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.

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

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.

You can start building your process once you know the capabilities of your machines. Similar to machine baselines, you also create process baselines specific to each mold in order to process “from the plastic’s point of view.” To do this, you must look at the four plastic variables: temperature, flow, pressure and cooling.

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

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

A collaboration between show organizer PLASTICS, recycler CPR and size reduction experts WEIMA and Conair recovered and recycled all production scrap at NPE2024.

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

Note the burn mark on this part, made in one cavity of a two-cavity disc mold. Though there are many causes of part defects, decoupling a process makes it easier and faster to diagnose their root causes and identify solutions. In this case the problem was solved not by frantic button pushing, but by collecting and analyzing data.

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.

Ask Apple’s Siri, “What does ‘systematic’ mean?” and she’ll respond, “The definition of ‘systematic’ is done or acting according to a fixed plan or system; methodical.” In injection molding, if processors just “button-push” their way through processing, they’ll eventually make a good part. However, molding from a systematic approach cuts the time it takes to build a robust and repeatable process. Using systematic molding techniques often results in decreased machine run time, cycle time, scrap rates, and so much more. The cumulative benefit of these cost reductions leads to increased profits.

In many molding plants, when a processing issue like this arises, operators are typically seen frantically pushing lots of buttons to solve the problem based on their various opinions. However, burns can be traced to one of five areas: part design, material, mold, machine, or process. Regardless of the main cause of the burns, the process is also influenced by the other four areas. Therefore, if you want the process to be successful, all five pieces must fit together nicely. For example, if the part design is not engineered for the material, or the machine cannot produce enough clamp force to support the mold, then the chances of building a robust and repeatable process are unlikely. By making sure that all these pieces fit, you are following a proven methodology or system.

There are five specific areas that designers and manufacturers need to consider to realize the potential of these unique materials.

In many cases, decreasing the discharge temperature will improve product quality and perhaps even boost rate. Here are ways to do it.

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

Pressure: Plastic pressure involves the pressurization stage of the process. This includes both second stage in a DII process (pack and hold) and second stage (pack) and third stage (hold) in a DIII process. Pack focuses on two things: 1) It finishes filling the part and applies pressure to imprint the cavity onto the plastic; and 2) plastic is non-hydrostatic, meaning that the melt does not transmit pressure equally. This is evident when you compare pressures at the screw tip vs. pressure just past the gate cavity (post gate) vs. pressure at the end of cavity. In most cases, you will see that pressure at the screw tip is greater than at post gate. Likewise, you will generally see the post-gate pressure is higher than at the end of cavity during the pack stage.

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

By decoupling your processes, you can separate defects by whether they are related to fill or to pressure. Some part defects that commonly relate back to the fill stage would be splay, jetting and burn. On the other hand, warp, sinks, voids and bubbles are more commonly related to pack and hold stages.

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).

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.

Establishing machine and process baselines as well as learning to interpret data do not happen overnight. These things take time, and what works for one molder is not necessarily going to work for another. What you can do is continue to learn from each other’s experiences and trust what your data tells you. Ultimately, continue to apply systematic molding principles because they work to improve processes and, ultimately, profits.

So, what is the benefit of processing with Decoupled Molding? When you decouple your processes, you minimize the impact of viscosity fluctuations. Change in material viscosity is a molder’s greatest processing variable and can cause a process to go from producing short shots to parts with flash in the of blink of an eye. Like stopping the car right at the tennis ball in the garage consistently, the goal in Decoupled Molding is to stop the flow of plastic at the end of cavity consistently.

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

An overview on the use of chemical foaming agents (CFAs) to successfully foam single and multilayered rotational molding parts, this webinar will illustrate the multiple benefits rotational molders can achieve, including reducing resin consumption, decreasing part weight, enhancing wall thickness and improving structural rigidity. Agenda: Charging the mold Dosing ratios Venting Optimal decomposition temperatures, cycle times and drop times for drop box applications Cooling considerations

Whether you are relatively new or have been molding for many years, you have probably heard the terms “scientific molding” and “systematic molding.” These terms are often used interchangeably, but there is a subtle difference. Scientific molding is centered around learning about key molding principles and theories. The strategic application of those principles and theories is what is known as systematic molding.

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.

With this information, we decided to put a sticky note at the top of the mold at the parting line. Putting the sticky note between the mold halves at the parting line allows the air to properly vent from the cavities (effective, but not recommended). When we did that, the burn went away. This was the final piece of information we needed to isolate the cause of the burn issue. The vents in the mold were not at the proper depth to let air escape from the cavity during fill. To eliminate the burn, we added a second fill speed that was significantly slower than the first speed. This allowed the air to escape before transitioning into pack and hold.

