Clearly, this is not easy or practical to perform in a day-to-day operation. To keep things simpler, there is a widely used formula to calculate the number of shots in the barrel:

Showing off multi-material joining, natural fiber composites. With three iterations in development and poised to go on the market, KTM Technologies’ new motorcycle brake disc covers demonstrate potential for its Conexus joining technology to combine thermoset parts with thermoplastics. Photo Credit, all images: KTM Technologies

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.

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.

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.

For this part, KTM Technologies partnered with Akro-Plastic GmbH (Niederzissen, Germany), a company that specializes in plastic compounds and that recently introduced a product line of bio-based thermoplastics. Again, the teams began by testing materials at the coupon level, and for the SPE-presented part, decided to demonstrate the brake disc cover using Akro-Plastic’s Akromid Next 5.10 3 GF 30 glass fiber-filled PA6, chosen for its high bio-based content and higher mechanical properties due to the additional glass fiber. This version of the brake disc cover is said to enable up to 70% CO2 reduction for the materials used compared to the series model.

Once we know the amount of plastic in the barrel, we can divide this number by the shot weight and that will be equal to the number of shots in the barrel. Multiplying the number of shots by the cycle time will give the total time the plastic spends in the barrel.

Production-ready. KTM Technologies plans to produce its carbon fiber and flax fiber composite brake disc covers commercially. Beyond motorsports, the company plans to use its now-proven Conexus technology for automotive and even urban air mobility (UAM) applications in the future.

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.

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.

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

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

FIG 1 Studies with SABIC’s Valox 420 PBT show that the molecules break down and viscosity properties of the material are lost when it is subjected to a temperature of 500 F for 6 min.

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

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

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

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

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 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

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.

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.

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

If the color showed up on the eighth shot, then there are at least seven shots in the barrel. The eighth shot has some color. To be on the safe side, you could say there are eight shots in the barrel. Multiply eight by the cycle time to get the residence time of the plastic in the barrel. As an example, if the cycle time is 40 sec then the residence time would be 8 × 40 = 320 sec or 5.4 min. If the maximum residence time for this plastic is say 6 min, then the parts do not have any degraded plastic. However, if the maximum residence time for this material is 4 min, then degradation is a definite concern.

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.

There is a very easy and practical method to determine the number of shots in the barrel, however, it does not work well on dark-colored parts. In such cases, if possible, running the same mold with a lighter color or natural material will help. In this method, start molding the parts, move the hopper away from the feed throat and, using a mirror or a phone camera, observe the plastic being fed onto the screw. Please observe safety and never look directly into the hopper.

“We don’t need a gluing step, or rivets or bolting or screwing. Directly out of the injection molding process we have a part that we can directly mount to the motorcycle,” Heider says.

Most thermoplastics are organic materials, and their chemistry is such that they are not able to withstand melt-processing temperatures beyond a certain time. Data from studies with Valox 420, a commonly available PBT from SABIC, show that when it is subjected to a temperature of 500 F for 6 min, the molecules will have broken down and the properties of the plastic are lost (Fig. 1).

The brake disc cover project, and motorsports in general, is only the first step for Conexus technology, says von Czarnecki. “This enables the possibility to combine materials without bonding, increasing sustainability and reducing complexity in the process. It is offering a whole new range of applications.”

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

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.

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

Flax fiber/epoxy and flax fiber/bio-based PA. For its second and third iterations of the brake disc cover, KTM Technologies used Bcomp flax fiber with epoxy (shown here) and flax fiber with a bio-based polyamide. Both versions of the cover won awards in 2022.

“The strategy driving the whole process on our side was to enable us to use these materials together, and to use each material for what it does best,” von Czarnecki explains. “That is, to use the thermoset for the mechanical properties where they were needed, and where the customer can see it to really appreciate [the flax fiber], and to use thermoplastic for functions such as ribs and integration of inserts, and by this we achieve the most cost-efficient design.”

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

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.

