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).

During this CW Tech Days event, sponsored by Composites One, experts will offer presentations to review and evaluate the composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

This sidebar to CW’s August 2024 feature article reviews this technology for more efficient composites manufacturing and why it aligns with Koridion active core molding.

The composites industry plays a crucial role in developing lightweight and durable materials for a range of applications, including those critical to national defense. One key focus area is the development of advanced structural materials and manufacturing technologies that support next-generation space, missile and aircraft systems for the U.S. Department of Defense (DOD). ARC Technologies LLC (ARC), a division of Hexcel Corporation, based in Amesbury, Massachusetts, is a provider of advanced composites structures, specialty materials and other unique products that provide the U.S. Department of Defense with advanced capabilities to protect service members while in harm’s way. This team’s specialty is to understand a specific need from a program office, PEO, platform manufacturer or other offices within the DOD. With that understanding, the team can design a solution, develop a prototype for test and evaluation, perform extensive in-house testing — including electromagnetic, environmental and structural testing — and then partner with the customer through platform evaluation. The Hexcel Amesbury division has a team of engineers on staff, including mechanical, chemical, electrical and research and development specialists that can provide design, testing and manufacturing capabilities to service customer requirements from concept through production. This presentation will illustrate capabilities in advanced composites and other specialty materials structures, focusing on the Hexcel Amesbury team's niche in electromagnetic signature reduction and other unique capabilities.

Recoat temperature, part orientation and bead geometry are some key design variables to consider for a successful and reliable large-format additive manufacturing (LFAM) process.

This session is designed to demonstrate the benefits of ultra polymers for aerospace applications with real case examples of Syensqo's polymer portfolio. Agenda:  Introduction to ultra polymers (PAEK, PEKK, PEEK, PAI) key features Application of ultra polymers in aerospace: concrete examples Benefits of ultra polymers: enhanced performance, durability and cost-efficiency

A combination of Airtech’s 3D printing materials and Ascent’s production capabilities aim to support increased use of composite additive tooling in spaces like defense and aerospace.

Celebrating National Composites Week 2024, CW looks at how composites are being used to provide the next generation of energy.

The first project is underway to recover carbon fiber used in an A330-200 aircraft, which will then be regenerated for other end uses by HRC.

Wheel brand Parcours reveals composite bike wheels using Hypetex colored carbon fiber to achieve aesthetic, lightweight and performance goals.

Herone, Spiral RTC, Teijin Carbon Europe and Collins Aerospace Almere recycle A350 thermoplastic composite clips/cleats waste into rods for the all-thermoplastic composite Multifunctional Fuselage Demonstrator’s crown.

This idler wheel that is part of a performance compound archery bow was originally produced in machined aluminum. The customer wanted to convert to composites, so initially tried 50% FWF long glass PA6/6. However, that material had challenges filling the complex geometry, which led to premature failure of the part. MCAM formulated a 20% FWF short carbon fiber-reinforced PA6/6 composite (KyronMAX S 2220) for the application. Not only was the new composite able to be molded in the same tool as the LFT grade without modification, but failures were eliminated and weight was reduced 21% versus the LFT material and 50% versus the original aluminum.

Analyzing structural resonance of the aircraft under various loads becomes a critical step in obtaining flight certification.

X-ray based CT scanners have gained a reputation as the ultimate metrology tool. Systems like Omnia’s Zeiss Metrotom 800 can generate a “point cloud” of millions of measurements in 1 hr. No fixturing is needed, and the scanner can measure internal features and even entire assemblies. “If you want to measure a critical hole with ±1 mil tolerance in an invisible location inside the part—you need a CT scan,” states Schuler.

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

The composites-intensive VTOL platform is next expected to undergo a series of test flights in various conditions to validate its performance, safety and reliability, leading up to eventual certification.

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

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.

“With Omnia, what is most paramount is the team,” says Wigton. “TJ and his engineers are not only metrologists, they are experts in every aspect of injection molding from tool design to the finished product. Their experience in plastics manufacturing and materials, and their understanding of how molding truly works, gives them an edge our competitors simply don’t have. In fact, to my knowledge, there is not a single metrology house that operates as we do. Competitors provide the dimensional geometry of your part, where we provide a full metrology review, which includes everything from dimensional analysis to troubleshooting the tool, troubleshooting the component, and understanding the application and material. We’re able to make suggestions on how issues can be fixed at the tooling, design and manufacturing stages. That helps explain why we have customers who are high-level molders with their own in-house CT scanning, but they still come to Omnia because they are so confident in our ability to provide the most comprehensive analysis.”

