After attending IMTS, it's clear that the integration of advanced technologies is ready to enhance precision, efficiency and automation in mold manufacturing processes. It’s a massive event, so here’s a glimpse of what the MMT team experienced firsthand.

While rapid cycle molding has been used for more than 30 years, it hasn’t hit the mainstream, mostly because early process proponents could not deliver consistent results. They did not understand the inherent process limitations and the required mathematics to predict outcomes. New techniques and equipment make rapid cycle molding worth a second look, however. Earlier techniques encouraged the use of large, fixed reservoirs to create the rapid-cycle effect. Modern techniques now favor smaller, higher-kilowatt (kW) units with adjustable volume to achieve the effect.

After attending IMTS, it's clear that the integration of advanced technologies is ready to enhance precision, efficiency and automation in mold manufacturing processes. It’s a massive event, so here’s a glimpse of what the MMT team experienced firsthand.

Pressurized water offers numerous advantages when applied to rapid cycle injection, composite, medical, micro, compression and liquid silicone rubber (LSR) molding. These benefits include inherent energy savings, a high temperature spectrum (to 437°F), precise temperature control and fast ramp rates (in excess of 150°F per minute.

In Use Today Many automotive, composite, optical and medical parts are produced today using a rapid heating and cooling method, most notably cell phone cases, sunglasses, large flat-screen TV bezels, automotive bumper skins and automotive interior parts. With its ease of retrofit, pressurized water will continue to add more parts to the list as moldmakers and molders look for ways to reduce downstream processes while increasing part quality.

Rapid Cycle Technology A typical rapid cycle system consists of one reservoir for cold pressurized water and one for hot pressurized water (see Figure 1). The differential between the two is leveraged through the use of a valve station that creates rapid cycling of the mold. With adjustable system volume, the cycle times can be tailored to individual customer requirements.

Released earlier, this video remains a valuable recruitment tool and is being re-promoted in celebration of Manufacturing Day 2024.

In ISO 9001 quality management systems, the Management Representative (MR) plays a crucial role. While the 2015 version of ISO 9001 no longer mandates this position, having a trusted management member serve as an MR remains vital for streamlining operations and maintaining quality standards.

Engineers use properly preloaded bolts, blocks, springs and side-action cores to enhance functionality and reliability in various mechanical systems.

Discover how to enhance your mold design process with CAD/CAM software specifically tailored for the moldmaking industry. In part two of this webinar series, Cimatron will demonstrate how to intelligently design mold components, such as slides and lifters, using powerful CAD/CAM tools to accelerate the design process. Additionally, it will cover how to avoid errors and ensure design accuracy for ejector pins by checking clearance distances, calculating cutoff heights correctly, and thoroughly documenting all ejector components. Agenda: Slides Lifters Inserts Ejection pins and charts

Diamond compounds, with their varied grades, colors and base options, provide a comprehensive solution for mold builders in need of precise and superior polishing across diverse materials and applications.

This roundup is full of products and services that help answer concerns and meet needs for the industry. Featured in this roundup are hot runners, mold components, mold materials and more.

Gerardo (Jerry) Miranda III, former global tooling manager for Oakley sunglasses, reshares his complete mold design checklist, an essential part of the product time and cost-to-market process.

A review of the considerations and adaptations required to design hot runners and implement highly productive injection molding operations.

In the past, due to errors in theoretical cycle time predictions, molders and moldmakers were mistakenly led to believe that many processes were good candidates for rapid cycling. However, today, with the proper mold, material, process information and mathematical relationships, cycle times and ramp rates can be determined in advance of running an actual trial. This helps ensure that acceptable times can be achieved, as many processes cannot tolerate substantially longer cycle times due to production volumes.

A water-based, eco-friendly plastic mold cleaning system helps Rankine-Hinman Manufacturing restore flow rates and avoid big-ticket failures on complex and costly molds.

Join this webinar where Hexagon will explore how state-of-the-art CAD/CAM technology can drive your business forward. Learn how to optimize tool paths, enhance design accuracy and reduce lead times with advanced simulation. Discover the power of automation and real-time data for continuous improvement. Tailored for mold and die manufacturers, this session offers actionable insights to boost productivity and quality. Don’t miss this opportunity to gain a competitive edge in progressive die manufacturing. Agenda:  Key challenges in progressive die manufacturing Optimizing tool paths Enhancing mold and die design accuracy Reducing lead times with simulation Automating processes for greater efficiency Leveraging real-time data for continuous improvement

Join MoldMaking Technology Editorial Director Christina Fuges as she gets the latest news on this mold builder's use of VR for mold design education.

