Metal 3D printing offers a faster way to obtain injection mold inserts, such as this mold slide for an automotive trim tool 3D printed with Mantle’s technology. Printing this slide required only 4 hours of active labor from the customer’s toolmakers versus several hundred hours to produce it conventionally.

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.

While mold inserts and directly 3D printed polymer parts were the primary areas of emphasis for AM at NPE2024, the technology is also helping manufacturers achieve other benefits in their operations. In one conversation at the show, I spoke with a member of a new additive manufacturing services company which is specifically targeting the jigs and fixtures market for clients with large factories and assembly lines, seeing this as an underserved market.

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

ARBURG had an extremely satisfactory trade fair appearance at Chinaplas 2024, which attracted a great deal of attention. Returning to Shanghai after a six-year break, the trade fair saw huge crowds at the National Exhibition and Convention Center and the ARBURG stand. A key highlight was the premiere and unveiling of the ALLROUNDER 470 E GOLDEN ELECTRIC EVO – the new electric entry-level machine for the Asian market. There was also great interest in arburgSOLUTIONworld and the focal topics of digitalisation, mobility and medicine.

NPE: The Plastics Show returned for the first time in six years, bringing plastics manufacturing technology to Orlando, Florida, May 6-10, 2024. In the interim since the previous edition of this trade show, additive manufacturing’s adoption in plastics has advanced and expanded. While AM technology lacked a centralized footprint within NPE’s two exhibit halls, its presence was felt throughout the show — from the 3D Printing for Plastics Processors Workshop held on Wednesday to material- and technology-focused exhibits scattered throughout the exhibit floor.

One of just a few 3D printing machines physically present on the show floor was Xact Metal’s XM200G2, a laser powder bed fusion printer which is positioned for accessibility. The machine is small enough to fit through a standard doorway, runs on 110-V electricity and offers a compact build volume that keeps operating costs down by limiting how much powder is needed to fill the bed and how much argon is required to keep the environment inert. But, just to the right of this 3D printer was a postprocessing machine, a DLyte electropolisher from GPAInnova, one of Xact Metal’s equipment partners. The company has found that, while some buyers want to research and choose their own auxiliary equipment, 3D printer adoption (and sales) can be eased by offering customers a more complete package of equipment.

The arburgXworld customer portal gives you access to a wide range of digital apps and features that make your daily work easier.

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

“Peripherals are the challenge,” says Travis Langford, channel and business development manager at Universal Robots (UR). “It’s the interface between the robot and the machine, the safety measures, the end-of-arm tooling.”

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.

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.

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.

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

In this 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.

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.

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

With a total of four machine exhibits at Chinaplas 2024, ARBURG presented exciting examples of applications in the key areas of medicine and mobility, which feature prominently in the dynamic Asian market. ARBURG's ability to also implement very successful turnkey systems in China and Asia in collaboration with local partners was demonstrated by a production cell built around an ALLROUNDER 1600 T vertical rotary table machine, which overmoulded metal inserts with glass fibre-reinforced PBT to form complex fluid distributors. Visitors from the medical technology sector familiarised themselves with the advantages of the hybrid ALLROUNDER 470 H. The production cell made two different adapters for medical technology on a fully automatic basis, including camera inspection and sample part storage. A FLEXLIFT 10+2 linear robotic system was used for handling.

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.

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

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

A new 3D printing process that shapes extruded metal paste before sintering can produce fine detail and surface finish suitable for injection mold cores and cavities with limited or no additional postprocessing.

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.

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

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).

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.

Beyond Plastic and partners have created a certified biodegradable PHA compound that can be injection molded into 38-mm closures in a sub 6-second cycle from a multicavity hot runner tool.

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

While 3D printing was scattered across the show, most AM-focused exhibitors could be found in the Advanced Manufacturing Zone. Xact Metal’s booth included both support equipment, in the form of the polishing machine seen in the foreground, and its 3D printer, located just beyond.

Stephanie Hendrixson reports on 3D printing technology and applications as executive editor for Additive Manufacturing. She is also co-host of The Cool Parts Show, a video series that highlights unique, unusual and weird 3D printed parts, and co-host and creator of the AM Radio podcast. SUBSCRIBE HERE

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

For reliable performance, a slimline design and an unbeatable price, there is only one choice: the new ALLROUNDER 720 E GOLDEN ELECTRIC!

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.

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

For reliable performance, a slimline design, and an unbeatable price, there is only one choice: the new ALLROUNDER 720 E GOLDEN ELECTRIC!

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

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

The costs of injection molding had Dustless Technologies making tooling and many parts offshore. Additive manufacturing promises an alternative, as in the case of the company's newest product, which is entirely U.S.-made.

Additive manufacturing also has a role to play in aiding the adoption of other technologies. This demo in the Universal Robots booth combines a UR cobot with a vacuum gripper, part nests and other 3D printed integration elements produced by EMI Corp.

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.

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

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.

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 prevalence of 3D printing technology in the mainstream may also help with recruiting the next generation of toolmakers. Xact Metal, which showcased the tooling production capabilities of its laser powder bed fusion platform (described in more detail below), sees 3D printing as an aid to reshoring manufacturing as well as meeting workforce challenges. “Kids today know 3D printing,” says Scott Kraemer, application engineer, “and bringing this technology into this space could entice them into a career in toolmaking.”

"arburgSOLUTIONworld", an exhibition area centred around a four-metre-high LED column, also met with great interest. This is where ARBURG experts offered individual advice on important topics including digitalisation, automation, moulds, sustainability and service. New features for the "arburgXworld" customer portal were also presented, including "ask ARBURG", an AI-supported premium app. The app incorporates the company's extensive injection moulding expertise and can answer specific questions about machines and processes as well as identify and rectify the causes of faults – with no need for an on-site service.

