The open design of the three-blade cutting rotor makes the G-Max XL ideal for grinding heat-sensitive materials that still retain heat from processing, according to Wittmann. Open spaces between the blades and rotor shaft ensure ventilation, and the knives can be easily changed. The rotating and fixed blades, which are angled in opposite directions, ensure a clean scissor cut.

The RWS system, for example, can help car manufacturers integrate numerous individual parts into increasingly large castings, which are processed with heavier dies in larger presses and punches.

The new Airtect Plastic Leak Detection System from PCS Co. is designed to provide 24/7 protection of injection molding machine nozzles and manifold systems, reducing downtime and costly repairs.

New T-Flow HRS control units from Oerlikon HRSflow increase the precision and reliability of temperature control in hot-runner injection molding. Modular in design, three models are configurable to multiples of six zones.

The system sends tiny volumes of low-pressure air through robust stainless-steel sensor tubes to quickly detect most leaks thanks to a self-teaching algorithm, said PCS.

A standardized base plate accepts dies of various sizes, and the integrated control system enables semi- and fully automatic die changes and precise positioning to within ±0.3 mm.

Ultimakers new Metal Expansion Kit combines the geometric versatility of 3D printing and the strength of MIM parts in a convenient desktop package. The kit works with the Ultimaker S5 dual-extruder 3D printer. The kit contains two print cores and two filament types. The first filament is BASF Forward AM Ultrafuse 17-4 PH and the second filament is BASF Forward AM Ultrafuse Support Layer. It also contains Magigoo Pro Metal adhesive and special green part packaging.

The combination of integrated touchscreen, clear text display, smart navigation, and guided operation results in a particularly user-friendly concept without the need for instruction or prior knowledge, according to Oerlikon HRSflow. Recipes and test reports can be installed and transferred quickly and efficiently via the integrated USB port. Data is exchanged with the injection molding machine via the OPC UA interface in accordance with the new Euromap 82.2 standard protocol for hot-runner controllers. The integrated VNC server also enables convenient operation via notebook, tablet, or smartphone.

The die changing table travels on floor-level round rails, with a rolling resistance so low that up to five-ton loads can be moved manually by one person. In addition, the rails are designed to facilitate precise carriage guidance and to prevent dirt deposits and tripping hazards in the floor.

Desktop metal 3D printing is something of a holy grail within the industry. While metal 3D printing processes do exist, they are very expensive and require large machines that are unsuitable for desktop use. Even the least expensive SLS (Selective Laser Sintering) 3D printers compatible with metal powders start at around $40,000 and often cost several times that number. But desktop metal 3D printing may soon become an affordable reality, thanks to a new Metal Expansion Kit from Ultimaker that harnesses metal injection molding technology.

Because of its compact footprint, performance, and maximum material throughput of 100 kg per hour, the G-Max XL can be used as a beside-the-press granulator for inline recycling of sprues and reject parts during machine startup. It can also be used as a central granulator.

T-Flow HRS precisely controls the nozzle temperatures, allowing universal use, even in demanding high-performance applications with compact nozzles. Several heating options are available, and different recipes can be saved, stored, compared, and quickly called up.

While the post-process conditioning steps may deter many users, this system is quite appealing. At a relatively low cost, users can print several iterations of green parts until they get the results they require. Then they can send the final iteration into BASF for conditioning and receive back a usable metal part.

The integrated pull-push mechanism moves dies on and off the press bed via the roller rails. A safety device ensures that loads can only be moved when the RWS die changing table is firmly attached to the press or storage space.

No tools are required to access the cutting chamber or the screen fixture, which also facilitates cleaning and maintenance operations. Even material and color changes can be carried out very quickly, further increasing productivity.

If a user wants to switch back to standard plastic 3D printing, it is a simple matter of swapping to the original print cores.

The starter kit comes with a small controller, an air regulator, silicone tubing, stainless-steel tubing, and polyurethane tubing. Users can build onto the starter kit with additional accessories that make it possible to perform full hot-runner manifold leak detection.

After swapping in the two new print cores, users can setup prints as usual within Ultimaker Cura slicing software. The Ultimaker S5 will then print the green part as it would with any other material. Once the green part finishes, users can ship it to a post-processing facility in BASF's network. Within 10 business days, BASF facility will perform the debinding and sintering conditioning. They will then mail the finished part back to the user.

Editor in chief of PlasticsToday since 2015, Norbert Sparrow has more than 30 years of editorial experience in business-to-business media. He studied journalism at the Centre Universitaire d'Etudes du Journalisme in Strasbourg, France, where he earned a master's degree.

Ultimaker hasn't yet announced pricing for either the Metal Expansion Kit or the BASF conditioning process. But they do anticipate that the kit will be available for order sometime this summer.

Metal injection molding (MIM) is a metalworking process in which fine metal powder, mixed with a binding agent, fills cavities in a mold through a method similar to conventional plastic injection molding. The parts are fragile after they come out of the molds and require additional conditioning steps to become usable. That conditioning removes the binder material to leave a "green" part. The green part then enters a sintering oven that fuses the metal powder, resulting in a solid, dense metal part. The downside of MIM is that it retains the constraints of traditional injection molding, which limits the complexity of the part geometry.

Wittmann’s new beside-the-press blade granulator is suited for grinding large injection molded parts up to 500 x 200 mm (19.7 x 7.9 in.) in size.

From nozzle leak-detection systems to precision-ground ejector pins, these recently introduced products promise to save injection molders time and money.

Designed to fit into small, crowded cavity and core inserts, the pins are manufactured with hardened M-2 steel and are available in diameters from 0.060 to 0.320 in. and in 2.5- and 5.5- in. lengths. Cut-to-length and custom options are also available.

Unlike stamping punches, which are sometimes used as core pins in molds, the heads of TI pins are precision ground to mold tolerances. Also, rather than beginning with a fractional-diameter core pin, step grinding can be eliminated with mold inserts fabricated to the molded part diameter via wire electrical discharge machining. The TI pins only need to be cut to the finished length.

“The Airtect Plastic Leak Detection System is an essential tool that can be installed directly onto the injection molding machine nozzle or hot runner manifold system," said PCS VP of sales Derrick Jones. “It quickly alerts users of leaks in the form of an alarm and/or the suspension of production, enabling faster operator response and repair. The system can be adapted to any hot runner system, either new or retrofit.”

A new rail-guided die changing table for transporting heavy dies and molds is available in three versions for loads up to 15, 25, or 40 tonnes per die. The electric RWS system from Roemheld is equipped with two different pull-push mechanisms for the safe, automatic transport of dies to set-up presses. It is compatible with most machines.