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

While extruder speed is directly related to cycle time, it should be noted that PHA is a shear heating material similar to PVC (polyvinyl chloride). As production rates and extruder speeds increase, you will see temperature override in your extruder zones. If your machine has heat cool bands, you can employ those to keep temperatures inline or you can try to introduce some heat earlier in the extruder to reduce friction and shear heating.

When combining PHA with PLA, you will find that the processing requirements for the PHA will drive most of your processing strategies. PHA is hygroscopic and needs to be dry. It is sensitive to residence time and requires a warm (120-130°F) mold to crystallize.

External gas assisted injection molding is fundamentally different from the internal process. The gas does not penetrate the material to create hollow sections. Rather, it enters into the mold through microchannels from one side only. It packs the molten resin against the mold’s walls by applying pressure from the backside/non-aesthetic side of the part.

In addition to good surface quality, this technique also allows for thicker sections due to better packing and shrinkage-countering ability. Especially, for ribbed/boss features the rib/wall ratio can be up to 1, which is much better than some other methods. This lends strength and stability to the molded part.

This strategic collaboration will support long-term growth of bioplastics production requiring a blend of PHA and PLA inputs.

The extremely high level of precision needed within the aerospace industry makes CNC machining a suitable manufacturing process for the sector.

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.

Private label manufacturer Eagle Beverage to use Danimer Scientific’s Nodax PHA for marine degradable straws and other product categories in the future.

An important part of any blow-molding process is how you handle the parts once molded. The handling of parts made from PHA/PLA blends will become more difficult as production speeds increase.

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

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.

It is recommended to purge the machine completely with LDPE to remove the previous resin and, after cooling the extruder to the process set points referenced below, introduce the PHA/PLA blend. This procedure should get you into the production material without degrading the resin. PHA/PLA blends have an upper temperature limit of around 400°F and will rapidly degrade around this temperature.

Gas assist has several pros that make it the go-to technique for many manufacturers. Summarized below are all of its main advantages and disadvantages.

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).

As noted, PHA is a hygroscopic polyester that will absorb environmental moisture. Having the material dry before processing will prevent degradation and melt thinning. A moisture content of less than 0.04% (400 ppm) is required. Recommended drying conditions are four hours at no greater than 170°F (80°C) with a desiccant dryer.

When evaluating ERP solutions, consider the power of interactive production scheduling to effectively plan and allocate primary and secondary equipment, materials and resources on the overall production capacity of the business and conclude that this is a key area that cannot be overlooked.   __PRESENT

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.

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

Plastic manufacturing is a versatile field that is continually developing. When it comes to complex geometries and top-of-the-class manufacturing capabilities, gas-assisted injection molding is one of the number one options.

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.

This process is well-suited to manufacture hollow, lightweight geometries. Additionally, the gas exerts constant pressure on the resin, which helps to minimize shrinkage and distortion/warpage. These factors are usually the main reason for the deteriorating dimensional accuracy of thin walls. Thus, thin-walled parts are another special application of this process.

The gas assist injection molding process takes place in three stages (refer to the injection molding diagram below). Each stage constitutes an important step of the process and requires design sense and practical skill from the manufacturing team.

To facilitate our customers, we have developed an efficient online quotation platform that provides rapid quotes based on the design files you upload. Augmenting these quotes is a detailed design feasibility analysis and DFM feedback, which is just one example of the personalized attention you will get here at RapidDirect. Contact us to get in touch with our team for your custom plastic manufacturing needs.

For your plastic parts, RapidDirect can help you become more competitive in your market through our specialized injection molding services!

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.

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.

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.

One of the opportunities to use PHA and its compostable characteristics is in blow-molded articles. The positive end-of-life scenarios offer one possible solution to the overabundance of plastic in the market. PHA can be blow molded into various shapes, sizes and designs for many applications, from personal use to food and drink storage.

Our state-of-the-art equipment and years of experience guarantee that you will get high-quality plastic parts that will help you beat the competition.

PHAs are a naturally occurring biodegradable material produced via bacterial fermentation, similar to brewing alcohol. During fermentation, when nutrients and food sources are optimized, the bacterial strains start making and storing PHA as a food source, eventually producing a peak amount of PHA.

