Machine-integrated simulation seems to be still in the developmental stages, and information about its practical utility has trickled out gradually. At Fakuma 2018, the first public appearance of such machine-integrated simulation, Arburg stated that this involves giving the molding press information about the part geometry, which it has never had before. Intriguing, I thought, but not highly illuminating.

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.

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

“Converters are always looking to enhance their efficiency,” said Eugene Tabone, Rotational Molding Market Manager. “Our new Novapol TRx0338 and TRx0535 grades will help roto-molders leverage the fast sintering properties of these new resins to improve their molding operations.”

One response could be to send the affected parts back to the simulation engineer—who may not be on-site at the molding plant—and wait for a proposed solution based on rerunning the simulation with modified process conditions.

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.

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.

Depending on whether or not your chosen material is in the simulation database — and sometimes even if it is — analysts will have some important choices to make and factors to be aware of. Learn them here.

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

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.

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

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

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.

A reduction in cycle time enables manufacturers to produce more parts in less time at lower oven temperatures, noted Nova Chemicals, while a broader processing window allows them to run different part sizes and thicknesses on the same arm under identical conditions without sacrificing part quality. Processability characteristics support consolidation of traditional 3.5 and 5.0 melt index or 5.0 and 7.0 melt index grades to a single resin, added the Calgary-based chemicals company.

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

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

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.

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.

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.

The molder notices some defects in the molded parts—flash, shorts, burns, weld lines, flow lines, etc.—that may be related to the part or tool design but could possibly be ameliorated with process adjustments.

I’ve been noodling that question around in my head for the last three years, since injection machine suppliers like Arburg, Engel, Wittmann Battenfeld and Sumitomo (SHI) Demag started showing up at trade shows with mold-filling displays on their machine controller screens. I’ve been writing about plastic flow simulation since 1984, and I consider it to be one of the most important technological advances in molding I’ve seen in my career.

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

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

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

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

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.

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.

Next, at K 2019, Engel offered one hint of how this approach could help engineers perform more accurate simulations: Using Engel’s e-connect customer portal, the engineer could go online and select the machine intended for a molding job, and then download from Engel the parameters for machine capabilities—speeds, pressures, acceleration ramps, and temperatures. That way, Engel said, the simulation wouldn’t recommend process values that the machine could not achieve. Sounds sensible, but doesn’t require a display of mold filling on the machine’s control panel.

Two new polyethylene (PE) resins from Nova Chemicals Corp. for rotational molding are designed to accelerate production, lower cost, and improve flexibility. The Novapol TRx0338-U and TRx0535-U hexene co-monomer resins reportedly can reduce cycle times by up to 30% and provide a processing window at least 15% broader than traditional hexene roto-molding resins, said Nova Chemicals. The findings are based on extensive internal and customer testing, said the company.

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

Engel’s simlink will refine offline simulation with results from actual molding and use Engel’s machine data to constrain simulation within the actual machine’s capabilities.

Engel’s sim link data interface for two-way exchange of simulation and process data between Engel machines and simulation programs has been extended to include Simcon’s CADMOULD program.

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

The melt index and density profile of Novapol TRx 0535 resin makes it an ideal candidate for molding playsets. Image courtesy Nova Chemicals.

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.

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

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.

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.

So, naturally, I was excited to see it applied directly at the molding press. But the question was, what can you do with it there?

With a melt index of 3.5 and a density of 0.938, Novapol TRx0338 resin is suited for molding small tanks, intermediate bulk containers, roll-out waste carts, and material-handling containers for laundry and dry bulk goods. The 5.0 melt index, 0.935 density Novapol TRx 0535 resin is suited for manufacturing toys, recreational vehicle components, kayaks, stand-up paddleboards, and custom parts.

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

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.

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

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

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.

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.

Arburg’s integration of flow simulation on its Gestica controller (aXw Control FillAssist) enables real-time animation of mold filling correlated with screw position. (Photo: Arburg)

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.

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.

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 PE resins from Nova Chemicals reportedly can reduce cycle times by up to 30% and provide a processing window at least 15% broader than traditional hexene roto-molding resins.

Molding simulation software is a powerful tool, but what you get out of it depends very much on your initial inputs. Follow these tips to create the most successful simulation possible.

It started coming together clearer for me with Engel’s news from Fakuma 2021 that its sim link machine interface is now available for Cadmould simulation software from Simcon, in addition to Autodesk’s Moldflow. As noted in a recent news item, Simcon illuminated the importance of such integration: For one thing, Simcon pointed out that injection molding simulations can capture process parameters in a format different from that of the actual press control settings, forcing process technicians to translate the information into a format the machine can utilize. Second, if the real-world process is tweaked from what the simulation called for, those changes often never get back to the engineers that ran the simulation, limiting their ability to learn what needed to be adjusted. The benefit of sim link is that it not only translates the simulation software into parameters the machine can understand, but it records and saves any changes to the process from what the simulation specified, so the engineers can see how what Cadmould called for differs from real-world molding of the part.

Also at K 2019, Arburg unveiled a new digital “filling assistant,” which provides a 3D graphic of the degree of part filling relative to screw position, which can be animated in real time. Huh, I thought. Wonder what you can do with that.

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

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.

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).

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

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.

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

Join 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

What I’d really like to see is first-hand experience from a molder with this new integration technology. Where the rubber meets the road, so to speak. That’s where we’ll learn how, and how much, this innovation could help advance the state of the art in injection molding.

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

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 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.

Now this was starting to make sense to me, and it led me back to Arburg’s announcement of its “aXw Control FillAssist” real-time animation of mold filling on the press, correlated with screw position. I’m just spitballing here, but consider this potential scenario:

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

At Fakuma 2021, Engel’s sim link enables simulation software and injection machine controls to talk to each other in the same language. (Photo: Engel)

Or ... perhaps a process technician at the molding plant could examine the flow simulation on the press control panel and observe exactly when and where the problems occurred during the filling process. Perhaps that examination might suggest some tailoring of the process—maybe an adjustment of the injection speed or pressure profile, correlated with the melt’s arrival at the problem areas in the part. Besides saving time (and perhaps money), this solution might benefit from the molding technician’s closer familiarity with the machine and actual molding than might be the case with the simulation engineer (no offense intended).