Omnia Scientific has been a separate operating company since 2016, and its revenue is up 400% since then. Every molding project at Octex utilizes Omnia’s metrology services, though 85% of Omnia’s revenue comes from outside business. Its growth has been largely through word of mouth. “People mail parts to my house on weekends for me to look at,” says Schuler, shaking his head.

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

The composite tubes white paper explores some of the considerations for specifying composite tubes, such as mechanical properties, maintenance requirements and more.

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.’

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

“Metrology geared specifically to plastics injection molding is special to us. There isn’t a single other metrology house out there that’s dedicated to that.” He adds, “We can accelerate data reporting because we work 24/5 or 24/7, unlike most metrology houses.”

Kennametal will cover the influence of different composite materials characteristics on drilling performance and how to optimize the process. Agenda:  Who is Kennametal? Hole making challenges in composite materials Innovations for hole making applications Upcoming events and academic partnerships

Finally, last summer MCAM acquired carbonNXT GmbH and sister company CFK Valley State Recycling GmbH and Co. KG (both Wischhafen, Germany), bringing a complete line of carbon fiber recycling technology into the group’s product offering. The MCAM team is said to be testing multiple formulas using recycled carbon fiber ahead of qualifying commercial products.

Collaboration aims to deliver the next generation of thinner, lighter, stronger and more sustainable composite materials used in consumer electronics and automotive industries.

This collection features detail the current state of the industry and recent success stories across aerospace, automotive and rail applications.

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

The composites industry is increasingly recognizing the imperative of sustainability in its operations. As demand for lightweight and durable materials rises across various sectors, such as automotive, aerospace, and construction, there is a growing awareness of the environmental impact associated with traditional composite manufacturing processes.

How the predictive tool “CZone” is applied to simulate the axial crushing response of composites, providing valuable insights into their use for motorsport applications.

CompositesWorld’s Tech Days: Design, Simulation and Testing Technologies for Next-Gen Composite Structures is designed to provide a multi-perspective view of the state of the art in design, simulation, failure analysis, digital twins, virtual testing and virtual inspection.

This collection details the basics, challenges, and future of thermoplastic composites technology, with particular emphasis on their use for commercial aerospace primary structures.

Base Materials introduces a high-performance, toughened epoxy tooling board designed for thermoforming and vacuum forming processes, direct-to-part applications and more.

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.

Closed mold processes have many advantages over open molding. In this knowledge center, learn the basics and vital tools needed to produce parts accurately.

“It’s not so much that we set out to create a broad range of CFRTP compounds but that each one was developed to meet the specific needs of a particular customer,” adds Clint Newell, MCAM global composites technology manager. “As our formulation capabilities grew, we entered new markets, met with new customers, asked what they needed and set about creating a perfect compound to meet those needs.”

Unsurprisingly, because these compounds were initially formulated by a molder for a molder, they were designed to provide properties that made them easy to process and to consistently yield higher quality, better performing parts. “We formulated our KyronMAX product line to provide higher flow and fiber interaction, lower internal stresses, less anisotropy, stronger weld lines, fewer sink marks, less tendency for warpage and greater dimensional accuracy — regardless of whether wall sections were thick or thin,” notes Dave Wilkinson, MCAM R&D director. “In addition to our formulation work and unique sizing technology, we also made our own press modifications to run these materials more efficiently.”

“Our philosophy is that wherever you are in the manufacturing process, we can make it better,”says Wigton. “We ask the important questions up front: How are we going to make this? How will we deal with the tooling challenges? How will we deal with the metrology challenges? How will it be cost-effective to measure this part in production?”

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.

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

Continuous fiber-reinforced thermoplastic composite targets full circularity in aircraft interior applications, with FST, impact resistance and toughness features.

