plant - structural foam injection molding

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.

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

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.

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 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.

Two of the new machines, which were supplied by Hurco Europe, High Wycombe, through its local sales representative in Ireland, Michael Gannon, have been automated with pallet changers so that they can be operated around the clock, unmanned at night. All are installed in a temperature controlled environment. GTM's owner and managing director, Padraig McFadden, comments: “As a result of this and other measures, mould leadtimes have been cut by up to 20% to typically 14 weeks and we have increased productivity significantly.” The main specialism of the company, which was founded in 1990, is the manufacture of high precision injection moulds for the medical, pharmaceutical and high volume packaging sectors worldwide, from single impression moulds for prototyping to 48 cavity moulds for producing complex plastic devices such as inhalers. In addition, a small number of micro moulds are produced to make, for example, miniature rotor gears and screws for medical assemblies or for over moulding stents. Components down to 10 milligrams can be moulded to tolerances of ±0.005mm, consistently and reliably. The successful working practices implemented by GTM at its Galway factory resulted in a doubling of turnover between 2012 and 2015 and an increase in floor area from 4,000 to 15,000ft² with an extension of an additional 8,000ft² currently being added. There are now 30 employees of which three are apprentices. Move from EDM Migration from EDM to high-speed milling is one factor in that success, but others are the opening of a metrology laboratory for tool validation and an in-house trial facility for moulds equipped with Fanuc electric moulding machines ranging from 100 to 300 tons capacity. Mr McFadden emphasised that customers get a perfect turnkey mould every time, which has been designed, manufactured and tested for process viability, including correct shrinkage allowance. 2007 was a year of change for GTM, which until then derived a large proportion of turnover from automotive mould making. Much of this work rapidly disappeared overseas, notably to China, so Mr McFadden diversified into other areas, particularly the medical industry for which Ireland had become a global manufacturing centre. Characteristic of medical mould work are the requirement for tighter tolerances and better surface finishes as well as shorter lead-times than are normal in the automotive sector. GTM was sparking a lot of small parts for moulds, but electrode manufacture is time-consuming and EDM is itself a slow process. The decision was taken to replace as much EDM as possible with high-speed machining using small diameter, ball nose milling cutters. It was a move that would save 70% of the time needed for this part of the manufacturing process, according to shop floor manager, Mark Walsh. Every mould that passes through the Galway factory now undergoes some high-speed cutting on one of the Roeders. Mr Walsh explains: “Back in 2007 we asked several potential HSC machine suppliers to make test cuts on one of our moulds. The Roeders machine beat all the others in terms of speed, accuracy and surface finish. It was noticeably better in all areas, partly because the German machine builder was an early adopter of linear motors for the axis drives. “Coupled with glass scale feedback to the control and compensation for spindle growth via a high precision sensor, it allows us to hold ±2µm accuracy. This was three times better than on a ballscrew driven machine we trialled, which also had the drawback of not being able to achieve the surface finish we require for our moulds.” Mr Walsh adds that an online search revealed Roeders' reputation for machine reliability, high spindle uptime and good service, so in the end the purchase decision was straightforward. Eight years running A Roeders RXP500 3-axis VMC with a 40 tool magazine was duly installed. Despite it having to run 24/5 plus extensively at weekends for more than eight years, Mr Walsh confirmed that the machine is just as good today in terms of the accuracies and surface finishes achieved as when it was new. This level of performance led automatically to the purchase of a second Roeders 3-axis RXP 500 in 2013 to cope with raised production levels. Automation was fitted in the form of an automatic, eight pallet changer that allows any mix of jobs to be set up and run unattended overnight, or over an entire weekend if longer running jobs are selected. During the day, both RXP500s can be attended by one person due to the automation fitted to the second machine. Mr Walsh was enthusiastic when he spoke of how many more hours they were getting out of the spindles for the same number of operator hours. More recently, work has been more heavily centred on pharmaceutical moulds, entailing machining of even greater complexity that requires multiple set-ups on a 3-axis machine, the use of long cutters to access awkward areas from above, and repeated repositioning for side features to be included. A 5-axis VMC was the obvious solution, so in May 2015 a Roeders RXP601 DSH with a 96 tool magazine was installed, again with automation but this time provided by a 38 position pallet change system to allow longer periods of unattended running. A second RXP601 could be served by the same automation equipment if required in the future. The advantage of using 5-axis machining on some jobs is dramatic. For example, the aforementioned inhaler mould was previously machined in a total of eight hours on a 3-axis Roeders and an EDM machine in five operations. They comprised milling with an 80mm long, 16mm diameter cutter that was slowed to 3,000rpm to avoid undue vibration, followed by a set-up on either side for further milling, then sparking on four sides and around the skirt. The 5-axis HSC machine tackles the same job in a single set-up in a quarter of the time – just two hours complete. The time saving is a result of eliminating four set-ups and maintaining spindle speed at 30,000rpm as the better access afforded by a 5-axis configuration allows the use of shorter cutters. Consequently, more and more work is finding its way onto the 5-axis cell at the Galway factory. The latest innovation is the introduction of offline set-up of jobs on a coordinate measuring machine, which when fully implemented will add an extra 10 hours of production per week across the three Roeders machines. HURCO www.hurco.co.uk GALWAY TOOL & MOULD www.galwaytoolandmould.com

