Injection Molding Facility - low volume injection molding

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

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

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.

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.

John Sewell, CEO, cites the company’s policy of “celebrating the dignity of every human life. We treat our employees with dignity and respect. In return, they would walk through a wall for us. Some employees have been with the company for 30, 40 and even 50 years. “We have fourth-generation employees in the same family working here.” This extraordinary loyalty has helped the company deal with labor shortages, especially during the recent pandemic. “We’re like everyone else in needing more workers. But when we’re down a few people due to sickness or otherwise, everyone chips in to make up for it.”

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.

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.

As part of its growing commitment to EMEA, and in service of its growing reseller partner network, Ventura, CA–based Nexa3D plans to immediately leverage Addifab’s Copenhagen facility as its Customer Experience Center, comprising a product showroom, service and support hub for Europe-based customers, and warehouse and logistics center.

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

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

Copenhagen-based Addifab developed, patented, and successfully brought to market a proprietary end-to-end digital tooling solution that includes a CAD-to-tool software generator, dissolvable tooling resins, and a 3D printing and production injection molding process. By combining the freedom of 3D printing with the industrial strength of injection molding, Addifab said its technology unlocks tremendous potential for contract manufacturers, regional molders, medical device companies, service providers, and low-volume manufacturers that want to offer same-day and next-day part production.

The company’s Second Chance hires include shift supervisors, technicians and even a plant manager. “We’re starting a veterans outreach program now,” Drew adds.

Last month, Mel O’Leary, president and CEO of Meredith-Springfield Associates, Inc. (MSA) in Ludlow, Mass., was honored by the Hampden County Sheriff’s Office’s All-Inclusive Support Services (AISS) for his two decades as a “second-chance” employer in collaboration with AISS. O’Leary, 69, co-founded MSA, which will celebrate its 40th anniversary this year. I interviewed him for a feature profile of his company, which specializes in bottles and technical articles made by extrusion blow and injection-blow molding, in our March 2019 issue. The firm operates 14 blow molders and employs around 100 people.

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

“We let them know we have a vacancy, and they’ll look for three candidates that we can interview. They’ve known us for 20 years, so they know who would be a good fit with us. The beauty part is that they offer us pre-qualified candidates.”

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

Making something out of (almost) nothing is an ‘eye opener’ for youngsters in their first exposure to plastics processing.

O’Leary has encouraged other manufacturers to follow his example, with some (limited) success. “I always preach and promote this program. I’ve seen how it changes lives.”

“Many of these hires are younger people for whom this is their first real job. We give them mostly unskilled and semi-skilled jobs as a packer/inspector, material handler or automation operator. But we also get some skilled workers—welders, heavy equipment mechanics, licensed forklift operators. We even had a teacher and an architect.”

“Soon after teaming up with Nexa3D, it became increasingly apparent that our combined solution unlocks tremendous opportunities for customers looking to create complex injection molding tools quickly and affordably. A year into our enormously successful commercial collaboration and dozens of customer implementations with the likes of PepsiCo and Wilson Sporting Goods, I’m thrilled that we are officially joining forces,” said Lasse G. Staal, co-founder and business development leader at Addifab.

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

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

“We’re in regular communication with the Sheriff’s Office. They have a whole staff at the Corrections Dept. just to find employment for pre-release and post-release offenders. This is for low-level offenders who have shown good behavior.

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.

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).

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

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.

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

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

“Information automation” is one of the keys to running a successful custom blow molding business for Meredith-Springfield Associates.

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.

The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda:  Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

This family-run firm fills a specialized niche with a culture of innovation and environmental stewardship that realizes the dreams of its founders, its employees and its customers.

John Sewell, CEO of CKS Packaging (center), with brothers Scott, co-COO in charge of operations (left), and Drew, co-COO for sales. Their Second Chance program for low-level offenders and recovered drug addicts has produced long-term employees even at the managerial level. (Photo: CKS Packaging)

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

Nexa3D’s ultra-fast printers combine with Addifab’s soluble resins to print complex tools compatible with any injection molding feedstock.

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.

“Do well by doing good” is advice often attributed to Benjamin Franklin — a directive characteristically both moral and practical. The briefest internet search will reveal that this principle is integral to today’s concepts of sustainable management, yielding references to McKinsey, Harvard Business Review, Penn Wharton, Forbes, and so on. By chance, I recently happened upon two plastics blow molders who have taken it to heart, with good results for their communities and their companies.

Meredith-Springfield thrives on technically difficult blow molding jobs that others avoid. Its latest pioneering effort is pushing the limits in the new field of EPET.

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

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

“We also get some post-release offenders on probation with an ankle bracelet. Either way, Corrections provides regular monitoring and supervision for the first six months to see that everything is working out.

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.

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.

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.

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.

