Unmentioned was the substantial advantage in toughness that the ABS possessed. This type of comparison of a rigid, filled thermoset with an unfilled and ductile thermoplastic like ABS or polycarbonate missed the point that these tough, unfilled materials were not the competition.

Injection molding of thermosets did start to become feasible in the late 1970s. I can remember at NPE1979 watching a Cincinnati Milacron injection molding machine producing phenolic parts. A sign prominently displayed at the machine warned attendees not to pick up the parts coming out of the tool, as they were ejected at temperatures of around 150oC (302oF). And, yes, they still had to be deflashed.

This downward trajectory is expected to continue, primarily due to slowed demand, lower feedstock costs and adequate-to-ample supplies.

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

While some of the thermoplastic offerings did become commercial, the most successful early introductions were crosslinked materials, the most notable of these being the first truly synthetic polymer, phenolic. This was followed in the first half of the 20th century by the introduction of epoxies, unsaturated polyesters and silicones.

That all changed when Nunnery assumed ownership. He immediately understood the implications of the DMA data and how it could be leveraged into a competitive edge. We characterized some of his flagship materials at our lab along with some appropriate competitive thermoplastics such as highly glass fiber-reinforced nylons, PBT and PET polyesters, PPS and sulfone polymers. The comparisons showed the superior performance of the crosslinked materials at elevated temperatures and Nunnery and his people took it from there, running advertisements showing the graphs and highlighting the superior dimensional stability and resistance to warpage that the crosslinked materials exhibited.

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

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

In 1988, I gave my first presentation at this conference, providing data that compared the properties of thermoset materials with filled and reinforced semicrystalline materials and high-performance amorphous polymers using the relatively new tool of dynamic mechanical analysis (DMA). DMA had been developed as an analytical method in the 1960s, but much of the early equipment was custom built by individual researchers and little had been done to create test standards around the method. By the mid-to-late 1980s, instrument manufacturers had perfected forced oscillation devices that greatly enhanced the ability of the method to characterize material properties, and ASTM and ISO standards had been developed.

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

Thermosets dominated the early history of plastics. This was foreshadowed by the emergence of the rubber industry in the mid-1800s fueled by the development of vulcanization. Attempts to introduce early thermoplastics based on cellulose were met with fierce and sometimes questionable competitive strategies by the entrenched rubber industry.

Thermoplastic polyesters soon followed, and by the 1950s and early 1960s the development of new thermoplastic polymers with higher performance profiles became an avalanche. By the mid-1970s there was a general sentiment within the industry that sooner or later a thermoplastic could be developed that would replace any thermoset. Polyimides represented the pinnacle of performance in crosslinked materials, but were closely matched with similar thermoplastic chemistries that included polyamide-imide, thermoplastic polyimides, polyetherimide and even higher heat variants.

The drive to seek these alternatives was due in large part to productivity concerns. While thermosets offered impressive properties, they were not readily converted into molded parts by the big up-and-coming processing method, injection molding. The traditional thermoset molding processes — compression molding and transfer molding — were slower, more manual processes. In addition, because of the low viscosity of the pre-gelled materials, the parts almost always required the secondary process of deflashing, much like aluminum and zinc die casting. Thermoplastic parts came out of the mold quickly and required little to no secondary finishing.

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.

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.

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.

This became a platform for a new type of presentation of thermoset materials to the industry that was unfamiliar to both the thermoplastic and the thermoset community.

Figure 1: At room temperature, the PPS is superior. At the elevated temperatures at which the two materials are likely to be used, the phenolic outperforms the PPS and at a lower cost per pound.

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

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.

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

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.

Figures 1 and 2 show typical comparisons that were made, focusing solely on a property that was readily understood, the modulus of the material as a function of temperature. Figure 1 compares the performance of a phenolic compound to a 40% glass fiber-reinforced PPS and shows that: while at room temperature, the PPS is superior; at the elevated temperatures (at which the two materials are likely to be used), the phenolic outperforms the PPS and at a lower cost per pound. Figure 2 compares a thermoset polyester to a long glass fiber-reinforced thermoplastic polyester. These two materials have the same heat deflection temperature, but the full temperature map clearly shows the advantages of the crosslinked material.

Thermosets were the prevalent material in the early history of plastics, but were soon overtaken by thermoplastics in injection molding applications.

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

If you need to produce parts in smaller production batches, you should consider low volume injection molding (LVIM) machines:

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.

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

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.

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.

One of the prominent advertisements that one thermoset material supplier ran during the late 1970s and early 1980s demonstrated the large deflections that flexural bars molded in thermoplastics exhibited when compared with phenolic. I recall sitting through a presentation where the case being made on behalf of phenolic was a head-to-head comparison with unfilled ABS. The two materials exhibited comparable tensile and flexural strength at room temperature and, of course, the phenolic displayed a higher heat deflection temperature.

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.

