Any molder will tell you there’s a difference in working with electric vs. hydraulic drives. Servohydraulic is still hydraulic; a hybrid machine is something different. Imprecise use of terms causes needless confusion.

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.

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

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

Wittmann Battenfeld will introduce the new EcoPower B8X injection molding machine line and show direct current as an energy source for a concept machine that will power its own robot.

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

“A molding shop run by two women—you don’t see that everyday,” says Lynn Momrow-Zielinski (left), who cofounded Extreme Molding with Joanne Moon in 2002. On the table in front of them are YogaJellies yoga pads (yogajellies.com), compression molded of about 1 lb of LSR.

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.

Using a sensor, an edge device and machine learning software, sensXPERT sees into processes and is improving quality and cutting scrap, cycle time and energy use for composites customers like ZF and Carbon Revolution.

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.

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.

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

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.

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

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

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.

CW has written a lot about sensor technologies and how they can be used to improve composites manufacturing. See our Sensors microsite, which discusses sensor types and data, and includes CW articles and videos from technology suppliers. Dielectric sensors, or dielectric analysis (DEA), is one of the main technologies we’ve covered because it offers the ability to assess the actual state of a polymer or composite material in situ, during molding, including its degree of cure and Tg — which then enables managing processing on the actual state of the material, instead of legacy time and temperature recipes.

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

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

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.

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

In 2019, Netzsch created NedgeX, a digital incubator company to work with its 4,600 employees globally and find teams with new ideas and business models for startups, as well as to support new developments and inventions at universities. “In 2019, I pitched the idea for sensXPERT along with NedgeX to our review board,” says Chaloupka. “It was like being in ‘Shark Tank’: Here’s how to use an existing measurement technology but equipped with new data science in order to combine sensors and material science for an entirely new product that really benefits the customer. This new venture was approved and we started as an incubator business in 2020.”

ZF was getting ready to start series production for an OEM’s next generation of electric motor control systems. “We looked at the material behavior within their manufacturing process and found potential for a cycle time reduction of around 21%,” says Chaloupka. “We could also see the material in the process was deviating, even when we worked with ZF to ensure all process and material parameters were the same for 100 parts in a row made using a single batch of material.”

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

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.

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

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

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

With sensXPERT, Netzsch has advanced DEA technology into the rapidly growing field of material informatics, enabling dynamic material behavior prediction in real time based on sensor data combined with process data from machines and the sensXPERT machine learning algorithms.

This, says Chaloupka, is the real value of sensXPERT because, “As humans, we are not really capable of taking 10 process parameters and relating them to the material behavior and to the material science in order to know that if I change this parameter, then this is what to expect. That’s just too much for our brains to do quickly, much less in real time.” There are some experts with decades of experience who can quickly assess manufacturing irregularities and adjust the right parameters, he adds. “But not every company has these experts and there are simply less of them around, which emphasizes the need for technology tools that can provide this type of assistance.”

Chaloupka says sensXPERT can work with a range of materials, including adhesives, coatings, preceramic polymers and thermoplastic composites. “We have grown within the thermoset resin market, and 95% of our existing customers are thermoset-oriented,” he concedes, “but we are reaching out to more and more thermoplastic customers. Yes, we can measure crystallization in semi-crystalline thermoplastics [e.g., PEEK, PEKK, PAEK] and also solidification in amorphous thermoplastics. We have a use case, but it is for in-situ polymerization of caprolactam into polyamide 6 [PA6] in Six Sigma product manufacturing. We have a series installation at a German company that is manufacturing volumetric semi-finished products where we have to optimize the manufacturing processes for different materials and with adapted chemistry (mixing ratio and additives) for different plate thicknesses.”

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

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

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.

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

This Digital Mold technology can be used in a wide variety of plastic and composite processes including injection molding, compression molding, resin infusion and resin transfer molding (RTM), as well as autoclave curing of prepreg. It enables manufacturers to stop the curing process, for example, when the desired degree of cure/polymerization or glass transition temperature (Tg) has been reached. It also enables tracking material viscosity and flow front position, as well as deviations in materials, helping to identify how to adapt processes to prevent scrapped parts.