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

Assuming that all processing parameters other than the shot size are identical in both scenarios, you can see that the amount of plastic in the metering section and in the compression section of the screw is identical (Fig. 3). However, the amount of plastic in the feed section will be higher in the second scenario, where 20% of the shot size is used compared to the 100%.

The carbon fiber version of the brake disc cover is now available for the aftermarket and will be equipped on some special edition motorcycles beginning in 2023. About 5,000 CFRP covers will be produced annually for KTM’s MX and enduro full-size models, Heider says. The company says the natural fiber cover may be introduced into KTM’s PowerParts portfolio as an aftermarket option once tests are completed.

With the new design, the goal was to develop a part with three layers. The top outer layer would be an epoxy thermoset-based composite to increase the overall impact resistance and stiffness of the part, and a bottom layer would be unreinforced thermoplastic that would be fitted with the metal insert, with the Conexus coupling layer in between joining the two halves together, acting as the third layer. The thermoset and thermoplastic layers ultimately overlap slightly — “but this isn’t for connecting,” Heider explains. The overlap protects the edges from moisture and wear over time.

Von Czarnecki emphasizes that the process and technology haven’t only been designed for use by KTM itself. “Our strategy is to qualify the technology and de-risk it for ourselves, and then enable our production partners to use it in other industries,” he says.

Addressing hot-runner benefits, improvements, and everyday issues from the perspective of decades of experience with probably every brand on the market. Part 1 of 2.

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

Thermoset composite parts — in motorsports and many other end markets — are often combined with parts made of other materials, such as unreinforced plastic or metal. Multi-material joining with thermoset composites generally involves either mechanical fasteners, which add weight to the part, or adhesives. In addition to adding weight, the latter includes chemicals that are generally not considered to be sustainable, and often requires pre-treatment and a challenging process and quality control due to stringent nondestructive testing standards.

In this case, the thermoplastic component could then be melted and reformed for additional uses, while the flax fiber component would ideally be pyrolyzed, with the energy recaptured for another use such as cement kiln coprocessing or waste-to-energy cogeneration plants.

Testing material samples. Before proving out its technology on its brake disc covers, KTM started with coupon-level testing of Conexus on a range of fibers and plastic part combinations.

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.

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

Resin drying is a crucial, but often-misunderstood area. This collection includes details on why and what you need to dry, how to specify a dryer, and best practices.

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

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

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).

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).

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.

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.

KTM Technologies sought a joining solution that would avoid the use of fasteners and adhesives. The basis of the Conexus technology that KTM ultimately developed over the past few years is a thermoplastic film — called a “coupling layer” — that can be added to a traditional thermoset composite layup in a curing process, such as, in this case, prepreg compression molding. During the cure process, the Conexus layer bonds to the thermoset composite part, acting as a chemical release agent and serving as an outer, unreinforced thermoplastic layer onto which the thermoplastic material can be directly joined. “You can then functionalize the part by injection molding, 3D printing or welding,” explains Michael Heider, lead engineer at KTM Technologies. Conexus can also be used with a variety of resin and fiber types.

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.

For speed, compression molding was chosen for the thermoset part, and injection molding for the thermoplastic part. “We designed the process for easy processability and low scrap,” Heider adds.

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.

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

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.

An example of this experiment is shown in Fig. 4, where the color showed up in the third shot. These set of parts will be used to continue this topic in Part 2 of this column, which will focus on residence-time distribution.

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

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

Once validated at the coupon level, the same tooling and part design as the original carbon fiber cover were used to manufacture new demonstrator covers.

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 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.

Heider explains, “We were looking for a semi-structural part to showcase the feasibility that the connection is working on the same level as a structural adhesive. The brake cover was chosen because it’s a very visible part on the motorcycle.”

The brake disc cover project originated as a way to demonstrate the Conexus technology, and is in serial production at KTM as a carbon fiber/epoxy version that features a metal insert directly joined to a thermoplastic component via injection molding. Based on this serial part and the processes and tools used to manufacture it, the more sustainable flax fiber/epoxy demonstrator presented at JEC World was built.

