Manufacturing Sensitive Products in the USA - plastic molding and manufacturing

In 2010, Flexcraft made a different sort of acquisition—Primus Mold in Middlesex, N.J., a maker of blow molds. “We wanted in-house mold manufacturing,” Smith explains, “because a lot of our programs, especially tight-tolerance jobs, require multiple mold trials and tooling adjustments. We need flexibility to try new ideas ‘outside the box.’ This way, we can dictate the shop schedule.” Flexcraft now has six people dedicated to the toolroom, which builds about 10% of the company’s molds and also performs maintenance and repairs and builds downstream automation equipment.

You’ve probably heard of molders that start out in high-volume commodity products and then diversify to take on more high-tech, engineered custom applications. What you may not have encountered is a molder that does the reverse—starting from a base in highly engineered, lower-volume products and then expanding into high-volume consumer packaging, while retaining the custom focus and high level of customer service that made it successful in the first place.

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.

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

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

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.

In 2015, Russ Sr.’s four sons acquired the company (flexcraft.com) and moved it to the 210,000-ft2 Neptune City plant, which today employs 150 people. Besides Ben Smith as CEO, the firm is operated by his brothers, Russ Jr, president and CFO; Dan, COO; and Tucker, program manager. Dan and Tucker run the factory floor.

The carbon fiber version of the cover was a successful demonstrator of the Conexus technology, Heider says, but “one of our goals is to reduce the overall carbon footprint of our components, so we thought next about how to make a more sustainable version. As a first step, we decided to replace the carbon fibers since it was the material with the highest CO2 footprint.”

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.

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

Once validated at the coupon level, the same tooling and part design as the original carbon fiber cover were used to manufacture new demonstrator covers.

Since its founding, Flexcraft has been devoted mainly to complex parts for medical and biosciences, often using engineering resins. Examples of current applications in that field include custom diagnostic reagent bottles, PC vacuum chambers for medical equipment, large flasks of PC and EPET for COVID vaccine production, a flexible TPE pump for bariatric surgery, and a TPE inflatable medical device.

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.

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.

“We wanted in-house mold manufacturing because a lot of our programs, especially tight-tolerance jobs, require multiple mold trials and tooling adjustments.”

•  2020 saw completion of a two-year project with Bekum to develop a large machine for the burgeoning field of extrusion blow molded PET, or EPET (see Jan.’19 Close-Up.) That year also brought in two more Bekum machines, plus an expansion of the cleanroom molding area, addition of a 50,000 ft2 warehouse, and automatic bagging and palletization on two molding lines.

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.

For the carbon fiber-reinforced polymer (CFRP) and flax fiber covers, KTM Technologies ultimately demonstrated the technology on in-house specimen- and part-level tests to prove adhesion for the joined parts, impact resistance, UV resistance and more, according to the company’s internal quality standards. “Our parts go directly onto the motorcycle where they’re tested by actual riders,” Heider says. “We do mechanical tests on the component separately, then test real-world performance on the motorcycle.”

KTM’s industrial design department began with technical specifications for one of the company’s standard brake disc covers. Generally, these covers are made from metal or injection molded plastic, and include several holes to allow airflow to the brake disc underneath. Metal inserts fit into the bottom of the cover to enable the cover to mount and latch to the bike.

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.

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.

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.

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.

Flax fiber/epoxy and flax fiber/bio-based PA. For its second and third iterations of the brake disc cover, KTM Technologies used Bcomp flax fiber with epoxy (shown here) and flax fiber with a bio-based polyamide. Both versions of the cover won awards in 2022.

Award-winning motorcycle brake disc cover showcases potential for KTM Technologies’ Conexus joining technology and flax fiber composites.

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.

The design team began with CAD files of the existing design and used digital simulation to design a new part, with the goal of incorporating the right materials in the right place. Additional simulations were performed to help avoid warping and assure good filling and temperature distribution for the coupling layer during the injection molding process.

