Point of Pivot: 3D Printing vs. Injection Molding - integrity injection molding/Point of Pivot: 3D Printing vs. Injection Molding

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Point of Pivot: 3D Printing vs. Injection Molding - integrity injection molding

Author：gly Date: 2024-09-30

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

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.

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.

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

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.

Lock angles and shutoffs can also create debris that can fall into the cavity and cause defects in the part. This is usually the result of the shutoffs or lock angles hitting too hard or running different water temps between the halves. These can be cleaned up by a tool maker, and at times a light layer of grease can reduce this issue.

Venting issues are common problems that can contribute to burns, splay, and gloss issues. Repair outside the press is the best option, where machining, surface grinding, or hand work can be done more accurately. But I still open vents in the press when the situation is urgent and time is not available to remove the mold. This should be done by an experienced tool maker to prevent causing flash issues. Some people will back off on the clamp tonnage to assist venting, but that can contribute to other issues such as flash. If the vent is properly opened, this is not necessary. If you do struggle with venting issues, refer to my columns on venting.

In this collection of articles, two of the industry’s foremost authorities on screw design — Jim Frankand and Mark Spalding — offer their sage advice on screw design...what works, what doesn’t, and what to look for when things start going wrong.

After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.

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.

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

First, the cavity should be looked at for burrs, cutter marks, EDM, and the surface finish. I have seen many cases where the polish was too shiny for that specific material, which caused the sticking, and simple 320-paper draw polish addressed the issue. If the cavity is polished correctly for the plastic being used, we then need to look at the opposite half and see what we can do to help the part stick to it. Typically, undercuts can be added to help with this issue. They are a good option but in some cases are not allowed by the part design.

One of the first to utilize Mold-Masters’ newest, largest auxiliary injection units —the E-Multi 5 (EM5) — Core Technology Molding Corp., Greensboro, North Carolina, was able to produce a 2-shot “bumper” component for a rolling toolbox cart four times faster and at half the cost compared to the prior production setup. “The previous process couldn’t make sellable parts in the same day,” explains Brandon Frederick, Core’s engineering manager. “Prior production had two different processes, two different tools and two operators. We’re half the cost — we didn’t need two machines.”

Scuffing or drag marks on textured surfaces are not easily resolved in the press without the help of someone experienced with textured surfaces. In most cases the grain is too deep for the draft angle of the side wall. Gloss is usually a concern with textured surfaces, which also limits what can be done in the press. But if you have access to a pencil blaster and are very careful to protect the machine and mold components from the blast media, this will allow more options.

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

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 EM5 supports the same concept, but costs less, has a better lead time and helps us be more competitive because speed to market these days is everything,” Frederick says.

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.

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

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

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.

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.

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

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

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

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.

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.

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

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.

Made for a well-known American industrial tool brand, the plastic bumper component is a decorative and functional all-plastic part assembled onto a large, rolling, automotive mechanic toolbox cart. Featuring high finish and surface quality requirements, the bumper is roughly three feet in length, and incorporates two colors and clean shutoffs for a crisp, sharp imprint of the company brand, including the trademark icon. The design calls for red nylon 6/6 substrate to be overmolded with soft TPU in a 2+2 mold, with the black rubber framing the red logo.

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.

To solve part sticking problems, a dovetail burr with a positive stop ground on it is a safer method for grinding undercuts than a round burr.

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

Like Core, the customer is based in the Southeast — a region wanting when it comes to molders with 2-shot capabilities in the medium tonnage range (which is one reason Core got into multimaterial molding back in 2019). Core has a lot of exposure and expertise in automotive but serves a variety of markets beyond that, including medical, packaging and outdoor power equipment, among others.

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).

Anytime you use hand tools in the press, exercise extreme caution to prevent cavity damage. That’s especially true when using slide hammers to avoid hitting the opposite side of the mold being worked on.

Buildup issues on the cavity from lack of venting or plate-out from volatiles in the material can cause issues with gloss or sticking in the mold. Most of these can be taken care of in the press with polishing by a tool maker or some solvents. Textured surfaces typically require blasting with media to maintain the proper gloss. But there is a non-toxic cleaner, called Zap-Ox that will remove rust and buildup.

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.

When adding undercuts with a grinder, I prefer to use a dovetail bit that has been ground with a positive stop to prevent going too deep (see photo). You need to be careful not to go too deep and cause flaking, sink marks, or read-through on the part.

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.

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.

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

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

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

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

One other trick I have found very effective at solving part sticking problems, and that often performs better than undercuts, is adding a very fine stipple texture to side walls to retain the part. I use a Dremel engraver with a fine carbide tip to add the fine texture to side walls. This is a $40 tool that has many uses with various tip configurations. It can also be used for some texture repair, but not unless you are experienced with the details of texture. (For more on texture, see my column on the Mysteries of Mold texture last April.)

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.

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.

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.

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

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.

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.

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.

A customer request for multi-material molding presented a market opportunity and potential financial peril: How do you add two-shot without also overextending yourself from an investment perspective?

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

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.

Mold-Masters has extended the capabilities of its E-Multi auxiliary injection platform, introducing the new larger capacity EM5 model.

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.

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

Lifters also can drag on the part and create plastic flakes. This typically also can be addressed in the press. In cases where the solution cannot be achieved on press, you can consider using air blow-off until the problem can be fixed.

Plastic flakes or debris in the cavity or parting line can cause part defects and parting-line damage. First you need to identify where the flakes are coming from. I have seen cases where the top edge of a sub-gate at the parting line is left sharp, which can create plastic flakes when the sub-gate drags on this sharp edge during ejection. The sharp edge can easily have a radius added to it in the press.