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.

FIG 3 Here, assuming that all processing parameters other than shot size are identical to the Fig. 1 scenario, you can see that the amount of plastic in the metering section and in the compression section of the screw is identical. However, the amount of plastic in the feed section will be higher here, where 20% of the shot size is used, vs. 100% used in Fig 2.

Stefan von Czarnecki, director of sales and business development at KTM Technologies, explains that the entire company is emphasizing  sustainability initiatives, including manufacturing, part design and end-of-life (EOL) solutions, starting with R&D initiatives aimed to qualify and evaluate opportunities for series production. One of these initiatives was the creation of an innovative joining technology called Conexus, which the award-winning brake cover was designed to demonstrate.

The cover, a circular panel designed to mount to the wheels of a racing motorcycle to protect the brake system from debris or impact, was entered into the competition by flax fiber supplier Bcomp Ltd. (Fribourg, Switzerland) and built by KTM Technologies (Salzburg, Austria), the R&D and innovation unit of motorcycle manufacturer KTM AG (Mattighofen, Austria).

Here also, residence time is calculated by multiplying the number of shots in the barrel by the cycle time. This formula works well for the most part but as we now know is not 100% accurate.

The Tier One automotive supplier with compounding and blowmolding machine capabilities adds the 50-yr-old molder and moldmaker.

The real-world testing is key, von Czarnecki notes. “You can predict or simulate a lot of scenarios but there are a range of situations — impacts, weather events, stone chipping — that you can’t guess.”

The JEC Award-winning flax fiber/epoxy part was only the first step toward demonstrating the use of sustainable materials for brake disc covers. In October 2022, KTM Technologies was awarded an SPE (Society of Plastics Engineers) Automotive Award in the “Body Exteriors” category for a new version of the cover that uses flax fiber in combination with a bio-based glass-filled polyamide.

FIG 4 To help determine the number of shots in the barrel, start molding parts; move the hopper away from the feedthroat and use a mirror or a phone camera to observe the plastic being fed onto the screw. When you see the bare screw, drop one or two pellets of any dark compatible color into the feed throat and pull the material hopper back in place. Let the mold open and eject the shot. Now start counting the number of shots (three, in this case) until you see the color show up on the parts.

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

Heider notes that the Conexus technology both assures a strong chemical bond between the thermoplastic and thermoset materials involved, and, because it is thermoplastic-based, enables separation at the correct temperature.

Conexus layering. Conexus technology was developed to be a thermoplastic coupling layer in between a molded thermoset component and a thermoplastic material, integrated via 3D printing or injection overmolding.

KTM had worked with flax fiber supplier Bcomp on motorsports projects in the past, so a trial version of the cover using Bcomp materials felt like an obvious next step.

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

The property studied here is viscosity. We conclude that the maximum residence time for this PBT at 500 F is 6 min. However, I’d consider this to be too broad a definition of the maximum residence time for a given material, since there is no mention anywhere of any absolute or percentage drop in any specific property. An over-designed part, or a part that is not subjected to a load, could probably function even if it is molded with some number of molecules that are degraded and have a lower molecular weight. There are also additives that can degrade base resins, adding another layer of complexity.

It is clear that estimating the amount of plastic inside the barrel is a function of several factors. Not mentioned so far is the effect of processing parameters, especially backpressure. To truly calculate the maximum amount of molten plastic in the barrel, a molder must add the amount of plastic in front of the screw to the amount of molten plastic on the screw in each of the sections.

However, with the carbon fiber version of the brake disc cover, “it’s another game,” Wacht says, “because carbon fiber is very energy-intensive to produce. Carbon fiber makes absolute sense to recycle.” Depending on the specific recycling method, the energy consumption that goes into recycling carbon fiber generally still results in a lower overall carbon footprint for the material, he notes.

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.