With the new design, the goal was to develop a part with three layers. The top outer layer would be an epoxy thermoset-based composite to increase the overall impact resistance and stiffness of the part, and a bottom layer would be unreinforced thermoplastic that would be fitted with the metal insert, with the Conexus coupling layer in between joining the two halves together, acting as the third layer. The thermoset and thermoplastic layers ultimately overlap slightly — “but this isn’t for connecting,” Heider explains. The overlap protects the edges from moisture and wear over time.

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.

The part combines three technologies: a compression-molded flax fiber/epoxy base structure, an injection overmolded thermoplastic outer layer and an innovative technology to join the two layers together without the use of adhesives.

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

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

Flexcraft built its reputation on highly customized, tight-tolerance medical components, such as these, made of polycarbonate and PE.

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.

According to Heider, the CO2 footprint of the materials is reduced by up to 60% by switching to flax fiber from carbon fiber. “We wanted to show that we can use our Conexus technology to produce aesthetic and performance parts on the one hand, and to be able to fulfill sustainability targets on the other hand. By using established manufacturing methods where we can easily implement other fibers or thermoplastic materials, we have an innovative joining technology ready for the market, which can adapt easily to the needs of every customer without the necessity to invest in additional machinery,” Heider says.

Plans for capacity expansion continue apace. A former toolroom space is being converted to make room for four more blow molding machines. One additional Bekum machine cell with automated material handling was purchased, and a second ISBM machine is on order. A 12,000-ft2 cleanroom expansion is nearly complete, and the first machine to occupy it was due to arrive as this article went to press.

The Tier One automotive supplier with compounding and blowmolding machine capabilities adds the 50-yr-old molder and moldmaker.

Why not recycle or repurpose the flax fiber thermoset component? Johann Wacht, manager of motorsports and supercars at Bcomp, explains, “With recycling, you need to think about your base materials.” He claims that the company’s flax fiber materials are produced as CO2-negative materials, whereas any of today’s recycling methods would consume energy and result in a larger overall carbon footprint. “In this case, simply recovering energy from the natural fiber and epoxy [at the part’s EOL] is the better solution, because you can recuperate 80% of the energy stored in the material. It makes a lot of sense from a CO2 footprint perspective.”

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.

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

The real-world testing is key, von Czarnecki notes. “You can predict or simulate a lot of scenarios but there are a range of situations — impacts, weather events, stone chipping — that you can’t guess.”

This year, Flexcraft also enhanced its ability to recycle internal waste. Trim scrap is already reground and blended at the molding machines; a brand-new shredder allows reclaiming purgings, too. “Our goal is to reprocess 100% of our scrap within the next three years,” notes Smith. He adds, “We’ve been using a lot of HDPE post-consumer reclaim for going on six years, but right now there’s a crazy shortage of PCR availability and extreme volatility in pricing.” He says the firm is also looking into additives that make PE and PP biodegradable. “We see the demand coming, and we want to be ready—to know we can process it.”

Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

“In the past five years, we have diversified to compete in high-volume custom bottles for consumer packaging, food and beverages,” says Smith. One example is growing investment in ISBM. “We see a lot of applications going to PET for food and beverage packaging, so that will be a focus for us going forward.” Examples include custom long-neck bottles for fuel additives and a 1-gal, wide-neck food container.

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

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

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.

This project also demonstrated natural fiber composites as a good fit for Conexus. Von Czarnecki notes, “Expecting carbon fiber shortages, the Conexus technology offers an opportunity to use less carbon fiber on one side [of the part] and more natural fiber on the other — still light and cost-efficient.”

First iteration: Carbon fiber/epoxy. The initial carbon fiber/epoxy brake disc cover successfully proved out the technology for end-use parts. From there, KTM Technologies went back to the drawing board to use even more sustainable materials.

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

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.

In addition to demonstrating natural fiber materials, thanks to the Conexus coupling layer, the flax fiber composite cover “has a drastically reduced global warming potential, and a very nice end-of-life scenario compared to the carbon fiber version,” Heider says.

