Molding of Metals, Ceramics and Carbides - injection tooling

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.

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

Trexel completed training its first class of MuCell-certified tooling engineers and designers at moldmaker Proper Group International. Proper Group also houses Trexel's latest cener for customer trials and application/process development.

Injection molding is still the go-to technology for high-volume plastic part production, but it is characterized by significant up-front capital investment in tooling, which is also time-consuming and difficult and expensive to adapt. The technology can use several molds at the same time, which means that it is ideally suited to the mass manufacturer of parts and components cost effectively—its cost effectiveness also promoted by the fact that there is minimal wastage as material is precisely dosed to match specific mold requirements.

A high-gloss surface equivalent to automotive Class-A solid molding can now be achieved with the weight savings and other benefits of microcellular foam molding, thanks to a new licensing agreement between Trexel Inc., Waltham, Mass., and Ono Sangyo Co.

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.

Although not necessarily relevant to automotive today, Braig notes that Trexel has experimented with MuCell and RHCM using PLA biopolymer. “They were beautiful parts,”he says.

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

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

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

Resin supplier Celanese turned to startup Rafinex and its Möbius software to optimize the design for an engine bracket, ultimately reducing weight by 25% while maintaining mechanical performance and function.

3D printing is a highly reliable, cost-effective and relatively easy-to-use production technology for small- to medium-volume applications and can rival injection molding.

9T Labs continues to enhance the efficiency of its technology, which produces composite parts with intentionally oriented fibers.

Perhaps the biggest advantage of the use of 3D printing, however, is that although per part it is slow compared with injection molding, its advantages in terms of design freedom, creation of geometric complexity, and part consolidation all stimulate innovation. These factors alone may be a spur to using 3D printing for multiple smaller batch runs rather than bowing purely to the economics of using injection molding for high-volume manufacture.

Injection molding finds its sweet spot in large-batch production, where the requirement is for the manufacture of many thousands of identical products simultaneously. It is also best suited to robust designs based on one continuous form, and the process can produce products with superior smooth surface finish without the need for post-processing (which is typically needed with 3D printing parts).

The 3D printing machines that achieve production level repeatability and accuracy are typically costly beasts. Because of this, many potential users are put off by the large capital outlay required, and therefore approach 3D printing subcontract specialists, who not only have the levels of necessary high-quality 3D printing machines in-house but also the experience to get the most out of them.

Beyond non-costly part complexity, using 3D printing for production also facilitates nearly unlimited geometric freedom, exhibits very low to zero iteration costs, and has low downtime in the production cycle.

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.

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

Also, as 3D printing is a digital process, it can be stopped post-part build or post-run and started again without punitive cost. Production volumes can be exactly aligned with demand day to day, week to week, month to month. With injection molding, once the production process is initiated, it needs to fulfill the full run immediately to remain economic, which therefore necessitates the need for warehousing—which increases the cost per part.

Good news for automotive molders is the ability to achieve all these advantages while achieving the equivalent of a Class-A glossy surface, free of the usual splay caused by gas bubbles. Aimed at auto interior parts, the new solution is the result of applying OSK’s Rapid Heat Cycle Molding (RHCM) technology to MuCell. RHCM technology, also known as Variotherm or Heat/Cool molding, is patented globally by OSK. Under license from OSK, Trexel can now offer RHCM technology to customers, using a combination of steam and cooling water to thermally cycle the mold from hot to cold. Trexel also can supply the Steam Jet heat/cool mold control system, produced by Matsui Mfg. Co. in Japan (matsui-mfg.net).

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.

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.

The patented MuCell process injects a pressurized gas (nitrogen or carbon dioxide) into the injection barrel. When the melt expands in the mold, it forms tiny bubbles that aid flow and help pack out the part without stresses and with lower injection and clamp pressures, potentially allowing use of smaller presses. Benefits include weight savings up to 25%, cycles up to 40% faster, and absence of sinks and weld lines. OEMs are also said to be interested in the smaller carbon footprint of parts made with MuCell

3D printing finds its sweet spot in the area of prototyping and small to medium-sized production runs of geometrically complex parts and components with gaps, holes or voids. It is also the best fit for the manufacture or parts where the design will frequently evolve or where customization is required, as design changes can be accommodated even in production.