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

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

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.

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

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

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

To drive future developments in polymer foams, SABIC operates a Foam Innovation Center in The Netherlands. This center, which is equipped with foam process capabilities as well as analytical equipment, enables the company to develop new foam solutions and technology innovations and collaborate with customers.

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.

The largest number of young people ever are now studying at University Technical Colleges, enrolment figures for the network of 44 technical education schools have revealed.

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.

Plastics Technology covers technical and business Information for Plastics Processors in Injection Molding, Extrusion, Blow Molding, Plastic Additives, Compounding, Plastic Materials, and Resin Pricing. About Us

Mixed in among thought leaders from leading suppliers to injection molders and mold makers at the 2023 Molding and MoldMaking conferences will be molders and toolmakers themselves.

Three new mineral-reinforced PP compounds from SABIC have been shown to deliver excellent aesthetics for visible automotive interior parts with complex geometries, such as door panels and trim, seat and trunk cladding, A/B/C/D pillar covers and center consoles. SABIC PPc F9005, PPc F9007 and PPc F9015 grades, unlike standard foam injection molding (FIM) materials which typically exhibit surface defects, reportedly feature uniformly high surface quality similar to solid injection molded parts. The new SABIC PP compounds have launched in Europe, with upcoming availability in the Americas and Asia/Pacific.

The UK manufacturing industry made a positive start to the second half of 2024, with growth of output and new orders strengthening according to the latest PMI data.

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.

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.

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.

Weight reduction results with SABIC PP compounds depend on several factors, including the type of FIM technique used. Short-shot molding, which uses the same tooling as an injection molded part, can reduce weight by up to 10%. SABIC PPc 9007 is formulated for short-shot FIM and low-impact applications. Core-back molding, which requires part redesign and new tooling, can lower weight by as much as 30%. Both SABIC PPc 9005 and PPc 9015 grades are formulated for core-back molding and deliver medium stiffness and impact.

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

Previously, the FIM process was essentially limited to non-visible parts, restricting its usefulness in automotive applications. Foaming can underperform in surface aesthetics: silver streaking, swirl lines and dimples are common defects. The new SABIC PP compounds for foamed interior parts deliver low-gloss textured (grained) surfaces with uniformly high quality, including the elimination of streaking and swirling. Talc filler in these grades acts as a nucleator that promotes the generation of finer bubbles, which contribute to a consistent surface appearance. For enhanced aesthetics, these grades are currently available in selected automotive interior colors with custom coloring also available.

The UK manufacturing industry made a positive start to the second half of 2024, with growth of output and new orders strengthening according to the latest PMI data.

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.

One of the UK’s leading manufacturers of flat rolled aluminium coils showcased the talents of its budding engineers at the recent UK Metals Expo.

Compounders face a number of processing challenges when incorporating a high loading of low-bulk-density mineral filler into polyolefins. Here are some possible solutions.