MPM machines are cost effective and easy to set up and get running. The single cavity V-mold and tooling inserts can be produced quickly and economically. High quality initial or low volume production runs of finished product are easily produced by MPM injection molded machines. Our application engineering team can guide you through the machine selection process to meet your Bridge Manufacturing requirements.

To make matters worse, thermosets tried to compete with thermoplastics on the terrain of short-term data, with a focus on room-temperature properties. This was a losing proposition because properties like tensile strength and impact resistance are not generally strong points for thermosets. These materials offer advantages at elevated temperatures that are not addressed by short-term properties published on datasheets.

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.

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.

Many injection molded parts do not require a high volume (greater than 100,000 parts per year) injection molding machine. Higher production machines are expensive, require considerable floor space, and require expensive multi-cavity hard steel tooling. MPM machines are optimized for lower volume plastic molded parts. They are cost effective, require a small footprint, and can use single cavity low cost tooling. Low Volume injection molding machines are a good fit for smaller production orders, prototyping, bridge manufacturing, and ASTM specimen applications.

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

MPM low volume injection molding machines are ideal for bridge manufacturing, research and development, product testing, and low-volume production. A wide range of industries use our machines, including medical, automotive, consumer products, and more. With the ability to use the same plastic grade as a multi-cavity mold, engineers can test plastic blends and manufacturing optimization, marketers can test designs and colors, and your entire part or product can be optimized before full-volume production begins.

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

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.

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.

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.

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 parallel, many of the commodity thermoplastics were being developed in the 1920s and 1930s, including polyethylene, polystyrene, PVC and acrylic. The performance profiles of these early introductions were relatively unimpressive, particularly when it came to heat resistance, and the two classes of materials coexisted. But with the introduction of nylons, things began to change. Here was a material with a melting point of 260oC (500oF) that could replace some of the thermoset materials.

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

In 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

But there was another element that drew the industry toward the thermoplastic market. The material suppliers developing these materials represented an all-star lineup of the major chemical companies and included General Electric, Bayer Material Science, DuPont, Dow, Union Carbide and Celanese. These companies produced a wealth of information on part design, mold design, material properties and processing, and they did so in attractively packaged brochures and technical documents delivered by polished sales people and knowledgeable tech service personnel.

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.

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.

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.

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

The thermoset manufacturers were outgunned when it came to resources. Many of the thermoset manufacturers had qualified experts who understood very well the parameters associated with good design and processing practices. But most of them worked behind the scenes developing formulations and customers rarely saw them.

Previously we have discussed the effects of temperature and time on the long-term behavior of polymers. Now let's take a look at stress.

ABOUT THE AUTHOR: Michael Sepe is an independent materials and processing consultant based in Sedona, Arizona, with clients throughout North America, Europe and Asia. He has more than 45 years of experience in the plastics industry and assists clients with material selection, designing for manufacturability, process optimization, troubleshooting and failure analysis. Contact: 928-203-0408 • mike@thematerialanalyst.com.

Heartland Polymers’ new Alberta, Canada facility will produce 525 KTA propylene and 525 KTA polypropylene. It is expected to stabilize supply chains across the continent.

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).

Like many thermoset resin manufacturers, BMC Corp was small when compared to the major thermoplastic resin juggernauts. For many years, it maintained a presence in the industry by catering to niche markets and always had a small booth at NPE because, at that time, the triennial show was held right down the road at McCormick Place in Chicago.

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

Figure 2:  In comparing a thermoset polyester to a long glass fiber- reinforced thermoplastic polyester, the two materials have the same heat deflection temperature, but the full temperature map clearly shows the advantages of the crosslinked material.

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.

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

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.

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

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.

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

Going from a product design to full production can be costly, time consuming, and cumbersome. The MPM machines are ideally suited to produce prototypes and first article parts for approval or test marketing.

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

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.

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.

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

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.

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

The response to this “new” approach to material comparisons was overwhelming, at least for the moment. But, ultimately, one individual pursued this line of thinking, Larry Nunnery. He was a newcomer to the thermoset side of the plastics industry, but Nunnery was no stranger to the world of polymers, having spent most of his career up to that point at GE Plastics. GE was a master at brand marketing, and Nunnery brought this tradition and know-how to a company he had just purchased, Bulk Molding Compound Corp. (BMC Corp.) in St. Charles, Illinois.

Bridge Manufacturing is the step between producing high volume finished production parts and smaller quantities that may be needed as prototypes, first articles for approval, test marketing or initial customer orders. You may need to get initial parts produced while you are waiting for a production machine to be received or available. Also, production tooling can often require considerable time to be designed and produced (16-24 weeks) delaying the time to get product to the customer or approval party.

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.

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.

One of the conferences that reflected the vitality of the thermoset industry in the Midwest was an annual event held in Madison, Wisconsin, each October. In the 1970s and 1980s this conference drew more than 300 attendees every year to an event that included two days of presentations. Booths were hosted by processing equipment manufacturers and most of the major thermoset material suppliers located in Indiana, Illinois and Wisconsin. Some attendees came from as far away as Germany.

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

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.