Octex is more than a molder. The Octex Group in Sarasota, Fla., comprises three companies: Octex custom injection molding division, which has a growing emphasis on value-added secondary operations like decorating and assembly; Choice Tool & Mold, the moldmaking arm; and Omnia Scientific, the metrology business. The latter two units serve primarily outside customers. Omnia, one of the faster-growing parts of the Group, has become a major focus in differentiating Octex from its competitors.

Schuler is an example of what makes the Omnia “team” special. “I grew up in plastics manufacturing. Fifteen years ago, as a summer intern at Octex, I was shoveling buckets of plastic pellets into a hopper. That gives you respect for the real challenges of manufacturing.” He has RJG training in processing, materials and troubleshooting, as well as training in Scientific Molding with John Bozzelli (a columnist for this magazine). He has tooling experience, too.

CompositesWorld's Carbon Fiber conference offers you cutting-edge information and access to industry experts in streamlining manufacturing costs, market outlooks and forecasting, and more. You will make invaluable contacts as you meet and network with the industry's most innovative and influential leaders at Carbon Fiber. __PRESENT

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

Wigton points out another factor in the Octex competitive strategy: “Omnia shines in its ability to compress the timeline of a product launch. Our enhanced tool qualification and pre-production process development and validation are faster than any market competitor, large or small. We accomplish this by having design validation, tooling, molding and metrology under one roof.” The accompanying infographic, supplied by Wigton, shows a 45% to 65% reduction in the overall timeline of a launch.

Low-melt polyaryletherketone (LMPAEK) unidirectional tapes provide outstanding thermal and fire protection, demonstrating their effectiveness through rigorous testing. These tapes are fire, smoke and toxicity compliant with FAR25.853 and meet OSU Heat Release Rate standards. The tapes were tested under ISO 2685/AC 20-135 Change 1, meeting the fireproof criteria. Additionally, they met UL 2596 requirements for battery thermal runaway tests. These tapes are crucial for high-temperature applications showcasing their resilience and safety in both aerospace and automotive applications. Part of a broader range that includes films and compounds, Victrex LMPAEK materials are valued for their excellent processability and weldability. They offer versatile solutions for complex needs beyond traditional structural parts, such as: thermal runaway and lightning strike protection, heat sinking, and intricate bracketry. Victrex LMPAEK materials facilitate automation and high-rate production while addressing performance and sustainability challenges. With reduced environmental impact, lower weight and cost-efficiency, they meet the evolving demands of the transportation industry and support innovative design solutions. Agenda:  Introduction to LMPAEK ecosystem, highlighting unidirectional tapes Thermal and fire protection performance: applications and benefits Material forms and processability Sustainability and efficiency Conclusion and future innovations

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.

Initial demonstration in furniture shows properties two to nine times higher than plywood, OOA molding for uniquely shaped components.

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.

What’s next? With access to the broader Mitsubishi organization globally, the MCAM team can access technology representing a  broader composites portfolio that spans thermoplastic as well as thermoset chemistries, with a range of reinforcement types and lengths. For example, another Mitsubishi group produces split and chopped tow carbon fiber-reinforced forged molding compound (FMC), an advanced form of sheet molding compound (SMC) that helps bridge the performance and processing gap between short glass or carbon fiber-reinforced SMC and continuous carbon fiber-reinforced prepreg. Still another group produces woven and nonwoven carbon fiber reinforced prepreg and rapid-cure prepreg compression molding (PCM) materials.

Whether you’re exploring new applications or seeking to gain a foothold in emerging markets, Carbon Fiber 2024 is where you’ll discover the insights and connections needed to shape your business strategy. Register now.

Krones adds PET preform injection molding to its bottle blowing and filling capabilities, as well as cap molding and expansion into medical, food and other markets.

Additionally, stitch-bonded non-crimp fabrics (NCFs) provide manufacturers and asset owners even more ways to gain a competitive advantage with products built specifically for the environments and loading conditions in which they will be utilized. Join Vectorply Corporation and Creative Composites Group (CCG) for this in-depth webinar detailing the process of engineering NCFs to build composite parts that will stand the test of time. Unlike steel, concrete and wood, composite NCFs can be optimized utilizing various fiber types, architectures and substrates to achieve the specific goals of their application efficiently. High corrosion resistance, strength and stiffness, and longevity can all be accomplished with custom-designed laminates for these heavily abused applications. Vectorply Vice President of Engineering Trevor Gundberg and Creative Composites Group Chief Sales Officer Dustin Troutman will share their industry-leading expertise on the process of laminate design and part production. Attendees can expect to learn when to use composite NCFs in their production process and the wide range of fiber-reinforced plastic (FRP) composites that Creative Composites Group produces for the industrial and infrastructure markets. Whether you want to learn more about utilizing NCFs in your production process or why CCG’s extensive product line may be the choice for your project, this webinar is the place learn the process and how to take the next steps. Agenda:  Distinct advantages of non-crimp fabrics versus alternative materials How to design laminates for specific processes such as pultrusion and infusion Real-world success spotlights of NCFs in industrial applications

