Editor in chief of PlasticsToday since 2015, Norbert Sparrow has more than 30 years of editorial experience in business-to-business media. He studied journalism at the Centre Universitaire d'Etudes du Journalisme in Strasbourg, France, where he earned a master's degree.

The program began within a small lab space at NIAR’s headquarters on the main Wichita State campus, and has since grown to employ more than 100 research engineers and student technicians in multiple laboratory and office spaces, including a new south Wichita facility. In total, the operation covers roughly 150,000 square feet.

Next to ATLAS , experienced mechanics at NIAR  work with students converting multiple passenger aircraft into freighters and special missions aircraft. As part of a three-year training program, the students get hands-on experience as aircraft mechanics.

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

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.

Addifab has customers in industries ranging from medical and automotive to consumer electronics — in 2020, the company ran more than 300 client projects, according to Carsten Jarfelt, US Chief Commercial Officer. FIM is compatible with an extensive range of polymers, including biocompatible resins for medical and FDA-regulated projects. A 2019 study conducted by the Technological Institute in Denmark demonstrated that material from the FIM molds did not transfer to the product during the injection molding process and, thereby, did not compromise biocompatibility.

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

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.

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

Based on 3D printing technology, the FIM process allows users to additively manufacture complex injection mold tooling in hours instead of weeks or months. The tools are compatible with most thermoplastic materials, including reinforced high-performance feedstocks. The tooling can be dissolved, which allows the molding of complex components that would otherwise be difficult — or even impossible — to mold with conventional metal tooling, said Addifab.

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

As those experienced mechanics and technicians age out of the workforce, their decades of knowledge are passed on. “It’s great applied learning and, at the same time, it is a solution to get the next generation of students up to speed with an experience they cannot get from a classroom,” Seneviratne says. It’s a hands-on experience that pays in terms of the pocketbook as well. Seneviratne notes that undergraduate students working in NIAR labs with equipment like the KM press can earn a decent salary to support themselves through school while gaining hands-on experience using cutting-edge technologies.

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

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

“In automotive we see already things like organo sheet thermoforming materials that are bonded in injection molding being utilized.”

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).

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.

The KraussMaffei system will enable Wichita State students to learn about molded thermoplastic composite parts, while giving industry a production level machine to develop new programs. Photo Credit: Wichita State University, NIAR, ATLAS.

KraussMaffei commissioned a full injection molding cell to support the development of molded thermoplastic composite structures at NIAR’s ATLAS facility in Wichita. Photo Credit: Wichita State University, NIAR, ATLAS.

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.

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

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.

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

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.

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

Denmark’s Addifab, the developer of Freeform Injection Molding (FIM) technology that allows plastics processors to additively manufacture complex injection mold tooling in a matter of hours, announced today a partnership with Nexa3D, a maker of ultrafast 3D printers for industrial applications based in Ventura, CA. Through the collaboration, Nexa3D will supply its NXE 400 system — including the industrial 3D printer as well as wash and cure units — to FIM users. Addifab, which has its US office in Palo Alto, CA, will supply its proprietary tooling resins and post-processing equipment through the partnership. The agreement will broaden capabilities for industrial injection molding with ultrafast, large-format 3D printing, said the companies in today’s news release.

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.

“We wanted to democratize the access to these technologies,” Seneviratne explains. “We have established a world-class manufacturing innovation center where inventors can make ideas reality by converting laborious hand layup manufacturing processes into automated processes using advanced materials without spending a single penny on infrastructure or equipment.”

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.

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.

“KraussMaffei is delighted to be able to forge this strong partnership with NIAR, bringing these industry-proven automated, high-rate, out-of-autoclave solutions to the aerospace and space industry,” says Nolan Strall, KM’s North American president. “One reason we’re excited about this is because in automotive we see already things like organo sheet thermoforming materials that are bonded in injection molding being utilized, so we know it can be done. It’s typically reserved for the high-end autos, and the volumes just haven’t been there, but as this goes forward, we’re optimistic that we’ll see more and more uses.”

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

Oak Ridge National Laboratory's Sustainable Manufacturing Technologies Group helps industrial partners tackle the sustainability challenges presented by fiber-reinforced composite materials.

“We’re set up to create an applied learning environment,” Seneviratne says, “Our technicians are getting more than just a quick 18-month textbook license. They are getting three years of intensive hands-on paid training alongside mechanics with 20 or 30 years of industry experience.”

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

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

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

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

The so-called Scale-Up Platform promoted by the partnership reportedly enables development of 3D-printed injection mold tooling at 15% of the cost, 12% of the time, and with 75% fewer CO2 emissions compared with the use of conventional steel tools.

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.

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 Freeform Injection Molding process slashes the manufacture of injection mold tooling from weeks or months to a few hours.

“We are looking forward to engaging with the team at NIAR for future development and industrialization of the technology needed to meet the in-situ process and qualification standards of the aviation industry,” Strall says.

The partners will come full circle when they showcase their joint solution at the RAPID + TCT show in Detroit on May 17 to 19, 2022. The companies are also setting up joint Silicon Valley demo facilities in Palo Alto.

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.

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.

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

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.

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.

