With Demand Surging 127% MoM, Plastic Injection Molding Market to Reach/With Demand Surging 127% MoM, Plastic Injection Molding Market to Reach

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With Demand Surging 127% MoM, Plastic Injection Molding Market to Reach

Author：gly Date: 2024-09-30

$513 Billion in 5 Years - plastic injection molding services

In less than a decade in injection molding, US Merchants has acquired hundreds of machines spread across facilities in California, Texas, Virginia and Arizona, with even more growth coming.

I asked Bozzelli what he thinks of this approach. He responds, “Adding the overflow channel to improve weld-line strength is not common, but I have seen it done a number of times. Yes, it does help, for two reasons: Often the weld line traps air and the ‘dump’ acts as a vent to allow the air to escape. That helps. Second, depending on the size of the overflow well, you get a little bit of flow melding together, and that helps strength so that you have some intertwining of the polymer chains. This is similar to putting whatever is causing the weld line, like a hole in a part, away from the end of fill. Plastic then has a chance to flow around the hole and re-meld as it continues to fill the part. That really helps to improve strength.”

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

In August 2015, Rodney Davenport helped establish in-house molding for the Recreational Group in Dalton, Ga. Photo Credit: Plastics Technology

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

In addition, Davenport says CH3 vigorously adheres to preventive-maintenance schedules for all its equipment, as dictated by the equipment OEM. “Just like your car — you’ve got to get your oil changes; you’ve got to do your fluid flushes at 30,000 miles, 60,000 miles, whatever. You’re spending millions of dollars on this equipment, why not take care of it?”

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.

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.

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.

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

Join 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

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

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

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.

If all this isn’t enough to inspire a righteous fear of the harm that weld lines can cause if placed in critical locations, Bozzelli knows of one more “evil” that lurks within those weld lines: “Take another look at the TEM photo of the ABS keycap. First is the air gap; but on one side, note the black line separating two flow fronts. That’s not supposed to be there. Yet another problem!”

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.

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.

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

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

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

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

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

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.

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

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.

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.

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.

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.

The desire to establish a molding operation where workers are challenged to think critically and learn is core to Davenport’s bid to buck the shopfloor dynamics that he’s seen over the years. “The industry has grown a lot; it’s changed a lot,” Davenport says. “Machinery has really changed over the years, but the real deep down at every shop is the same. You have one guy who usually fixes everything who ends up being a process engineer. You have one guy that’s been there forever so he has all the tribal knowledge, and he’s the one they get to fix the widget, and those are the types of things that always drove me crazy. I want everybody to know everything.”

Maguire loaders/blenders are utilized to feed virgin resin, reclaimed resin, colorant and Asaclean purging compount during color changes.

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.

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

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.

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.

And where would we be without the handful of uber-experienced plastics veterans who generously share their hard-earned knowledge about industry-wide problems like this?

This August, Davenport will mark his 30th anniversary in injection molding, starting life as a floor person and working every job since then. Today he oversees an operation that reflects what he views as the molding ideal, but he acknowledges the unique opportunity CH3 Solutions presented.

Reflecting on past consumer-products molding, Davenport offers an example of the inherent challenge. “I used to make a lot of stuff for Colgate — deodorant caps and things. If the caps were slightly off it wasn’t that big a deal because you’re seeing just one at a time. Once in a while, if they were all lined up on the shelf, you might see a difference but it had to be pretty drastic. With the tiles, you’ve got parts touching on every side, and then you can look across and if something’s off, you will see it, it will pop out.”

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.

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

No pre-colored resins are used by CH3 solutions, which must ensure consistent color across a given project utilizing color additives..

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

When determining the best ejection option for a tool, molders must consider the ejector’s surface area, location and style.

After more than two decades in the industry, Rodney Davenport was given the opportunity to create an injection molding operation in his own vision, and — in keeping with the product he was making — to do so from the ground up.

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

Hundreds of tons of demonstration products will be created this week. Commercial Plastics Recycling is striving to recycle ALL of it.

In its 50th year, Matrix Tool applies moldmaking and injection molding expertise, plus a long family heritage, to high-precision jobs that many would deem impossible.