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.

The Marservis PROeco is a mass transportation marine vessel using Bcomp natural fiber for interior parts in place of standard materials.

CompositesWorld’s CW Tech Days: Infrastructure event offers a series of expert presentations on composite materials, processes and applications that should and will be considered for use in the infrastructure and construction markets.

Over the last 8 months, Archer Aviation has completed a total of 402 test flights with its composites-intensive aircraft, adding to key milestones.

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.

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.

Other automotive grades introduced at the 2019 SPE AutoEPCON include a high-temperature carbon fiber-reinforced PPA grade specifically developed for underhood applications. That grade is said to have a glass transition temperature (Tg) and continuous-use temperature (CUT) rivaling that of PEEK, but is easier to mold. Given the cost sensitivity of high-volume industries like automotive and small appliances, it comes as no surprise to learn that the team also is working on a polypropylene (PP)-based KyronMAX product.

The custom molder has secured multiple projects in health care and will be adding cleanroom and white-room spaces, as well as injection molding machines, in support.

CW Tech Days are virtual events dedicated to the topics impacting the composites industry today. Access past event recordings and register for upcoming Tech Days.

During this webinar, the audience will be introduced to a variety of fiber composite technologies — as well as the machines and equipment — from short fibers to continuous fibers, from thermoset to thermoplastic, as well as the according process technology, including a special focus on long-fiber injection (LFI) and structural composite spray (SCS). Focus markets include automotive, aviation and AAM, transportation, and construction. This webinar will provide a detailed overview of according application examples. Agenda: Long fiber injection (LFI) Structural composite spray (SCS) Resin transfer molding (RTM), wet compression molding, etc. Pultrusion FiberForm

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

How the predictive tool “CZone” is applied to simulate the axial crushing response of composites, providing valuable insights into their use for motorsport applications.

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.

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

Recoat temperature, part orientation and bead geometry are some key design variables to consider for a successful and reliable large-format additive manufacturing (LFAM) process.

Nowadays, Octex Group pursues mainly medical business, which accounts for 65-70% of its revenue. The remainder is a mix of high-end electronics, aerospace/defense R&D projects, and some consumer and industrial jobs. (For an overall company profile, see Feb. ’18 On-Site feature.)

Jetcam’s latest white paper explores the critical aspects of nesting in composites manufacturing, and strategies to balance material efficiency and kitting speed.

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).

An on-demand mapping tool for anisotropic materials and polymer material fracture prediction model, i-Lupe, aims to help predict impact, crash behaviors.

A family of short carbon fiber-reinforced thermoplastic (CFRTP) compounds specifically formulated for injection molding is being used to extend the capabilities of thermoplastic composites in a variety of part sizes and complexities. Interestingly, these materials have been shown to outperform long fiber thermoplastic (LFT) composites (in fiberglass or carbon fiber) as well as metals in a growing range of applications — from sporting goods and car parts to medical devices and aerospace components.

EU project will develop bio-based, repairable and recyclable vitrimer composites and advanced sensors for highly reliable, sustainable wind blades.

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.

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.

Ohio-based Canvus Inc. upcycles fiberglass wind blades, car tires and post-consumer plastics to create outdoor furniture that amplifies sustainability messages in community spaces.

By having design validation, tooling, molding and metrology under one roof, Octex Group says it can cut project launch time by 45-65%.

Metrology services dedicated to plastics injection molding is an important factor differentiating Octex from its competition.

Cevotec, a tank manufacturer, Roth Composite Machinery and Cikoni, have undertaken a comprehensive project to explore and demonstrate the impact of dome reinforcements using FPP technology for composite tanks.