The design team began with CAD files of the existing design and used digital simulation to design a new part, with the goal of incorporating the right materials in the right place. Additional simulations were performed to help avoid warping and assure good filling and temperature distribution for the coupling layer during the injection molding process.

The 51st annual SPE Automotive Innovation awards gave nods to several ‘firsts’ and added alternative vehicle systems category.

In a case where the percentage usage of the maximum shot size is high—say 70% of the maximum—the resin may be subjected to the processing melting temperatures even in the feed zone. The amount of plastic that we talk about here is the melt-processable plastic, and it is difficult to estimate where on the screw the plastic has reached the melt-processable temperature. Surely, screw-design information from the manufacturer can provide insights about the volume of the plastic in each of the sections, and this can be used for calculations.

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.

Currently, KTM Technologies is investigating several racing motorsports projects and exterior automotive non-structural parts using the Conexus technology. In addition, as demonstrated in a joint research project with Airbus’ Composite Technology Center (CTC, Stade, Germany) which focused on the use of Conexus technology with ultrasonic welding (see video below for a demonstration of this technology), one goal for Conexus is to enable smart and efficient manufacturing in emerging industries such as advanced air mobility (AAM).

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.

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

A homogenous melt is required for consistent part quality, but achieving it requires balancing a number of factors, including barrel usage and temperature as well as screw speed, backpressure and residence time. Learn how to prepare your melt for molding success in this two-part 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.

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.

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

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.

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

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.

For Bcomp, Wacht says that this project has been “a perfect example to show the design freedom you have thanks to this process. When you think about the potential of this technology, you can see how it could be used for an even more complex shape, such as in a supercar interior or in larger bodywork components.”

Why not recycle or repurpose the flax fiber thermoset component? Johann Wacht, manager of motorsports and supercars at Bcomp, explains, “With recycling, you need to think about your base materials.” He claims that the company’s flax fiber materials are produced as CO2-negative materials, whereas any of today’s recycling methods would consume energy and result in a larger overall carbon footprint. “In this case, simply recovering energy from the natural fiber and epoxy [at the part’s EOL] is the better solution, because you can recuperate 80% of the energy stored in the material. It makes a lot of sense from a CO2 footprint perspective.”

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

First iteration: Carbon fiber/epoxy. The initial carbon fiber/epoxy brake disc cover successfully proved out the technology for end-use parts. From there, KTM Technologies went back to the drawing board to use even more sustainable materials.

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.

According to Heider, the CO2 footprint of the materials is reduced by up to 60% by switching to flax fiber from carbon fiber. “We wanted to show that we can use our Conexus technology to produce aesthetic and performance parts on the one hand, and to be able to fulfill sustainability targets on the other hand. By using established manufacturing methods where we can easily implement other fibers or thermoplastic materials, we have an innovative joining technology ready for the market, which can adapt easily to the needs of every customer without the necessity to invest in additional machinery,” Heider says.

Understanding the concepts of pack and hold and applying them during process development is critical for molders to achieve consistent part quality.

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.

“Design for manufacture was key,” Heider notes. To be able to serially produce the covers, the manufacturing process had to be relatively fast, with part costs as low as possible. “We knew we wanted to produce an attractive optical part and give visibility to the hybrid construction, but we also needed a part that can be produced using known and approved processes, to give us the opportunity to make parts very quickly and efficiently,” he explains.

CW associate editor Hannah Mason recaps several technologies seen on display at JEC World 2022, including new developments from Bcomp, Massivit 3D, Gen 2 Carbon and more.

Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics:  Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

This should never be the case, but let’s say the shot weight is 100 g; in other words, 100% of the maximum shot capacity is being used to mold the parts. If the screw is retracted all the way back to its maximum-shot-size position, then there are 100 g of plastic in front of the screw tip (Fig. 2). In addition to this material, there is plastic on the screw. All the plastic in the metering section of the screw is molten; the plastic in the compression section is partially molten; and the plastic in the feed section is in the process of softening and will be melted soon.

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.

