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.

Feedstocks were mixed using UNEEC proprietary multi-component polyoxymethylene-based (POM) binder system via a Z-Blade mixer.

[26] S.A. Matar, M.J. Edirisinghe, J.R.G. Evans, E.H. Twizell: Int. J. Powder Metall., 1987, vol. 23, no. 4, pp. 237-245.

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.

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

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.

Some well-known 3C electronic application examples for these advanced alloys are camera components (switches and buttons), wearable devices (watch cases), soft magnetic devices, electronic packages, heat sink/ heat spreaders for electronic cooling, laptop hinges and USB connectors, etc.

The ASTM F75 Co-Cr-Mo alloy was subsequently modified to make it forgeable, and this advance led to the development of the ASTM specification for Co-28Cr-6Mo alloy forgings for surgical implants (F799). The alloy is available in mill products such as bar stock, which is used either for the direct machining of a device (such as the femoral head of hip prostheses) or its forging (such as cemented hip stems). Before 1994, both bar stock and forgings were covered under ASTM F799. The specification was split in 1994-95 into F799 for forgings and F1537 for bar stock.

An optical microscope (HM-3006, Jia Yu Apparatus Co., Ltd., Taiwan) was used for morphological examination. X-ray diffraction (XRD) (D2, Bruker, Karlsruhe, Germany) was used for crystal structure identification. Element distribution was assessed via EPMA (JXA-8200SX, JEOL, Japan) with EDS (X-MAX 50, Oxford Instruments, UK). In addition, higher resolution microscopic images and phase investigations were conducted via a Fesem (JSM-7800F Prime, JEOL, Japan) with an electron backscatter diffraction (EBSD) detector (NordlysNano, Oxford Instruments, UK).

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.

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

Tensile bar specimens were prepared by injection moulding using a Nissei NEX 50T machine and the injection parameters are summarised in Table 2. Moulded green parts were then subject to a debinding process via a Winteam HT-220LTZL furnace in fuming nitric acid. Various sintering parameter trials were carried out in Cremer Thermoprozessanlagen GmbH walking beam continuous furnaces.

MIM is a promising method for production of 3C electronic and medical parts with high precision. The experimental results found in this study indicated that Co-Cr-Mo F75 alloys could be made via MIM using POM-based catalytic debinding feedstocks, and could be sintered in large-scale continuous furnaces without requiring post-treatment processes. The sintering atmosphere significantly affects the mechanical properties of Co-Cr-Mo F75 alloys. Various combinations of the sintering atmosphere were explored and discussed in this research. Sintering in a nitrogen-containing atmosphere enhanced the mechanical behaviour of the alloys compared to those sintered in non-nitrogen atmospheric conditions. Sintering in a hydrogen and argon mixed atmosphere led to poor mechanical properties. Optimised sintering conditions are based on a mixed atmosphere of hydrogen to nitrogen ratio as 25:3 in flow rate and conducted at 1315°C. This effect is attributed to nitrogenisation, which compensates for low carbon levels and an increase in strength, while the Cr2N precipitation issue is a function of the relative nitrogen fraction. The microstructure shows a typical F75 FCC crystal. For optimal conditions, all mechanical properties comply with the International Standard ASTM F75. The study’s proposed objectives were achieved. Continuous furnace sintering parameters in this study may not be fully applicable for all MIM cases due to the feedstock chemistry, solid loading, tooling mould geometry, and dimension differences, but these results still serve as a demonstration and reference for the MIM industry.

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.

Firstly, the sintering process was conducted in a mixed atmosphere based on the hydrogen to argon ratio at 22:6 m3/h flow rate at 1315°C. Mechanical properties of 4 sintered tensile bars are shown in Fig. 4. This result does not comply with the ASTM F75 standard (UTS ≥ 655 MPa; YS ≥ 455 MPa; Elongation ≥ 8%), owing to inferior UTS and YS performance.

The Co-Cr-Mo alloys have long been widely applied in surgical implants such as joint replacement prostheses (the femoral component in total knee replacement and femoral head in total hip replacement), elbows, fingers, bone plates, screws, rods and dental implants. However, due to cobalt’s classification in many regions as a strategic mineral/metal, global supply shortages and metal price fluctuations might be critical factors for long-term production.