The importance of that dedication and that background of plastics knowledge, Schuler says, is “we’re not just about data on part dimensions, but about the Why? Why are we seeing what we’re seeing? Is a measurement different from spec a tooling issue, or can a shift in process window fix it without expensive tool rework?”

Validation of 80-100% tensile strength and comparability to injection molding via Voxelfill extrusion process was achieved through plastic and fiber-filled test series.

The first problem was solved by applying a focused R&D effort on various base resins and fiber sizing technologies, which led to the development of a family of high-performance, injection moldable CFRTP compounds called KyronMAX. These materials feature matrices such as polyamide 6/6 (PA6/6), polyphthalamide (PPA), polyetherimide (PEI), polyphenylene sulfide (PPS), polyetheretherketone (PEEK) and polyaryletherketone (PAEK) reinforced with short chopped carbon fiber. The compounds — most of which offer high thermal performance, broad chemical resistance, good mechanicals and low flame/smoke/toxicity (FST) values — were formulated not only to replace short glass fiber-reinforced and mineral-filled injection molding grades, but also LFT compounds (with average starting fiber length of 13 millimeters) and even metals.

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

Thomas “TJ” Schuler, director of Omnia Scientific, brings experience in molding, tooling and quality assurance to his firm’s metrology services.

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

Now, with greater production capacity and access to a broader array of polymer and carbon fiber materials, the MCAM team has been busy developing an array of new products — several of them specifically formulated for the automotive market. One of the most interesting is KyronMAX ES 4240, said to be the world’s first short carbon fiber injection molding compound to break the 414 MPa (60,000 psi) tensile strength barrier. That grade, which was introduced at the 2019 SPE Automotive Engineered Plastics Conference (AutoEPCON) in the Detroit suburbs, is a 40% fiber weight fraction (FWF) carbon fiber-reinforced PPA that also offers tensile modulus values of 41.2 GPa, flexural modulus values of 34.5 GPa and flexural strength values of 552 MPa. PPA is a specialized form of polyamide with better thermal and broader chemical resistance and far lower tendency toward hydrolysis than conventional PA6 and PA6/6.

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.

The materials are formulated and sold by Mitsubishi Chemical Advanced Materials Inc. (MCAM, Tokyo, Japan). MCAM combines several previously separate businesses acquired by the parent company over the last decade. These include the former Quadrant AG (Lenzburg, Switzerland), a producer of glass mat thermoplastic (GMT) and organosheet composites as well as thermoplastic engineered shapes, and what had been Piper Plastics Inc. (Chandler, Ariz., U.S.), which started life as an injection molder and producer of precision machined parts, and later expanded into custom CFRTP compounding — first for its own use and later for other molders.

Aerospace manufacturer joins forces with composite materials company to achieve sustainable manufacturing practices that overcome traditional composite layup tooling.

It’s all part of process validation, Schuler says—“Putting all the systems in place to control and analyze the quality of parts. We develop calibration and control plans. We use Scientific Molding for process development—testing high and low threshholds, finding out what the machine and tool can handle. It’s always a delicate balance between tooling, manufacturing and quality assurance. We fight over 10 thou.”

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

To demonstrate the performance capabilities of KyronMAX composites to aerospace customers, MCAM designed and produced a generic quarter-turn retaining latch for use in aircraft galleys. The parts are currently produced in aluminum owing to high load requirements. A 30% FWF short carbon fiber/PEI grade (KyronMAX S 6230) was selected both for its mechanical performance as well as its flame/smoke/toxicity (FST) listing. The composite parts meet the performance requirements of aluminum at half the weight and are currently being evaluated by several customers. They also permit painting to match aircraft interiors.

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.

One factor contributing to this compressed timeline is a fiber-optic data superhighway, installed by Wigton to handle the massive load generated by CT scans. Where other metrology firms might require weeks to provide usable data from scans of parts from 32 cavities in a single mold, Omnia can do it minutes.

Foundational research discusses the current carbon fiber recycling landscape in Utah, and evaluates potential strategies and policies that could enhance this sustainable practice in the region.

In these sessions, experts will discuss the emerging hydrogen economy and the opportunities for composites in this lucrative space.