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.

Why is this a problem? “If we had followed the prescribed process recipe generated by the material supplier from their materials lab testing, we would supposedly have ended up with 100 good parts,” explains Chaloupka. “But what happens in reality is that every single part is different. To deal with this, material suppliers and molders add time onto cycles to give a kind of safety margin. But using our Digital Mold technology, we can eliminate these safety times by having a look into the material behavior and deviations that are affecting cure. And we can calculate the degree of cure and Tg in real time.”

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.

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

The sensXPERT technology has been developed by Netzsch (Selb, Germany), a company founded in 1873 that developed into three divisions: Pumps & Systems, Grinding & Dispersing and Analyzing & Testing. In 2000, Netzsch bought Holometrix Micromet (Bedford, Mass., U.S.) and its DEA technology, which was spun off from MIT.

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).

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

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.

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).

SensXPERT worked with ZF to analyze transfer molding of epoxy molding compound materials for EV control unit circuit boards (top left) using in-mold sensors (top right) to provide data on cycle time and material deviation (bottom). Photo Credit: ZF, sensXPERT

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.

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

Another alpha customer is an aircraft manufacturer, which is using sensXPERT technology in series production of carbon fiber/epoxy beams and panels. “After several years of working together, they have now completed a sensXPERT installation for RTM processes in a cascaded manufacturing line,” notes Chaloupka. “Here, we have identified a potential 30% reduction in cycle time. But there is also interest to apply this technology in different manufacturing environments, future development programs, where new materials are presenting new production challenges.”

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.

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

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.

Chaloupka joined Netzsch Analyzing and Testing in 2016, where he worked for 2 years to advance the DEA sensor technology’s signal quality and ability to work with carbon fiber, which can create a short circuit because it’s electrically conductive. “And then in 2018, we decided to create a new business field within Netzsch Analyzing and Testing for process analytics,” he explains. “My job was to take our DEA technology into production applications around the globe and get feedback on what customers actually need. And while doing this, we doubled our revenue in both the first and second year of starting this new business.”

The company has already developed a second product, sensXPERT Pipe, for in-situ analysis of cured in place pipe (CIPP) liners made with glass fiber-reinforced polymer (GFRP). It uses touchless DEA sensors that are fitted to the robot carrying the ultraviolet (UV) light source through the pipe to cure the FRP liner. These sensors use radio frequency technology to provide non-contact cure analysis as the UV light is pulled through the pipe. “Now, you can see at what velocity the UV light should be moving,” says Chaloupka, “and, in real time, if there are deviations from the optimum degree of cure.” Again, dynamic processing is now possible — the speed of the light source can be modified on the fly. “And you have a built-in record of your quality assurance,” notes Chaloupka. “You are doing QA as part of the installation, not afterward.”

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.

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

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.

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.

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.

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

Extreme Molding defines its special niche as overmolding, especially with LSR, for applications in female-oriented and children’s healthcare.

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.

–  Netzsch buys DEA technology, pushes outside the lab –  NedgeX incubator, sensXPERT venture –  Alpha customers and use cases –  Basic components –  How does the installation process work? –  Process transparency and optimization –  Use with thermoplastic composites? –  Further applications, collaboration with supply chain

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

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.

SensXPERT is working with the aviation supply chain and various resin manufacturers to reduce cycle time for RTM and enable higher volume, faster parts manufacturing by using two-component resin systems for HP-RTM parts. Photo Credit: sensXPERT

“This industrial PC edge device is also equipped with software developed by sensXPERT, which includes machine learning algorithms,” he continues. “The system can perform a lot of analytics and machine learning model execution at the edge device, but enabling the machine learning training and retraining requires working in the cloud. For this, we need an IT infrastructure that we will verify together with the customer. And when the first data has been generated and the first parts manufactured, we will then create the machine learning models for the customer and use case, based on the material science and the real-time process information.”