Reach a truly international audience that includes component manufacturers, end-users, industry suppliers, analysts, researchers and more.

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

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

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

Demanding criteria for freedom of geometrical design, sophistication, high-strength, high-volume production capability, fine surface finish, accurate tolerance and flexible materials choice have made MIM thrive in the 3C electronics area. The electronics industry is a major user of metal injection moulded parts, accounting for robust and growing global sales, especially in Asia. Connectors with complex geometries are now the main MIM products. Miniaturisation of electronic devices requires smaller components to achieve better performance at a lower cost. MIM has a competitive advantage for such applications.

HP’s Metal Jet has undergone significant refinement in the years since it was first unveiled in 2018. Now, by incorporating nearly the whole Bind...»

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

Hao-Ming Chen, Yun-Feng Yang, Fan Yang, Chong-Gen Mai, Run-Ming Mai, Zhang-Yi Huang, Dr. Chung-Huei Chueh, I-Shiuan Chen

Since the very first PM Titanium conference in Brisbane, Australia, in 2011, the PMTi series has been the essential meeting point where technical a...»

As shown in Figs. 9 – 14, it is obvious that the main matrix of the sintered compact is based on FCC crystal, while some of the Cr2N precipitation existed near the upper surface region, which is in line with the phenomenon reported in the literature [43-44]. Fig. 14 shows the X-ray diffraction patterns for alloys sintered in hydrogen to nitrogen ratio at 14:14 m3/h flow rate at 1315°C. The results indicate that the FCC structure is the predominant phase with a small amount of Cr2N phase in the sintered compact.

“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.

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.

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

The electronic devices industry emerged in the 20th century and is one of the largest industries worldwide today. Society uses a vast array of electronic devices built in automated or semi-automated factories. These devices are now ubiquitous, with billions of people using them in their daily lives.

[17] S.H. Hsieh, C.H. Chueh, I.S. Chen, M.A. Kearns, P.A. Davies, K. Murray, M-K. Johnston, S. Kubal: Powder Inject. Mould. Int., 2020, vol. 14, no. 1, pp. 81-93.

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

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.

[16] S.H. Hsieh, C.H. Chueh, I.S. Chen, M.A. Kearns, P.A. Davies, K. Murray, M-K. Johnston: Int. J. Powder Metall, 2020, vol. 56, no. 1, pp. 41-49.

Cobalt-base alloy implants can be conventionally manufactured using wrought or cast techniques. Wrought cobalt alloys are made by forging the material at elevated temperatures under high pressure. Additionally, novel methods for the near-net-shape formation of parts from metal powders via Metal Injection Moulding (MIM) are currently being explored. New applications for MIM components are trending toward smaller, more-complex devices for minimally invasive surgery, especially laparoscopic instruments for grasping tissue, cutting and suturing. Such devices are being designed for greater freedom of movement, which has increased the number of metal components used in the assembly.

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.

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.

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.

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 trend in colour transformation implied that the N fraction in the furnace atmosphere plays an important role. It is rational to prevent the Cr2N formation in a sintered compact by an even lower N percentage as a strategy. Therefore, the hydrogen to nitrogen ratio at 25:3 m3/h at 1315°C was selected, with the results shown in Fig. 16. Sintered density is higher than 7.8 g/cm3, and all mechanical properties are in accordance with ASTM F75 standard.

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.

“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.”

As shown in Fig. 17(a), the dark colour in the sintered specimen is due to Cr2N formation. This trend is less pronounced for the 22:6 atmosphere ratio shown in Fig. 17(b), owing to relatively less precipitation during sintering. The 25:3 atmosphere ratio, shown in Fig. 17(c), exhibited the colour of the conventional Co-Cr-Mo metallic nature. Its corresponding EPMA analysis is shown in Fig. 18, which revealed the absence of Cr2N near the surface region, as estimated, due to the lower nitrogen ratio in the atmosphere.

“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.”

From the discussion in previous sections, it is rational to further reduce the nitrogen fraction in the sintering atmosphere to a flow rate of hydrogen to nitrogen ratio at 22:6 m3/h at 1315°C. The effect on the mechanical properties is shown in Fig. 15. Even under this relatively lower nitrogen fraction sintering condition, the UTS, YS and elongation properties still meet the F75 standard. The colour of the sintered alloy is light grey.

