By 3D printing the molds for the stretch blow molding process, however, the companies can now create realistic packaging prototypes that cut those lead times by six weeks and reduce costs by up to 90%. The blow molding process itself consists of placing a plastic preform (such as PET) into a mold and inflating it to conform to the mold’s geometry. Stretch blow molding is a specific form of this technique that is standard across the packaging industry to make anything from water bottles to dish soap containers.

As reported in March, Absolute Haitian  introduced Zhafir Mercury all-electrics to the U.S. This novel tiebarless design with two-stage injection now is available in 55, 100, and 150 metric tons. Later this year, the company will add 250- and 400-m.t. models, which will later be followed by 75 and 125 m.t.

Netstal ran 2.18-g HDPE PCO 1881 carbonated soft-drink closures in 72 cavities in 3.5 sec using a 280-m.t. Elion hybrid press with regenerative braking on the clamp. Netstal cited energy consumption for the machine as 0.48 kWh/kg and for the system overall as 0.52 kWh/kg. Caps were inspected by an Intravis vision system.

•Plenty of new hybrids as well, including many space-saving two-platen models. Many “hybrids” only in the sense that servo or inverter motors drove their hydraulic pumps.

The prototypes made using the 3D printed molds also have the benefit of allowing Unilever to test and improve elements of its production line before going into full-scale production. Thanks to the high-degree of fidelity between the prototype and the final part, the prototype bottle can be tested in terms of filling, capping, packing and more. Overall, this innovative use of 3D printing is solving challenges that direct 3D printing and traditional tooling simply couldn’t. “The big impact we have with the 3D printer is the possibility to have your dreams come true,” concluded Stefano Cademartiri, CAD & Prototyping Owner at Unilever. “Something that’s on your screen is in your hands in a couple of weeks. A real product, with a real bottle, with a real cap, and a real label.”

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

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.

As we reported in a Dec.’11 Close Up, Milacron has converted its Magna Toggle line to the Magna T Servo series with servo-driven hydraulics. The company is now doing the same with its Maxima Servo two-platen series and plans to offer only servo-hydraulic models by next year.

The new screw works together with a GS Loader from Spiral Logic, which provides controlled feeding, rather than the usual “flood” feeding, and Spiral Logic’s GS check valve, which is said to provide 100% positive shutoff when the screw rotates 120° in reverse. Benefits of this system reportedly include 13% lower power consumption, less screw and barrel wear, 60% less cushion fluctuation, 74% less variation in cavity pressure, and elimination of black spots from stagnant, degraded material on the screw.

Sumitomo demonstrated the SL screw at the show in a high-precision medical micromolding application on a 55-ton SE50DUZ press. The part was a 57.5-mm-long, hairpin-shaped device molded of Ultem polyetherimide. The barbed legs are around 400 μm wide at the barbs and the end where they are joined has a 500-μm hole. Molding tolerances are 25 μm. The two-cavity mold came from micromolder Makuta Technics, Shelbyville, Ind.

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

Arburg’s LSR demonstration involved overmolding LSR onto PBT in a coupling cushion for a car windshield rain sensor. The part consist of a PBT frame and a silicone diaphragm into which a sensor is inserted. The soft silicone conforms to the windshield curvature. The PBT frame was molded in an all-electric Allrounder 570 A (220 tons) with a 4+4 cavity mold from Rico Elastomere of Austria (rico.at). After hot-runner injection of the PBT, an Arburg Multilift V robot transferred the first shot to the LSR cold-runner overmolding cavities. Cycle time was 38 sec.

1,346 polymer and metal AM companies and 143 end-users. Consumer products AM generated $2.6 billion in 2023. Segment expected to grow to $28 billion by 2033 at 26.8% CAGR. This new market study fro...

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

Milacron also showed off some new features on its PowerPAK all-electric series of 440 to 1125 tons. These include water-cooled drives and enhanced diagnostic and maintenance information on the drives in the control system, which includes a built-in energy monitor. Also new is optional high-force electric injection, designed especially for PET preforms. These machines offer optional accumulator-assisted hydraulic injection and ejection (a 330-ton model is available only in this configuration).

Also new was Niigata’s MDVR vertical electric press series (35 to 165 tons), also with wider tiebar spacing and new controls, as well as a faster oscillating mold table. It can mold two different parts on alternate cycles with separate injection profiles for each part.

