Automotive Lighting - thermal molding plastic

The N-SAPLI control system can also be applied to thermoset molding to precisely control the flow of the liquid polymer into the mold, thereby raising the precision of the final part to a tolerance of 0.3 mm compared with the 0.7 mm typically achievable. “We are targeting a precision of 0.2 mm by applying N-SAPLI to the injection-compression molding of a thermoset resin,” added Yoda.

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

Mike Sepe has authored more than 25 ANTEC papers and more than 250 articles illustrating the importance of this interdisciplanary approach. In this collection, we present some of his best work during the years he has been contributing for Plastics Technology Magazine.

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.

Long perceived to be in decline, thermoset resin molding is being revived by two Japanese companies as a process with ample potential to contribute to lightweighting in electric vehicles (EVs). Injection machine builder Nissei Plastic and development partner Sumitomo Bakelite, a supplier of thermoset resins, held an in-house event at the Nagoya Congress Center on Aug. 2 to 4, 2023, in Aichi Prefecture, showcasing multiple thermoset molding solutions and more to 230 companies from the automotive industry, including OEMs and tiers. Home to Toyota Motor and Honda plants, Aichi is considered the capital of automobile manufacturing in Japan.

At its in-house event, Nissei Plastic exhibited the 180-tonne clamping force NEX180III-5ELM all-electric press outfitted with a dosing system from Elmet and its own spiral plunger system that combines the first-in/first-out benefits of an inline screw with the dosing accuracy of a plunger system.

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

New system automatically cleans mold-cooling lines—including conformal channels—removing rust and calcium, among other deposits, while simultaneously testing for leaks, measuring flow rate and applying rust inhibitor.

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.

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

As stated by Michael Durina, president of Md Plastics, the Inject-EX plasticating system was developed “to ensure that each pellet is exposed to the exact same amount of energy during its journey from the hopper to the mold. The result is a melt that is more uniform and homogeneous than is produced by today’s reciprocating-screw systems.” He explains that as the conventional reciprocating screw retracts during recovery, the pellets entering the feed throat are exposed to a continuously changing L/D, so their shear exposure is inconsistent, which leads to viscosity variation. That effect is exacerbated by the fact that when the screw moves forward during injection, pellets fall from the hopper into the empty screw flights. Those pellets are not compacted efficiently during the next recovery cycle, creating further melt variability. Add to these problems the well-known issue in conventional machines of inconsistent shot volume due to inconsistent closing of the check valve at the end of the screw at the start of injection.

The ‘DryerGenie’ marries drying technology and input moisture measurement with a goal to putting an end to drying based on time.

Traditionally, thermoset injection molding has been utilized in Japan to mold relatively small components for the electrical sector, typically weighing in at 150 g or less. Nissei Plastic and Sumitomo Bakelite, however, have their sights set on components tipping the scales at 1 kg or more for applications such as e-axle invertor covers. Prototype parts molded on a Nissei FWX760III-130BK thermoset injection molding press using biomass-derived phenolic resin tip the scales at 1.4 kg but nevertheless are reportedly 50 to 70% lighter than conventional steel covers and 20 to 50% lighter than aluminum versions.

While the EdeX models initially offered by Md Plastics are designed for thermoplastics, Durina hopes to offer LSR versions in the future. (An Inject-EX system for LSR was shown at NPE2018). “They won’t need a screw at all,” Durina says. “The silicone material can feed directly into the inner barrel of the injection plunger where the end of the screw would normally be. And we can put a static mixer at that entry point, so there would be no need to premix the two LSR components in the feed system.”

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

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.

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.

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.

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.

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.

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.

Md Plastics, a supplier of screws, check valves, shutoff nozzles and other plasticating components, is now marketing its first injection press, built by EdeX Technology Co., Ltd. in Taiwan. EdeX (edex.com.tw) is a privately owned firm started in 2009, which builds around xx injection machines a year. It is mounting Inject-EX plasticating systems on a selection of press sizes from its ATOM and ATOP series of CE-certified, servohydraulic horizontal presses (see accompanying table). These are space-saving two-platen designs with four platen-mounted clamp cylinders, air-cooled hydraulics and INV7800A controls with 15-in. screen from LNC Technology Co., Ltd. (lnc.com.tw) in Taiwan. The company has built two-stage machines before, with an angled screw above the plunger barrel, a design used by a number of injection machine builders. A 70-metric-ton EdeX machine with Inject-EX system is newly arrived at Md Plastics’ plant in Columbiana, Ohio.

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.

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

At NPE2018, Md Plastics showed off the prototype of a novel inline screw/plunger system called Inject-EX, designed to overcome the limitations of standard reciprocating-screw injection molding machines. Since then, the design has evolved, with an improved heating system and, most importantly, a Taiwanese machine builder has adopted the Inject-EX system for a series of presses to be marketed here by Md Plastics.

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).