“We then analyzed what our next step should be,” Chaloupka continues. “We had a good measurement technology and some customers who could analyze the dielectric data, but it wasn’t necessarily easy for them to translate that data into added value. We therefore decided that what we really needed was a new level of data science — a way to match material science from the lab with the production environment, to combine the information from the sensors with the machine parameters and the influencing factors that can affect the material behavior as the part is being produced.”

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

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

Chaloupka notes that the aviation supply chain, “is looking at high-pressure RTM [HP-RTM] using two-part resins for cycle times of roughly 1.5 hours for really big structures, versus current cycles of 4-6 hours.” He adds that multiple resin companies have been working in this area, including Hexcel, Solvay and Westlake, looking at high-volume production of parts for future airplanes.

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

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

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

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

Cured in place pipe (CIPP) can use UV light to cure FRP pipe liners for trenchless repair without having to dig out old, corroded pipes. Photo Credit: Lightstream LP, “Cured in place pipe”, CW Dec 2012.

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.

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.

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!

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.

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

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

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

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

“A customer tells us they want to optimize a process,” explains Chaloupka. “We then discuss their challenges and long-term targets. Some customers want to reduce cycle times or scrap, while others just want to have transparency in the process to know what is happening and build knowledge around the parameters and material interrelations.”

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.

A speed gain of 1,000 to 10,000 times greater than traditional FE models has been achieved using machine learning models, enabling near real-time simulation for large composite components.

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.

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

By applying machine learning algorithms, sensXPERT can enable material behavior characterization in real time and adapting processes for improved quality control and dynamic cycle times. This then improves efficiency and reduces energy consumption, giving composites material suppliers and parts manufacturers a new tool to improve sustainability. For more details, watch the Sep. 28 webinar on CW.

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

Product engineering manager Michael Fil often has to tweak customers’ designs to ensure they can be molded successfully. There aren’t a lot of designers familiar with LSR, especially when it comes to overmolding.

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.

Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.

The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

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

“We are also talking to companies working with thermoplastics who want to increase their recyclate content,” says Chaloupka. “Due to new EU regulations, there is no way for the plastics industry to avoid using more recycled content, even post-consumer material, which makes it harder to characterize every batch of material before you mold it. Therefore, new technologies are needed that can deal with material deviations and help to ensure proper manufacturing. Those deviations can happen from one batch to another, and you may need to change many different parameters in different directions to be able to produce good parts. We are looking into that because we can see and evaluate those deviations in real time.”

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.

This is what the sensXPERT technology achieves, but instead of creating digital models, it collects machine and process data and combines it with data from dielectric analysis (DEA) sensor(s) in the mold that monitor viscosity and cure behavior in polymers and composites. It then applies data analytics via an edge device to let manufacturers see what’s actually going on inside the part — and control cycle times dynamically, for each part.

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.

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

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

“Initially, our focus was to optimize plastic and composites processes for production,” says Corneila Beyer, CEO of sensXPERT, “and sustainability was a side effect. But now the demands of customers have changed. They are faced with making significant changes to meet new requirements for increased biocontent and/or recycling, as well as reduced energy usage. But they still need a stable process and assured quality for high-performance products. Our technology enables dynamic part production where they can optimize their processes in real time. But we go one step farther, using machine learning and AI to look across all of their parts and data to make predictions. For example, the system can send an alert saying the process is moving outside the allowed window and suggest adjusting X, Y and Z to bring it back in line.”

“And then, from the edge device, we send all the data into a cloud environment,” he continues, “and our software uses the historic data to recalculate the machine learning models going forward, which will further enhance these models running on the edge device and increase the ability to identify areas for improvement. Meanwhile, the data is also fed into dashboards for everyday monitoring and operations.”

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

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

The sensXPERT edge device on the factory floor is connected to the customer’s intranet, giving them access to the system. Ideally, says Chaloupka, it is also connected to the internet, allowing data to be sent into a cloud environment for advanced analytics. “We have developed the necessary data security infrastructure and are accustomed to working with risk assessment frameworks for large corporations as well as providing the assistance necessary for smaller companies,” he adds. This final part of the installation is then completed working together with the customer.