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

As reported in March, Sumitomo (SHI) Demag brought to the show its new SE-EV all-electric, direct-drive series (55 to 198 tons). It replaces the Demag DUZ series at no increase in price. The SE-EV line reportedly uses 20% less energy than other all-electrics. For example, it requires no power to hold the clamp closed. It also has a shorter machine base but 100 mm more daylight than before, as well as 50 mm more vertical tiebar spacing. Faster servomotors are said to provide greater injection speed—350 mm/sec, up from 300 mm/sec previously. New linear guides on the moving platen replace tiebar bushings, providing greater rigidity and at least 20% more mold-weight capacity while eliminating grease on the tiebars. Two pull-in cylinders add more nozzle-touch force.

Milacron demonstrated the PowerPAK’s suitability for high-speed, high-volume stack-mold applications: A 550-tonner with two-stage, screw/plunger electric injection unit molded thin-wall PP lids in a 2 x 4-cavity stack mold on a 4.8-sec cycle. The machine had stack-mold support shoes and “greaseless” tiebars—said to be unusual for all-electric stack-mold operation.

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.

Engel combined two-component molding with IML in an unusual sequence. Thin-walled lids for ice-cream containers were molded on an e-motion 200 T US combi all-electric machine. Using a core-back process, the machine first injected the colored frame, then the label was placed in the same mold and the clear center panel of the lid was molded over the label.

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

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.

More speed, more power, more precision, and more automated functions accomplished in and out of the mold. That’s exactly what injection machinery suppliers were offering at NPE2012.

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

Arburg demonstrated high-speed IML production of twin 1-liter PP buckets with separately molded handles in a 2+2 cavity family mold on an Allrounder 720 H press (350 tons). Total part weight was 62 g for each bucket and handle. The robotics from Van den Brink B.V. of The Netherlands inserted the labels, removed the buckets and handles, assembled them together, and placed the finished products on a conveyor—all in 4.8 sec.

Those coated areas trapped the foaming gas that naturally migrates out of the plastic part after molding, resulting in permanently raised lettering.

Hot buttons at the show will be multi-component molding, in-mold labeling/decorating (IML/IMD), in-mold assembly, medical molding, liquid silicone rubber (LSR), micro-molding, and high-speed packaging.

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

In addition, the models have 2.5X greater electrical capacity than a standard machine so they won’t overheat during high-speed molding. The regenerative braking system recovers around 6% of energy from mold open/close operations.

Also new from Milacron is the Varian Turntable, a rotary platen for multi-shot molding. Servo drive makes it faster and more precise. It’s also grease-free. It comes in seven standard sizes to fit machines from 330 to 3300 tons.

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

This “naked” view of Toyo’s new Si500V (with exterior panels removed) is one of several new all-electric machines beefed up with extra power for high-speed molding.

Maruka USA exhibited the latest all-electric model from Toyo Machinery & Metal Co. of Japan. The Si500V is a 500-ton model in the Si-V series from 35 to 940 tons. These models are beefed up with 30-40% larger servomotors than competing machines, as well as larger ballscrew systems. The series also has wider tiebar spacing and a new V-slant toggle with a greater tilt angle that reportedly provides more uniform distribution of clamp force over the platen. The upgraded System 500 controller has a 5X faster processor than before.

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.

An innovation not reported previously is so-called “3D IML,” which won the Emerging Technology award in SPI’s International Design Competition. The application is a PP margarine tub molded by Paccor Packaging Deutschland for Planta in The Netherlands. It uses the MuCell microcellular foam process from Trexel Inc. (trexel.com). Foaming helped lightweight the package by 13% (9% through thinwalling and 4% from density reduction)and allowed 15% lower injection pressure and 36% lower clamp force. However, the novelty here is the raised logo lettering, which has an embossed, soft-touch feel. This was accomplished by applying a barrier coating to the back of the label in selective areas (behind the lettering).

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

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

Toshiba operated a new 200-ton EC200SX all-electric press in an automotive cell, showing off special technology developed by Japanese molder Taisei Plas Co.  for bonding sheet metal to overmolded plastics. The key is a process for nano-texturing the surface of the metal to enhance bonding. Toshiba molded an automotive circuit-board holder with the help of its own new jointed-arm robot that demolded parts and inspected them with a laser mounted on the robot. Taisei technology is also used in Japan to mold a tablet computer case in which PPS attachments are overmolded onto metal. Toshiba says tight control of injection pressure afforded by the EC SX series is essential to this process.