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

“Injection molding is a complex process, and tool building is the most complex part of the process,” said Lasse Staal, co-founding CEO of Addifab. “With Freeform Injection Molding, we provide injection molders with a fully transparent set of tools — no pun intended — that will allow them to fast-track tool designs and validations while raising the bar on tool innovation. Now we can take these capabilities to the next level by partnering with Nexa3D to broaden access and super power 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.

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

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.

As an example, when Plastics Technology visited, student trainees were busy working alongside KraussMaffei experts with more than 20 years of experience developing processes for injection molding. Similarly, in the automated fiber placement labs, students were working side-by-side with experienced staff members and engaging with certification agencies carrying out inspections and completing certification paperwork. These students are mentored by full-time ATLAS researchers and engineers with industry experience. In some labs, students were troubleshooting manufacturing issues to develop guidance materials and process specifications.

This particular site has a rich aviation history, dating back to its days as a key wartime production plant for Boeing. On this same site from 1943 to 1946, the facility cranked out roughly 100 B29 bombers/month — more than four airplanes a day — including the Enola Gay. From 1957 to 1963, 437 B52s were manufactured there.

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

KraussMaffei (KM) is working to bring its automated, high production-rate, injection molding-based thermoplastic composite technologies to the burgeoning advanced and urban air mobility markets. In partnership with Wichita State University’s National Institute for Aviation Research (NIAR) and its Advanced Technologies Lab for Aerospace Systems (ATLAS) operation, KM has installed a 450-ton multimaterial injection molding machine to support high-pressure resin transfer molding (HP-RTM), ColorForm polyurethane overmolding and the FiberForm process for infrared oven preheating of composite sheets.

The FIM process begins with high-precision, tight-tolerance, dissolvable tools printed by means of digital light processing. The tools can be used in injection molding machines with injection pressures up 2500 bar and maximum melt temperatures of 842°F (450°C), and are compatible with composites, thermoplastics, thermoplastic elastomers, silicones, ceramics, and metals. Rather than ejecting the component from the tool, as is customary in injection molding, the tool itself dissolves to release the molded part. The demolding takes between 12 and 48 hours.

In addition to getting work-ready students through the program, it also enables the advanced composite industry to test materials and structures at an otherwise impossible scale. In 2012, NIAR converted an arena into a test lab where strain gauges can run a flight profile on multiple full-scale aircraft simultaneously. “You need three things for success: cutting-edge equipment, talented people and challenging projects,” Seneviratne says, “We’re set up to teach students and provide critical  support for industry at the same time.”

Krauss Maffei's FiberForm technology in an injection molding macine enables the production of fiber-reinforced plastic components.

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.

A newly degreed engineer will theoretically have much of the book knowledge needed to enter the workforce but typically lack the real-world experience to have an immediate, productive impact. Wichita State’s applied learning model, NIAR, is changing that, according to Seneviratne, who estimates that it typically takes up to 2 years to make a new engineer productive.

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

The KM press, along with a 1,900-ton vertical Engel machine that can also apply HP-RTM and run molds as large as 5.7 × 7.1 feet, is located in ATLAS’s Sector A facility — a 128,000-square-foot space adjacent to Spirit AeroSystems in south Wichita. This area is also home to material supplier Solvay’s Manufacturing Innovation Center.

Today, among other technologies, it houses the new 450-ton KM press with dual 1,400 injection units and a rotary table for multimaterial molding. The multifunction press can support high-pressure resin transfer molding (HP-RTM) as well as the ColorForm polyurethane coating technology, in addition to the integrated FiberForm infrared oven for preheating composite sheet prior to over or back molding.

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

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.

Nexa3D CEO Avi Reichental first encountered FIM at the RAPID + TCT conference in 2019, and saw the potential to reimagine additive tooling, he said in a prepared statement. “As both Addifab and Nexa3D have since productized and industrialized our respective processes, it became obvious that together we can achieve much more by digitizing injection molding at convincing scale sustainably. I can’t wait to see the far-reaching impact of our collaboration,” said Reichental.

Waruna Seneviratne, the director of ATLAS and a senior research scientist for Composites & Structures at NIAR, notes that prior to the creation of this makerspace, many companies interested in investigating new composite structures and processes were forced to go overseas to find lab time and equipment, limiting how many businesses could afford to take on such R&D.

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 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.

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.

New system automatically cleans mold-cooling lines—including conformal channels—removing rust and calcium, among other deposits, while simultaneously testing for leaks, measuring flow rate and applying rust inhibitor.

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

In 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.

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.

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.

Established in 2019, ATLAS was conceived as a makerspace for industry-scale automated composites manufacturing research, including automated fiber placement (AFP), fiber patch placement for complex geometries, thermoplastic welding, and thermoplastic overmolding for multifunctional integrated structures. In 2023, ATLAS received AS9100D and ISO 9001 certification concurrently to expand its support to industry for automated manufacturing, nondestructive inspections and machining of advanced materials.

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

“These undergraduate students had zero experience with advanced manufacturing technology when they started working here,” Seneviratne says. “None of them came with automation or injection molding experience, and they’re getting trained here. They’re getting paid well; getting hands-on experience with industry-scale advanced machines; and making contacts because they are working alongside  industry partners on-site solving real-world problems.” Seneviratne notes that in 2022, the university paid $28 million in student salaries, not scholarships, to undergraduate students working alongside industry veterans with the very latest equipment and technologies.