The low melt temperature aims to achieve a parison with enough melt strength to hold together. You will find that PHA/PLA blends are sensitive to the smallest temperature changes, and viscosity will drop rapidly as melt temperature increases. We typically advise processors new to PHA/PLA blends to think of adjusting temperatures by two or three degrees at a time, not the usual five-degree changes.

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

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.

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 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.

Moreover, parts with large surfaces and curved profiles are tackled quite efficiently. The gas channels are in line with the entire surface, allowing the gas to apply pressure all over the wide surface area. As a result, manufacturing large surfaces is not a considerable issue.

Gas assisted injection molding is a plastic molding process that combines principles of conventional injection molding with the application of pressurized inert gas. It uses mold cavities in the form of the product’s shape. The mold is partially filled with ~70%-80% molten plastic raw material. Injecting Nitrogen gas fills the remaining volume to pack the plastic material against the mold’s walls.

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.

You need to pay attention to the inherent characteristics of biopolymers PHA/PLA materials when setting process parameters to realize better and more consistent outcomes.

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.

It is a very popular method to manufacture large, hollow molded plastic parts. It enjoys numerous advantages such as remarkable surface finish and geometric accuracy.

The pressure and growing volume of the gas bubble push the molten resin to the boundaries of the mold. The pressure of the gas remains constant during this process, ensuring that the resin reaches all corners of the mold, filling it up.

Once more, the PHA component will drive your temperature strategy. To achieve a stable and workable parison, you must keep your heat near the low end of processing temperatures for PHA.

Now that you know about the ins and outs of gas assisted injection molding, it is time to know who does it best. RapidDirect is your best choice in injection molding services. Our ever-growing establishment boasts a talented team of professional engineers and technicians, supported by powerful manufacturing capabilities. For our esteemed clientele, we offer plastic manufacturing services in a wide variety of plastic materials.

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

To successfully extrusion blow mold PHA/PLA bottles you need to take heed of the unique processing charactertics of the material. Photos: Danimer Scientific

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

This molten resin then enters the mold cavity. However, the resin injection mechanism does not fill up the mold since the product has hollow sections. The amount of injected resin material depends upon the volume of the part. It typically depends on geometrical factors like wall thickness, ribbed features, holes, etc. Usually, around ~70%-80% of the mold fills up with plastic material.

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

It would also be helpful to look at your extruder screw design and avoid screws with higher compression ratios or very short, aggressive compression sections.

Towards the end of the primary gas penetration phase, the resin starts to cool down and contract. Due to the gap created by this thermal contraction, the gas pressure slightly decreases. This can cause part deformations and induce geometric errors, which are never desirable.

The manufacturing sector is one of the most innovative in today’s fast-paced world, setting new standards with each stride. Gas assisted injection molding is one such novel plastic manufacturing technique that offers great product quality.

As cycle and crystallizing times decrease, the bottles will become softer and easier to damage. It may require some engineering and automation adjustments to enable some post-molding cure time before the parts are bulk packaged.

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

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 area requires particular attention. The PHA component of the PHA/PLA blend requires a warm tool to promote timely crystallization. If you process into a cold tool at 40-60°F, the parts will come out soft and pliable and then, over the next 60-90 sec, become firm. What is happening is the part is crystallizing in your hand. The cold temperature is retarding the crystallization rate. When working with PHA/PLA blends, crystallizing and cooling are different. Parts can be cold and not crystallized.

At first, the mold clamps shut, and raw resin is fed into the hopper of the injection molding equipment. Just as in a regular injection molding process, the machine melts and pressurizes the resin in its screw-feed section.

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.

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

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.

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 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

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.

About the Authors: Russell Mullins is Danimer Scientific’s special operations technical advisor and has more than 45 years of experience in plastics injection molding and product design. Dr. Karson Durie is associate director of Danimer’s facility in Athens, Georgia, and earned a Ph.D. in chemistry from the University of Georgia. Contact: 229-243-7075; russellmullins@danimer.com; danimerscientific.com.

A major advantage of this manufacturing technique is that it can handle a wide range of plastic materials. We will discuss below the main plastic materials compatible with this process.

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

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

Hopefully, this outline will provide some basis for developing a process for your parts. If you go at it slowly and methodically, you should be able to create a stable process and then improve from there. Remember that PHA/PLA blends are relatively new and different materials that require some new and different processing techniques.