Fig. 6 shows results of the N strengthening approach for a flow rate of hydrogen to nitrogen at 14:14 m3/h at 1315°C. Apparently, mechanical values are significantly improved compared with previous rounds, and this result obviously can reach ASTM F75 standard. However, the sintered alloy’s appearance is black, which is abnormal compared with conventional F75 alloys, as shown in Fig. 7.

Cobalt-base alloys were introduced to what is now called the superalloy field mainly because of the suitability of the Co-Cr-Mo alloy named ‘Vitallium’ for reproducing complex shapes by precision lost‐wax casting [1]. Many of the properties of the cobalt-base alloys arise from the crystallographic nature of cobalt element. These properties include: the cobalt and solid-solution strengthening effects of chromium, tungsten, and molybdenum; the formation of metal carbides; and the corrosion resistance imparted by chromium. Cobalt-base alloys are strengthened through solid-solution hardening and carbide precipitation hardening by adding carbon, chromium and molybdenum.

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.

An optical microscope analysis was first carried out to investigate this phenomenon further, and the images of the surface region compared with the central core region are presented in Fig. 8.

Besides the previously mentioned applications of Co-Cr-Mo alloys, recently much attention has been paid to their use in the 3C telecommunication industry. For example, smartphone camera bracket components are a promising application for these alloys due to their combination of strength, corrosion resistance, wear performance and non-magnetic properties.

Electromagnetic components based on advanced metallic materials are one of the most significant developments in the modern 3C industry (computer, communication and consumer-electronics). These materials combine excellent mechanical strength with reasonably high corrosion resistance, wear resistance and specific magnetic properties (ferromagnetism or paramagnetism, depending on product design and function). They include stainless steels, cobalt alloys and other leading-edge alloys.

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

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

[35] C. Ballard, M. Zedalis: Advances in powder injection molding, in: Annual Technical Conference–ANTEC, Conference Proceedings, 1998, vol. 1, pp. 358-361.

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.

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

In this collection 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.

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.

The free-to-access PIM International magazine archive offers unparalleled insight into the world of MIM, CIM and sinter-based AM from a commercial and technological perspective through:

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Components made of these materials are integrated into countless devices and are widely used in almost all sectors. These include information and communication technologies, healthcare, manufacturing, automation and control, robotics, process industries, instrumentation, energy and power systems, defence and security.

MIM Co-Cr-Mo alloys were prepared via UNEEC’s POM-base feedstocks and using UNEEC mass-production scale continuous furnaces at various atmospheric combinations. Variations in atmospheric combinations led to differences in mechanical properties and microstructures. Neither Hot Isostatic Pressing (HIP) nor heat treatment was applied after sintering.

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.

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.

The main goal of this study was to evaluate whether low-carbon grade cobalt alloy feedstocks could achieve the ASTM F75 standard via tuning only sintering parameters/atmosphere, i.e. without applying any post-treatment. Reaching this goal would demonstrate a cost-efficient route for industrial mass production.

MIM has provided the design freedom to produce such components cost-effectively. A new area of exploration for the process is the production of micro-sized components, which should help meet future medical criteria as parts continue to shrink for minimally invasive surgery.

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.

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

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.

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.

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

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

[3] J. Giacchi, C. Morando, O. Fornaro, P. Microstructural: Mater Charact., 2011, vol. 62, pp. 53-61.[4] H. Mancha, E. Carranza, J. Escalante, G. Mendoza, M. Méndez: Metall Mater Trans., 2001, vol. 32, pp. 979-984.

Conventionally, MIM sintered compacts’ mechanical strengths could be further enhanced via appropriate post-treatment, such as HIP or solution-annealing heat treatment. Nitrogen (N) solution strengthening is one of the most promising approaches to achieving the aforementioned goal. It is well known that the addition of N to stainless steels stabilises the γ-phase, and high N additions can considerably improve the tensile and fatigue strength of austenitic stainless steels [38-39]. It is also expected that the stability of the γ-phase would be enhanced by N addition in Co-Cr-Mo alloys. Both Fe-Cr and Co-Cr alloy systems have the FCC structure at high temperatures and similar lattice parameters of approximately 0.357 to 0.360 nm [40]. As mentioned in the literature, adding N to the Co-Cr-Mo alloys is a potential strengthening element to change the microstructural characteristics and improve the mechanical properties of alloys [40-42].