Advanced Engineering is the UK’s largest annual gathering of engineering and manufacturing professionals. The event will help you to source new suppliers, network, build connections and learn about the latest industry developments all in one place. Get involved and exhibit alongside 400+ exhibitors offering solutions and products across all industries and sectors to help improve your productivity and inspire creativity. With over 9,000+ of your peers due to attend and ready to network with and inspire you, this is the event you can’t afford to miss!

To illustrate the importance of those choices, Schuler cites various measuring technologies available at Omnia. One is touch CMM, very common throughout industry. “It’s very accurate, but limited by how many points it is cost-effective to measure. Do you want to measure four points or 4000? On how many cavities? Time is cost.”

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.

Explore the technologies, materials and strategies used by composites manufacturers working in the evolving space market.

Metrology is still poorly understood by a large part of the industry, in Schuler’s view. “Customers say, ‘These dimensions, these tolerances, are what I need to make my part work.’ But no one thinks about what’s needed to make the part manufacturable, the tool maintainable (what’s going to wear out first), and quality measurable. We can be that bridge.”

American Bureau of Shipping (ABS) certifies use of jointly developed CFRP repair technique on FPSO and FSO industrial systems, addressing traditional steel restoration challenges.

An MCAM customer wanted to replace metal injection molded (MIM) magnesium with a composite on a performance mountain bike’s suspension elements with the goals of reducing mass and avoiding processing concerns with the reactive alkaline earth metal. Given the complexity of the part and the production volumes involved, only injection molding could meet the customer’s price point. MCAM formulated a 30% FWF short carbon fiber-reinforced polyphenylene sulfide (PPS) composite (KyronMAX S-8230) that met all mechanical requirements — including challenging fatigue targets — and successfully replaced magnesium in this application. Photo Credit, all images: Mitsubishi Chemical Advanced Materials Inc.

The ITHEC 2024 will take place from the 9 to 10 October 2024 in Bremen, Germany. At the 7th International Conference, more than 300 participants from around the world will be presenting and discussing newest scientific results, meet leading international specialists, share their expertise and start business co-operations in the field of thermoplastic composite technologies. The international exhibition will feature 40+ exhibitors showcasing all steps of the supply-chain. Be it materials, machines, testing, processes, or solutions. By combining the exhibition and the conference ITHEC is further fostering the inter-connectivity between science and industry.

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 DOMMINIO project combines AFP with 3D printed gyroid cores, embedded SHM sensors and smart materials for induction-driven disassembly of parts at end of life.

The JEC Forum DACH is a business meetings event organised by JEC The JEC Forum DACH is organised on October 22 and 23, 2024 by JEC, in partnership with the AVK, gathering the composite materials community from the DACH Region (Germany, Austria and Switzerland).

Arris presents mechanical testing results of an Arris-designed natural fiber thermoplastic composite in comparison to similarly produced glass and carbon fiber-based materials.

With fiber weight fractions of up to 50% and an array of thermoplastic matrices available, injection molding compounds are expanding composites’ capabilities.

An integral supplier in the effort to fast-track COVID-19 vaccine deployment, Retractable Technologies turned to Arburg and its PressurePilot technology to help deliver more than 500 million syringes during the pandemic.

Why the unusual product name? “In ancient Greek myths, Kyron (also spelled Chiron) was part centaur and part human,” explains Randy White, MCAM chief innovation officer. “Kyron used his unique personal skills to rise above his beastly nature. We likened that to our compounds, which are half carbon fiber and half resin, so as strong as a horse and as smart as a human for ease of processing.”

While the world continues to wait for new single-aisle program announcements from Airbus and Boeing, it’s clear composites will play a role in their fabrication. But in what ways, and what capacity?

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.

CompPair and Composite Recycling introduce a roof scoop made of recycled fibers to an eco-efficient rally buggy, which channels airflow to the engine for optimal, sustainable performance.

Stephen Heinz, vice president of R&I for Syensqo delivered an inspirational keynote at SAMPE 2024, highlighting the significant role of composite materials in emerging technologies and encouraging broader collaboration within the manufacturing community.