In addition to demonstrating natural fiber materials, thanks to the Conexus coupling layer, the flax fiber composite cover “has a drastically reduced global warming potential, and a very nice end-of-life scenario compared to the carbon fiber version,” Heider says.

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.

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.

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.

FIG 2 Here, if the shot weight is 100 g, 100% of the maximum shot capacity is being used to mold the parts. If the screw is retracted all the way back to its maximum-shot position, then there are 100 g of plastic in front of the screw tip.

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.

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.

Automotive molder ITW Deltar Fasteners found new life for the battered bolt holes on its machine platens with a solution that’s designed to last.

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

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

First all-composite brake pedals developed by Boge Rubber & Plastics Group are lighter, stiffer, stronger and offer improved driving haptics.

The Conexus coupling layer is designed to have a lower melting temperature than the thermoplastic part in a given application, he explains. At the part’s EOL, if heat is introduced at the coupling layer’s melting temperature, the Conexus layer will melt and allow the thermoset and thermoplastic parts to be easily separated without damaging or melting either part.

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.

ABOUT THE AUTHOR: Suhas Kulkarni is president of Fimmtech Inc., which specializes in services and training related to plastic injection molding. He earned his Masters in Plastics Engineering from the University of Massachusetts, Lowell, as well as a Bachelors in Polymer Engineering from the University of Poona, India. He has 27 years’ experience as a process engineer and is the author of Robust Process Development and Scientific Molding, published by Hanser Publications, now in its second edition. He also works as a contract faculty member at U.Mass.-Lowell. Contact: suhas@fimmtech.com; fimmtech.com.

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

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

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.

Award-winning motorcycle brake disc cover showcases potential for KTM Technologies’ Conexus joining technology and flax fiber composites.

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

First, the thermoset composite layer is formed via compression molding. During layup, a single layer of the Conexus film, about 100 microns thick in the final part after processing, is applied as the bottom layer in the mold. The Conexus layer uses a copolymer that works with the selected thermoplastic and thermoset — in this case, epoxy and polyamide — to join them together. Additionally, the Conexus layer acts as a release film in the tool. The carbon fiber fabric is then added on top, and subsequent molding at 150°C (302°F) creates a bond between the thermoset and Conexus layer. After molding, the part and a central metal insert are transferred to an injection molding station, where the PA6/ABS layer is injection overmolded directly onto the Conexus film, creating an additional bond between the coupling layer and thermoplastic.

The carbon fiber version of the cover was a successful demonstrator of the Conexus technology, Heider says, but “one of our goals is to reduce the overall carbon footprint of our components, so we thought next about how to make a more sustainable version. As a first step, we decided to replace the carbon fibers since it was the material with the highest CO2 footprint.”

Of the overall process, von Czarnecki explains, “We start our parts basically as a demonstrator as a first step, then to small series application, then to higher volumes. This is how we enable and qualify new technologies for the company and then scale it up.”

Failing to calculate and accurately account for residence time can compromise material integrity before it’s even injected.

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

For our next example, let’s say the shot weight is 20 g, meaning 20% of the maximum shot capacity is being used. Similar to the discussion in Scenario 1, the total amount of molten plastic in the barrel will be 20 g in addition to the molten plastic on the screw.

The original design of the cover involved a compression molded, carbon fiber/epoxy top layer joined via Conexus to an injection molded bottom layer made from a blend of polyamide 6 (PA6) and ABS (acrylonitrile butadiene styrene) from INEOS Styrolution (Frankfurt, Germany). KTM Technologies developed tooling for the thermoset part with partner Alba Tooling & Engineering GmbH (Forstau, Austria), and for the injection molding tool with Altendorfer Kunststofftechnik GmbH (Neureichenau, Germany).

As soon as you see the bare screw, drop one or two pellets of any dark compatible color into the feed throat and pull the material hopper back in place. Let the mold open and eject the shot. Now start counting the number of shots until you see the color show up on the parts.

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.