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.

The surface and central core region exhibited microhardness values of 556 HV and 416 HV, respectively. These measurements also implied a difference in microstructure of the surface and central core region and are consistent with the morphologies shown in Fig. 8.

Cobalt is more widely used as an alloying element for heat-resistant applications in nickel-base superalloys, with cobalt tonnages above those used in cobalt-base heat-resistant alloys. Moreover, cobalt-base alloys exhibit excellent resistance to various forms of high-temperature corrosive attack, including oxidation, sulfidation and carburisation reactions.

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 (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.

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.

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

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

Discover suppliers of these and more in our advertisers’ index and buyer’s guide, available in the back of PIM International.

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 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.

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.

How has the global Metal Injection Molding industry weathered the most turbulent years in recent history, and what has the impact been on MIM’s k...»

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

Several ASTM specifications cover material properties for various Co-Cr-Mo compositions and processing routes. The Co-Cr-Mo as-cast alloys conforming to ASTM F75 standards have been widely used for many years to produce surgical implant devices and are still widely used today in many applications such as the femoral component of knee prostheses and the humeral component of shoulder prostheses. A close analogue of this alloy, Stellite 21, was initially used in aircraft turbocharger blades and is still used for wear resistance.

Within the relatively broad ASTM F75 chemistry specification, it is important to note that minor variations in levels of carbon can lead to significantly different sintering responses and concomitant effects on the density and mechanical properties. Carbides give strength and wear resistance by taking up chromium and molybdenum from the surrounding area during the solidification process. Co-Cr-Mo F75 alloys for mobile phone camera bracket components are one successful commercial MIM application in 3C electronics. There are emerging opportunities for this alloy to be applied in other MIM electronic devices.

Significant skill and precision engineering are needed to create the components of the devices noted above, and there are many hurdles to overcome. It is important that product designers can find and select appropriate materials quickly and efficiently to keep up with fast-paced developments.

Extensive MIM, CIM industry and sinter-based AM industry news, plus the following exclusive deep-dive articles and reports:

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

Cobalt-base alloys have long been developed for implantable medical devices and have recently been applied to the 3C electronics industry. They exhibit wear-resistant, corrosion-resistant and heat-resistant properties. The most effective use for cobalt-base alloys is in wear-resistant components.

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.

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.

Communication and computing devices such as smartphones, smart watches, tablets and laptop computers are built with complex combinations of components, many using materials optimised for electronics production. These materials have been the basis for the current age of electronic, information and communication technology and have been a large contributor to worldwide economic growth.

Many of the commercial cobalt-base alloys that are derived from the Co-Cr-W and Co-Cr-Mo ternaries were first investigated by Elwood Haynes, who discovered the strengthening effect and corrosion resistance imparted to cobalt by chromium in 1907. He later identified tungsten and molybdenum as powerful strengthening agents within the cobalt-chromium system. Co-Cr-Mo alloys, one of the advanced cobalt-base alloys, are widely applied for aircraft engines, medical total hip replacements, dental devices, support structures for heart valves, etc. Co-Cr-Mo alloys are well known for their combination of strong mechanical performance, wear resistance, corrosion resistance and acceptable biocompatibility. However, their main attribute is corrosion resistance in chloride environments.

[10] Y. Koizumi, S. Suzuki, K. Yamanaka, B.S. Lee, K. Sato, Y. Li, S. Kurosu, H. Matsumoto, A. Chiba: Acta Mater.,2013, vol. 61, issue 5, pp. 1648-1661.

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

In the case of F75 produced by MIM, the sintering behaviour of this alloy is of critical importance to obtaining a high-performance product. High sintering temperature in a MIM process is needed to obtain a high sintered density (more than 95% of theoretical) and a homogeneous microstructure. Some of the variables affecting the sintering characteristics of this alloy are the starting particle size, chemistry, porosity and the sintering atmosphere. [7-13].