After just 20 min of gathering and examining data, we accomplished two things: 1) We were able to determine the cause of the burn; and 2) We found a way to mold the part without burn. Some might call it witchcraft, and others claim we were plain lucky. But neither is true. Though there are many causes for part defects, decoupling a process makes it faster and easier to systematically diagnose their root causes and identify possible solutions.

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

When choosing a flow rate or fill speed, select it based on part quality, not machine capability. Just because you have a press that is capable of filling at a rate of 20 in./sec does not mean you should fill at 20 in./sec. There are two tests we use to help determine an optimal flow rate: the Fill Flow Study and the Dynamic Cavity-Imbalance Study. During the Fill Flow Study, you look for defects that appear on the parts when using a range of different speeds. With the Dynamic Cavity-Imbalance Study, you want to see the effect of different speeds on the balance of the cavities. With the results of these two tests, you can choose a flow rate that will yield quality parts.

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, 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 Top Shops Benchmarking Survey provided both unanimous responses and divided results, but pervasive throughout is the sense of an industry still grappling with the aftermath of 2020’s global pandemic.

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

Molders and their customers are becoming increasingly data oriented. This business strategy aligns well with utilizing Systematic Molding principles. When you complete studies on machines and molds, you’ll be equipped with the information needed to build robust decoupled processes. The data drives our processing, thus creating greater transparency between companies, customers, and co-workers. As you make changes, you can defend them with data.

This baseline machine data will tell you which of your presses is your “limiting” press. For example, if you have three machines where the mold will be used, and one of the presses has a much slower injection rate, build your process using the limitations of the least capable press. When you build your process for the “limiting” press, you accomplish three things:

Imagine decoupling to be like pulling into your garage after work. You’ve suspended a tennis ball from the ceiling to help you know exactly where to park. The tennis ball represents a full shot. Traditional molding would have you drive 45 mph from start to finish. With this method, how many times are you likely to stop exactly at that tennis ball without going out the back wall? Probably not very many. Using a DII process, you’ll drive 45 mph to your driveway and then slow down to 15 mph until you reach the tennis ball. Your chances of stopping at that tennis ball just became a lot more likely, but you can do even better. Using a DIII process, you’ll drive 45 mph to the driveway, 15 mph to the door of the garage, and then slow down to 5 mph until you reach the tennis ball.

Despite its integral role in a stable process and consistent parts, true melt temperature in injection molding can be an enigma. Learning more about these seven parameters may help you solve the puzzle.

This CW Tech Days virtual event will explore the technologies, materials and strategies used by composites manufacturers working in the evolving space market. Presentations from industry experts will emphasize the use of composite materials in applications requiring the weight savings, structural benefits and ability to withstand extreme temperatures that only composites can provide.

Temperature: When logging plastic temperatures, it is critical to document plastic melt temperatures, and not barrel temperatures. Just because barrel temperatures are set at 500 F does not mean the actual plastic temperature will be 500 F. There are three machine settings that will affect plastic temperature: Barrel temperatures (electrical), Screw rpm (mechanical), and backpressure. Generally, a large portion of melt energy comes from the mechanical shear generated via screw rpm. In most cases, you can monitor the plastic temperature by taking a melt temperature at the nozzle. If you’re happy with the results, maintain the settings. If not, then make adjustments.

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

In 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

Late last year, a coworker and I were assisting a third party to process a mold that they hadn’t run before—a disc mold (essentially two round discs). We did some initial calculations and found a press where it would fit. As we were building our process, we noticed that there were burn marks at the end of fill.

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.

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.’

NPE2024: FimmTech is introducing online versions of its Nautilus process development software as well as its Scientific Molding and Design of Experiments (DOE) process development course.

Start by picking a target melt temperature, and double-check data sheets for the resin supplier’s recommendations. Now for the rest...

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

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.

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 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.

Taking a systematic approach involves separating the three stages of the molding process: fill (first stage), pack (second stage) and hold (third stage). Separating the stages is called Decoupled Molding and is the focus of systematic molding. There are two main types of decoupled processes: Decoupled Molding II (DII) and Decoupled Molding (DIII). In a DII process, fill is separated from pack and hold. To accomplish a DII process, during first stage the part is filled to a minimum of 95% visually full and to a maximum of 98% full by part weight before transferring to second stage. This is accomplished by adjusting the transfer position until the desired fill-only part is reached. For a DIII process, pack and hold are also separated. This is generally achieved by transferring based on cavity pressure. Building a DIII process requires extra training, equipment and software.

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.

AIM Processing has parlayed small part molding expertise and aggressive automation, even for short run production, into a highly successful custom molding business.

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.

More than four years on, there are aspects of the COVID-19 pandemic that linger in their impacts to the plastics market and are made visible in our annual survey.

