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.

The patented FIM process uses high-speed Nexa3D printers and xMOLD resin to print injection molding tools that are compatible with thousands of off-the-shelf injection molding materials, including reinforced high-performance feedstocks. The process reduces design, iteration, and validation cycles using end-product materials to a matter of hours rather than weeks.

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.

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.

You must also consider the cross-sectional area between the tube and the water-line diameter so that you are using the proper tube size. Some will assume that with a 0.250-in. hole you would use a 0.125-in. bubbler tube, thinking it’s half of the diameter. But you must consider the area. The area outside of the tube is 0.0368 in.2 and the ID area of the high-flow 0.125-in. tube is 0.009-in.2— that’s 400% less area or GPM. With a 0.125-in. brass tube, the area is only 0.0036 in.2, which would mean 1000% less GPM. So with a 0.250-in. diam. hole, use a 0.187-in. high-flow tube.

I have rarely seen bubbler hole sizes and tube diameters properly sized to achieve maximum GPM. It is very simple using basic math to figure the areas of the ID and the OD of the tube and the hole. Just take the radius2 x 3.14 to figure the areas of the tube ID, OD, and the hole. For the area outside of the tube you subtract the tube OD area from the area of the hole.

One aspect of bubblers that is commonly overlooked is the cross-sectional area of the ID of the tube and the area between the OD and the water-line diameter. This is one reason I always recommend using high-flow stainless-steel bubbler tubes versus the common brass bubbler tubes. For example, with a 0.125-in. diameter tube, the high-flow tube has an ID of 0.109 in.; a brass tube at best has an ID of 0.069 in. The high-flow tube thus has 250% more cross-sectional area, which translates to an increase of 250% in GPM. That’s why I never use standard brass tubes: They decrease your GPM potential.

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.

Based on input collected from the first two iterations, the design of the silicone part was approved and manufacturing of a metal tool was initiated with full confidence of part moldability and performance. The in-house tool shop built the final metal tooling in four weeks without iterations.

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.

Injection-molded silicone parts were produced within two days, allowing early verification of key design and performance aspects.

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

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

When determining the best ejection option for a tool, molders must consider the ejector’s surface area, location and style.

We EDM hole-popped some 0.060-in. water lines with a circuit that looped through all four cavities. This was one of those cases where you really don’t know what to expect until you try it. When we set the tool, water was just trickling out of the new line because it was so small. The results were amazing: This small amount of water flow through the thin steel had such a big cooling effect that even at a 17-sec cycle time (a 23-sec reduction) the notch gap on the parts were now too large! Our option was to run the small cooling line at a much higher water temperature to keep the part from cooling too quickly.

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

Heat pipes or cooling tubes are also an option in some cases, but flowing water is always the best choice. I have proven this in trials—heat pipes definitely assist in cooling mold details, but never as much as actual water flow. With that said, I still use heat pipes in some situations because they are easily added in cases where adding water or a bubbler would require more work.

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

A supplier of development and manufacturing services to medical device OEMs used Freeform Injection Molding from Nexa3D to accelerate time-to-market and slash prototyping costs for a complex silicone-based IV device. SPT Vilecon explained the process in a recent press release.

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.

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.

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

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

Robust and valid prototyping and verification are key to minimizing cost, time, and risk factors in developing medical devices, said SPI Vilecon. FIM is a new toolbox for medical device companies seeking to accelerate their innovation and obtain early verification of part performance and moldability, added the company.

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

Don’t assume you know everything there is to know about PE because it’s been around so long. Here is yet another example of how the performance of PE is influenced by molecular weight and density.

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.

Out of curiosity, we then ran compressed air instead of water through the micro cooling line. This also had a big impact on cooling  and the specified notch gap was still too large, though the dimensions among the four cavities varied, with the fourth cavity being slightly smaller because the air was heating up as it ran through the hot steel. The point is: Do not overlook options that may not have been the norm for years. Think outside of the box and re-invent.

On another tool we were running glass-filled nylon on a round part with a 0.312-in. diam. hole through it that was approximately 5 in. long. A 0.156-in. hole with a 0.125-in. high-flow bubbler tube was used to cool the core. Even when running glass-filled nylon, the core stayed cool to the touch. So the results you can achieve with basic cooling methods and a little outside-the-box thinking can be amazing. If you look at the big picture and the payback, the excuse of plugged-up water lines from untreated water can really cost you a lot of money.

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 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.

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.

For example, over the course of my career I have been part of many discussions about small cooling lines and bubblers and their tendency to plug up. This is something that you should not overlook in your water-treatment procedures. If your small water lines are plugging up, you obviously are having some sort of buildup in your other water lines too. This may not reduce your flow volume in gal/min (GPM), but will certainly have an impact on cooling and your ability to pull heat out of the plastic. So if buildup or plugging issues are a reason to not maximize your cooling and cycle times, you should focus on the root cause of the issue with the water treatment and not cut short your potential to reduce cycle times by exploring various cooling options. You always have to look at the big picture to understand the overall payback.

Certified to ISO 13485, Denmark-based SPT Vilecon describes itself as a fully integrated provider of development and manufacturing services to the medical device industry. It offers in-house tool making and injection molding along with other manufacturing services to companies in northern Europe.

