new ED two-platen series which ranges from 720 to 1950 tons.

And for a totally different type of in-mold finishing, Ube Machinery announced that the first U.S. machine with its new Imprest in-mold painting technology (developed with Sherwin-Williams) will arrive next spring for a large, non-automotive application. In Japan, Ube has sold several in-mold painting systems for automotive and appliance jobs. The system was developed for ABS, but Ube and Sherwin-Williams are testing nylon and PP.

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.

The process takes place in one Engel Duo two-platen machine with the multi-component Combi M configuration and Trexel’s Mucell microcellular foaming process. Dolphin uses a rigid carrier of PBT/ASA alloy (BASF’s Ultradur S) and a special copolyester thermoplastic elastomer called Pibiflex from P-Group of Ferrara, Italy. Pibiflex can be foamed with the MuCell process yet delivers a high-class surface—unlike most TPEs—and bonds well to PBT.

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-mold demonstrations abounded at NPE. Ferromatik Milacron demonstrated two-component molding and in-mold assembly of PP dispenser caps on a 275-ton K-Tec machine with a 48-cavity Foboha twin-turning-cube stack mold. Moldmaker Electroform showed off two-shot molding with black and white ABS, in-mold film decorating, and in-mold assembly. Its new tooling with twin rotating turrets ran on a 200-ton Engel tiebarless machine where it molded and snapped together the top, bottom, and four wheels of this model race car.

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.

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

Battenfeld introduced its upgraded HM series two-platen presses, showing 28- and 450-ton models. Upgrades include injection pressures up to 42,630 psi and injection speeds up to 300 mm/sec.Demag beefed up its Titan two-platen line with new 1500- and 1760-ton models.

In addition, careful selection of color concentrate carriers is needed to ensure good TPE adhesion to nylons. In general, LDPE and EVA are preferred carriers with nylon substrates.

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

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.

• Vent design: Air entrapment in the cavity during TPE overmolding is also detrimental to adhesion and is best addressed by adequate venting in the tool. Insufficient venting can show up as poor adhesion at the end-of-flow points, scorching of the TPE, or even short shots. Typical vent depths are between 0.0005 and 0.001 in. The right vent depth for a given part depends partly on the flow properties of the TPE involved.

Nylon-based materials are an increasingly popular substrate in several high-growth overmolding markets—handles and grips for power and hand tools, appliances, and lawn/garden products. The downside is that nylons are often difficult to overmold with good adhesion. TPEs bond relatively well to unmodified and glass-filled nylons, but fall short when joined to versions that are highly formulated with additive packages.

Milacron rolled out a new Fanuc Roboshot S2000i-B series from 55 to 330 tons featuring 330-mm/sec injection speed with 36-millisec response standard. A new moving-platen design produces more equal pressure distribution across the mold face. Fanuc’s new 310iS CNC control is said to deliver faster control, higher acceleration, faster injection, and simultaneous sled-forward and clamp-close motions. A 110-ton model at the show demonstrated a coining process to produce ultra-thin-wall medical parts.

Adhesion is not the only important consideration in overmolding, so here is some advice on aspects of tool design that will optimize other areas of performance:

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

Preheating inserts prior to overmolding often improves adhesion strength. The extent of improvement depends on the degree of compatibility between insert material and TPE. The appropriate insert temperature depends on the substrate and TPE and is best determined through discussions with the materials suppliers.

Nissei debuted its new FNX presses with servomotor-driven, variable-volume hydraulic X-Pump. Machine sizes are 88 to 198 tons. They use the same direct hydraulic clamp as Nissei’s FN series. The hybrid design delivers the combined capabilities of hydraulic clamping with most of the energy savings, quick response, high position repeatability, and fast injection of an all-electric. Injection response is 40 millisec, and maximum injection speed is 300 mm/sec standard. The servo motor runs the pump only when needed, requiring 55% less oil and 40% less energy than Nissei’s fully hydraulic FN units. Part-weight variation with FNX is only one-third as much as with the FN series.

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

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

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

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

Husky introduced its new HyPac line for thin-wall applications. The series will range from 300 to 600 tons and features several new technologies, including the new Ultra Packaging (UP) hot-runner system. A new direct-drive electric injection unit boosts acceleration rates to twice the industry standard, and maximum speed is 30% higher (300 g/sec), which allows for 10% lighter parts. There is also a new fast-acting pneumatic pin shutoff.