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

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

A freeformer 300-3X demonstrated how associated EOAT can be additively manufactured quickly and cost effectively. In the ARBURG Plastic Freeforming (APF) process, this was used to 3D print grippers in a multi-material combination. In general, freeformers are suitable for the 3D printing of functional components, EOAT and operating equipment based on original plastic granules – even from very soft materials and in hard-soft combinations.

This mold insert for an automotive suspension ring is 3D printed from BASF’s Ultracur3D RG3280. The tool was produced in about 12 hours with 3D printing versus about 6 weeks to source a conventional tool cut from aluminum.

Xact Metal highlighted other potential benefits of 3D printed metal tooling with this insert. Leaving areas open enables printing this tool faster and with less material; supports cooling in injection molding; and also enables faster press operation due to lighter weight.

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.

For contract manufacturers such as Xometry, additive manufacturing enables faster on-demand manufacturing and product development. New designs can be iterated in a “shotgun approach” in which multiple designs are 3D printed at once to quickly arrive at the best choice, says Greg Paulsen, director of applications engineering and marketing, in his presentation during NPE’s 3D Printing for Plastics Processors Workshop.

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 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.

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

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.

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.

Many experienced toolmakers are retiring or near to it, and “There’s no second bench,” as Mantle co-founder and CEO Ted Sorom puts it. Additive manufacturing technologies like Mantle’s TrueShape process (a technique that builds tooling by extruding, milling and then sintering metal paste) are gaining traction because they can consolidate workflow steps to produce mold inserts. Mantle’s process, for example, often reduces or eliminates the need for sinker EDM operations (and the associated tooling). Avoiding or reducing the time spent on process steps like this enables toolmakers to be more efficient in their work and shortens the time line from insert design to use.

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

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.

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

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.

Other speakers at this event emphasized the speed at which 3D printing can deliver end-use polymer parts, not necessarily as a competitor to injection molding but to support applications that would be time-consuming or expensive to mold. Daniel Baker, program manager for plastics at Endeavor 3D, shared a case study in which his company delivered a short run of about 500 parts for a new high-end gaming controller still in development, which would have suffered a long lead time waiting for injection molding. Andrew Roderick, senior applications and sales engineer for Extol, described how his company 3D printed 53,000 automotive parts over three months in a bridge production application to prevent the shutdown of the customer’s assembly line. Spencer Loveless, founder and CEO of Merit3D, described how his company manufactured 62,000 binocular case tether components in just 7 hours, delivering the parts more quickly than injection molding and saving the customer about $300,000 in potential tooling costs.

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.

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

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

ARBURG is taking a new approach with its local-to-local activities: Whereas ALLROUNDERs were previously built exclusively at the German headquarters in Lossburg, value-added stages are now being internationalised. ARBURG has systematically tailored the ALLROUNDER GOLDEN ELECTRIC EVO, which is available in sizes 370, 470, 520 and 570, to the Asian market. The production of all components and parts requiring expertise and key technologies continues to take place in Germany. Assembly is carried out at the ARBURG Technology Factory in Pinghu, where the range of automation and turnkey solutions is also being continuously expanded in cooperation with local partners. An important point to note here is that "Made by ARBURG" remains "Made by ARBURG"! The new electric entry-level machine is characterised by the high precision of its injection units, short cycle times, faster dry cycle times and a reduction in the energy requirement of up to 50 per cent. At Chinaplas 2024, the exhibit produced precise LSR components for use in cars. A FLEXLIFT linear robotic system was tasked with handling the parts.

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.

In each case, additive manufacturing was presented less as an industry disruptor and much more as an aid to toolmakers, molders and OEMs, and a means to augment what these companies are already doing. Here are a few takeaways from the show:

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.

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 another meeting, I talked with team members from automation technology company Universal Robots and its partner EMI Corp. about the ways in which 3D printing is enabling the adoption of collaborative robots (cobots).

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.

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

The break-even point between direct polymer 3D printing and injection molding depends on a number of factors, including the part’s design, dimensions and ability to be nested within a build volume, as Greg Paulsen illustrated through several examples. Slide source: Xometry

Contract manufacturers and OEMs are seeing additive manufacturing “win” when it can provide the fastest route to a part or tool. Material supplier BASF showed several sets of mold inserts in its booth printed with a ceramic material called Ultracur3D RG3280 intended for SLA and DLP-style printers. The chemistry of the slurry makes it possible to achieve a usable injection mold tool with just a short 10- to 15-minute UV cure to crosslink and densify the material, says David Constant, sales and business development manager for BASF 3D Printing Solutions North America. A longer heat treat can be done as a secondary step, if necessary, but avoiding this lengthy procedure (often 7 hours or more) helps to accelerate mold creation such that turnaround time on a new molded part can be as little as 24 hours.

To solve the latter challenge, UR often works with and recommends EMI’s services. The company, which supports automation through many services, has been applying Multi Jet Fusion (MJF) 3D printing primarily in nylon to supply automation peripherals such as cable management brackets, part nests and vacuum grippers. According to George Baker, EMI regional sales manager, the 3D printing technology from HP is cost-effective, helps to reduce the weight of peripherals and enables accelerated lead times.

“There’s a solution for everything out there, from software to polishing to auxiliary equipment,” Kraemer says. Xact now has relationships with a number of other companies whose products it can recommend to customers — including materials. The company recently announced a new partnership with Uddeholm to supply the latter’s Corrax tool steel in powder form.

Benefit from our expertise and lower the costs for your injection moulding production by optimising your energy requirement.