[11] W.C. Rodriguez, L. R. Broilo, L. Schaeffer, G. H. Knörnschild, F. H.R. Espinoza: Powder Technol., 2011, vol. 206, issue 3, pp. 233-238.

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

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

This 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.

The pre-alloyed Co-Cr-Mo powders used in this study were manufactured by Mitsubishi Steel MFG using its proprietary water atomisation technology. SEM of the powder morphology and major elemental mapping analysis are shown in Fig. 3. Chemical compositions and powder size distribution are summarised in Table 1.

The authors gratefully acknowledge colleagues at Chenming Electronic Technology Corp. (UNEEC) and R&D centre for sharing their pearls of wisdom during this research, and for their assistance at every point. Without them this task would not have been possible to accomplish.

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

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.

[7] R. Tandon, in Cobalt‐Base Alloys for Biomedical Applications, ASTM STP 1365, J.A. Disegi, R.L. Kennedy,R. Pilliar eds., West Conshohocken, PA, ASTM, 1999, pp. 3‐10.

“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.”

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

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.

This advanced technology has grown in popularity in the past three decades as an effective approach to producing geometrically complicated near-net shape parts with accurate dimensions and excellent surface finish. It can make thin-walled parts to tight tolerance in various industries with cost-efficient processes for large-scale manufacturing, such as medical, automotive, aerospace and 3C electronics components [19-37].

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.

Many efforts have been made to improve the mechanical and tribological properties of cast Co-Cr-Mo alloys. There are Co-Cr-Mo alloys available in several different conditions defined primarily by their starting composition (e.g., low or high carbon content) [2], the conditions of manufacture (e.g., casting or forging) [3], subsequent thermal treatments (solution heat treatment, hot isostatic pressing or sintering) [4,5] and engineering surfaces by physical and chemical vapour deposition [6].

Results for an argon-rich atmosphere (flow rate of hydrogen to argon ratio at 6:22 m3/h at 1315°C) revealed a similar trend of poor mechanical properties, as shown in Fig. 5.

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.”

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

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.

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

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).

Chromium and molybdenum enhance the corrosion resistance of alloys and improve their mechanical properties by reducing abrasive wear and lowering the stacking fault energy. Co-Cr-Mo alloy, an advanced cobalt-base alloy, is widely used in nuclear power plants, aerospace engine vanes and biomedical surgical implants. In the latter case, they are used to make artificial metal-on-metal hip and knee joints. These Co-Cr-Mo alloys are known for their combination of strong mechanical performance, fatigue resistance, low creep, high resistance to wear/corrosion, and biocompatibility, but their main attribute is corrosion resistance in chloride environments. This property is related to their bulk composition (principally the high chromium content) and the formation of a protective surface oxide layer (nominally Cr2O3).

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.

[14] S.H. Hsieh, C.H. Chueh, I.S. Chen, M.A. Kearns, P.A. Davies, K. Murray, M-K. Johnston: Powder Inject. Mould. Int., 2018, vol. 12, no. 3, pp. 104-108.

Powder metallurgical processes are increasingly deployed to manufacture mechanical components for numerous industrial and consumer applications [14-18]. When suitably compounded with polymeric binder materials, these inorganic powders can be moulded in the same manner as thermoplastics. The products obtained via this process can avoid the density gradient, which is peculiar to the conventional press/sinter process. MIM is most commonly used to make parts with small dimensions, complex shapes, and tight tolerances in high volume. Extrusion or simple compression moulding may be used for parts with simple shapes. Production by MIM brings the shaping advantage of plastic injection moulding but expands the applications to numerous high-performance metals, alloys and technical ceramics.

“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.

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.

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 2023 International Conference on Injection Moulding of Metals, Ceramics and Carbides (MIM2023), organised by the Metal Powder Industries Federa...»

Finally, this article is dedicated in memory of Arnold-JiunHung Tsai (蔡駿宏 先生), who passed away in May 2017. Arnold contributed significantly to understanding Powder Injection Moulding binders, feedstocks, tooling mould design, manufacturing, analysis, and R&D innovations. We treasure the memory of his enormous energy, generosity, and selflessness in sharing ideas, contributing towards making PIM a miracle of materials science, and making UNEEC a great company.

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.