In addition, while there is an increasing number of material options that can be used with 3D printing, it still cannot match the choice of materials compatible with injection molding.

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.

A high-gloss surface equivalent to automotive Class-A solid molding can now be achieved with the weight savings and other benefits of microcellular foam molding, thanks to a new licensing agreement between Trexel Inc., Waltham, Mass., and Ono Sangyo Co. Ltd. (OSK) of Japan (onosg.co.jp). Another recent industry alliance has created a MuCell Trial and Development Center in the Detroit area to allow automotive OEMs and Tier 1 molders to experiment with the process. Meanwhile, Trexel has just completed the sale of its MuCell Extrusion unit, which it had spun off into separate business with a partner.

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.

The idea that 3D printing is a plug-and-play technology is a myth. Entry-level desktop model printers only require a modicum of knowledge to operate. But for production applications, achieving the necessary build parameters, quality, costs per part and timeliness of build requires a heap of experience, which subcontract agencies have in spades.

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.

With it acquisition of DuPont’s engineering resins, Celanese’s resin solutions for automotive electrification, e-mobility and consumer electronics are plentiful.

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

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.

There will be few manufacturing enterprises that will not either have used or are flirting with the adoption of 3D printing at some level in 2021, be it as a complementary technology to existing legacy manufacturing processes, or indeed as an alternative. Many OEMs will be using desktop 3D printers for rapid prototyping, purely to get an early reasonably accurate 3D model of their product designs, but these printers are not designed for more exacting production applications, where repeatability and accuracy / tolerance attainment are vital.

The 51st annual SPE Automotive Innovation awards gave nods to several ‘firsts’ and added alternative vehicle systems category.

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

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

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.

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

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.

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.

3D printing requires no tooling and is agile, which facilitates quick production turnaround. With 3D printing, part cost is not connected with part complexity. As soon as complexity is introduced to an injection molded part, the requirement is for more and more expensive mold tools, which leads to an exponential increase in costs until part production is no longer viable. As 3D printing adds material, complexity of design and different incorporated shapes do not affect the amount of time that it takes to produce a part, and therefore does not lead to increased costs.

In 2008, Trexel created MuCell Extrusion LLC in partnership with Zotefoams plc (zotefoams.com), a major extruder of polyolefin foams based in the U.K. and with a plant in Walton, Ky. In March, Zotefoams bought out Trexel’s remaining share of the extrusion business. This will allow Trexel to focus on its core injection molding business and on automotive blow molding applications, such as ducts, fluid bottles, and air intakes for trucks and other large diesel engines. Final density reductions of 15% to 20% were obtained in early blow molding trials.

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.

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.

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.

Molders of MuCell microcellular foam parts now can eliminate surface splay (left) and achieve an automotive Class-A level of gloss (right) with Rapid Heat Cycle Molding (RHCM).

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 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.

These respective sweet spots are quite discrete and play to the fact that forward-thinking manufacturers could in fact be looking at 3D printing and injection molding as complementary processes rather than competitive processes. When used constructively together, for example, pre-production cycles can be dramatically shortened before large volume production is undertaken.

3D printing also promotes what can be called the consolidation of complexity. The technology can combine parts and features in one build that would otherwise have to be post-processed or assembled using conventional injection molding and allied technologies. And, printed parts can be more ergonomic and incorporate multiple parts and features that would be impossible or prohibitively expensive to achieve via the fabrication of highly complex injection molding tooling.

Implementing a production monitoring system as the foundation of a ‘smart factory’ is about integrating people with new technology as much as it is about integrating machines and computers. Here are tips from a company that has gone through the process.

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

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).