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

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

Now let’s consider some mold repairs that be addressed in the press rather than by pulling the tool. One very common problem is with parts sticking to the cavity or components such as lifters. There are numerous root causes that can contribute to this. Let’s start by looking at the cavities. In most cases the part stays with the ejector or moving half of the mold unless the stationary half has reverse ejection. So if the part is sticking to the wrong half of the mold, some things need to be investigated before trying to adjust the process or water temperatures.

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

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.

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

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

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

In a world of rising costs and uncertain market conditions, the ability to wring maximum profits from existing business was truly the mark of a Top Shop in 2022.

A slide hammer is a common tool for removing stuck plastic from mold cavities in the press. But it requires caution to avoid hitting the opposite side of the mold being worked on

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

Typically the texture will need to be lightened up by removing the peaks of the texture and reducing the depth. The least aggressive method is to start with a fine wire brush by hand. This will polish the texture surface and will increase the gloss. Polishing compounds can be used along with the wire brush and will polish the texture on a micro level. If the grain needs to be reduced in depth, you can use papers or polishing stones. Again, this should only be performed by an expert and in most cases will require the area to be hit with blast media to achieve the required gloss. If the drag mark is on a highly polished surface free of defects, there is a coating that can be applied in the press made by NanoPlas Inc., Grandville, Mich.

FCS Group’s X-Type parallel quartet injection molding machine features four injection units aligned in parallel for a smaller footprint.

The EM5 is attached to the molding machine in an L-shaped configuration on the non-operator side of the press with an injection point on the hot half, stationary half of the tool. E-Multi’s can be installed vertically, horizontally or at any custom angle to accommodate the cell. Freise says that due to the EM5’s size, Mold-Masters expect most of its installs will be horizontal.

“The logo aspect,” Frederick says, “that’s everything to the customer, and it’s really precision molding at that point. This is not a shoot-and-ship part, that’s an A surface, and we have to make sure our process is robust.”

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.

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

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 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

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.

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

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

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

Core Technology Molding became one of the first users of Mold-Masters’ E-Multi 5 auxiliary injection unit. The inset shows a replica of the toolbox part showcasing the precision shutoffs required to help the red logo “pop.” Source: Mold-Masters

Scuffing or drag marks on the part are also a common problem that at times can be resolved in the press. One common cause is parting-line burrs from damage or the parting lines getting coined-in over time. Many people will use polishing stones to remove the burr, but I prefer to use diamond files with various widths and flat or round, depending on the contour of the cavity edge. These files will not break down like a stone and will maintain their shape. You just need to be careful with the angle of the file or stone when removing the burr. You do not want to roll the edge or scratch the cavity and create another defect.

When removing plastic that is stuck in the cavity, you need to be very careful about which tools are used. Brass is the most common alloy that is used, but it can still cause damage if you’re not careful. Brass screws can be heated up and melted into the plastic, and then cooled. Then you can use a slide hammer to pull the plastic out. The brass screws can also be hammered flat to insert into thin details or ribs. Brass blades can be heated to melt through the plastic in the cavity and divide it into smaller sections to assist with removal. Bronze pliers are the safer choice over steel pliers but can still cause damage.

This is the final part of a series on tooling in the press. This column will cover repairs that can be accomplished in the press.

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

Water leaks can cause tool damage and quality issues. Most water issues with hoses or fittings are usually taken care of in the press. For a more severe issue such as a cracked cavity or other tooling component, there is an option if you don’t have time to repair the mold. A negative-pressure or reverse-flow temperature-control unit (TCU) pulls the water through the mold rather than pushing it, which can allow you to run the mold temporarily until you can repair it.

If the part is sticking to the proper mold half but is sticking too hard—causing pin push, hanging up on lifters or slides, or other problems—you need to look again at whether the surface finish is appropriate for the material. If the surface finish is in order, you typically are now facing issues of mold design that cannot be fixed in the press, such as insufficient ejection, lifter travel, etc.

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.

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.

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

The EM5 was used to inject the red nylon 6/6 substrate while the black overmolded rubber was injected by the machine’s primary injection unit. In the design, the EM5 injected 864 g for the nylon 6/6 substrate, while the machine’s primary injection unit delivered the 800-g TPU overmold with a total cycle time of 70 seconds for the 2+2 mold. Normally, Frederick notes that the auxiliary unit would handle the rubber overmolding, but because the nylon 6/6 could degrade if the residence time was too long, Core utilized the EM5’s smaller barrel and shot size for the nylon. Shot sizes for the EM5 range from 550 to 1,200 g, says Dave Silva, Mold-Masters’ director of product development.

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.

Improvements in nozzle design in recent years overcome some of the limitations of previous filter, mixing, and shut-off nozzles.

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.

When there’s a problem, my focus has always been: What can I do to fix the tool to address the issue, versus processing around it? When you process around issues, many times you make the process window smaller and put yourself at risk for other part-quality issues. If you can make a physical change to the tool to correct the problem, that is always a more robust solution than processing around it.

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.

AE Plast opted for tiebarless multimaterial Engel victory machines as it took on complex parts for the appliance and power tool market, including a 3K housing for Dremel’s rotary tool.

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

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.

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 biggest advantage for Core in shifting this production to two-shot versus insertion and overmolding was staffing. “The biggest piece is the labor aspect,” Frederick says. “You go from taking molded substrates and placing them in the tool, dedicating half an operator for just putting parts into boxes, to now where machines do all the work in one press with one mold.”

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.

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.

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.

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 efficiency, Core said lead time and total cost helped make the case for the EM5. When quoting a dedicated 2K injection molding machine with a rotary table, Core was given lead times of 50 to 52 weeks, compared to 14-16 weeks for the EM5, which was slightly less than the quoted mold-build time for the job, creating a scenario where the EM5 could be installed and ready for the new tool to start production on day 1.