Design input collected from the first tests was integrated in a second iteration that took only a couple of hours to complete. By contrast, conventional metal tooling would have taken more than six weeks to design and procure, and the adjustments needed for the second iteration would have taken an in-house tool-shop a week to complete.

Medical device manufacturers are tasked with developing elaborate test protocols to ensure that the product in development is safe and meets essential requirements. If these tests are conducted late in the development process, the more onerous and risky they become. SPT Vilecon often works with silicone, a material that is extensively used in medical applications because of its chemical resistance, mechanical performance, and biocompatibility. However, silicone parts are notoriously difficult to prototype and test, since most grades need to be injection molded to achieve their full performance potential, said the company. FIM enabled SPT Vilecon to offer an alternative to a customer developing an intravenous (IV) silicone product — the use of 3D-printed tooling to perform early design and material verification at a fraction of the cost of conventional methods.

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.

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.

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.

Bubblers are one of my favorite options for cooling in tight areas, so let’s look at them more closely. Bubblers are often overlooked as an easy solution to cool problem areas where normal water circuits are not an option. A bubbler only needs a drilled and tapped hole with clearance for the bubbler head and connections. There are also many options to implement bubblers internally without using the standard bubbler head. The water-line hole for a bubbler can be as small as 0.125 in.; the limitation is that the smallest bubbler tube available is 0.090 in. diam.

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

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

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

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.

SPT implemented Nexa3D’s Freeform Injection Molding (FIM) technology to help customers shorten time-to-market on complex medical devices in demanding medical-grade materials and to expand on the range of materials that can be quickly and reliably used in prototyping and early device test manufacturing.

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

Though we were greatly surprised by the effect, when considering ratio of this “micro” water-line size to the steel thickness surrounding it, the water line was actually quite large. A 0.060-in. water line in a steel section 0.100-0.150 in. thick compares to using a 0.600-in. cooling line in a steel section 1-1.5 in. thick.

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

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

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).

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.

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.

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.

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

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

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.

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.

Some creative thinking with conventional technology, like small cooling lines and bubblers, can generate big improvements in cooling and cycle times.

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

A 0.125-in. diam. hole with a 0.090 in. high-flow bubbler tube has greater area outside of the tube, at 0.0054 in.2, with the area of the ID of the tube being 0.0045 in.2. A 0.187-in. diam. hole with a 0.125-in. high-flow tube has area outside of the tube of 0.0153 in.2 and an ID area of 0.009 in.2.

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.

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.

On a tool running polypropylene with Ampco beryllium-alloy slides that cored out a large area, the cycle times were running higher than desired because of how hot the slides were. The slides did have water in them but not inside the cavity detail because it was assumed that water was not an option. We were able to drill three 0.125-in. diam. holes into the detail using three high-flow, 0.090-in. bubbler tubes. In this case, bubbler heads were not an option, so we installed an insert inside the slide to allow bubblers to be used. The slides went from being so hot that they would burn your fingers to staying cold. Cycle time was reduced by approximately 20 sec.

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

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

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.

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.

In last month’s column I referenced some new technologies for mold cooling and the positive impact they will have on the process. But there is still plenty going on with current cooling methods and how they are being underutilized in many cases.

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

The 3D-printed molds for the first and second iterations cost less than €2,000 combined. And the technology enabled a two-day design cycle, which is more than 90% faster than conventional metal tooling.

Randy Kerkstra has been in the plastics industry for more than 26 years, occupied frequently with troubleshooting injection molding. He is currently a tooling manager for a large, multi-plant molding and manufacturing company. Contact:kbmoldingsolutions@gmail.com.

In last month’s column I also mentioned how important it is to consider the plastic material being used and to focus on cavity details that create steel conditions that will maintain heat, which contributes to quality issues and excessive cycle times. I stress this because the mold design cannot treat all materials the same with regard to cooling, steel/alloy selection, ejection, and lifter travel. How small can you go with water lines? There is some new technology that uses liquid CO2 in lines as small as 0.060 in. to get into tight areas. I have not used this technology, but I can see where it could have a big impact in some situations. But in most cases, with a bit of creativity, we have been able to add water where others have said it was not an option. Let me give you some details on one such project.

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.

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.

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

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.

On a small four-cavity tool, the part had a U-shaped notch in the center. The steel that cored out and created the notch was very thin—roughly 0.100 to 0.150 in. thick, 0.750 in. tall, and 0.750 in. wide. This steel section retained heat, not allowing the plastic to cool and requiring an excessively long cycle time  of 40 sec. Any shorter cooling time would cause the hot plastic in the notch area to shrink smaller than the spec for the notch gap dimension. This steel was in the solid and adding water was not considered an option because the steel was so thin. A copper alloy material could have helped here, but to insert this area at such a late stage would have been very expensive. So we considered an option that most would have thrown out the window.

SPT Vilecon said it has begun expanding the range of injection mold prototyping with silicone, metal, and ceramic materials to provide medical device manufacturers with an even wider selection of product development and verification services.

Freeform Injection Molding technology from Nexa3D compresses design, iteration, and validation cycle times into a matter of hours rather than weeks.

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

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.