Two-shot molding combines molding and overmolding into a single process and can improve productivity and performance. Special machines and molds are required, but combining the processes can reduce variability, enhance aesthetics, and raise part quality. Technology has continued to advance with new manufacturing- process developments. One example is plasma treatment at atmospheric pressure. During molding of the second piece, the mold is momentarily opened, a precisely directed plasma is applied to the still warm surface, and then the mold reclosed. This expands the multimaterial combinations for potential cost savings, and opens the door to new design possibilities. Another proven example is using the residual heat in the just-molded PEEK part to initiate curing of a liquid silicone rubber as the second component.

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

Without adhesives, thin PEEK-based film can continuously operate at temperatures to 200°C (392°F). This makes PEEK well suited for applications that must withstand lead-free solder-processing temperatures that can sometimes reach 280°C (536°F) for short periods. PEEKfilm laminates also have proven reliability in areas like under-the-hood automotive, down-hole oil and gas exploration, and aerospace applications.

Five industry pros with more than 200 years of combined molding experience provide step-by-step best practices on mounting a mold in a horizontal injection molding machine.

The welding process passes infrared radiation through one transparent part that lies on top of a second lightabsorbent part. Natural PEEK grades are transparent, and black or dark grades are absorptive. A robot or motion system controls the laser path. Heat generated by absorption at the interface melts both surfaces, welding the two components together. Current laser-welding technology limits the thickness of the top transparent piece to <1 mm (0.039 in.). Anything greater will compromise weld strength. Designers can overcome this limitation by adding progressive layers of PEEK film.

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

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

The assembled part has more-precise dimensional accuracy than would be possible with a molded part of similar length. These ultrasonically welded PEEK components reduce costs and cycle times because they do not require fasteners, adhesives, or snap-fits to make the bond.

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

One supplier to major aircraft manufacturers has developed a process for joining segments of an aerospace structural component that’s been injection molded using a carbon-fiberfilled PEEK. Due to the part’s complexity and thin cross section, it must be injection molded in foot-long sections. The molder then simultaneously welds four segments into a continuous piece while holding strict dimensional and geometric tolerances for the overall 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.

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

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

PCS Company, Fraser, Michigan, has launched the Polimold Valve Gate Sequencer, providing injection molders with more precise control of the mold-filling sequence when using valve-gate hot runner systems.

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

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

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.

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

Design-for-assembly (DFA) techniques help reduce the overall number of assembly steps by consolidating components into more integrated designs. Snap-fits often eliminate metal fasteners, and one-piece composite chassis with integral locating pins can accept molded subassembly modules and replace stamped, spot-welded steel frames.

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.

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.

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.

Heat laminating Heat laminating joins two or more layered materials by heating and melting each layer together without adhesives. The process involves pressing the laminate structure between heated platens or rollers in a continuous process. The material may be preheated by infrared or another noncontact method, but in the press the heat is applied by conduction from the platens or rolls.

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

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.

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.

PCS Company has introduced the Polimold Valve Gate sequencer to control the opening and closing of hot runner valve-gate pins.

Clear-to-clear laser welding is an evolving area. This process has been in development over the last decade but was limited by laser capabilities. Within the last year, however, special lenses have been developed and tested that reach maximum density at the beam waist, applying the highest temperatures to a smaller area in the right wavelength, averaging around 1,700 nm. While not yet commercial, it should make it possible to weld two clear parts.

Eliminating the insulating adhesive layer also increases laminate thermal conductivity and can reduce laminate thickness. This leads to smaller, thinner devices. Adhesives can add up to 50% to the overall thickness and weight of a laminate structure, raising fuel costs for operators of aircraft and automobiles and adding to loads and stresses on other components.

PCS says each module of the Polimold Valve Gate Sequencer controls two zones, with the option to control up to 14 zones. In addition, multiple sequence injection capabilities enable the valve gates to be opened and closed simultaneously or individually.

PEEK basics PEEK (polyetheretherketone) is a semicrystalline thermoplastic with a melting point of 343°C (649°F). In addition to a high-operating temperature, PEEK’s molecular structure gives it inherent strength and stiffness, as well as wear, creep, chemical, and flame resistance. Thus, it can improve component durability and reduce weight and maintenance requirements for OEMs. Available unfilled or filled (typically with carbon, glass, or fluoropolymers), the thermoplastic can in many cases match the mechanical properties of metal while requiring less energy to manufacture a part.

Ken Korane holds a B.S. Mechanical Engineering from The Ohio State University. In addition to serving as an editor at Machine Design until August 2015, his prior work experience includes product engineer at Parker Hannifin Corp. and mechanical design engineer at Euclid Inc.

As with other types of welding, the bond is only as strong as the base materials. Metals would seem to offer stronger bonds than PEEK, but that’s not always the case. For instance, chemical reactions such as oxidation or nitriding may occur with metals such as aluminum and subsequently release unwanted gases that compromise joint strength. And if excessive energy absorption at the surface causing the metal to bubble, it can lead to critical failure at the weld seam.

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.

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.

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.

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.

