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.

3D printing makes it possible to support custom geometry and tweaks to a product design like a forearm cast, so that each part can be tailored to the user.

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

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

The various technologies behind recycling will not be elaborated in this article, but film extrusion applications require a more complex process to achieve the desired final quality. Recyclers focused on the film extrusion market need r-LDPE feedstock with a percentage of aluminium preferably less than 0.2%. The recyclers producing for the injection moulding market can accept up to 10% aluminium in the final product. Separating aluminium from the LDPE film, either mechanically or by chemical separation, is not an easy process and is not a necessity for many applications in injection moulding or compounding. This means that the compositions of polyAl will vary with the demand from each customer. In the meantime a catalogue has been built containing the average compositions of the polyAl end product from processors all over the world. This catalogue is a good step forward in making the products recyclable on their own.

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.

3D printed nests for CMM inspection can be created using the part’s existing CAD model, similar to the process for designing a mold.

Baystar's Borstar technology is helping customers deliver better, more reliable production methods to greenhouse agriculture.

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.

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.

Currently, most recycled polyAl is processed in Europe for main use in injection molded applications or compounding. The typical metallic look is a result of the aluminium is already known to various users in a number of (valuable niche) applications, where appearance and quality is important.

3D printing is a viable production choice for a variety of products, particularly where printing enables geometric complexity or other advantages. While 3D printing is capable of continuous production of tens of thousands of pieces, it is equally applicable to smaller batches of parts needed less frequently — with no minimum order quantity. Production use cases for this technology include brackets, phone cases, valves, medical implants, packaging solutions and much, much more.

This technical article by EXTR:ACT e.V in partnership with ACE explores new opportunities in material recycling made possible by the increase in collection of laminated paper packaging.

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

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.

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

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.

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.

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).

Cobots, pick-and-place robots and other automation can make plastics processing more productive, but in most cases these additions require specialized end-of-arm tooling (EOAT) and other fixturing. 3D printing can be applied to produce vacuum grippers and other specialized end effectors for handling parts. These devices can integrate vacuum lines, wire harnesses and other features to simplify assembly, and tend to be lighter weight than conventional options.

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.

Efforts have also been pushed by changes in legislation and a growing recognition to improve recycling technology. This has led to the formation of a two- step recycling process for beverage carton packaging.

The first recycling step in a paper mill is a pulper where the paper fibres are separated from the non-paper parts. The valuable recovered paper fibres are used for new paper products, such as boxes and transport packaging. The fibres in the beverage cartons are of very high quality and are thereafter a sought after source of fresh fibres in the ever-improving collection of paper for recycling throughout Europe. Fiber quality is important as paper has a finite number of recycling cycles.

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 clear model in the center shows the conformal cooling lines inside the metal 3D printed mold on the right, used to produce the plastic part on the left.

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

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

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.

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

The need for tooling adds automatic lead time to producing a new molded part, but 3D printing can enable a manufacturer to jump straight into production while waiting for that tooling. This means that new products can be launched into the marketplace sooner, and brand owners can get feedback before committing to the expense of a mold. The bridge need not start at the beginning of a product’s life span, either — many companies are now turning to 3D printing to bridge gaps due to supply chain disruptions as well.

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

Lead time delays for molded parts often originate from difficulties with sourcing tooling. 3D printing makes it possible to accelerate mold development and simplify design changes down the line. If a new design is needed, 3D printing offers a faster route to a new tool and even the chance to repair or modify an existing one. While metal 3D printing methods, such as laser powder bed fusion, have historically been the most common techniques applied to mold tooling, there are new innovations to explore in terms of more accessible metal printing methods and short-run molds made from other materials such as polymer composites.

Affordable desktop 3D printers make it possible to create affordable items for plant use such as inspection fixtures, assembly tools and check gages. CMM nests, for example, can be developed using mold design tools to generate the inverse of the part and arrive at a 3D-printable fixture design. As an added bonus, once fixtures have been developed for 3D printing, they can be saved as digital files. Should one be damaged or go missing, it can be quickly replaced by simply printing another.

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.

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 air diverter for a youth motorbike was designed for injection molding, but bikes produced before the mold tooling was ready used 3D printed parts like this.

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

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.

At NPE 2024: The Plastics Show, 3D printing and additive manufacturing (AM) suppliers are highlighted in the Advanced Manufacturing Zone, while AM users will take to the stage for Wednesday’s 3D Printing Workshop. But keep an eye out for promising developments and applications across the show floor, including:

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.

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

3D printing still plays a valuable role for rapid prototyping, as it is often the fastest way to get a look-and-feel prototype or iterate design ideas. However, the technology has advanced to the point that, with the right material and printer, a prototype can often be used just like a production part. Brackets, electronics enclosures, ducts, components of medical devices and more have made this leap.

Most polyAl processing is based on mechanical recycling with roughly two types of end markets served: injection moulding and film extrusion. After the cleaning and drying steps, the 3D caps and closures are separated from the 2D films in a wind shifting process and sold to HDPE/PP recyclers. The remaining films with both LDPE and LDPE/Al are agglomerated and often pelletized/granulated into a new raw material.