Flexcraft is broadening its focus to include custom, high-volume consumer packaging, such as the award-winning, dual-chamber HDPE drain cleaner package at left; EPET restaurant spice container (center); and stretch-blown PET fuel-additive bottle at right.

“We don’t need a gluing step, or rivets or bolting or screwing. Directly out of the injection molding process we have a part that we can directly mount to the motorcycle,” Heider says.

Heider notes that the Conexus technology both assures a strong chemical bond between the thermoplastic and thermoset materials involved, and, because it is thermoplastic-based, enables separation at the correct temperature.

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

Over the next 25-30 years, Flexcraft built a reputation as a highly technical blow molder for medical and biosciences applications. In 1980, the firm tackled a large metal-to-plastics conversion project, replacing 18 stainless-steel parts with a single polysulfone blow molded component. In 1985, Flexcraft claimed credit for being the first to extrusion blow mold Allied-Signal’s Halar ECTFE (now supplied by Solvay) and, in 1989, the first to blow mold GE’s Ultem PEI (now supplied by SABIC).

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

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.

First all-composite brake pedals developed by Boge Rubber & Plastics Group are lighter, stiffer, stronger and offer improved driving haptics.

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.

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

Heider explains, “We were looking for a semi-structural part to showcase the feasibility that the connection is working on the same level as a structural adhesive. The brake cover was chosen because it’s a very visible part on the motorcycle.”

The Conexus coupling layer is designed to have a lower melting temperature than the thermoplastic part in a given application, he explains. At the part’s EOL, if heat is introduced at the coupling layer’s melting temperature, the Conexus layer will melt and allow the thermoset and thermoplastic parts to be easily separated without damaging or melting either part.

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

The brake disc cover project, and motorsports in general, is only the first step for Conexus technology, says von Czarnecki. “This enables the possibility to combine materials without bonding, increasing sustainability and reducing complexity in the process. It is offering a whole new range of applications.”

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

Showing off multi-material joining, natural fiber composites. With three iterations in development and poised to go on the market, KTM Technologies’ new motorcycle brake disc covers demonstrate potential for its Conexus joining technology to combine thermoset parts with thermoplastics. Photo Credit, all images: KTM Technologies

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

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.

A new 500-ton central chiller will support a future tripling of machine capacity, but variable-frequency drive continuously tailors the energy consumption to the immediate load. Large customers are said to be looking for such sustainability measures from their suppliers.

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).

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.

EPET is another area of custom packaging where Flexcraft sees opportunity. Its multimillion-dollar development program with Bekum resulted in a version of Bekum’s model 607D with an oversized extruder capable of molding large, wide-mouth EPET containers in up to four cavities. Flexcraft’s first project in this area is a 160-oz jug with integral handle, designed to hold large quantities of dried spices used in restaurant kitchens. It is blow molded with a dome that is cut off to yield a very wide neck. The product is being converted from PVC to EPET, which is regarded as a more sustainable solution.

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

High clarity, easy incorporation of handles, and recycling resin code No. 1 are the principal drivers for converting to EPET resins for extrusion blow molding.

Starting with a converted chocolate extruder, the firm now has two plants with 150 employees and around 40 injection and blow molding machines.

That’s the evolving strategy of The Flexcraft Co., a custom blow molder headquartered in Neptune, N.J. To accomplish this, the firm has invested in a broader arsenal of blow molding technologies, as well as automation and employee development. Ben Smith, CEO, explains the strategy: “We don’t want to become a commodity blow molder. We’re not looking to the be the cheapest option. We offer value—customization in design, packaging and labeling. We’re a regional blow molder, so we offer freight savings to local clients. We’ve invested so much in our people and technical capabilities—more than $15 million in new equipment since 2015. We can offer what the larger guys do, but customer service is where we shine. We react fast. As we’ve grown, we have stayed true to the importance of every customer.”

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.

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 strategy driving the whole process on our side was to enable us to use these materials together, and to use each material for what it does best,” von Czarnecki explains. “That is, to use the thermoset for the mechanical properties where they were needed, and where the customer can see it to really appreciate [the flax fiber], and to use thermoplastic for functions such as ribs and integration of inserts, and by this we achieve the most cost-efficient design.”