An option for Ube’s new UF series is its Cav-Change system, which is just now being introduced to the U.S. It’s an electric-driven turning-stack mold system for multi-material molding.

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.

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

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.

Plastics processors are finding applications for 3D printing around the plant and across the supply chain. Here are 8 examples to look for at NPE2024.

3D printing was a clear solution to this problem, however Unilever and Serioplast had to find a suitable process and a material that could withstand both the pressure and heat generated in the stretch blow molding process as well as maintain dimensional accuracy and overall stability. This led them to Formlabs, which presented its Rigid 10K Resin, a glass-filled photopolymer with an HDT of 218°C and a tensile strength of 10,000 MPa.

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.

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

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.

Another new X-Pump hybrid is the N-PLAjet, designed specifically for PLA and other biopolymers. Nissei also displayed a vertical hybrid X-Pump model TNX50R2VLM (58 tons) customized to process LSR for insert molding. It has wide tiebar spacing, shot capacity down to 0.3 g, and a servo-powered turntable and ejector for fast cycles.

Niigata (niigata-us.com) had a new-generation all-electric line at the show. The MD-S6000 series comprises smaller models (55 to 150 tons), while the MD-W6000 series is medium-to-large sizes from 200 to 1100 tons. These units have wider tiebar spacing and updated controls with more user-programmable features.

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.

Prior to this new prototyping method, Serioplast would 3D print packaging prototypes directly or order metal tooling for blow molding prototyping. Both these process had their limitations: directly 3D printed prototypes could not match the transparency or feel of the final product, and metal tooling for blow molding prototypes came with long lead times and high costs. As Flavio Migliarelli, R&D Design Manager at Serioplast, said: “We have to wait six to 12 weeks before we can give a client the real sample, so we’re wasting so many weeks just to try a new bottle design. Sometimes it’s demanding and frustrating because maybe you have to start again.”

While highly effective for mass production scales, blow molding has traditionally not been economically viable for low-volume or prototyping applications due to the high cost of metal tooling (ranging from $2,000 to $100,000) and the time associated with having to outsource tooling (it should be said that even in-house tooling using CNC machining can take several weeks). In an industry like fast-moving consumer goods especially, where design innovation and marketing are vital, this slow pace and inflexibility are a roadblock.

Toshiba Machine Corp. demonstrated its latest-generation EC SX all-electric presses at work cells in its booth. The high-speed molding cell had a 390-ton EC390SX molding PS spoons in 32 cavities on a 3.9-sec cycle. The machine had a special high-speed clamp with a more powerful motor, which provides a 14% shorter dry-cycle than a standard EC SX model. Another packaging cell is discussed in the IML section below.

Not all the new hybrids were two-platen types. Nissei brought out a new hybrid model with a servo-driven hydraulic X-Pump, the 500-ton FNX460-200BN1. This successor to the FNX A1 type has an expanded range of applications in polyolefin food, beverage, and medical containers and caps. It is aimed at cycle times below 10 sec and comes with 48% higher injection pressure and 55% faster injection speed than conventional machines. It also boasts high plasticating and shot capacity and precise control of nozzle and barrel temperatures. It can support parallel functions and eject on the fly while using an oil tank half the size of a standard hydraulic press.

One unusual aspect is the fact that LSR encapsulates both sides of the PBT areas that span the diameter of the sensor. LSR is injected from one side, but pins hold the PBT so the LSR can flow around it on both sides. Second, the special LSR material from Wacker Chemical has a hardness of only 5 Shore A; its very low viscosity is challenging to process without flashing.

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.

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

A relative newcomer to NPE was Woojin Plaimm, Inc. of South Korea. It established an office in Brea, Calif. Although the company has at least 10 machine series, it highlighted three at NPE: the TE all-electric series from 33 to 500 tons; the TH-S series with energy-saving, servo-driven hydraulic pumps (55 to 500 tons); and the DL two-platen hydraulic series (servo-driven pumps optional) from 500 to 3300 tons.