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

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

For years, the Netzsch Analyzing and Testing business unit developed and marketed the DEA technology for laboratory use. However, as digital technology began to advance, “the decision was made to move beyond the traditional business of lab-based thermal analysis, and out to the manufacturing environment in order to achieve real benefits in production,” says Alex Chaloupka, managing director of Netzsch Process Intelligence.

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.

Products exemplifying Extreme Molding’s specialties are the Baby Banana Teething Toothbrush for infants (two colors and durometers of LSR overmolded) and the infant feeding nipple (below) of LSR overmolded onto Eastman’s Tritan copolyester.

“We then discuss their experience from their manufacturing environment,” he continues. “This is very important to develop the machine learning models so they aren’t focused in the wrong direction — not necessarily measuring every parameter but instead targeted to solve the customer’s challenge and provide real value. We create these machine learning models using material science that originated in the lab but that is now getting matched with real-time process information from sensors. And that lets us analyze how the material performs under different circumstances. We then combine that data with the machine data to bridge the gap between what we know from the original lab testing and what we see is actually happening with the material in the mold under different circumstances. This then allows us to relate all that information to each other.”

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

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.

“Within one year, we created a minimum viable product comprising a new edge device and algorithms that can calculate quality parameters like Tg and degree of cure in real time and in a cloud environment that is connected to the device,” says Chaloupka. “Within our first year, we created awareness within large corporations.” The team also developed use cases with alpha customers ZF Friedrichshafen (ZF Group, Friedrichshafen, Germany) and Carbon Revolution (Geelong, Australia). “And we were able to show Netzsch shareholders that this is really a product that the industry values and needs,” notes Chaloupka. In 2021, Netzsch Process Intelligence was founded and sensXPERT was established as its first commercial technology product.

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

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.

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

“And we are working with more than just parts manufacturers,” she continues, “because there is a whole supply chain involved, including machine manufacturers, raw material suppliers and toolmakers. We are already working with material suppliers, like Hexcel, to improve their products for their customers, and machine manufacturers like KrausMaffei and injection molding specialist Wittmann-Battenfeld . The momentum is changing for us to work with our part manufacturing customers and their suppliers in collaboration. The model is ‘better together,’ and we are beginning to see even the next developments this will enable.”

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

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.

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.

Today, most manufacturers use a variety of sensors to collect machine and process data (e.g., temperature, pressure, molding time) which can be fed into these simulations, but what if this modeling could be done in real time to adapt the molding process to each individual part?

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.

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

MTorres seeks to enable next-gen aircraft and open new markets for composites with low-cost, high-permeability tapes and versatile, high-speed production lines.

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

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

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.

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

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.

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.

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

Chaloupka describes one of sensXPERT’s first customers, ZF Group: “It is one of the largest Tier 1 automotive suppliers producing metal and plastic components for the powertrain, such as electronic circuit boards for vehicle control units. We have written a technical paper with ZF about electronics encapsulation, which involves transfer molding processes with epoxy molding compounds. These materials are inhomogeneous and involve a tricky process for fast curing times of roughly 1.5 to 3 minutes.”

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.

Cryomotive’s CRYOGAS solution claims the highest storage density, lowest refueling cost and widest operating range without H2 losses while using one-fifth the carbon fiber required in compressed gas tanks.

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.

Formerly a showroom for early-aughts-era Van Dorn hydraulics, the newest additions to Drummond Industries’ transforming fleet are all-electric Niigata injection molding machines.

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

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.

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.