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

As its product line has expanded, so too have the markets in which these materials are used. In addition to long-desired automotive business, the company now serves medical device (both durable and disposable), small appliance and consumer electronics (metal replacement cases/covers). Aviation/aerospace is still important, as is the sporting goods industry, which has grown to include applications on racing bikes, mountain bikes, golf clubs, firearms, compound bows and other archery parts. With several products offering coefficient of linear thermal expansion (CLTE) values similar to those of metal injection molded (MIM) aluminum and magnesium — albeit with better toughness, lighter weight and lower cost — the team finds itself replacing metals in an increasing array of applications.

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

Circa 2012, Piper was a midsize custom injection molder serving a customer base in aerospace and sporting goods/recreational equipment. Company leadership wanted to grow its parts-making business but had two challenges. First, it was having trouble sourcing the kinds of compounds the team felt would enable the company to compete in higher performance market segments. Second, the company wanted to enter the automotive market, but didn’t have enough available molding capacity to compete on major programs.

Among the new injection moldable CFRTP compounds specifically developed for automotive use is KyronMAX ES 4240, a 40 FWF short carbon fiber-reinforced PPA said to be the first to break the 414-MPa (60,000 psi) tensile strength barrier.

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.

Knowing the fundamentals for reading drawings — including master ply tables, ply definition diagrams and more — lays a foundation for proper composite design evaluation.

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

Explore the cutting-edge composites industry, as experts delve into the materials, tooling, and manufacturing hurdles of meeting the demands of the promising advanced air mobility (AAM) market. Join us at CW Tech Days to unlock the future of efficient composites fabrication operations.

Reliable news and information on where and how fiber-reinforced composites are being applied — that’s just the start of what you get from our team here at CompositesWorld.

There are also optical 2D vision systems. “This is fast, measuring 200 points in 2 sec,” says Schuler, “but it has multiple sources of bias—illumination intensity, use of backlighting or not, distance of the workpiece from the light source. These factors can all give different measurements of the same dimension. This technology is very repeatable, but not necessarily accurate.” To make it accurate, he recommends starting from a “known true standard”—a CT scan.

Performing regular maintenance of the layup tool for successful sealing and release is required to reduce the risk of part adherence.

An overview of ASTM Standard Guide D8509, and its coupon-level mechanical testing of design properties for analyzing composite bolted joints.

Program will focus on sustainable, next-gen wing solutions, including in wing design and manufacturing and advancements in carbon fiber-reinforced composite materials.

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.

CompositesWorld is the source for reliable news and information on what’s happening in fiber-reinforced composites manufacturing. About Us

“What we do at Omnia is special because I’m a molder, I’m a process guy, I’m a tooling guy. I know what it takes to make a good product. I’ve learned the symbiosis of tooling, manufacturing and quality departments. I don’t think there anyone else in the metrology business who does what I do. You’re not just getting a data sheet, you’re getting my experience in plastics manufacturing.

In 2018, Teijin broke ground on a facility that is reportedly the largest capacity carbon fiber line currently in existence. The line has been fully functional for nearly two years and has plenty of room for expansion.

Two examples illustrate how Octex is challenging its equipment and its people to achieve higher levels of quality and productivity. One application is a surgical device that involves a metal rod and spring overmolded with PP on both ends. Four housing parts are molded and assembled around the overmolded metal parts. The assembly receives three sonic welds and pad printing.

As formulation expertise grew, the company came to the attention of Mitsubishi Chemical Holdings Group (MCHC, Tokyo, Japan), which acquired Piper in 2016. MCHC immediately made a substantial multi-million dollar investment to increase the size of the compounding line in Arizona, automate operations and bring in its own carbon fiber sizing and chopping technologies to enable KyronMAX compounds to be produced faster and with greater consistency and efficiency. Subsequently, a second compounding line was set up in Michigan and a third in Japan. This expanded capacity meant that KyronMAX grades could compete for automotive business in North America and in Asia. Other markets have followed.

Molding good parts is not enough. Better and faster metrology services for tool qualification and process validation make the difference for Octex Group.

Increasingly, prototype and production-ready smart devices featuring thermoplastic composite cases and other components provide lightweight, optimized sustainable alternatives to metal.

Keyland Polymer's R&D chemist will demonstrate the UV powder coating application process followed by UV curing on a carbon fiber water bottle holder. (Sponsored)

Within MCAM itself, another technology that’s nearing commercialization is a new family of textile (nonwoven, woven and unidirectional)-reinforced dry prepregs with thermoplastic matrices called KyronTEX. These products are currently being strategically sampled.