The original design of the cover involved a compression molded, carbon fiber/epoxy top layer joined via Conexus to an injection molded bottom layer made from a blend of polyamide 6 (PA6) and ABS (acrylonitrile butadiene styrene) from INEOS Styrolution (Frankfurt, Germany). KTM Technologies developed tooling for the thermoset part with partner Alba Tooling & Engineering GmbH (Forstau, Austria), and for the injection molding tool with Altendorfer Kunststofftechnik GmbH (Neureichenau, Germany).

Currently, KTM Technologies is investigating several racing motorsports projects and exterior automotive non-structural parts using the Conexus technology. In addition, as demonstrated in a joint research project with Airbus’ Composite Technology Center (CTC, Stade, Germany) which focused on the use of Conexus technology with ultrasonic welding (see video below for a demonstration of this technology), one goal for Conexus is to enable smart and efficient manufacturing in emerging industries such as advanced air mobility (AAM).

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

Automation is a must-have for molders of pipettes. Make sure your supplier provides assurances of throughput and output, manpower utilization, floor space consumption and payback period.

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.

Another effort toward sustainability is Flexcraft’s plan to reuse every bit of its internal scrap, much of which is reground and reused at the press. A new shredder will allow purgings such as these to be reclaimed, too.

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

In this case, the thermoplastic component could then be melted and reformed for additional uses, while the flax fiber component would ideally be pyrolyzed, with the energy recaptured for another use such as cement kiln coprocessing or waste-to-energy cogeneration plants.

Thermoset composite parts — in motorsports and many other end markets — are often combined with parts made of other materials, such as unreinforced plastic or metal. Multi-material joining with thermoset composites generally involves either mechanical fasteners, which add weight to the part, or adhesives. In addition to adding weight, the latter includes chemicals that are generally not considered to be sustainable, and often requires pre-treatment and a challenging process and quality control due to stringent nondestructive testing standards.

Stefan von Czarnecki, director of sales and business development at KTM Technologies, explains that the entire company is emphasizing  sustainability initiatives, including manufacturing, part design and end-of-life (EOL) solutions, starting with R&D initiatives aimed to qualify and evaluate opportunities for series production. One of these initiatives was the creation of an innovative joining technology called Conexus, which the award-winning brake cover was designed to demonstrate.

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

Flexcraft bought a blow-mold maker to give it in-house control over complex, tight-tolerance jobs that require multiple tool revisions.

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.

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

•  So far this year, Flexcraft has made two significant additions. One is a sophisticated 500-ton central chiller system from Thermal Care. It’s large enough to support a future tripling of current machine capacity; but thanks to variable-frequency drive (VFD), the system uses only as much energy as the plant needs at any point in time. “That’s very important,” notes Smith. “A couple of large customers are looking for sustainability efforts by their suppliers.” The second key purchase is plant-wide air conditioning. “It provides a better work environment, and humidity changes can affect the molding process a lot,” says Smith.

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.

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.

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.

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

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.

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

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.

Teel Plastics opened new plant in record time, partnering with AEC & Aqua Poly Equipment Co. to expand production of swab sticks to fight pandemic.

Eliminating the need to contact each supplier for every individual quote, a new CRM for automotive supplier Axiom Group tracks past quotes as well as industry history to generate fast, reliable RFQs and more.

CW associate editor Hannah Mason recaps several technologies seen on display at JEC World 2022, including new developments from Bcomp, Massivit 3D, Gen 2 Carbon and more.

The carbon fiber version of the brake disc cover is now available for the aftermarket and will be equipped on some special edition motorcycles beginning in 2023. About 5,000 CFRP covers will be produced annually for KTM’s MX and enduro full-size models, Heider says. The company says the natural fiber cover may be introduced into KTM’s PowerParts portfolio as an aftermarket option once tests are completed.

Also in New Jersey are six injection molding machines of 35 to 310 tons, used to mold caps, closures and other packaging components.