Like stopping a car at exactly the right spot in the garage time after time, the goal in Decoupled Molding is to stop the flow of plastic consistently at the end of cavity.

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

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.

This 1-day technical conference and exhibition showcases innovative developments in materials, processing and equipment for the additive manufacturing industry. This conference is specifically designed to inform, update and educate plastic processors about implementing new additive manufacturing technologies. Hear technical presentations on the newest advances in additive manufacturing related to: design, materials development, processing equipment and enabling technologies, new applications and more. See exhibits from engineering plastic suppliers, compounders, molders, design and engineering firms and machinery suppliers. Experts will show you how to apply the latest technologies to your next project or program. The conference includes a full day of technical presentations, plenary and keynote presentations on business trends; breakfast, lunch and breaks; exhibits of advanced technologies and an evening networking reception.   Note: Additive Manufacturing Media executive editor Stephanie Hendrixson will moderate the Supporting AM Adoption in Northeast Ohio panel at 11:20 a.m.

Letting data drive your processing decisions also makes troubleshooting so much easier. This is how we systematically tackled our burn issue in the disc mold mentioned earlier. Using decoupled processing, the first thing we did was look at “fill-only parts” by removing second-stage time and pressure. The fill-only parts had no indication of burn. The burn was observed at the end of fill only when we packed the parts. We then decided to remove second stage (pack and hold) again and adjust our short shot so that the part was fuller before transitioning to second stage. As we progressively filled the part out further, we noticed the burn was returning.

Scientific molding is centered around learning about key molding principles and theories. The strategic application of those principles and theories is what’s known as systematic molding.

What are the basic building blocks of plastics and how do they affect the processing of that material and its potential applications in the real world? Meet the repeat unit.

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.

Flow: The impacts of plastic flow rate are the main focus of the plastic flow variable. Plastic flow is the first stage of a Decoupled Molding process. One of the main reasons plastic flow rate is important is because it has the biggest impact on the material’s viscosity. The faster the material is pushed, the thinner it becomes and the easier it flows. In contrast, the slower the material is pushed, the thicker it becomes and the harder it is to flow. This is known as Non-Newtonian behavior and explains why you might end up with flash when increasing the flow rate from 5 in./sec to 15 in./sec.

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.

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.

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

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

Cooling: The final—and often most overlooked—variable is plastic cooling. Cooling is critical and typically accounts for around 80% of cycle time. How is this possible? If you stop and think about when plastic really starts cooling, you’ll realize that it occurs as soon as the material hits steel. This variable focuses on the means of how plastic cools and includes things like cooling lines and their contents and achieving turbulent flow. A classic yet common issue processors encounter is forgetting to turn the water (coolant) on. Often, this can lead to extended hold times and ultimately longer cycle times. You can do a couple of things to ensure you have water flow. One option would be to monitor coolant flow by installing flow meters within the cooling circuits. Another option is to monitor mold surface temperature. Ideally, we monitor both coolant flow and mold temperature.

Currier Plastics had a major stake in small hotel amenity bottles until state legislators banned them. Here’s how Currier adapted to that challenge.

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.

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

Before you start generating a process, develop machine-performance baselines for each press that will potentially be running the mold. Some studies used to determine this baseline include the following: Injection-Speed Linearity, Check-Ring Repeatability, Load Sensitivity, and Pressure Response. These studies will tell you the current state of the machine to determine whether a particular press should be selected to run the mold. Each study should have an acceptable deviation limit set by your company to use as a type of grading scale. Keep in mind that if a machine’s performance falls outside of the desired deviation limit, it does not necessarily mean that the machine is bad. If you are still able to make good parts within a desired cycle time, then it is perfectly fine to continue processing on that machine. On the flip side, if the machine is producing bad parts, then that mold should not operate in that specific machine.

Logan Teut is a qualified Train the Trainer and Master Molder I, specializing in machine maintenance, grinding/blending, mold maintenance, scientific molding, and Decoupled Molding. As a consultant/trainer for RJG Inc., Traverse City, Mich., his responsibilities include teaching Injection Molding Essentials, Systematic Molding, Decoupled Molding Workshops, Successful Strategies for Tool Launches, and Master Molder I in the Midwest. Contact: 231-947-3111; logan.teut@rjginc.com; rjginc.com.

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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 other half of plastic pressure is the hold stage. Up to this point in the process, you have filled and packed the part. The last thing you want is to let plastic backflow out of the cavity. To prevent this, hold time and hold pressure are applied. To determine how much time is needed for the gate to freeze—at which point we know the plastic won’t backflow—perform a Gate-Seal Study. This involves increasing the hold-time setting on the machine until you see that the part weights stop increasing, or plateau.