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

In a time where sustainability is no longer just a buzzword, the food and beverage packaging industry is required to be at the forefront of this innovation. By adopting circular packaging processes and solutions, producers can meet regulatory requirements while also satisfying consumer demand and enhancing brand reputation. Join Husky to learn more about the broader implications of the circular economy — as well as how leading brands are leveraging this opportunity to reduce costs, increase design flexibility and boost product differentiation. Agenda: The cost and operational benefits of embracing circularity Key materials in circular packaging — including rPET and emerging bioplastics How to design a circular food and beverage package Strategies for selecting sustainable closures to future-proof packaging solutions Optimization and streamlining of production processes for enhanced efficiency How Husky Technologies can enable your sustainable success

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

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.

Injection machine builder Nissei Plastic teams up with materials supplier Sumitomo Bakelite to expand adoption of EV components molded from phenolic and epoxy resins.

Novel inline screw and plunger are designed to overcome limitations of conventional reciprocating screws, in a system more compact and less costly than other two-stage configurations.

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.

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

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

Portable, standalone data monitor replaces a laptop. Newest system uses melt thermal data to signal injection fill-to-pack switchover.

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

All these problems can be reduced or eliminated with two-stage screw/plunger systems, of which Inject-EX is a new variant. Like other two-stage systems, this one has a plasticating screw (Md Plastics’ Posi-Melt design) that is stationary with respect to the feed hopper and that feeds an injection plunger via a shutoff valve. What’s different about Inject-EX is that the screw and plunger are not housed within separate cylinders, but are directly coupled inline. The screw feeds melt through a channel or “inner barrel” in the center of the injection plunger, and the melt exits that channel at the front of the plunger. The valve between the screw and plunger sections is the same one used in Md Plastics’ Mini-Shut shutoff nozzle. This is a poppet valve that is spring loaded with Belleville washers. It therefore shuts immediately when the screw stops turning. This design provides true “first-in/first-out” melt inventory, unlike most other two-stage designs.

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.

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.

Durina also notes that the EdeX machines being sold here are built with provisions to accept Md Plastics’ special Temp-Sense melt-temperature sensor and the latest version of the Melt Profiler melt-temperature control system, called Melt iQ.

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

Join KraussMaffei for an insightful webinar designed for industry professionals, engineers and anyone interested in the manufacturing processes of PVC pipes. This session will provide a comprehensive understanding of the technology behind the production of high-quality PVC pipes: from raw material preparation to final product testing. Agenda: Introduction to PVC extrusion: overview of the basic principles of PVC pipe extrusion — including the process of melting and shaping PVC resin into pipe forms Equipment and machinery: detailed explanation of the key equipment involved — such as extruders, dies and cooling systems — and their roles in the extrusion process Process parameters: insight into the critical process parameters like temperature, pressure and cooling rates that influence the quality and consistency of the final PVC pipes Energy efficiency: examination of ways to save material and energy use when extruding PVC pipe products

A third thermoset resin in Nissei Plastic’s liquid silicone rubber (LSR) has potential for applications in battery cell spacers as well as high-voltage EV battery connectors that are water-resistant, to boot. The current material of choice for battery cell spacers, which compensate for cell expansion and contraction during charging and discharge, is EPDM rubber.

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.

Another area where Sumitomo Bakelite and Nissei Plastic are propelling innovation is in the encapsulation of circuit boards, which is conventionally carried out using the more costly and lower precision transfer molding process. Precision control of injection pressure at low levels is critical in this application to prevent damage to the circuit boards. “Typically, you need to limit injection pressure to less than 13 MPa and we have demonstrated on our FNX110III-18AK press that we can control pressure in the range of 6 to 10 MPa,” said Yoda.

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

Inject-EX machines incorporate Md Plastics’ inline two-stage injection unit, in which the fixed screw feeds melt through an inner channel in the center of the coaxial plunger to accumulate in front of the plunger. The entire screw/plunger assembly moves forward to inject and backward to recover the next shot. (Image: Md Plastics)

Also unique to this system, the entire screw/plunger barrel assembly moves forward to inject, emptying the melt chamber in front of the plunger through a Mini-Shut shutoff nozzle on the end of the barrel. This design is said to be simpler, more compact, and less costly than other two-stage designs.

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

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

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

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

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.

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

Aware that someday in the future the emergence of solid-state batteries might transform the material requirements of EV drive systems, this writer suggested a potential alternative application for the battery cell spacers being molded in Nagoya. He duly accepted two samples to take back to his base in Singapore and currently uses them as heat-resistant placemats.

Speaking to PlasticsToday at the event in Japan, Nissei Plastic CEO Hozumi Yoda highlighted the fact that the “760” in the machine’s model name refers to the tie-bar clearance of 760 x 760 mm, rather than the clamping force of 3,540 kN (360 tons). “In general, we feel injection machines tend to be over-specified for the application at hand, with molders tending to ram the resin through the injection cylinder at high pressure and compensating for this with a higher clamping force in the case of thermoplastic molding,” he explained. “Our approach is to optimize injection pressure using our N-SAPLI low-pressure molding system and apply the minimal clamping force.”

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.

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.

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.

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

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

Md Plastics is now marketing special Inject-EX versions of servohydraulic, two-platen injection presses from EdeX of Taiwan. (Photo: EdeX Technology Co.)

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.

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

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

Driven by brand owner demands and new worldwide legislation, the entire supply chain is working toward the shift to circularity, with some evidence the circular economy has already begun.

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

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and is a proud dachshund owner.

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

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.