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

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.

Gas assisted molded parts to have various applications. Generally, it is for injection molding hollow parts with ribbed/boss features and smooth surface finish requirements.

Because PHA can degrade quickly under heat and shear, it is recommended that you purge fresh material forward anytime the machine is idled for more than five minutes before starting up again. It is not only the temperature of the melt that matters but also the residence time. High residence times will cause the material viscosity to decrease and can cause problems with machine startup.

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

This process is well-known for its fine surface finish quality. Since the gas pressure acts uniformly on the non-aesthetic side, the opposite end tightly packs into the mold extremities, taking its exact shape. The resultant surface is so precise that it also includes fine textures and patterns of the mold. Consequently, external gas assisted molding is preferable if the part has surface patterns and imprints.

Here are processing guidelines aimed at both getting the PHA resin into the process without degrading it, and reducing residence time at melt temperatures.

If you want to produce high-quality machined parts with a sleek appearance, it’s essential to consider some critical factors related to CNC machining.

You may also have to explore some forms of ejection and part holding as the mold opens to keep the bottles releasing consistently due to some variability in whether the bottles will stick to one side or the other or release cleanly.

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.

Internal gas assisted molding is more widely used than the external process, so we shall discuss it first. Initially, molten plastic resin enters the mold through spruce channels. Then, the gas enters through a nozzle and forms a bubble inside the molten resin. The pressure of the growing gas bubble forces the resin against the walls of the mold, giving the parts their shape.

At Danimer Scientific, most of our research effort has been with extrusion blow molding (EBM), which is the process covered here.

Recently, many processors have been experimenting with running PHA/PLA blends in their blow molding operations, with mixed success due to the blends’ unique characteristics. However, proper attention to the inherent characteristics of PHA/PLA materials when setting the processing parameters can lead to better and more consistent outcomes.

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

At this point, the PHA is separated from the cellular components and processed, resulting in a light, white powder that can be combined with other materials like PLA to produce processable and usable bioplastic resins. These materials are typically compostable in home and industrial environments, and degradable in soil and marine environments.

In this article, we dive deep into this manufacturing process and discuss what it is and its types, applications, and materials.

The resin melts due to external heating and friction while the constantly decreasing pitch of the screw compresses it to pressurize it. For gas assist molding, pressure is lower than conventional injection molding as there is less material to pack into the mold due to hollow sections. Also, since the pressure comes from gas rather than a thick, viscous liquid, there are lower viscosity-based frictional losses inside the pressurized media itself.

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

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.

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.

Hence, there is a secondary gas penetration phase where more gas flows into the mold to fill up these gaps. This maintains uniform pressure and guarantees a neat fill.

Another reason to keep the tool warm is that most blow-molded PHA/PLA blends will stick to a cold mold surface, making it difficult to eject them.

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.

In the current legislative climate of bans on petroleum-based plastics and consumer requests for sustainable alternatives, bioplastics offer a unique opportunity. In prior decades, there has been significant resistance to bioplastics because of cost as well as unique, and often difficult, processing characteristics. Now, however, the development of many polyhydroxyalkanoate (PHA)-based resins — often combined with polylactic acid (PLA) — has resulted in bioplastic solutions that are well suited to current market needs.

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

Uniloy is revising its machinery lines across the board and strengthening after-sales services in tooling maintenance, spare parts and tech service.

Cycle times are also significantly lower for internal gas assisted molding. Due to the geometries having hollow portions and thin cross-sections, they cool down quickly in comparison to solid parts.

The gas assisted injection molding process has two main types, external and internal. It also follows a specific workflow with three steps. In the following sections, we distinguish between the two types and explain the step-by-step procedure.

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

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.

At the end of production, the machine should again be purged clear of the PHA/PLA blend — using LDPE at process temperatures — before increasing temperatures to go to the next resin.

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.

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

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

After the required amount of resin enters the mold, the process of primary gas penetration begins. A pressurized gas source releases nitrogen into the spruce network, which forms a bubble inside the resin material.

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.

To aid the crystallization rate, keeping the mold at 110-140°F (40-60°C) is recommended. The strategy is to get the mold warm enough to promote crystallization yet cool enough to enable part ejection and handling.

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.