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).

Steps to improve data-driven decision-making and key features of a cloud-based system for mold monitoring and asset management.

Explore the standout articles of September, featuring innovations, expert insights, and strategies to boost efficiency and quality for your moldmaking needs.

It’s easy to imagine the advantages automation offers the moldmaking process, but it's challenging to change one’s mindset, develop a plan and invest.

MoldMaking Technology addresses the complete lifecycle of the manufacture and maintenance of a mold—from design to first shot—by providing solutions and strategies to moldmaking professionals charged with designing, building and repairing molds. About Us

When used for conformal cooling in plastic injection, 3D printing opens a wide range of design freedom. This design freedom enables designers to develop highly-efficient thermal regulation networks. However, this blessing also comes at the expense of not only higher manufacturing cost but also higher design cost as the designer could spend weeks to develop optimal cooling channels. This webinar will explore strategies and tools — including SimForm, a front-end thermal simulation app — to help tool designers and tooling managers maximize the benefits of 3D printing while minimizing manufacturing and design costs. Agenda: 3D printing applied to the plastic injection industry 3D printing pros and cons Tools and methods to facilitate the integration of 3D printing

Rapid cycle equipment that uses pressurized water is a natural fit for most molds because moldmakers typically are already very familiar with water-based mold temperature controllers. Existing oil or steam systems can easily be converted to rapid cycle with pressurized water as well.

Induction heating has been used in R&D applications, but the molds must be built specifically for this type of system. Like steam and cartridge heaters, Induction heating systems consume large amounts of energy and need another system for cooling, and they require additional licensing and royalty fees to operate.

A review of rapid heating and cooling technology as part of the injection molding process and the role of injection simulation software.

Cost, product quality and cycle time demands continue to drive the elimination of downstream processes. Moldmakers and molders seeking solutions to common sink, weld line or discoloration issues that occur during processing should consider rapid heat cycle molding and mold temperature control, in conjunction with a properly designed mold.

Discover how CAD/CAM functionality tailored for the mold industry can significantly enhance the mold design process. In part three of the webinar series, Cimatron will focus on designing waterlines and cooling components. It will demonstrate how CAD/CAM tools can verify drill line depths for water lines and baffles, ensure that minimum steel requirements are met while placing water lines, and provide a complete list of all baffle cutoff lengths. Additionally, it will explore how to confidently design runners and gates using CAD functionality specifically developed for these aspects of mold design. Agenda: Waterlines and verification Conformal cooling Baffles and charts Runners and gates

Options for Improving Parts  Steam, cartridge heaters, induction and high-temperature pressurized water are methods used to bring mold surface temperatures closer to a polymer’s glass transition temperature (Tg). This improves the part’s finish, appearance and mechanical properties.

Steel supplier discusses high thermal conductivity metal powders that also address the skills gaps via user-friendly materials and promote sustainability via durability and higher cycle counts.

This webinar will provide an overview of new developments in hot runners, controllers, mold components, predesigned molds, process monitoring and mold maintenance equipment. These advancements are designed with the goals of lowering scrap rates, optimizing process temperatures and managing energy consumption. The solutions also aim to support productivity and may contribute to extending the operational lifespan of tooling equipment. Agenda: Innovative undercut and thread-forming components Predesign mold bases and plate control Melt delivery and control solutions Process monitoring and maintenance

To achieve the highest ramp rates with rapid cycle equipment, typical passage depths should not exceed 1/2 inch below the surface. However, good results can be achieved with passages as deep as 1 inch, if adequate passage diameter and flow are available. Sealing of the insert water passages usually requires Viton or Teflon seals in order to ensure long life of the joint.

Steam has been used for years to heat sheet molding compound (SMC) molds and has more recently also been used by rapid-cycle units to heat injection molds. Unfortunately, it requires very pristine water, consumes large amounts of electricity, requires a second system for cooling and is typically limited to a maximum temperature of 350°F.

Smart sensors and sophisticated process and measurement data management are driving intelligent moldmaking to new heights.

The need for data to track information and the history of the mold-building process is ever-increasing, and mold component solutions can help.

Figure 2 - Cycle time calculations for rapid cycle molding are a little more complex than for traditional injection molding. Figure courtesy of Regoplas Corp.

A connected software solution streamlines the moldmaking process by providing a unified source of design data, enhancing efficiency and reducing errors, with five key steps benefiting from this integration.