These phone case components are 3D printed in a machine that can produce several hundred of these parts per day; scaling production to higher quantities means simply adding additional machines.

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

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

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.

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.

Although LDPE and HDPE differ (e.g. LDPE has a lower crystallinity), the influence of aluminium on the polymer properties is at least qualitatively expected to be comparable as many parallels can be drawn between the two materials.

Wednesday, May 8  |  1:00 – 5:00 PM Orange County Convention Center The 3D Printing Workshop at NPE2024: The Plastics Show, is an immersive, half-day workshop focused on the emerging possibilities for part production via 3D printing and additive manufacturing.

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

The industry will keep steering towards solutions that ultimately yield as many mono-materials as possible from their recycling processes, provided that this can be done in a responsible manner and makes ecological sense. For economic reasons, mechanical recycling still prevails over chemical separation or chemical recycling. While there already are several good end applications available the industry remains open to finding more high quality applications for polyAl using its unique properties.

These smart ski goggles were developed with a 3D printed electronics enclosure. Originally meant as a prototype, the 3D printed assembly has since been used in sale units as well.

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.

Once relegated to rapid prototyping, 3D printing technology has now advanced far beyond the design studio. Machines have improved and material options have widened. Today molders, moldmakers and OEMs alike are turning to this layer-by-layer production technology to save time, serve new markets and even fill supply chain gaps.

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.

Attendees will benefit from a program focused on practical applications of 3D technologies related to plastics processing. This event will conclude with a 3D Printing Industry Reception sponsored by Additive Manufacturing Media.

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.

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

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.

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.

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

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

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

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.

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.

Sonja Bischoff (SIG Combibloc), Lilly Feng (LamiPak), Mats Haggquist (Billerud), Peter Hengesbach (Stora Enso), Štěpán Ledvina (Tetra Pak), Johan Sundblad (EloPak), Anna Svantesson (Graphic Packaging International), Raymond De Schrevel (EXTR:ACT)

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

The digital nature of 3D printing makes it possible to easily adjust a base product design via software to suit the specific customer or application. The technology can be applied to produce everything from custom medical devices such as splints and hearing aids to consumer products like shoe insoles and sporting equipment tailored to the buyer.

The recycling of laminated papers, especially beverage cartons, has been working successfully at scale in Europe since the mid-nineties. This is based on major efforts and an early developed sense of responsibility by the beverage carton industry. There are about 20 specialized paper mills in Europe that receive the lion’s share of the collection, all having installed appropriate equipment to process beverage cartons to recover their highly valuable fibres (Figure 1).

Although little has been found in literature about the properties of r-LDPE with metal particles, more has been found on r-HDPE with metal particles. For this material it was shown [3] that the aluminium significantly increases thermal conductivity, more so with filler content over 10vol%. However, aluminium also increases stiffness and therefore causes a more brittle composite. Tensile strength reduction is expected only with very high proportions of metal.

Files for 3D printing are more easily stored than physical parts, leading major OEMs, military branches and government agencies to adopt the technology as a way of sourcing spare parts and items needed for system maintenance. Digital inventory parts like clamps, clips and brackets can be 3D printed as needed, saving the hassle and expense of storing extras or keeping track of tooling. Even better, digital inventory can also be distributed. By working with manufacturing partners or placing printers at different facilities, organizations can produce these parts near where they will be used.

Partly due to its complexity, polyAl is however not a material that is widely known to the processors of recycled plastic. Its properties have an optically interesting metallic look, and the traces of very thin aluminium foil can provide additional chemical or mechanical properties that may be interesting for specific applications. Figure 6 shows an impression of the typical curled-up foil particles with an average thickness of ≈6 μm in a r-LDPE structure.

About 500 kt of beverage cartons are collected and sorted for recycling every year in Europe. The sustainability ambition and commitments agreed by ACE members in the 2030 Roadmap will ultimately lead to an increase of more than 700 kt/a. The average composition of a beverage carton is about 75 % fibres, which leaves 25% plastic and aluminium. This leads to an estimated additional recycling volume from 150 kt/a to 250 kt/a for polyAl which will be needed to manage the full recycling of beverage cartons. Current operational capacity is 50 kt/a, and growing yearly, leaving many good opportunities for investors.

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.

The residual product of this first step in the recycling process is called “rejects”, and was until recently recycled by incineration with heat recovery. However, these by-products can be used for new materials by using special recycling processes and special recycling methods. The reject material from the paper mills consists of flakes of two dimensional LDPE plastic and aluminium, three dimensional HDPE and PP plastics from the caps and closures and a small mix of various contaminants (<5%) from mistakes in the collection and sorting processes. It has been a long ambition among the manufacturers of laminated cartons to find a suitable material-to-material recycling process for the plastic and aluminium components to improve the total recyclability of beverage cartons.

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.

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.

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

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.’

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

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

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

The non fiber fraction from the paper mill are called polyAl, which is an abbreviation of polymers and aluminium, or PE-AL