The latest from Mitsubishi is the MMX Series of large two-platen machines with Smart Pump system, consisting of a servo-driven hydraulic pump as well as an induction motor driving a variable-volume pump. These presses (1300 to 3500 m.t.) are built in China. They are more standardized than Mitsubishi’s MMS line but offer faster delivery and lower prices.

Absolute Haitian introduced its own all-electric system for caps and closures, as well as cups, CD packaging, memory cards, and cellphone components. Its new Zhafir Venus/p is offered as an economical packaging alternative, since it is priced like a hydraulic machine. Features include a high-performance motor for faster injection and a longer screw (25:1) for greater plasticating capacity.

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

Sumitomo’s new El-Exis SP hybrid for ultra-high speed and precision has an accumulator with bigger valves, hoses, motor, and pump to provide 1000 mm/sec injection but also more precise transitions from boost to hold stages. It’s available from 165 to 825 tons and has linear bearings instead of tiebar bushings, eliminating wear on tiebars. At the show, a 500-tonner molded 1-g HDPE bottle caps in a 96-cavity Schottli hot-runner mold on a 1.98-sec cycle. The waterfall of caps leaving the mold became a horizontal blur as they were fed to a conveyor for 100% QC inspection by an IMDVista vision inspection system from IMD Ltd. in Switzerland. It inspected all caps for short shots, color, flash, ovality, and contamination.

JSW Plastics Machinery introduced all-electric models in its J-AD series from 220 to 650 tons specifically for high-speed packaging. They have reinforced bed frames to support heavy stack molds, along with linear guide rails for the moving platen and sliding shoes for stack-mold center plates. Besides 30% higher mold-weight capability, they have bigger motors, 50% faster injection acceleration/deceleration response, 24:1 mixing screw with higher rpm (yielding 20% greater PP plasticating capacity), extended daylight, 20% faster clamp movements, 20% less platen deflection, 100% greater nozzle-touch force (using a hydraulic cylinder), and greater heater capacity.

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

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 new concept of “3D IML” won the Emerging Technologies award in the SPI’s International Design Competition. It uses Trexel’s MuCell microcellular foaming process. Selective application of a barrier coating traps the foaming gas behind the logo lettering, giving it a raised, soft-touch feel.

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).

Ube Machinery Inc. introduced a new generation of large all-electric presses, the Ubemax UF series of 700 to 1400 tons. Features include the TAF clamp, whose increased rigidity is said to reduce platen deflection by 60% and base deflection by 50%. The new ballscrew design on the toggle reportedly adds wear life while reducing grease consumption by 90%. The new e-HUMMA controller has a large, high-resolution TFT color touchscreen with quick access to all screens from icons on the main menu. It’s also designed for easy addition of future software options. Also new is Flex Servo injection process control, which is said to improve molding accuracy and consistency and to reduce spikes and power consumption.

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.

KraussMaffei also announced that it installed an R&D system at Toronto University, consisting of an MX injection molding compounder with a twin-screw compounding extruder feeding a plunger injection unit. This system can feed, chop, and compound continuous glass rovings, and also has MuCell capability, making it the first in the world to produce foamed long-glass parts direct from raw fiber.

Boy Machines demonstrated a new LSR pumping station on its XS V vertical hydraulic press. The pneumatic unit is small and easily movable (photo at right). The system has a reportedly unique ability to lock the “back” position of the screw so as to eliminate the need for a shutoff valve on the mixing block. The screw has a special nonreturn valve that’s said to be easy to clean and to allow material changes with very little waste of costly LSR material.

The IMDVista system played a similar role in Engel’s booth, providing 100% inspection of HDPE water-bottle caps from a Plastisud 96-cavity mold. A 460-ton, all-electric Engel e-cap machine ran a 2.7-sec cycle without benefit of an accumulator, achieving very low energy utilization of 0.4 kwh/kg. Cam-operated mechanical slides for the tamper-evident band eliminated the need for a core pull.

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.

Available on the SE-EV series (and on SE DUZ all-electrics ) is a novel screw design described as “revolutionary” because it turns conventional plastication theory on its head. Decades-old single-screw theory holds that melting should be accomplished almost entirely by shear heating from mechanical work (friction) imparted by the screw. According to this theory, barrel heaters are intended only to prevent heat loss to the environment. But the new SL screw assembly, designed by Spiral Logic Ltd. of Hong Kong (spirallogic.com.hk) has no compression zone or compression ratio, and all the heat input for melting comes from the heater bands. Spiral Logic says this “non-compression” screw accomplishes better and more uniform melting in a shorter barrel—only 13:1. It avoids uncontrolled shear heating, which is said to result in inconsistent melt temperature, pressure, density, and viscosity.