Steel supplier discusses high thermal conductivity metal powders that also address the skills gaps via user-friendly materials and promote sustainability via durability and higher cycle counts.

Understanding and facing the moldmaking industry’s obstacles to growth requires a strategy focused on increased profitability.

While rapid cycle equipment can often maintain cycle times equivalent to traditional injection molding, the real magic happens when these high-temperature units take mold temperatures to or near the material’s Tg. Weld lines, sinks and streaks are eliminated when you get the mold’s temperature close to the Tg of materials such as polycarbonate (PC), polypropylene (PP), acrylonitrile butadiene styrene (ABS) and PC-ABS. Polycarbonates benefit the most with improved surface finish, weld line strength and optical clarity. The equipment’s return on investment can be obtained in as little as 30 days, depending on product volume and the labor costs associated with downstream processes.

MoldMaking Technology Editorial Director Christina Fuges sits down with Murphy Forsyth, GM – Injection Molding and Director Of Marketing for Zero Tolerance LLC in Clinton Township, MI.

Cycle time calculations for rapid cycle molding are a little more complex (see Figure 2) than for traditional injection molding in which an hour is necessary for mold warm up and steady state operation prevails. Typical rapid cycle times to achieve significant temperature changes are less than three minutes.

After attending IMTS, it's clear that the integration of advanced technologies is ready to enhance precision, efficiency and automation in mold manufacturing processes. It’s a massive event, so here’s a glimpse of what the MMT team experienced firsthand.

In ISO 9001 quality management systems, the Management Representative (MR) plays a crucial role. While the 2015 version of ISO 9001 no longer mandates this position, having a trusted management member serve as an MR remains vital for streamlining operations and maintaining quality standards.

A focus on electrode design and automation helps toolroom improve efficiency, reduce tooling costs and deliver higher quality products.

Intralox's integration of the Alpha Laser ALFlak has significantly improved their tool room efficiency when it comes to difficult welds and urgent repairs.

Rapid cycle molding can be applied to any mold if the unit is properly sized, but it is best-suited for inserted molds where a standard temperature control unit maintains the mold’s temperature. Conformal-cooled inserts are also preferred (see Figure 3). Mold life for commonly produced P20 or H13 molds has not shown degradation with the rapid cycle process. Good results have also been achieved with existing non-inserted molds or new molds with proper water passage layout. By reconfiguring water passage connections, the mold can be rapid-cycled in only the areas that need it.

Typically, water is heated to 400°F in order to capitalize on the largest temperature differential between the mold and water. This results in the fastest ramp rate. An external thermocouple in the mold alerts the units when the mold has reached the material’s Tg. At that point, the unit is triggered to charge the mold with cold water to start the cooling cycle. The hot water temperature is recharged during the cooling cycle, so small-kilowatt heating can be used, which reduces energy consumption.

Discover how to enhance your mold design process with the right CAD/CAM tool for parting and cavity design. This webinar will explore CAD/CAM capabilities including how hybrid solid/surface modeling can streamline workflow and improve accuracy. Learn how to confidently tackle parting, runoff, and shutoff, ensuring precision and efficiency in your designs. Agenda: Part analysis QuickSplit techniques Parting and runoff strategies Shutoff solutions

Join MoldMaking Technology Editorial Director Christina Fuges as she gets the latest news on this mold builder's use of VR for mold design education.

Figure 3 - Rapid cycle molding is best-suited for inserted molds such as this conformal-cooled insert. Figure courtesy of PEP, Center Technique Plastics.

After attending IMTS, it's clear that the integration of advanced technologies is ready to enhance precision, efficiency and automation in mold manufacturing processes. It’s a massive event, so here’s a glimpse of what the MMT team experienced firsthand.

Continued training helps moldmakers make tooling decisions and properly use the latest cutting tool to efficiently machine high-quality molds.

Electric cartridge heaters have also been used to heat rapid-cycle injection molds. They are easy to install and operate. Unfortunately, they also consume large amounts of electricity to operate and do not offer cooling, and they are prone to inconsistent heating and element failure.

Identify pain points, tackle each one strategically and maintain flexibility to keep your moldmaking business on a path to growth.

Figure 1 - A typical rapid cycle system consists of one reservoir for cold pressurized water and one for hot pressurized water. Figure courtesy of Regloplas Corp.

For example, using pressurized water offers more precise temperature control across the mold (<1°F) and faster ramp rates than using steam or oil. Also, as depressurized water is vaporized, pressurized water provides additional safety if system leaks develop. This dramatically decreases temperatures with only 10-percent energy release compared to steam.