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

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.

The conventional way to install a Cartesian robot on an injection moulding machine is to mount it on the fixed platen (injection end of the machine) so that the main beam (X axis) extends from the area immediately above the mould and parts are unloaded to the side of the moulding machine. Here they can be placed on a conveyor or immediately packaged. The parts may also undergo secondary operations such as gauging or assembly, using human operators or additional robotic automation.

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.

Figure 1: This shows the behavior of test specimens molded using the four different mold temperatures noted in the legend. The different levels of crystallinity that the polymer was able to achieve at these various mold temperatures are evident from the response of each sample.

Introduced by Zeiger and Spark Industries at the PTXPO, the nozzle is designed for maximum heat transfer and uniformity with a continuous taper for self cleaning.

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

Generally, higher performance in polymers is associated with the ability of a material to withstand exposure to elevated temperatures. In semi-crystalline polymers, two important transitions characterize this capability: The glass-transition temperature (Tg) and the melting point (Tm). Polypropylene, which we discussed at the end of the last article, is generally considered to be a commodity material with a Tg that is subambient, near 0°C, and a Tm for most grades at 320-329°F (160-165°C).

Three of the profiled materials—PP, nylon 6 and nylon 66—are materials with glass-transition temperatures below the temperature range shown in the graph. The PP, with a Tg of approximately 0°C, will show only a marginal increase in crystallinity at higher mold temperatures, while crystallization time increases significantly, slowing the cycle time. The nylons, with Tgs of 65-70°C, will reach “full” crystallization using mold temperatures of 90-100°C, and it is evident that in this temperature range the crystallization time is essentially constant. As it rises above this point, the crystallization time slowly increases, once again extending cycle time.

Starting in molding in 1993 and clocking in for nearly every job on the floor over the intervening decades, I’ve seen all sides of the hiring, training and retention process in the industry. Here are my thoughts on how to keep your most important asset — your people.

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.

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

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

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.

Figure 1 shows the behavior of test specimens molded using the four different mold temperatures noted in the legend: 135°, 194°, 257° and 318°F (57°, 90°, 125°, and 159°C). The material partially aromatic nylon (PPA) reinforced with 35-percent glass fiber. Specimens from each sample group were tested using dynamic mechanical analysis (DMA) to evaluate the temperature-dependent behavior of the material. This is provided as a plot of the elastic modulus of the material as a function of temperature. The different levels of crystallinity that the polymer was able to achieve at these various mold temperatures are evident from the response of each sample.

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.

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

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.

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

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.

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

The maker of plastics processing equipment has placed a machine and an injection molding expert in NIAR’s ATLAS lab in Wichita, Kansas, to help molding, composites and aerospace take off.

This temperature difference between the two transitions is typical for most semi-crystalline materials. Aliphatic nylons such as nylon 6 and nylon 66, and semi-crystalline polyesters such as PBT and PET, form the next tier on the performance ladder, with Tgs of 131-194°F (55-90°C) and melting points of 437-500°F (225-260°C).

Take a deep dive into all of the various aspects of part quoting to ensure you’ve got all the bases—as in costs—covered before preparing your customer’s quote for services.

Join 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

Unlike PP and polyethylene, which can be run at relatively low mold temperatures, these engineering polymers require higher mold temperatures to achieve their ideal structure. It is with these materials that the temptation to turn down the mold temperature can become problematic for part performance.

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.

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.

In any case, the moulding machine and the robot will need to be guarded to protect human operators from injury due to coming into contact with the moving robot. The metal profiles into which guarding panels are mounted should be closed on any side that doesn’t need to receive a panel. Instead of the wire mesh commonly used in general industrial applications, the guarding panels themselves should be made of PET polyester or other clear plastics that can be easily wiped clean. Cables should be routed in closed wiring ducts, and all ducts, drawers, and other components should be stainless steel, electro-polished for easy cleaning. The number of supporting legs on the floor should be kept to a minimum. Similar design rules apply to conveyors.

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

These schools and local industry are working together to close the workforce gap in the plastics industry by offering hefty plastics curricula and training programs for degree-seeking students as well as current plastics employees looking to upskill.

Sepro 6-axis articulated-arm robots, developed in partnership with Stäubli, have a sealed housing, and the standard robots are suitable for ISO 5 (class 100) cleanrooms without modification. Therefore, injection moulding robots can meet all but the most stringent requirements. In fact, they can exceed the level of cleanliness possible with injection moulding processes.

Using a mold temperature above a polymer’s Tg ensures a degree of crystallinity high enough to provide for dimensional stability, even if the part must be used at elevated temperatures. But POM is an exception. Why?

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.

The PET evaluated here is a non-nucleated material, so the behavior documented here is not typical of the highly filled semi-crystalline grades used for injection molding. The MXD6 is one of the partially aromatic nylons that we have been referring to. These materials, and others like them, such as PPS and PEEK, display a much different behavior than the polypropylene and the aliphatic nylons. With these materials, the rate of crystallization decreases significantly once the mold temperature declines below a certain point that is related to the Tg of the polymer. The effect is considerable.

Some suppliers of high-performance semi-crystalline materials tell molders that full crystallization is only important if the part is intended for use at temperatures above the glass transition. This is not at all true.

Naturally, for use in a cleanroom, like any other piece of equipment, a robot must be designed, installed and operated so as to prevent contamination of the clean space. In Cartesian or beam robots, which are the most commonly used in injection, areas where grease or other lubrication is used must be enclosed so that none can escape into the moulding area. All cables are protected in conduits and pneumatic air is filtered to 0.3 micron. All surfaces are smooth and free of logos, stickers, or other decoration to eliminate places where dust can accumulate and to make cleaning easier. Stainless steel is used in many components - like end-of-arm tooling - that come into contact with the moulded parts.