First, the two companies went back to the drawing board to perform coupon-level testing on an identical version of the carbon fiber/epoxy component, this time using Bcomp’s ampliTex 5040 300-gsm twill flax fabric combined with epoxy and a Conexus layer via compression molding. Again, this was followed by an injection overmolded PA6 bottom layer. A series of tests were done to prove that the flax fiber was compatible with the Conexus technology and that the combined parts would stay joined over time and in a variety of conditions. Heider notes that although the overall mechanical performance of the flax fiber is lower than that of carbon fiber, the material offers advantages like improved damping behavior, and that it does not splinter when broken, increasing safety.

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.

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.

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.

“Design for manufacture was key,” Heider notes. To be able to serially produce the covers, the manufacturing process had to be relatively fast, with part costs as low as possible. “We knew we wanted to produce an attractive optical part and give visibility to the hybrid construction, but we also needed a part that can be produced using known and approved processes, to give us the opportunity to make parts very quickly and efficiently,” he explains.

For Bcomp, Wacht says that this project has been “a perfect example to show the design freedom you have thanks to this process. When you think about the potential of this technology, you can see how it could be used for an even more complex shape, such as in a supercar interior or in larger bodywork components.”

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.

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.

First, the thermoset composite layer is formed via compression molding. During layup, a single layer of the Conexus film, about 100 microns thick in the final part after processing, is applied as the bottom layer in the mold. The Conexus layer uses a copolymer that works with the selected thermoplastic and thermoset — in this case, epoxy and polyamide — to join them together. Additionally, the Conexus layer acts as a release film in the tool. The carbon fiber fabric is then added on top, and subsequent molding at 150°C (302°F) creates a bond between the thermoset and Conexus layer. After molding, the part and a central metal insert are transferred to an injection molding station, where the PA6/ABS layer is injection overmolded directly onto the Conexus film, creating an additional bond between the coupling layer and thermoplastic.

CEO Ben Smith displays a large Styrolux “Bottle Bank” piggybank that has been blow molded on an accumulator head for more than a decade but will be transitioned to a continuous-extrusion process.

The brake disc cover project originated as a way to demonstrate the Conexus technology, and is in serial production at KTM as a carbon fiber/epoxy version that features a metal insert directly joined to a thermoplastic component via injection molding. Based on this serial part and the processes and tools used to manufacture it, the more sustainable flax fiber/epoxy demonstrator presented at JEC World was built.

Flexcraft in New Jersey currently has 18 extrusion blow molding machines, 13 of them continuous-extrusion shuttles from Bekum, plus one single-stage ISBM machine from Nissei ASB Co. The Rhode Island plant has 14 extrusion blow machines built by Rocheleau.

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While automation can free people from simple, repetitive tasks, Flexcraft is also working to develop its personnel for more challenging activities. “We want to help people build careers in molding,” explains Smith. “So this year, we made a massive investment in a complete Paulson Training package for injection and blow molding. It will allow us to track employees’ progress through the program. And we are transitioning one person into a full-time trainer.”

Automotive molder ITW Deltar Fasteners found new life for the battered bolt holes on its machine platens with a solution that’s designed to last.

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 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

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

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

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.

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

That growth has indeed been impressive: around 20% annually for the past five years. This was accomplished without a full-time sales force. “We’ve grown by word of mouth and reputation,” says Smith. “Our customers’ engineers get to know us, and when they move to new companies, they recommend us as a supplier. We make things easy for them—offering engineering, tooling, molding and secondary operations like surface treatment, printing, sleeving, labeling and more.”

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

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

Looking ahead, Smith foresees adopting coextrusion for personal-care packaging, where cost savings can be achieved by using only a thin external layer of colored resin over a virgin internal layer.

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

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

Two generations of Smiths—Russ Sr. (third from l.), who co-founded the company with his father, with sons (l. to r.) Russ Jr., Ben, Dan, Tucker. Behind them is a special machine they developed with Bekum to produce the large, wide-mouth EPET containers that they’re displaying, which represent part of the company’s new thrust into high-volume packaging.