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).

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

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

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.

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

With advocacy, communication and sustainability as three main pillars, Seaholm leads a trade association to NPE that ‘is more active today than we have ever been.’

Polyethylene parts can fail when an inappropriate density is selected. Let’s look at some examples and examine what happened and why.

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

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

The 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

Implementing a production monitoring system as the foundation of a ‘smart factory’ is about integrating people with new technology as much as it is about integrating machines and computers. Here are tips from a company that has gone through the 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.

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

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 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.

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

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

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

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.

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.

Two of the new machines, which were supplied by Hurco Europe, High Wycombe, through its local sales representative in Ireland, Michael Gannon, have been automated with pallet changers so that they can be operated around the clock, unmanned at night. All are installed in a temperature controlled environment. GTM's owner and managing director, Padraig McFadden, comments: “As a result of this and other measures, mould leadtimes have been cut by up to 20% to typically 14 weeks and we have increased productivity significantly.” The main specialism of the company, which was founded in 1990, is the manufacture of high precision injection moulds for the medical, pharmaceutical and high volume packaging sectors worldwide, from single impression moulds for prototyping to 48 cavity moulds for producing complex plastic devices such as inhalers. In addition, a small number of micro moulds are produced to make, for example, miniature rotor gears and screws for medical assemblies or for over moulding stents. Components down to 10 milligrams can be moulded to tolerances of ±0.005mm, consistently and reliably. The successful working practices implemented by GTM at its Galway factory resulted in a doubling of turnover between 2012 and 2015 and an increase in floor area from 4,000 to 15,000ft² with an extension of an additional 8,000ft² currently being added. There are now 30 employees of which three are apprentices. Move from EDM Migration from EDM to high-speed milling is one factor in that success, but others are the opening of a metrology laboratory for tool validation and an in-house trial facility for moulds equipped with Fanuc electric moulding machines ranging from 100 to 300 tons capacity. Mr McFadden emphasised that customers get a perfect turnkey mould every time, which has been designed, manufactured and tested for process viability, including correct shrinkage allowance. 2007 was a year of change for GTM, which until then derived a large proportion of turnover from automotive mould making. Much of this work rapidly disappeared overseas, notably to China, so Mr McFadden diversified into other areas, particularly the medical industry for which Ireland had become a global manufacturing centre. Characteristic of medical mould work are the requirement for tighter tolerances and better surface finishes as well as shorter lead-times than are normal in the automotive sector. GTM was sparking a lot of small parts for moulds, but electrode manufacture is time-consuming and EDM is itself a slow process. The decision was taken to replace as much EDM as possible with high-speed machining using small diameter, ball nose milling cutters. It was a move that would save 70% of the time needed for this part of the manufacturing process, according to shop floor manager, Mark Walsh. Every mould that passes through the Galway factory now undergoes some high-speed cutting on one of the Roeders. Mr Walsh explains: “Back in 2007 we asked several potential HSC machine suppliers to make test cuts on one of our moulds. The Roeders machine beat all the others in terms of speed, accuracy and surface finish. It was noticeably better in all areas, partly because the German machine builder was an early adopter of linear motors for the axis drives. “Coupled with glass scale feedback to the control and compensation for spindle growth via a high precision sensor, it allows us to hold ±2µm accuracy. This was three times better than on a ballscrew driven machine we trialled, which also had the drawback of not being able to achieve the surface finish we require for our moulds.” Mr Walsh adds that an online search revealed Roeders' reputation for machine reliability, high spindle uptime and good service, so in the end the purchase decision was straightforward. Eight years running A Roeders RXP500 3-axis VMC with a 40 tool magazine was duly installed. Despite it having to run 24/5 plus extensively at weekends for more than eight years, Mr Walsh confirmed that the machine is just as good today in terms of the accuracies and surface finishes achieved as when it was new. This level of performance led automatically to the purchase of a second Roeders 3-axis RXP 500 in 2013 to cope with raised production levels. Automation was fitted in the form of an automatic, eight pallet changer that allows any mix of jobs to be set up and run unattended overnight, or over an entire weekend if longer running jobs are selected. During the day, both RXP500s can be attended by one person due to the automation fitted to the second machine. Mr Walsh was enthusiastic when he spoke of how many more hours they were getting out of the spindles for the same number of operator hours. More recently, work has been more heavily centred on pharmaceutical moulds, entailing machining of even greater complexity that requires multiple set-ups on a 3-axis machine, the use of long cutters to access awkward areas from above, and repeated repositioning for side features to be included. A 5-axis VMC was the obvious solution, so in May 2015 a Roeders RXP601 DSH with a 96 tool magazine was installed, again with automation but this time provided by a 38 position pallet change system to allow longer periods of unattended running. A second RXP601 could be served by the same automation equipment if required in the future. The advantage of using 5-axis machining on some jobs is dramatic. For example, the aforementioned inhaler mould was previously machined in a total of eight hours on a 3-axis Roeders and an EDM machine in five operations. They comprised milling with an 80mm long, 16mm diameter cutter that was slowed to 3,000rpm to avoid undue vibration, followed by a set-up on either side for further milling, then sparking on four sides and around the skirt. The 5-axis HSC machine tackles the same job in a single set-up in a quarter of the time – just two hours complete. The time saving is a result of eliminating four set-ups and maintaining spindle speed at 30,000rpm as the better access afforded by a 5-axis configuration allows the use of shorter cutters. Consequently, more and more work is finding its way onto the 5-axis cell at the Galway factory. The latest innovation is the introduction of offline set-up of jobs on a coordinate measuring machine, which when fully implemented will add an extra 10 hours of production per week across the three Roeders machines. HURCO www.hurco.co.uk GALWAY TOOL & MOULD www.galwaytoolandmould.com