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

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

The acquisition follows a successful year of joint go-to-market collaboration between the two companies in both North America and EMEA, said Nexa3D in the announcement. The joint sales and marketing efforts reportedly resulted in converting dozens of customers from traditional to digital tooling thanks to the time and cost savings. The end-to-end solution formalized by the acquisition combines the speed of Nexa3D’s ultrafast 3D printers with Addifab’s high-impact, high-temperature soluble resins to print complex tools compatible with any injection molding feedstock.

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.

I first encountered the phrase “second chance” about a year ago in talking with John and Drew Sewell, two of three brothers in the second generation running family-owned CKS Packaging. Based in Atlanta, the firm has two dozen locations nationwide with over 400 blow molding machines and employing around 3000 people.

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

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.

Two blow molders with long-standing programs of hiring formerly incarcerated low-level offenders have helped these individuals re-enter their communities and have benefited from an additional resource during chronic labor shortages.

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.

Close to 300 of those employees came to CKS through the company’s Second Chance program started by v.p. of manufacturing Lloyd Martin. Says Drew Sewell, COO for sales, “We hire out of prison when nobody else will — nonviolent, non-sex offenders. We don’t judge.” In addition, the company offers a rehab program for people who want to kick alcohol or drug addiction. “After a year in the program we will hire them,” Drew says.

One high-profile adopter of the technology is Wilson Sporting Goods. Its R&D team was able to produce and test multiple designs simultaneously of its youth baseball bats using final manufacturing materials. This would not have been possible using any other 3D-printed tool, according to Nexa3D.

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.

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.

Polymer 3D-printing company Nexa3D has completed the acquisition of Addifab, the developer of Freeform Injection Molding, a proprietary and patented digital tooling process that couples the design freedom of 3D printing with the mechanical performance of injection molding using a full range of engineering materials.

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

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.

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

Addifab's xMold resin is compatible with the entire range of off-the-shelf thermoplastic materials, including reinforced high-performance feedstocks. Metals, ceramics, and silicones are also covered, enabling users of Nexa3D printers to tap into applications that otherwise would require a substantially larger capital investment. A tool printed with the xMOLD resin is soluble — it does not require complex slides and gates — giving customers the flexibility to test and iterate more frequently. Moreover, the user doesn't have to be an experienced toolmaker to quickly design an injection molding tool using Addifab software or Solidworks.

In a subsequent phone conversation, I asked O’Leary how the process works. He credited Hampden County in Western Massachusetts as having “the most innovative and progressive program — and one of the lowest recidivism rates — in the country.” He explained, “It starts with their first day in jai. They can’t just sit in their cell. They must engage in education, vocational training, or some constructive activity for at least 40 hours a week.”

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

“These hires are not treated any differently from regular employees,” O’Leary says. “They get the same pay, raises and reviews. We deposit their paychecks at the jail, which deducts for room and board and gives a weekly cash allowance of $25 to the workers. The rest is placed in a bank deposit for the workers until they are released.

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

Combining complementary technologies developed by the two companies unlocks the full potential of digital tooling by blending the design freedom of 3D printing with the reliability of injection molding. The acquisition positions Nexa3D for accelerated growth in the fast-growing additive manufacturing space, said the company. It adds foundational intellectual property and capabilities to Nexa3D’s product line and accelerates its resin formulation and industrial production initiatives. “We believe that the market-validated strategic fit between our businesses and products, combined with the expanded capabilities in product development, next-gen resin formulation, channel coverage, manufacturing, and marketing, will result in significant revenue and accretive growth,” said Avi Reichental, co-founder, chairman, and CEO of Nexa3D.

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

“I sincerely appreciate this honor,” O’Leary said at the ceremony, but what’s more important to me is the impact this program has on so many lives. It doesn’t just benefit ex-offenders, but also their families and communities. People make mistakes, and giving them a chance to turn their lives around is very important to me. We’re proud to have helped hundreds of formerly incarcerated people in the last 20 years to transition back into the community with gainful employment.”

Mel O’Leary, president and CEO of blow molder Meredith-Springfield Associates, was recently honored for hiring hundreds of people in two decades of collaborating with Massachusetts’ Hampden County Sheriff’s Department’s second-chance employment program for low-level offenders. (Photo: Matthew Naitove)

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

Average tenure of these second-chance hires is about six months—but that’s the same as, or better than, other entry-level unskilled workers, O’Leary says. “We have zero turnover at the technician level and above—but below that level, it’s a revolving door. We have 50% annual turnover no matter what we pay or what we do. Availability of some labor through Corrections provides us relief from these hiring difficulties.”

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.

MSA usually hires pre-release offenders with three to six months left on their jail sentence. The Corrections Dept. provides a bus for transportation to and from our plant (only three miles from the county jail) at the beginning and end of shift.

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.

Some second-chance hires have stayed with MSA for up to 15 years. “One even left and came back,” O’Leary recalls. These longer-term successes include one woman supervisor, two warehouse forklift operators, as well as machine mechanics and automation operators.

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.