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

Smith voices a complaint heard widely throughout the industry: “There’s a massive labor shortage, and it’s even worse in technical personnel.” Flexcraft is addressing that on two parallel tracks. On the one hand, says Smith, “We want to use automation to minimize the human element that can cause variation.” Almost all lines have fully automated material handling, and the toolroom has built several items of downstream automation, such as trim-and-transfer tooling that orients bottles upright on conveyors, and a box filler that counts bottles packed and indexes the box when it reaches a preset count.

Flexcraft has also grown through acquisitions. In 2003 and 2005, it absorbed two smaller blow molders, gaining new customers and some additional machines. In 2019, Flexcraft purchased another blow molder active in similar high-tech custom markets, Blow Molded Specialties in Pawtucket, R.I., whose 30,000-ft2 plant with 40 employees is now operating as a second Flexcraft facility. “This acquisition helped build our technical depth and provided additional cleanroom molding capacity,” says Ben Smith. “It also helped us to diversify our customer base in medical and specialty products. They have experienced people and the same basic operating philosophy and capabilities as us. But they have smaller machines, which are good for smaller parts with tight tolerances.” (See PT’s May ’13 profile of Blow Molded Specialties.)

In 2020, Flexcraft scored a win by working with a large packaging distributor to reshore from China a dual-chamber HDPE bottle for Green Gobbler Drain Clog Dissolver, a major feature of which is inline shrink sleeving of the label, which was a challenge to orient on such an irregularly shaped bottle (see photo). Flexcraft came up with an unusual approach—inverting the bottle for the sleeving operation so that the label could cover the container’s base. Flexcraft built the tooling and sleeving system for this bottle, which won three packaging awards in 2020. The application runs 5-7 million units/yr.

Low-cost and easy-to-program collaborative robots are a new solution to bottle handling, trimming and packing automation.

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).

A new Automation group focuses on making processes more consistent. Team members Adrian Mendez, technical manager (l.), and Kevin Izworski, plant engineer, design and build devices like this indexing box filler.

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.

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.

The cover, a circular panel designed to mount to the wheels of a racing motorcycle to protect the brake system from debris or impact, was entered into the competition by flax fiber supplier Bcomp Ltd. (Fribourg, Switzerland) and built by KTM Technologies (Salzburg, Austria), the R&D and innovation unit of motorcycle manufacturer KTM AG (Mattighofen, Austria).

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.

For most of the last two decades, the firm has invested aggressively in technology and capacity expansion—continuing right through the COVID-19 pandemic:

KTM had worked with flax fiber supplier Bcomp on motorsports projects in the past, so a trial version of the cover using Bcomp materials felt like an obvious next step.

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

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

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.

However, with the carbon fiber version of the brake disc cover, “it’s another game,” Wacht says, “because carbon fiber is very energy-intensive to produce. Carbon fiber makes absolute sense to recycle.” Depending on the specific recycling method, the energy consumption that goes into recycling carbon fiber generally still results in a lower overall carbon footprint for the material, he notes.

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.

Testing material samples. Before proving out its technology on its brake disc covers, KTM started with coupon-level testing of Conexus on a range of fibers and plastic part combinations.

For this part, KTM Technologies partnered with Akro-Plastic GmbH (Niederzissen, Germany), a company that specializes in plastic compounds and that recently introduced a product line of bio-based thermoplastics. Again, the teams began by testing materials at the coupon level, and for the SPE-presented part, decided to demonstrate the brake disc cover using Akro-Plastic’s Akromid Next 5.10 3 GF 30 glass fiber-filled PA6, chosen for its high bio-based content and higher mechanical properties due to the additional glass fiber. This version of the brake disc cover is said to enable up to 70% CO2 reduction for the materials used compared to the series model.

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

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

Conexus layering. Conexus technology was developed to be a thermoplastic coupling layer in between a molded thermoset component and a thermoplastic material, integrated via 3D printing or injection overmolding.

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.

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.