Dima plans to bring its hydraulic DTC line for two-component molding to North America. It has a rotary turntable and integrated second injector.

In addition, Demag Plastic Group offers a direct-drive injection unit with certain sizes of its IntElect electric press.

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

NPE2024: Wittmann is featuring five injection molding machines incorporating its range of robotics and auxiliaries, with all products employing industry 4.0 communications, energy measurement and a brand-new red color.

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

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.

Multi-shot molding requires a special press with multiple barrels that allow several materials to be shot into the same mold. (Most often, such parts use two-shot molding, but some parts require three or four shots.) Benefits are reduced overall production time, superior part quality, and lower labor requirements. The approach is economically viable in programs of 250,000 parts/yr or more and regions where labor costs are high.

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

Chen Hsong of Taiwan announced that it had developed a press series with a direct-drive electric injection system and hybrid clamp. An electric inverter motor is used for plasticating. The first model is the SM-180HC with 180-ton clamp. The company also plans to launch soon a new 460-ton hybrid with servo-electric plasticating and injection.

Engel also rolled out its new CC200 touchscreen controller. It features an intuitive control panel, said to permit faster initial set-up and synchronized movements. All Engel automation is fully integrated into the control using the RC 200 robot control.

Direct-drive servo-electric motors replaced belts and pulleys on a number of new machines, such as Sumitomo’s new U.S.-built SE-DU all-electric line. Direct drive is said to give higher speeds, faster response, higher precision, and lower maintenance.

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.

Niigata also developed the MD-W series, similar to the MD-X but in 200- and 385-ton sizes with 11% wider tiebar spacing and 100- to 110-mm increase in minimum mold height.

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

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.

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.

Machine shops are natural inventors, but not necessarily suited to supporting and marketing a product. This Minnesota shop with an invention related to micromolding will share it through licensing.

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

Sumitomo introduced its mid-sized SE-HD line of all-electrics for heavy-duty applications such as thick-wall parts. These U.S.-built presses can handle long holding pressures at up to 31,718 psi. Sumitomo’s new SE-HS line of mid-sized all-electrics is suited to high-speed, thin-wall parts requiring a cycle time under 15 sec. It ranges from 242 to 385 tons and features injection speeds of 300 mm/sec and 25-millisec response. A new twin cylinder delivers high nozzle-touch force, with 0.3-sec pressurization or depressurization. It has the new SM screw for low-shear plastication and a constant-feedback clamp-force correcting system.

The FNX model also demonstrates a new Nissei concept called “Eco Molding” that uses the X-Pump to automatically adjust clamp force to just the amount needed to counteract the filling pressure. This saves energy by avoiding over-clamping and prevents flash from under-clamping. The concept allows for bigger parts to be molded on smaller machines, says Nissei president Hozumi Yoda.

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 smaller 720-ton electric unit demonstrated high-speed packaging at the show by producing a 20-liter container in under 8 sec.

• Shut-off design: Design of the transition, or shut-off, area between the TPE and substrate is critical to adhesion. Designs should avoid “feathering,” or gradual thinning of the overmolded TPE. Thin layers cause inadequate bonding and can result in curling or fraying of the TPE layer at the tapered edges (see Fig. 1A).

Ube Machinery said it is now offering its largest all-electrics (the biggest in the industry) in the U.S. Introduced last fall in Japan, the Ultima UN 2750- and 3300-ton models have up to eight servo motors and up to 400 oz shot size. The 3300-tonner was built to mold bumper fascias in under 30 sec.

• “Feel” versus thickness: The tactile feel of an overmolded part is the sum of several factors, just one being the inherent softness (Shore A durometer) of the TPE. Part feel also depends on the TPE’s coefficient of friction, texture, and—most notably—wall thickness.

Engel has entered the field of direct in-line compounding and molding of long-glass thermoplastics by integrating PlastiComp’s Pushtrusion system atop an Engel machine. The device melts resin and then wets out continuous glass rovings, which are chopped and fed to the injection cylinder below.