The choice between the short-shot and core-back techniques, with their different tooling requirements, also helps to determine whether FIM with SABIC PP compounds is cost neutral or delivers cost savings. Additional cost savings are possible from cycle time reductions from flow improvements inherent in FIM.

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Don’t assume you know everything there is to know about PE because it’s been around so long. Here is yet another example of how the performance of PE is influenced by molecular weight and density.

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

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.

SABIC’s new mineral-reinforced PP compounds said to deliver excellent aesthetics for visible automotive interior parts with complex geometries.

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

Another consideration is the foaming process, which can use chemical or physical agents. The new SABIC PP compounds are good candidates for use with chemical blowing agents, which are typically preferred for visible foamed parts. These agents are introduced to the molding machine in the form of a masterbatch, along with the plastic pellets, and activate during the melt phase to release gases for foaming.

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.

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.

Compared to solid components, foamed parts made with SABIC PP compounds offer significant weight savings that can help cut emissions. According to a cradle-to-grave life cycle assessment study (pending third-party review), the advanced new materials can help OEMs lower carbon dioxide (CO2) emissions by as much as 15 %.

SABIC fully supports its new PP compound portfolio with extensive expertise in foamed part design, development and processing, as well as predictive engineering capability. The company can provide guidance on the selection of the appropriate chemical blowing agent for each grade, and a SABIC team will collaborate with customers to achieve excellent aesthetics at the lowest possible part weight.

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

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

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

Allied Machine and Engineering, a leading manufacturer of holemaking and finishing cutting tools, has announced the expansion of the T-A Pro replaceable insert drilling system into the Y series.

Join Wittmann for an engaging webinar on the transformative impact of manufacturing execution systems (MES) in the plastic injection molding industry. Discover how MES enhances production efficiency, quality control and real-time monitoring while also reducing downtime. It will explore the integration of MES with existing systems, emphasizing compliance and traceability for automotive and medical sectors. Learn about the latest advancements in IoT and AI technologies and how they drive innovation and continuous improvement in MES. Agenda: Overview of MES benefits What is MES? Definition, role and brief history Historical perspective and evolution Longevity and analytics Connectivity: importance, standards and integration Advantages of MES: efficiency, real-time data, traceability and cost savings Emerging technologies: IoT and AI in MES

In this collection of 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.