Production-ready. KTM Technologies plans to produce its carbon fiber and flax fiber composite brake disc covers commercially. Beyond motorsports, the company plans to use its now-proven Conexus technology for automotive and even urban air mobility (UAM) applications in the future.

“Sustainability” was the official theme of the JEC World 2022 exhibition in Paris, France. One project that exemplified this theme, and that took home the 2022 JEC Innovation Award in the Sports, Leisure and Recreation category, is a motorcycle brake disc cover that aimed to demonstrate three sustainability-focused technologies in one part.

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.

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

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

The JEC Award-winning flax fiber/epoxy part was only the first step toward demonstrating the use of sustainable materials for brake disc covers. In October 2022, KTM Technologies was awarded an SPE (Society of Plastics Engineers) Automotive Award in the “Body Exteriors” category for a new version of the cover that uses flax fiber in combination with a bio-based glass-filled polyamide.

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.

Agreement between Eastman and Ethicon will put copolyester derived from recycled materials in sterile barrier applications.

KTM Technologies sought a joining solution that would avoid the use of fasteners and adhesives. The basis of the Conexus technology that KTM ultimately developed over the past few years is a thermoplastic film — called a “coupling layer” — that can be added to a traditional thermoset composite layup in a curing process, such as, in this case, prepreg compression molding. During the cure process, the Conexus layer bonds to the thermoset composite part, acting as a chemical release agent and serving as an outer, unreinforced thermoplastic layer onto which the thermoplastic material can be directly joined. “You can then functionalize the part by injection molding, 3D printing or welding,” explains Michael Heider, lead engineer at KTM Technologies. Conexus can also be used with a variety of resin and fiber types.

The company’s second ISBM machine is on order to take advantage of what is seen to be major growth potential in oriented PET bottles. Here, large, wide-mouth bottles are packed upside-down, a potentially labor-intensive task that is now handled by a cobot.

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

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.

The headquarters plant also has five older Hayssen accumulator-head machines, which are being phased out. Flexcraft has worked with Bekum to learn how to convert the larger parts made on the accumulator machines to run with continuous extrusion. An example is a large piggybank shaped like a classic Coca-Cola bottle and made of Styrolux styrene-butadiene copolymer from Ineos Styrolution. Flexcraft has made the “Bottle Bank” on accumulator-head machines for 13 to 14 years, but will be switching it over to continuous extrusion.

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

Von Czarnecki emphasizes that the process and technology haven’t only been designed for use by KTM itself. “Our strategy is to qualify the technology and de-risk it for ourselves, and then enable our production partners to use it in other industries,” he says.

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.

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.

Flexcraft was founded in 1971 by the late George Smith together with his son Russ Smith Sr. George was a former GE Plastics engineer who hankered to make products from the resins he had spent his career developing. The Smiths bought a chocolate extruder from Hershey and converted it to a blow molding machine. For their first customer, they molded thick-walled polycarbonate and polysulfone vacuum canisters for medical equipment. Flexcraft still molds for that customer today.

For a new EPET application that requires large bottles to be packed upside down, Smith says the labor requirement was especially large, so the job was automated with a collaborative robot (“cobot”) from Universal Robots.

Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution

In this collection 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.

This family-owned firm is broadening its range of blow molding technologies to expand into new markets, while maintaining the strong service philosophy that has made it successful.

Of the overall process, von Czarnecki explains, “We start our parts basically as a demonstrator as a first step, then to small series application, then to higher volumes. This is how we enable and qualify new technologies for the company and then scale it up.”

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

This year, Flexcraft decided to approach the need for automation more systematically by forming an in-house Automation group, consisting initially of one employee from engineering and one from maintenance. Their charge, as Smith describes it, is to “focus on line improvement and automation to make processes more consistent.” They are considering potential use of autonomous mobile warehouse robots (AMR’s) to improve material flow through and between buildings. They are also investigating more automated quality-assurance inspection equipment to improve consistency of data and allow a greater quantity of samples to be analyzed more quickly.

For speed, compression molding was chosen for the thermoset part, and injection molding for the thermoplastic part. “We designed the process for easy processability and low scrap,” Heider adds.