Warpage is the biggest challenge for CH3 solutions to overcome in its floor tile molding, with color matching a close second. (Photo: Plastics Technology)

In addition to empowering his workers to wear multiple hats and exert autonomy over the shop floor, Davenport encourages them to continuously share the status of the machines they’re using, even if they have bad news. “Almost every shop that I’ve ever worked in has had the same philosophy,” Davenport says: “Keep ‘em running, keep ‘em running. The customer is going to be mad if we shut down. We’ve got to make product.”

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.

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.

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

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

Rodney Davenport’s professional and adult life has been in injection molding. Starting in 1993 right out of high school, he spent a decade at custom molder Clairson Industries in Florida, wearing every hat a worker can and working alongside his mentor, Archie Mann. After some ownership changes, he eventually found his way to Georgia and was running operations at ADCO Plastics in Marietta, when a floor tile mold ended up in his shop after posing problems for the last company that ran it. ADCO got the mold back into successful production, and Davenport found himself in conversation with the owner of the floor tile company, The Recreational Group (RG).

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.

To help manage the PM on everything from TCUs and blenders to molding machines and robots, CH3 deploys Progressive Components’ CVe monitor. Originally designed specifically for molds, CH3 has worked with Progressive to extend this online monitoring system to all equipment and to track overall efficiency as well as cycles and PMs.

Since its first Wintec machine purchase following NPE 2018, CH3 Solutions has added four more in addition to its dynasty Engel press. Photo Credit: Wintec

When Plastics Technology visited, a halfcourt basketball court in light brown was being finalized with the family’s surname and “Est. 2012” painted in the key, while the building’s far corner was occupied by two full-sized tennis courts receiving finishing touches. Here, using the customer’s order as a guide, workers laid down tape on the interconnected tiles prior to painting on lines, markings, logos and more. Once the paint dries, the workers disassemble and number the individual tiles, packing them up into a kit that will be reassembled in sequence using those numbers as a guide.

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.

St. Joseph Plastics grew from a simple grinding operation and now pursues growing markets in recycled PP, food-grade recycled materials, and customized post-industrial and post-consumer compounds.

In Part 1 of this series, we address long-fiber processing fundamentals and best practices, including practical tips and guidance on maintaining fiber length and deriving maximum advantages for demanding end applications. Part 2 will provide the same information for short-fiber materials.

Second quarter started with price hikes in PE and the four volume engineering resins, but relatively stable pricing was largely expected by the quarter’s end.

Davenport has always contrasted that with what injection molding consultant and trainer (and frequent Plastics Technology contributor) John Bozzelli told him and his classmates in a 1994 seminar: If a mold’s broke, fix it. If a machine’s broke, fix it. In that spirit, Davenport says his operators always have his ear, because he trusts theirs. “We listen to our operators a lot because they’re always on the machine, and they’ll say, ‘Hey, this sounds different.’ So instead of just shrugging that off, let’s look into it and see what they’re talking about.”

“At the end of the day, we had the advantage,” Davenport says. “CH3 is a brand-new company. We started it, and we built the culture the way we wanted it, so it was a little easier than trying to change everything.”

Following on a similar guide for long-fiber reinforced compounds, here are practical tips on designing and injection molding parts utilizing short-fiber reinforcements.

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

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.

“You should know what a good part is,” Davenport says. “It shouldn’t be that you mold a part, hand it to QC and ask, ‘Is this good?’’

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.

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.

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

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.

From avoiding warpage in parts that must be flat to keeping color completely consistent for larger courts with hundreds of tiles, to nailing precise dimensions every time, the tiles’ biggest challenge is how they’re presented in their end use. “Keeping the warpage out, keeping the size correct, matching everything perfectly,” Davenport says. “It’s not like some things where you might run a bunch of a color, but the parts don’t ever touch each other. These touch each other on four sides.” In addition to “using all the math we can to get all the wall thicknesses correct,” Davenport says CH3 has also figured out process steps and parameters to keep the tiles flat.

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.

CH3 molds proprietary products for RG, including tiles for athletic courts and some specific products for garages. The tiles range in size from 10 x 10 in. to 30 x 30 in., and all are molded from PP, in some cases talc-filled. Processing 6 million lb of resin/yr, with plans to add a resin silo this summer, CH3 moldstiles in 22 different colors, with all colorants blended into natural PP at the press via Maguire loaders and blenders.