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

This project also demonstrated natural fiber composites as a good fit for Conexus. Von Czarnecki notes, “Expecting carbon fiber shortages, the Conexus technology offers an opportunity to use less carbon fiber on one side [of the part] and more natural fiber on the other — still light and cost-efficient.”

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.

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.

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.

For the carbon fiber-reinforced polymer (CFRP) and flax fiber covers, KTM Technologies ultimately demonstrated the technology on in-house specimen- and part-level tests to prove adhesion for the joined parts, impact resistance, UV resistance and more, according to the company’s internal quality standards. “Our parts go directly onto the motorcycle where they’re tested by actual riders,” Heider says. “We do mechanical tests on the component separately, then test real-world performance on the motorcycle.”

Experiments reveal the relationship between vent depths and part thickness, allowing molders and moldmakers to more precisely determine vent dimensions.

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

The part combines three technologies: a compression-molded flax fiber/epoxy base structure, an injection overmolded thermoplastic outer layer and an innovative technology to join the two layers together without the use of adhesives.

First, the two companies went back to the drawing board to perform coupon-level testing on an identical version of the carbon fiber/epoxy component, this time using Bcomp’s ampliTex 5040 300-gsm twill flax fabric combined with epoxy and a Conexus layer via compression molding. Again, this was followed by an injection overmolded PA6 bottom layer. A series of tests were done to prove that the flax fiber was compatible with the Conexus technology and that the combined parts would stay joined over time and in a variety of conditions. Heider notes that although the overall mechanical performance of the flax fiber is lower than that of carbon fiber, the material offers advantages like improved damping behavior, and that it does not splinter when broken, increasing safety.

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.

“Sustainability” was the official theme of the JEC World 2022 exhibition in Paris, France. One project that exemplified this theme, and that took home the 2022 JEC Innovation Award in the Sports, Leisure and Recreation category, is a motorcycle brake disc cover that aimed to demonstrate three sustainability-focused technologies in one part.

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

To keep things simple, let’s say the parts we’re concerned with are molded in PS, the standard material that machine shot capacity is specified in. Consider the maximum shot capacity of this machine to be 100 g. Shot weight is defined as the total weight of the parts and runners. For the discussion below, let us also ignore the small amount of cushion that must be present at the end of the compensation—pack and hold—phase.

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.

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

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

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.

Baystar's Borstar technology is helping customers deliver better, more reliable production methods to greenhouse agriculture.

KTM’s industrial design department began with technical specifications for one of the company’s standard brake disc covers. Generally, these covers are made from metal or injection molded plastic, and include several holes to allow airflow to the brake disc underneath. Metal inserts fit into the bottom of the cover to enable the cover to mount and latch to the bike.

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.

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.

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

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

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

Residence time is the time that the plastic spends in the molding barrel. To be precise, it is the time from when the plastic pellet is at the bottom of the hopper and on the screw ready to be conveyed until the time it reaches the tip of the nozzle. It can be calculated with a very simple formula, but that formula is really just an estimate. To understand this, let us first understand the calculation for the maximum amount of plastic inside the barrel. Many molders would just use the published value of the maximum shot capacity of the machine. This is acceptable, but not entirely accurate.

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

In such a situation, the maximum amount of molten plastic is more than 100 g. It is clear here that screw-design factors—L/D ratio, compression ratio, ratio of the length of the feed section to compression to metering, and the screw type—will play a role in determining the amount of molten plastic on the screw.

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.

Eliminating the need to contact each supplier for every individual quote, a new CRM for automotive supplier Axiom Group tracks past quotes as well as industry history to generate fast, reliable RFQs and more.

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

For example, if the amount of the plastic on the screw and a built-up shot is 150 g and the shot weight is 25 g, then we can calculate that the number of shots in the barrel is six. If the cycle time for these parts is 30 sec, then we multiple that cycle time by the number of shots to determine it will take 180 sec (3 min) for the plastic to be conveyed from the location where it melts to the nozzle tip. Again, this does not include the material that has not yet reached the melt temperature, and so some portion of the plastic in the feed zone is not considered.