Besides showing two new E Series hybrids with servo-driven pumps, Boy Machines demonstrated its new auxiliary injector for converting a standard machine to multi-component molding. This add-on injection unit is based on Boy’s XS hydraulic machine. It can be mounted in various positions and comes in sizes of 12, 14, and 16 mm screw diam. with its own hydraulic drive and control, which can be interfaced with most makes and models of presses.

These coupling cushions for an auto windshield rain sensor have a PBT frame overmolded with 5 Shore A LSR. Silicone encapsulated both sides of the PBT spanning the center of the circular parts. Arburg molded on them on a two-shot press in 38 sec, including robot transfer of the parts between cavities.

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

Also emphasizing caps and closures was Husky Injection Molding Systems Ltd., which introduced its next-generation HyCAP system for high-output beverage closures. The new HyCAP system ran a 300-ton hybrid press and a 0.95-g 26/22 closure in a 96-cavity KTW mold (Husky acquired KTW last year) on a 2.2-sec cycle. Husky launched the first HyCAP system at NPE 2009, where a 300-ton press molded a similar closure in 72 cavities on a 2.4-sec cycle. The 45% productivity improvement since then is attributed to improvements in the mold, machine, and controls. And that’s not all: Later in April, the Chinaplas show in Shanghai saw the debut of Husky’s HyCAP High Performance Package, billed as the “world’s fastest closure system.” It ran a 1.2-g 29/25 lightweight water cap in a 72-cavity KTW mold in 1.85 sec. This system is said to save up 20% in energy consumption vs. the previous HyCAP generation.

Like many companies, Unilever—the fast-moving consumer goods company with brands like Dove, Persil and Ben & Jerry’s under its umbrella—has turned to additive manufacturing for its prototyping needs. However, rather than print prototypes of its product packaging directly, it has taken an alternative route, leveraging SLA 3D printing to produce blow molding tools. This approach, which it has taken in partnership with packaging manufacturer Serioplast and Formlabs, has dramatically cut product development cycles for new plastic bottle packaging and tooling costs.

Swedish compounders HEXPOL TPE AB and Polykemi AB have collaborated on a 2K sustainable development project for consumer products.

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

Toshiba’s packaging work cell demonstrated a 200-ton EC200SX with IML automation from Imdecol of Israel. The cell molded and labeled two PP deli containers in a 4.9-sec cycle. A clean-room enclosure over the clamp provided positive air pressure and included a particle counter to verify Class 100,000 conditions.

Coverage of single-use plastics can be both misleading and demoralizing. Here are 10 tips for changing the perception of the plastics industry at your company and in your community.

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Injection molding news at the show was too voluminous to present in one article. Next month, we’ll report on controls, robots, hot runners, and other tooling developments from NPE. Also, see our March show preview for additional news that isn’t repeated here.

Today’s hyper-competitive molding environment requires more—more speed, more power, more precision, and more automated functions accomplished in and out of the mold. That’s exactly what injection machinery suppliers were offering at NPE2012 in complex molding demonstrations aimed largely at automotive, medical, and packaging applications. These were some key themes of the exhibits:

As reported in our March preview, NPE was the U.S. debut of Vesta all-electric machines (88 to 470 tons) from Negri Bossi  that were introduced at K 2010 in Dusseldorf. Designed for heavy-duty custom molding, they have direct-drive toggle clamps, regenerative braking on the clamp, and a beefed-up injection system (up to 40 oz) with bigger, more durable ballscrews.

Ube’s other new series is the UU2e Fusion line of two-platen hybid machines. Built in the U.S. and spanning 1100 to 2200 tons, these machines use multiple servomotors and gear pumps to drive the hydraulic pumps. There is also a servomotor and ballscrew for clamp traverse motions, so hydraulic screw recovery can run in parallel with clamp opening and closing. Modular design lets users choose a clamp, injection unit, servomotors, and gear pumps according to their needs. These units also have the same e-HUMMA controller and Flex Servo technology as the UF electric series.