In many part designs, flow fronts will inevitably be split, but how and where they come back together is hugely important to the molded part’s finished strength.

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.

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

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 tiles CH3 molds range in size from 10 x 10 in. up to 30 x 30 in. and are available in 22 different colors. (Photo: Plastics Technology)

Dubbed the Carpet Capital of America — or the World, depending on who you ask — Dalton has been a hub for flooring production as far back as the 1890s when the tufted bedspread industry that precipitated modern carpeting was born here and Bedspread Alley sprouted up along U.S. Highway 41. Today the factories of flooring giants like Mohawk and Shaw surround Interstate 75, and alternative flooring producers like RG also call the area home. RG’s brands include XGrass, Versacourt, Tour Greens, Swisstrax, and Landmark Designs and encompass everything from interlocking garage-floor tiles and synthetic turf to playground surfacing and inline-hockey flooring.

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

What else can you do about weld lines—besides redesigning the mold or gate locations or adjust the flow pattern during fill with sequential valve gating? I recently saw a report on this issue from Moldex3D, the maker of molding simulation software. It explored the use of an overflow well (see illustration) that is designed to fill after the weld line forms, such that filling the well causes melt flow across the weld line. Simulations of 35% glass-reinforced nylon 66 indicated that higher mechanical properties should result from use of the overflow well.

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

Fast-forward to April 2022, and CH3 Solutions is completing a move into a new 200,000-ft2 facility that will house it and its RG sister companies. The company now has six injection molding machines, ranging from 730 to 1500 tons. Apart from a 1997 Engel, all the machines are from Engel’s Wintec brand of economical two-platen presses. Davenport initially scoped out the Wintec machine during its U.S. debut at the NPE2018 trade show, and CH3 soon became the company’s first U.S. customer. The press bought that day is at the front of the line on the company’s molding floor, and it has been running nonstop since installation, molding tiles for for basketball and tennis courts.

Those defects will “pop out” in the same building were they were made since flooring assembly and painting occurs on the opposite end of the facility where CH3 molds the tiles. From backyard basketball and shuffleboard courts to full-sized tennis courts, the bulk of the flooring ordered from RG and molded by CH3 is customized in size, color, decoration, etc.

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

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

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.

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

It’s widely known that when flow fronts converge at a weld line, the polymer chains (like fiber reinforcements) tend not to intermingle across the boundary. As Bozzelli puts it, “Weld lines are weak because you do not have any polymer chain bridging the weld line.” But his TEM photo (not available for publication) shows that’s not just a matter of polymer chains butting up against each other without intermingling. In some, or perhaps many, areas of the weld line, the polymer chains do not even meet!

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

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.

Determining the source of streaking or contamination in your molded parts is a critical step in perfecting your purging procedures ultimately saving you time and money.

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.

Who knows what evil lurks within weld lines? One who does know is molding expert, trainer and technical guru John Bozzelli, a prolific contributor to this magazine. When he worked in R&D at Dow Chemical, Bozzelli had access to an electron microscopy lab. He recalls the case of an unfilled ABS computer keycap back in 1987: The weld line where three flow fronts came together was “barely visible—barely a scratch to the human eye.” Under a transmission electron microscope (TEM), the ABS flow fronts appeared as a gray “soup,” larded with darker blobs of the rubber phase; but between the flow fronts, the scan was pure white. “Nobody could believe there was nothing between the flow fronts,” Bozzelli states. That was a revelation of the true nature of weld lines.

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.

Higher costs for materials, wages, utilities and more, coupled with delivery difficulties for both incoming supplies and outgoing production, posed unique challenges to 2022’s class of Top Shops.

“He brought sheets of tiles and said, ‘Tell me what’s wrong with these,’ and I told him, and he said, ‘Well this is not what the other molder is telling me,’ and I was like, ‘Well, we’re transparent; we’re going to tell you what’s going on — good or bad or whatever.’” That evening, Davenport got a LinkedIn message from the owner: “Call me tomorrow.”

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.

Given the strict quality requirements of the product being made, a visitor might expect to see a large quality-control department — not here at CH3. QC is handled by operators and supervisors, Davenport says, noting that CH3 requires its workers to wear multiple hats. Case in point: maintenance crews are trained to start up presses.

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

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.