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

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

It seems likely that moving forward, runs of perhaps 10,000 and below will soon be the domain of 3D printing, which for such volumes will render injection molding if not redundant, increasingly irrelevant when looked at through the prism of cost and time of production. However, injection molding will never be replaced, as it will typically be the technology of choice for higher volume runs.

These industry alliances are part of Trexel’s new strategy to enhance its MuCell foam technology and expand its presence in industry. As explained by recently appointed Trexel president Steve Braig, this strategy is aimed at transitioning MuCell from its current niche status into a “generally accepted process enhancement” where users take advantage of the technology’s “full value proposition.” To get there, Trexel aims to focus on training OEMs and Tier 1 processors to “think MuCell.”

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.

This is based on the fact that today, 3D printing technologies have been refined to such an extent that they are truly viable production technologies. Now the conversation among manufacturers is around the most judicious use of 3D printing for production, what its advantages are, where the sweet spot is in terms of preferable volumes, what are the opportunities that exist through it use, and what are the barriers to entry?

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

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.

Most obviously, 3D printing can make components either impossible or expensive and difficult to achieve using injection molding, such as components that are hollow in certain areas. This is possible, as in 3D printing material is added in layers, and material density of the core can be altered. So, not only can some areas be hollow, but other critical areas can be reinforced. This means that 3D printing is a key facilitator when it comes to lightweighting, but with increased strength.

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.

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.

LATE NEWS: Arburg Turnkey Agreement After our print edition went to press, Trexel announced that it had signed an agreement whereby Arburg can now supply turnkey MuCell injection molding systems, complete with Trexel gas dosing equipment and technology license. In the past, Arburg was able to supply an MuCell-ready injection machine with technology license, but customers had to purchase he supercritical foam (SCF) gas dosing hardware separatedly from Trexel. Purchasing has now been simplified to a one-stop process.Trexel implemented a similar reselling agreement last year with KraussMaffei.

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

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

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.

For customers to “think MuCell” and take full advantage of its benefits means not merely applying the microcellular process to conventional part designs, but engineering parts for the process from the beginning. To help reach that goal, Trexel formed a strategic partnership with Proper Group International, a moldmaker based in Warren, Mich. (propergroupintl.com). Proper houses Trexel’s newest center for customer trials and application/process development. It currently has two machines of 1100 and 3000 tons equipped for MuCell. Trexel has completed training and MuCell certification of a group of Proper’s tooling engineers and designers.

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.

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.

Conversely, injection molding makes design iterations costly. Beyond the high cost of upfront tooling, which as mentioned increases the more complex the part, production is restricted to the location of the production tooling. 3D printing technologies manufacture direct from 3D CAD files, so the location of manufacture is much more flexible.

3D printing is unique as a disruptive technology in one key respect, and that is having disrupted the manufacturing paradigm through the introduction of rapid prototyping some 25 to 30 years ago. It is disrupting manufacturing again.

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

3D printing exhibits a number of advantages when compared to legacy processes such as injection molding. The most important of these is the added flexibility 3D printing allows in design.

With 3D printing, ideal material conditions throughout a part are dictated by design, not by the vagaries of various production and post-production processes used.

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

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

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

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.

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

After our print edition went to press, Trexel announced that it had signed an agreement whereby Arburg can now supply turnkey MuCell injection molding systems, complete with Trexel gas dosing equipment and technology license. In the past, Arburg was able to supply an MuCell-ready injection machine with technology license, but customers had to purchase he supercritical foam (SCF) gas dosing hardware separatedly from Trexel. Purchasing has now been simplified to a one-stop process.

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

A significant drawback, however, is the fact that there are design limitations inherent in injection molding, with some geometries being difficult to remove from the mold, and precise and delicate designs being difficult and expensive to mold accurately. Also, it is difficult, costly and sometimes impossible to correct tooling mistakes or change tooling to optimize or iterate new designs. Often, new tools are required, with all this implies in terms of cost and time—tools often taking weeks if not months to fabricate.

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.

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.

When it comes to producing plastic parts, 3D printing is working in a space where the conventional processing technology is injection molding.