These polymers have been used for decades in demanding applications that were previously the exclusive domain of metals and ceramics. For instance, antilock-brake poppets, compressor-valve plates, and oil-field downhole-tool bushings, seals, and connectors are just a few applications where PEEK handles extreme heat, pressure, and chemical exposure combined with long-term wear and fatigue cycling.

Authored by: Patrick Clemensen Technical Manager - Americas Victrex Polymer Solutions West Conshohocken, Pa. Edited by Kenneth J. Korane [email protected] Key points: • Engineers are replacing metals with highperformance plastics to cut weight and eliminate material-related failures. • Designers should reconsider conventional mechanical joining techniques and look to thermal bonding as a better way to assemble parts. Resources: Victrex Polymer Solutions

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.

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.

Overmolding is a two-step process. First, the rigid PEEK part is injection molded. Then after cooling, the part is loaded into a second cavity where the elastomer is overmolded. Note that mechanical interlock designs are typically unacceptable, as they can add unnecessary weight or create uneven loading conditions that can premature break down the elastomeric layer. A simple flat interface is recommended for even compression forces. Macromechanical interlocking provides good bond strength, so part design is crucial to the success of a finished overmolded part.

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

Modular and compact, the Polimold Valve Gate Sequencer can be used for both pneumatic and hydraulic valve-gate systems, enabling molders to move weld lines on cosmetic surfaces or to improve part strength.

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.

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 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

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.

Ultrasonic welding Ultrasonic welding is a well-established process that uses vibration energy to bond components. Parts are sandwiched between an anvil and horn that emits low-amplitude acoustic vibrations. Vibrations of 15 to 70 kHz concentrated on the surface cause friction and heat, making the two components soften and join together. PEEK polymers lend themselves to ultrasonic joining techniques mainly due to their thermal stability during the welding process.

PEEK melts and recrystallizes over a relatively narrow temperature range and has excellent thermal stability, allowing for several different joining and assembly methods. These techniques are providing engineers a new set of material and process options to expand design possibilities. Here’s a closer look at some thermal joining methods that can improve part performance and lower costs.

Laser welding is unique in that it produces extremely precise and uniform bonds without generating particulates or contaminants. The process does not mar the part surface, as is common with ultrasonic welding. And because the laser focuses energy only into the weld area, this minimizes thermal stresses on adjacent components. It also creates gas-tight hermetic seals and joints without weak spots that ensure a cohesive failure mode.

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

Overmolding and two-shot molding Overmolding and two-shot molding can be used to seamlessly apply elastomers directly onto a rigid PEEK part surface, for instance, to give pressure seals tighter tolerances or serve as a tactile cushion on top of a relatively hard, slick surface.

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.

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

Changing market demands increasingly have engineers replacing metals and other traditional materials with thermoplastics like PEEK. Reasons include weight reduction in aerospace and automotive applications, to improve fuel economy and cut emissions; and eliminating material-related failures, downtime, and maintenance, such as in oil-field operations as rigs drill deeper wells and encounter higher temperatures and pressures.

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.

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.

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.

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.

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

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.

Process developments now permit direct lamination of roll-to-roll and flat-panel laminate structures. This lets engineers combine film with metal foils like copper, brass, and aluminum, as well as other materials like aramid and glass fibers. Each laminate can be tailor-made with the required materials along with PEEK film to meet specific application requirements.

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

Polymer films are more commonly used as insulators or barrier materials because they have the added benefit of being their own adhesive. They offer advantages over adhesively bonded structures because they eliminate the cost of the adhesive, the processing time required to apply it, and the possibility of adhesive deterioration or delamination that leads to premature product failure. Eliminating adhesives can also reduce emissions of volatile organic compounds (VOCs).

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).

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.

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

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

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.

It can also lower overall costs. Conventional injection molding, extrusion, and other thermoplastic conversion processes let manufacturers make parts with complex 3D geometries and close tolerances in a fraction of the time it would take to produce the same part in a machined metal, and it usually eliminates secondary finishing operations. Plastic parts are much lighter than their metal predecessors and, therefore, are easier to ship, handle, and assemble.

It can also eliminate flash and short shots with precisely controlled material flow, while reducing the amount of clamp force needed. Cosmetically, sequential valve gates can also decrease flow marks on the part surface.

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.

As a result, conventional joining techniques — for instance using mechanical fasteners — are now being revisited as manufacturers look for new and better ways to assemble equipment.

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

Today’s laser-welding equipment readily handles varying surfaces and geometries. Simultaneous welding, for example, uses one or more lasers to simultaneously heat the entire weld path, helping ensure even and continuous bonds. More-precise welds are possible by welding the entire joint at once, or mask welding, which is well suited for large parts and proven effective with PEEK.

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

Laser welding Laser welding, also referred to as laser-transmission welding, offers high-speed production, pin-point accuracy, and good bond strength when joining PEEK parts. Unlike hot-melt and gluing methods, laser welding is more cost effective because no additional material is needed to create the bond. It’s environmentally safe and the tools don’t clog or wear, eliminating maintenance headaches.