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

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

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

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

Michael Sepe is an independent, global materials and processing consultant whose company, Michael P. Sepe LLC, is based in Sedona, Arizona. He has more than 40 years of experience in the plastics industry and assists clients with material selection, designing for manufacturability, process optimization, troubleshooting and failure analysis. Contact: 928-203-0408 • mike@thematerialanalyst.com.

In our next article, we will look at a semi-crystalline polymer that does not follow the rule that maintaining a mold temperature above the Tg is the only requirement for achieving appropriate crystallinity.

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

Semi-crystalline polymers exhibit a significant decline in modulus as they pass through the glass transition. When polyamides (nylons) are filled with this level of glass fiber it is expected that the material will retain approximately 50 percent of its room-temperature modulus above the Tg. This is exactly what is observed for the specimen molded at the highest mold temperature. The samples molded at the lower mold temperatures exhibit progressively larger modulus reductions as the mold temperatures used to produce the samples decline. At the lowest mold temperature, the modulus decline is nearly 75 percent. This will have implications for long-term performance characteristics such as creep resistance and fatigue resistance, even at temperatures below the glass transition.

For the MXD6 the crystallization time is 25 seconds at a mold temperature of 160°C, while it increases to 180 seconds at a mold temperature of 120°C. For these materials, not only does the lower mold temperature prevent the achievement of the desired level of crystallization, it increases the time required to reach an ejectable modulus, which in turn increases cycle time. Understanding the consequences of changing the mold temperature requires knowledge of the specific polymer being processed.

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.

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

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.

Second-ever PTXPO will feature a robust education program on flexible film, with more technical programming in the works.

Robots and automation systems will continue to play a crucial role in medical injection moulding. Automation technology can be expected to continue to advance as market forces demand it to do more, and as robot technology evolves.

Robots are being used with increasing frequency in cleanrooms, for most of the same reasons they are becoming more common across all industries. For instance, robots can improve efficiency, stabilise the process, and enhance workflow. Within the cleanroom market, robots can be used across the entire production process - from moulding to assembly to inspection, traceability and packaging.

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.

This is part four of an eleven-part series focused on the most important job of a processor. To read the rest of this series, click these links:

As we go up the performance scale to SPS, PPS, partially aromatic nylons—sometimes referred to as PPA, and very high-performance materials such as PEEK, the stakes get higher. These materials have Tg’s that exceed the boiling point of water (230-302°F). Therefore, maintaining mold temperatures high enough to allow these materials to crystallize to a satisfactory level requires the use of pressurized water, oil or electric cartridges. Not all processors are willing to adopt these technologies. But at this high-performance level, the consequences of failing to achieve the mold temperatures required to promote adequate crystallinity become especially severe.

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.

Engineering polymers require higher mold temperatures to achieve their ideal structure. The temptation to turn down the mold temperatures can hurt part performance.

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.

Another notable difference between the sample molded at the highest mold temperature and the other three samples can be observed at the conclusion of the glass transition. The part molded at the highest mold temperature enters a slowly declining plateau region between the end of the glass transition and the onset of the melting point near 572°F (300°C). This is typical behavior for a properly crystallized polymer. The other three samples show another symptom of incomplete crystallization. As soon as the glass transition is complete, the modulus begins to increase, even though the temperature is increasing. This is caused by the formation of crystals that were intended to be produced during the molding process. But because these mold temperatures are too low to allow for a complete level of crystallinity, the shortfall has to be made up in the solid state once the mobility needed to form crystals has been re-established. This upturn in the modulus is also associated with the previously discussed dimensional changes that always accompany crystallization.

Robots can also be mounted axially, where the X-axis beam extends from the space above the moulding area along the centre line of the moulding machine so that moulded parts are discharged at the clamp end of the machine. In cleanrooms, this arrangement offers several advantages. Firstly, when parts don’t need to be discharged to the side, it allows the machines to be placed closer together. In cleanrooms where floor space is often at premium, this can be a considerable benefit. Another potential advantage of axial mounting comes into play in applications that require the highest levels of environmental control. The IMM and the robot (installed in axial configuration) can be installed outside of the actual cleanroom, with the clamp end of the machine near a wall with an opening leading into a second room where higher cleanliness standards may be maintained. Parts can be quickly shuttled into the cleaner environment for final processing or assembly.

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

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.

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

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.

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

It is unfortunate that some suppliers of high-performance semi-crystalline materials tell molders that full crystallization is only important if the part is intended for use at temperatures above the glass transition. This is not at all true, something we will address in a later article.

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

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).

It is not a coincidence that the dividing line between the properly crystallized sample and the ones that fall short is the glass transition temperature of the polymer being molded. Maintaining a temperature above the Tg provides the molecular mobility needed to form crystals. Figure 2 shows the relationship between mold temperature and the rate of crystallization for various materials.

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.

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

Processors are often expected to compensate for ill-advised decisions made earlier in the product-development process. In the case of shrinkage, one of the most common ‘fixes’ is to simply reduce the mold temperature.

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.

Notice that the initial modulus of the material trends upward with increasing mold temperature. The modulus of the sample molded at 57°C is approximately 9,000 MPa (1,300 ksi) while the sample molded at 159°C has a room-temperature modulus of 10,350 MPa (1,500 ksi). This is a 15-percent improvement. The largest increase occurs between the samples molded at 125°C and 159°C. A much greater difference in performance is evident as the test temperature increases. As the temperature of the tests reaches 266°F (130°C) the modulus of all four samples begins to decline rapidly. This is the onset of the glass transition. An exact measurement of the Tg for this material gives a value of 293°F (145°C).

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.

Figure 2: As this graph indicates, knowledge of the specific polymer being processed is crucial to understanding the impact of changing the mold temperature.

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