Two mammoth hybrid-electric machines, both with four direct-drive electric motors on the injection unit, were announced by Mitsubishi Heavy Industries (MHI) of Japan. As we reported last month, its 3300- and 3900-ton “em” models of hybrid-clamp, two-platen presses use low-speed/high-torque electric motors coupled directly to the ball screws.

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

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

Husky also upgraded the CoolPik robot on its HyPET preform systems. The bladder-type transfer system was replaced by a vacuum transfer system to reduce maintenance and ease setup.

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.

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

Husky challenged this achievement with a new and larger model of HyPET preform machine and unveiled the world’s largest PET perform mold, a 216-cavity tool that it developed in partnership with Amcor PET Packaging. Husky’s new 715-ton HyPET 650 model features a new injection unit capable of throughputs up to 3960 lb/hr. The mold makes PET preforms with thread diam. up to 30 mm. It is configured with 60-mm spacing between the cavities rather than the 50-mm pitch common to molds for this size of preform. The larger-pitch allows for a more rugged and longer-lasting design, Husky says.

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.

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.

Meiki America molded a prototype two-component roof panel on a new a 3400-ton model in its Meiki Dynamic Injection Press (MDIP) series for large, thin-wall parts. The press was designed in cooperation with Japan’s Teijin Chemicals, which makes special PC grades for auto glazing. The MDIP-2100-HR2 is said to be the world’s largest two-component rotary injection-compression machine. Platen parallelism is said to be within ±25 microns. Platen movements are controlled with hydraulic servo valves. The machine has 2100 x 2100 mm tiebar spacing and the 1900 x 1900 mm rotary table is indexed hydraulically.

Krauss-Maffei showed its new CX line of two-platen machines in 385, 880, and 1760 tons, which replace its C series. Clamp length is 30% shorter, and it has improved hydraulics for better performance. Access to the clamp is easier, too. The CX line has an electric screw drive as standard. For clean-room applications, CX models incorporate a new drive system that retracts the clamping unit from the clean room for mold changing or maintenance. In addition, K-M’s new MC 5 control is standard.

As reported in April, Arburg’s Allrounder C Golden Edition of horizontal hydraulic presses features improved controls and valve technology for greater accuracy. Sized from 44 to 220 tons, they have the “Selogica direct” controller with new 15-in. color touchscreen instead of a keypad.

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.

One solution is to incorporate a “step” in the substrate profile to create an abrupt transition between TPE and substrate (Fig. 1B). Alternatively, the substrate might include an indentation, with the shut-off designed to put the TPE flush against the substrate (Fig. 1C). Both approaches reduce feathering, neutralize curling, and eliminate tear points that might initiate fraying.

• Gate design: In parts that are subject to high wear during use, and consequently prone to layer delamination, gates should be positioned in the areas that will receive highest wear. That’s because TPEs are hotter (and thus generally adhere better) at the gate rather than at the end of flow. When appearance is a priority, as in cosmetics packaging, gating from the back of the substrate via a pin is preferred since it hides gate blemishes on the TPE.

Nissei applied its X-Pump technology to its new vertical hybrid machine, the 118-ton Ecoject TNS100RE18E with horizontal injection, hydraulic three-tiebar clamp, and high-speed rotary table (180° in 1.6 sec). All operations except clamping and nozzle touch are electric. TNS models less than 75 tons will remain all-electric.

Sodick Plustech Co. of Japan (represented here by Plustech, Inc.) offers its LSR series of machines in 44 and 88 tons. These hybrids have two-stage injection and hydraulic clamp.

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.

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

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

Crisp finish lines between the opaque TPE skin and clear PC substrate are essential in this computer lap station, both for appearance and strong adhesion.

The system is an alternative to the use of pre-compounded long-glass pellets. ILC allows flexibility in the material formulation, as well as improved mechanical properties at reduced material cost, says Jeff McDonald, Husky’s automotive v.p. A system is installed at a global Tier I automotive supplier. It can produce front-end modules, door-module carriers, and instrument-panel carriers.

The best way to reach the optimal TPE melt temperature is to approach it gradually, not necessarily by increasing barrel temperature, but via higher screw rpm or injection speed. A problem in determining the actual melt temperature is that it is not always equivalent to injection nozzle temperature. A sensible approach is to use a pyrometer to measure melt temperature of a TPE air shot.

Over the past decade, soft-touch overmolding has radically changed the look, feel, and function of a broad range of consumer products.