SensXPERT uses an edge device to collect data from its DEA sensors as well as third party sensors and then analyzes these data with software to track degree of cure/polymerization/crystallization, Tg, material viscosity and more (top), which helps to achieve a range of benefits that increase sustainability. Photo Credit: sensXPERT

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

The sensXPERT technology has four basic components: sensors, an edge device, software and an IT framework for data analytics. “The DEA sensors are typically installed in the mold and create information about material behavior,” explains Chaloupka. “The edge device is a small industrial PC where the sensors are connected, receiving information from the material in the mold. The edge device is equipped with the dielectric measurement unit that can also connect to other sensors, such as pressure or temperature sensors from other companies. Thus, the customer can have just one edge device that is receiving an array of different signals/data streams. The edge device also communicates with the machine/molding control system so that we can exchange parameters and process data with the production machines. We not only receive machine data, but we can also send information back to the machine to initiate process actions or if a customer wants to see one of our signals directly on an HMI at the machine.”

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.

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

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.

Once the initial scope is finalized with the customer, sensXPERT then works with them to install the sensor(s), edge device and software/IT infrastructure. Parts are made and the machine learning models are built. “We then start the data analytics and evaluation process,” says Chaloupka.

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.

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

SensXPERT uses in-mold DEA sensors, an edge device and software to convert the data from the DEA (and other) sensors plus the machine data into useful, actionable information. Photo Credit: sensXPERT

However, going from the current use of premixed RTM6 resin — which demands cold storage and has a limited shelf life — to long shelf life two-component (2K) systems that will be mixed just prior to resin injection in the RTM mold presents its own challenges (see “HP-RTM for serial production” and “2-part epoxy …”). Efforts continue to ensure mix ratios are correct throughout the injection and across the part. “We are working with CTC and an equipment manufacturer in a funded R&D project to implement sensors in the mixing heads to measure the mix ratio,” says Chaloupka. “The challenge is that operations within the mixing head are numerous and complex, such as turbulent flow, which affects measurement. We are analyzing how we can evaluate the mix ratio, what the precision is and how we can use this information to improve the manufacturing. We are also measuring the RTM’d part and directly relating that to mix ratio, and we’ve already seen trends. But we’re continuing this work with the parts manufacturers and the resin manufacturers, as there are still some open topics that need to be resolved.”

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.

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 importance of digital tools and simulation for successful composite parts design is well established, whether for aircraft wings, automotive bumper beams or bicycle frames. Over the past decade, these digital tools have extended into simulation and modeling of the processes as well, to explore materials-process interactions and address problems before production begins.

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

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.

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.

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

For a small custom injection molder competing in today’s global market, Lynn Momrow-Zielinski has two pieces of advice: 1) Develop a business plan and stick to it. 2) Find a technical and/or market niche and stick to that, too.

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.

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

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

Eden Manufacturing was founded on a vision of vertical integration, adding advanced injection molding capabilities to a base of precision moldmaking and more recently bringing Swiss-type machining capabilities in-house.