But there are limitations here, too. Schuler has noticed that CT scanners are becoming more common among custom molders—despite price tags in the mid-six figures. But in the last year he has seen a trend among other users to packing in more and more parts per scan to save time and cost, though this means greater differences between individual parts’ distances from the emitter source, which affects accuracy. “Others may be willing to sacrifice microns for dollars, but we won’t. Others will give you scan data but won’t show you how they scanned your part. We do, as part of our metrology review.”

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.

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

CW’s editors are tracking the latest trends and developments in tooling, from the basics to new developments. This collection, presented by Composites One, features four recent CW stories that detail a range of tooling technologies, processes and materials.

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.

He explains further, “We do a metrology review with customers at the start of a project. “How exactly do you want this measured in production? The circularity on this diameter is not called out on the print—how do you want it measured?”

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.

New aircraft is expected to deliver wind turbine blades from 105 meters up to expand the reach of wind energy and achieve global climate goals.

“On a datasheet, LFT compounds look stronger, but often they’re unable to fill the kinds of part geometry we can fill with short carbon fiber technology,” explains Alex Wojtysiak, MCAM key accounts manager – composites. “Because our flow is so much higher, we’re better able to fill intricate geometry, so our compounds produce parts that are dramatically stronger.”

Prepreg co-molding compound by IDI Composites International and A&P Technology enables new geometries and levels of strength and resiliency for automotive, mobility.

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.

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, 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.

At other companies, where tooling, manufacturing and metrology are often dispersed among different providers, the “blame game” is all too common: The tool is bad! You can’t process this part! You can’t measure this dimension!

Thermoplastics for Large Structures, experts explored the materials and processing technologies that are enabling the transition to large-part manufacturing.

He adds, “Our equipment is becoming specialized for difficult molding.” That means high cavitation (up to 32 with full cavity separation); tight tolerances, such as ±8 mils across 16 cavities for parts “smaller than your pinky tip”; complex geometries, including parts with 1.5-2 mil walls; and micromolding, with a Wittmann Battenfeld 15-ton MicroPower machine.

The Octex molding business and Omnia Scientific occupy a 70,000-ft2 main building, with Choice Tool & Mold housed in 10,000-ft2 next door. The main building has a 5500-ft2 Class 8 clean room with five injection presses, while the rest of the 30,000-ft2 manufacturing area is an ISO Class 6 white room with 24/7 particulate monitoring throughout. The plant operates 15 to 25 injection presses from 15 to 400 tons. “We bring in and release presses according to the programs we have running,” says Brett Wigton, chief technology officer. “When we don’t need a press anymore, we sell it.”

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 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

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

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

Whether you’re exploring new applications or seeking to gain a foothold in emerging markets, Carbon Fiber 2024 is where you’ll discover the insights and connections needed to shape your business strategy. Register now.

In the Automated Composites Knowledge Center, CGTech brings you vital information about all things automated composites.

Another medical device, for administering intravenous fluids, uses Eastman’s Tritan copolyester, which is recommended by the supplier for molding no thinner than 60 to 80 mils. But Octex engineers gambled that the part could be run at 8-10 mil wall thickness, thanks to the firm’s ample experience with the material, its in-house tooling capability, and its ability to measure and maintain precise tool tolerances. According to Thomas “TJ” Schuler, director of Omnia Scientific, “We had run Tritan for years—we knew about its outgassing and the importance of good venting. We knew what kind of injection pressure we’d need, and what kind of screw and barrel. The cores had to be almost perfectly straight across 16 cavities, because any core wobble would take up 15-20% of the total part thickness. So we CT scanned the tool—including vents, core pins and even cavity-pressure sensors—which helped us modify the tolerance stack-up to less than 16 millionths of an inch (0.016 mils).”

A report on the demand for hydrogen as an energy source and the role composites might play in the transport and storage of hydrogen.

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

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

Six U.S. companies have proven their recycling technologies for composites and rare earth elements, and will be supported for relevant scale demonstration and validation.

Extrusion simulations can be useful in anticipating issues and running “what-if” scenarios to size extruders and design dies for extrusion projects. It should be used at early stages of any project to avoid trial and error and remaking tooling.