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.

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.

Taking an opposite tack, Demag demonstrated overmolding of dissimilar materials chosen so that they would not adhere to each other. Demag’s 120-ton Multi machine with two injection units produced a magnifying glass with protective case from optical-grade PC and glass-filled nylon. The two materials are combined by a flip hinge, and ran in a two-cavity mold with indexing plate in 20 sec. When cooled, the two materials do not stick, so the magnifying glass can rotate in and out of the case on pin-type hinges.

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

Compounding in-line with injection in order to incorporate longer glass fibers and reduce material cost was demonstrated by two machinery OEMs. Both systems involve a twin-screw compounder mounted on top of an injection machine. The twin screws pull in and chop continuous glass rovings. Husky has revived its development of this technology through cooperation with twin-screw extruder supplier Coperion Werner & Pfleiderer. Husky’s In-Line Compounding (ILC) cell mounts a Coperion ZSK70 extruder on a 2500-ton Quadloc two-platen press with a hot-runner system and robot.

A U.S. molder ordered the first ET-90HR4 all-electric vertical-clamp/horizontal-injection press from Toyo/Maruka. The new four-station rotary table indexes 90° in about 1 sec. Toyo/Maruka also showed its new 90-ton vertical/vertical electric press, the ET-90VR2. This toggle press joins a 45-ton model and allows users to set up separate injection profiles for different molds on the same table.

The Boy XS E, successor to the XS series, features servodriven pump drives and different clamp configurations, as well as a special mold holder for optional micromolding operation.

Dima also announced its new DCI series of vertical-clamp/horizontal-injection presses in sizes from 35 to 70 tons. Two machines can be mounted on one rotary table for multi-shot uses.

In selecting a gating method, it is advisable to begin with a “steel-safe” design of the gates and to size them initially on the small side, enlarging them later as required. Certain TPEs (like SEBS) require a smaller gate to boost shear and ensure complete mold fill. Other TPEs (TPVs and TPUs) generally require larger-than-normal gates to compensate for their high melt viscosity.

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.

• Concentrate carrier compatibility: Overmolding with TPEs containing color concentrates can be tricky, one danger being conflict between the colorant carrier and the TPE. The workhorse carrier for TPEs has long been PP, but this carrier frequently performs poorly when bonding certain TPE families to nylon, PC/ABS, and other engineered substrates.

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

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).

Niigata’s new MD-X series of all-electric toggles comes in 55, 85, and 110 tons. The new injection unit, servomotor, and control reportedly allow holding pressures as long as 60 to 100 sec at 19,575 psi for molding thick parts. Injection response time is 55 millisec.

• Predrying: Some TPE types—including TPU, TPV, and copolyesters—tend to be hygroscopic, or prone to moisture pick-up. If not appropriately dried prior to molding, absorbed moisture can turn to steam and harm adhesion at the interface of the two materials. Moisture also can hydrolyze some resins, harm surface properties, and increase ejection difficulty. Moisture at the time of molding generally should not exceed 0.05% by volume. Common practice is to dry TPEs in a desiccant dryer with a –40 F dewpoint.

Driving this change is the increasingly diverse range of thermoplastic elastomer (TPE) materials. In overmolding, a TPE is injection molded over or around a compatible substrate using either insert or multi-shot processes. The resulting hard-soft structures are quite effective in comfortable, non-slip, and abrasion-resistant handles, grips, and buttons.

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 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

In a few cases (e.g., parts with exceptionally long flow paths or highly wear-prone areas), features are designed into the substrate to create a mechanical interlock after overmolding with TPE.

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.

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.

• Surface texture: Designers are sometimes tempted to underscore the texture and grip properties of a TPE by polishing the mold to add a smooth finish. Yet a smooth finish sometimes actually highlights flaws like knit lines and blemishes in the part. Conversely, texturing of part surfaces is often effective in hiding flaws and imparting a “grippy” or leather-like feel. Certain textures have the effect of imparting a harder or softer feel than might be anticipated in light of the TPE’s Shore A durometer. The goal is to balance the surface texture and durometer values of the TPE to get the intended product feel.