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

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

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

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

For a small custom injection molder competing in today’s global market, Lynn Momrow-Zielinski has two pieces of advice: •Develop a business plan and stick to it. •Find a technical and/or market niche and stick to that, too. “The world does not need another injection molder of commodity plastics. The key to business success as a domestic injection molder today is business focus and technical specialization,” she told an audience of molders at last January’s Molding 2013 Conference in New Orleans. By practicing what she preaches, Extreme Molding LLC, the company she co-founded and co-manages with Joanne Moon, achieved profitability within 18 months of its opening in 2002 and has achieved double-digit growth in most (non-recession) years since then. Momrow-Zielinski is a straight talker who’s not shy about making no-nonsense pronouncements about the economic pressures on a small molder facing a world of competitors, about domestic vs. overseas pricing, molding market trends, achieving business focus, winning and managing customers, and buying molds abroad; the place of rapid prototyping, social media, and ISO certification; and the growth of liquid silicone (LSR) molding and overmolding. Having built a business from scratch—one of the few female-owned plastics molding companies—Momrow-Zielinski speaks from hard-earned experience. A native of upstate New York, she has two engineering degrees (chemical and industrial) from Rensselaer Polytechnic Institute in Troy, N.Y. She was a development engineer for the plastics operations of Mobil Chemical for four years and then operations manager and global technical marketing manager for GE Silicones for eight years. She then became general manager of Canton Bio-Medical, a maker of silicone and other rubber products in Poestenkill, N.Y., which was acquired in 2000 by Saint-Gobain Performance Plastics, where she became the worldwide general manager of the Laboratory Products Business Unit. That’s how she met her future business partner. Joanne Moon had pursued an MBA from Seton Hall University in New Jersey and had been a product supervisor for L’Oreal-Lancôme cosmetics and then plant manager and director of manufacturing for CR Bard, a medical products company. After 13 years there, she left to join UroMed, a medical device startup company, and then in 2000 became worldwide general manager of healthcare products for Saint-Gobain Performance Plastics. When they met as managers at Saint-Gobain, the two women found that they shared a particular ambition. Moon had always wanted to run her own business, and Momrow-Zielinski came from a family-owned business in Christmas trees, firewood, and tree service. They decided to strike out on their own and spent a year formulating a business plan. They resolved to accept no outside investors and no startup money from family. Instead, Moon took out a second mortgage on her home. While scouting for locations, they came across the Watervliet Arsenal, run by the U.S. Army in Watervliet, N.Y., just across the Hudson River from Troy. The Arsenal’s newly formed Business & Technology Partnership was looking to fill vacant space with private businesses. Extreme Molding became the first major non-military manufacturing tenant there, occupying part of the third floor of a building devoted to Army machine shops. The U.S. government paid for site preparation and provides round-the-clock security and fire and emergency services. Why the name Extreme Molding? “We do wacky things that you might say shouldn’t be molded,” says Momrow-Zielinski. “We’ve used intrusion molding to make parts greater than the shot capacity of our machines. Challenging materials and complex designs are our specialty. We take on tough jobs that other molders won’t do. We work with complex molds with lots of actions and undercuts. We tinker with materials to accommodate such molds—such as going to a lower durometer that can be pulled over the undercuts.” The two managing partners had already decided that their new firm would focus on business areas they knew and liked—healthcare for women and infants and LSR molding. Their first machines were a pair of brand-new Toshiba all-electric presses, one of 65 tons for thermoplastics and a 45-tonner for LSR molding. They chose all-electrics for their energy efficiency, quietness, and “state-of-the-art” precision, which is especially important in LSR molding, says Momrow-Zielinski, who is the firm’s top technical officer. She recalls her initial difficulty in convincing the vendor to sell machines to her. “They told us, ‘We never shipped to a woman before.’” Since then, Extreme Molding has acquired four more new all-electric presses from Toshiba and Sumitomo Demag, as well as five used machines (Arburg, Engel, Milacron, and Van Dorn). All told, seven of the 11 machines are outfitted for LSR and four for thermoplastics. They span a range of 45 to 110 tons. The firm also has a few small vertical compression presses for molding silicone and other rubbers. Besides LSR, Extreme Molding uses TPEs, polycarbonate, Tritan copolyester from Eastman Chemical, and occasionally more exotic resins like fluoropolymers, PEEK, PEI, or LCP. The firm employs more than 40 people, many of them young engineering graduates from Rensselaer Polytechnic. It operates 24/5 or 24/7 and business is growing steadily towards $5 million. Currently occupying 15,000 ft2, Extreme Molding plans to take over another 3000 ft2 in a separate building in July. CHOOSE YOUR NICHE “Almost all domestic molders have been forced to develop specialized capabilities in the last 10 to 15 years,” says Momrow-Zielinski. “You have to have something you’re known for and do better than most everyone else—or you can’t stay in this business. Our claim to fame is overmolded combinations of  materials in applications for female-oriented and pediatric healthcare.”

“So, we started with a small team of four people that were taken out of Netzsch Analyzing and Testing,” explains Chaloupka, “and now we’ve grown to 34 people. And this team can focus on our customers because services like manufacturing, shipping and accounting are outsourced to our sister businesses that already have that necessary structure, which is another benefit of operating within the Netzsch Group.”

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