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.

Netstal, which claims to be number one in the world in IML installations, molded tubs on an Evos 3500 (350 m.t.) hybrid in eight cavities in 5.75 sec with automation from Ilsemann.

KraussMaffei, emphasized multi-component molding and in-mold assembly at the show with its SpinForm “swivel-platen” system. The firm reported that it has sold two 4400-ton, double SpinForm systems with two turning stacks to BMW in Leipzig, Germany. They will produce polyolefin structural components for electric cars next year. The system is equipped with two six-axis robots, a second injection unit in an “L” configuration, and an oven station. The system will mold an outer skin and a substructure and then, as the stacks rotate, heat-weld them together in the mold, along with a third component.

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 addition, Sumitomo (SHI) Demag demonstrated unusual “full-cover” IML in which a food package gains barrier protection from being completely covered by the label.

There are also other benefits to using 3D printing in the production of blow molding tools. For example, Serioplast can more easily validate the blow molding process and the PET preforms it uses. Migliarelli explained: “We are using the same process window as with a standard pilot mold. This is super good, because we can test the final process windows and see what happens to the bottle. We are talking about up to 30 bar pressure. It’s absolutely good and reliable on that. We are also talking about 100 °C heating for the preform, without any wearing on the cavity of the 3D printed mold.  We could produce very easily up to 100, 200 bottles every day. We can go up to 1000 with more time.”

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.

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.

Engel demonstrated 64-cavity, flashless molding of a medical diaphragm using cold-runner valve gates on a 7-sec cycle—very fast for LSR. The e-victory 130-ton hybrid had ecodrive servo-driven hydraulics and a servo-driven screw. Because the runner was cooled right up to the gate, the mold could be run hotter (410 F vs. the typical 350-360 F) for faster cycles. The moldmaker, ACH Solution from Austria also supplied a top-entry, servo-driven mold sweep that demolded all 64 parts faster than would be possible with a pneumatic sweep. The sweep consisted of an aluminum brush that was positioned 0.015 in. away from the mold face. Automated deflashing was also integrated into the cell.

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

Wittmann Battenfeld exhibited the two-platen hydraulic MacroPower line, to which smaller sizes are being added. At the Milan Plast show in Italy later in April, Wittmann brought out a new 500-metric-ton model that is now the smallest in the line (down from 650 m.t. previously).

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

Negri Bossi also introduced its brand-new EOSSE series of small two-platen models (the company’s first) from 55 to 130 tons with a variable-displacement pump powered by an electric variable-frequency drive. These presses boast long opening strokes and unusually wide tiebar spacing. The clamp rides on linear bearings and uses two diagonal pistons for traverse movements. At the Milan Plast show in Italy last month, Negri Bossi brought out a modified version of the EOS with almost fully electric operation except for self-contained hydraulic clamp cylinders.

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

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

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.

Wittmann Battenfeld showed off its EcoPower all-electric presses, for which it will add multicomponent injection capability this year.

As noted in our March show preview, there were some impressive demonstrations of in-mold labeling. CBW Automation showed off a challenging application in labeling small syringes, requiring super-precise positioning of 16 small, extra-thin labels at high speed.

•Lots of new all-electric machines, especially beefed-up models meant to prove that servos can compete in high-output packaging applictions.

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

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.

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.

Using a combination of this material and Formlabs’ SLA technology, Serioplast was able to produce blow mold tooling within just two days and accelerate the time to start pilot testing (from six weeks down to two weeks). This is in combination with the ability to create highly realistic packaging prototypes made from the same material used for finished products and to pilot test multiple different designs at once. “With the 3D printed mold, we can save up to 70% time and 90% cost compared to the standard mold. In the past, [clients] had to wait up to 12 weeks just for one design, now we can make five designs,” said Migliarelli.

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.

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.

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.

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.

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.

This process has been used for 15 years, mostly abroad, to mold automotive, healthcare, and consumer products, including auto fuel and water tanks and intake manifolds. It involves molding two halves of a hollow part in a mold that then slides to bring the mating halves together and overmolds a seal around them in a second cycle. Both shots use the same material.

JSW announced that its Die Slide Injection system for molding hollow parts is now available in the U.S. That’s because the Japanese molder that owns the patent, Sakamoto Kanagata, recently established a branch in S. Elgin, Ill.