The wave of new direct-drive electric machines, in which ball screws are coupled directly to the motor shaft, is prompted by the ability to achieve faster response, higher speeds, greater precision, and reduced maintenance by eliminating belts and pulleys. Some sources say direct drive is also cleaner because belts generate particulates as they wear.

Engel molded a two-color sunroof panel using its Glazemelt technology on a Duo 1650 US Combi-M machine. Unlike Milacron, Engel used a rotary stack tool from INglass of Italy.

Netstal and Husky pushed the productivity limits for PET preform molding: Netstal operated a new 192-cavity mold in a Pet-Line machine, and Husky displayed a brand-new 216-cavity tool.

Scientists use the Otter Box to gather data in demanding outdoor environments. The soft TPE’s roles are to provide a waterproof seal, impart a grippy feel, and adhere strongly to the PC-ABS substrate.

Selecting a target melt temperature for the TPE depends on the substrate and the adhesion level required. Most TPE suppliers provide a recommended range of melt temperatures for their products. For maximum adhesion, aim towards the upper end of the supplier’s recommended range.

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

Meanwhile, Boy introduced to the U.S. its new 60.5-ton 55 M VV vertical/vertical hydraulic machine. It has Boy’s standard two-platen clamp turned 90°, shot weights up to 5.6 oz, and Procan CT color touchscreen control.

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.

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

Nissei introduced a new all-electric press specially engineered for two-color or dissimilar materials. A horizontal 154-ton DCE140-9E Elject model with a servo-driven rotary table employs a new “shockless” rotation mechanism for higher precision and longer life. It indexes 180° in 0.9 sec. It uses two NEX-style electric injectors arranged side by side and a toggle clamp. Simultaneous motions allowed molding a two-color mug in two cavities in a 20-sec cycle. The system also has a new high-performance mold protection function.

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

Advances in electric drive technology were evident in nearly every injection machine builder’s booth in Chicago. New electric and hybrid models sported direct-drive motors for injection and other functions, and direct drives showed up on bigger presses, too. Thanks to these drives, several electric machine lines can now mold thick parts with long hold times.

• Substrate preparation: Proper preparation and handling of inserts is critical to adhesion performance. The cleaner the insert, the better the bond. The optimal production method is to overmold inserts directly after they are produced, since that minimizes chances of contaminants collecting on the insert surface. If storing inserts is unavoidable, they should be scrupulously protected against dust or dirt. Those who handle inserts should wear gloves, since skin oil can impair adhesion. Also, mold releases are best avoided since they seriously impair bond strength between TPE and substrate.

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.

Engel showed a 300-ton model of its new Engel Speed accumulator-assisted hydraulic toggle series designed expressly for packaging. Engel will add a 440-tonner in the fall, followed next year with 550- and 710-ton units. They have a redesigned base, toggle, and moving platen.

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

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.

Over the past decade, soft-touch overmolding has radically changed the look, feel, and function of a broad range of consumer products. Abundant new color, texture, and tactile options are available in such products as toothbrushes, razors, power tools, cameras, kitchen items, hand-held electronics, and auto-interior parts.

Milacron’s Powerline NT550 all-electric press at the show featured a new high-capacity (54-oz) direct-drive injection unit. It uses a single roller-screw to reduce noise and inertia and eliminates having to synchronize two actuators. It is also five times faster than a ball screw, and delivers up to 20,600 psi at 41 in.3/sec with certain screw designs. A servo motor drives the toggle clamp and allows the toggle to relax during part cooling to eliminate the wait for tonnage release before opening the clamp. Other features include Milacron’s new Mosaic control, the global standard now for all Milacron presses, as we reported in June.

In both processes, strength and durability of adhesion between TPE and substrate require compatible hard and soft materials. The type of overmolding method used also affects adhesion performance: Multi-shot molding, by bringing together several melt fronts, generally offers superior adhesion. Adhesion performance is also affected by a number of additional factors:

Negri Bossi rolled out its new 1500-ton Bi-Power two-platen hybrid model featuring electric injection, hydraulic clamping, and two traversing cylinders on the moving platen. A low profile and compact footprint allows for easier clamp access and integration of automation.

MHI rolled out the next generation of its MetII all-electric series, ranging from 35 to 300 tons. It incorporates Super Resin Control (SRC) II metering system, which ensures consistent part weight and density by applying packing pressure to the melt with the screw after recovery.

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