Under a microscope, air gap is visible between flow fronts of a fully packed ABS part. Striations are due to incomplete color mixing. (Photo: John Bozzelli)

When a job is started, a standard tile is pulled from a wall display holding the benchmark products for comparison, with a keen eye on the material. “We really keep our lots close,” Davenport says of the PP used for the tiles. “We try not to mix too many lots to keep the color consistent.”

Prior to shipment and after molding by CH3, all the custom courts created by RG are laid out, taped off and hand painted.

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

CH3 has 100 active tools, 90 that run continuously producing floor tiles in hot-runner molds with two or four cavities. (Photo: Plastics Technology)

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

Over his three decades of injection molding, Davenport has worked on extremely challenging parts from medical, including implants, to automotive, consumer produces and more. But despite their seeming simplicity, floor tiles have posed the biggest challenge. “It looks super simple, but it’s the hardest molding I’ve ever done,” Davenport says.

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

How common is this, really? Bozzelli answers, “As I remember, nearly all of the TEMs that I had done at Dow showed an air gap, whether the resin was filled or unfilled, filled being a bit worse. Since I left Dow, I try to break the part at the weld line and look at the surface of the break on both sides under a simple magnifying glass. Sometimes the areas on both sides of the weld line are glossy and cupped inward, an indication of a bubble or air. Also, often they do not match or mate, so to me that is an indication that the flow fronts were separated by an air gap. Filled or unfilled, I see this about 65% of the time. Now, I just assume it is there and do what I can to eliminate or reduce the weld line. Installing vents near the area often helps, But once you put in a vent on the parting line near the weld line, the weld line often moves and then you have to put in another vent. Vacuum on the mold does help and many times eliminates the weld line.”

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

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

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

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).

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.

RG’s owner was as direct on the phone as he’d been over LinkedIn. “He says, ‘I’m tired of dealing with everybody outside; we want to mold our own product inside and bring it all in-house; would you be interested in coming and starting a company for me?’’’ With the support of (and a gentle nudge from) his wife, Davenport told RG he was in and CH3 Solutions, Dalton, Ga., was born. He started with the company in April 2015; equipment was ordered by June and the first tiles molded on August 3, running from two machines.

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

From his earliest days in molding, Davenport was often puzzled by how injection molders manage quality. “You should know what a good part is,” he says. “It shouldn’t be that you mold a part, hand it to QC and ask, ‘Is this good?’’ CH3 runs lean with four people per shift and, at present, two shifts. Aiding in quality control is a Keyence XM Series portable CMM for 3D and geometric dimensioning and tolerancing (GD&T) measurements. Located among the machines instead of being cordoned off in its own room, the device allows workers to quickly inspect the tiles’ dimensions. Average scrap at CH3 is less than 1%, and most of that comes from color changeovers, with transition parts scrapped as the previous run is purged. That low scrap rate is one reason why CH3 has twice been honored as a Top Shop in Plastics Technology’s Benchmarking survey.

I’ve been thinking about weld lines lately. We published in Plastics Technology a two-part series from Avient on molding long- and short-fiber reinforced thermoplastics; Part 2 comes out in March. Both parts note that fiber-reinforced plastics lose much of their robustness at weld lines, because the fibers tend to line up side by side, rather than “reach across” the point where flow fronts meet. It’s not just a problem for reinforced plastics.

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 everyone knows, weld lines are weak points. What’s less well known is just what’s going on inside that weld line on a microstructural level. Here’s a close-up look at some nasty little secrets.

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

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.

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

Image used by John Bozzelli in his training seminars shows a short shot with a weld line forming around a square hole. In his experience, a microscopic air gap is apt to remain between the flow fronts even after the part is fully packed. (The training tool was designed by consultant Glenn Beall to illustrate design and molding problems.)

Bozzelli explains, “It’s a huge issue in the industry that few know about. Many resin suppliers actually make thing worse by putting in too much lube, wax or flow aids. The black line of material is not ABS, but a wax, oil or other additive that phase-separated. It is much lower in molecular weight and rushes to the flow front because it is much easier flowing than the plastic and forms a barrier preventing the two flow fronts from melding together. Again, no wonder weld lines are weak—this is not a junction of plastic to plastic, but of plastic to wax. Most plastics have some additive that is low in molecular weight and has the potential to phase-separate. Make a guess how many plastics people even have a hint about this issue.”