All-electric injection moulding machine supports medical device development - me/All-electric injection moulding machine supports medical device development

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All-electric injection moulding machine supports medical device development - me

Author：gly Date: 2024-09-30

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

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

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.

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

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

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

Notice that the initial modulus of the material trends upward with increasing mold temperature. The modulus of the sample molded at 57°C is approximately 9,000 MPa (1,300 ksi) while the sample molded at 159°C has a room-temperature modulus of 10,350 MPa (1,500 ksi). This is a 15-percent improvement. The largest increase occurs between the samples molded at 125°C and 159°C. A much greater difference in performance is evident as the test temperature increases. As the temperature of the tests reaches 266°F (130°C) the modulus of all four samples begins to decline rapidly. This is the onset of the glass transition. An exact measurement of the Tg for this material gives a value of 293°F (145°C).

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.

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

Say “manufacturing automation” and thoughts immediately go to the shop floor and specialized production equipment, robotics and material handling systems. But there is another realm of possible automation — the front office.

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

Another notable difference between the sample molded at the highest mold temperature and the other three samples can be observed at the conclusion of the glass transition. The part molded at the highest mold temperature enters a slowly declining plateau region between the end of the glass transition and the onset of the melting point near 572°F (300°C). This is typical behavior for a properly crystallized polymer. The other three samples show another symptom of incomplete crystallization. As soon as the glass transition is complete, the modulus begins to increase, even though the temperature is increasing. This is caused by the formation of crystals that were intended to be produced during the molding process. But because these mold temperatures are too low to allow for a complete level of crystallinity, the shortfall has to be made up in the solid state once the mobility needed to form crystals has been re-established. This upturn in the modulus is also associated with the previously discussed dimensional changes that always accompany crystallization.

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

At captive processor McConkey, a new generation of artificial intelligence models, highlighted by ChatGPT, is helping it wade through the shortage of skilled labor and keep its production lines churning out good parts.

Engineering polymers require higher mold temperatures to achieve their ideal structure. The temptation to turn down the mold temperatures can hurt part performance.

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.

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

Some suppliers of high-performance semi-crystalline materials tell molders that full crystallization is only important if the part is intended for use at temperatures above the glass transition. This is not at all true.

For the MXD6 the crystallization time is 25 seconds at a mold temperature of 160°C, while it increases to 180 seconds at a mold temperature of 120°C. For these materials, not only does the lower mold temperature prevent the achievement of the desired level of crystallization, it increases the time required to reach an ejectable modulus, which in turn increases cycle time. Understanding the consequences of changing the mold temperature requires knowledge of the specific polymer being processed.

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.

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.

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.

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 temperature difference between the two transitions is typical for most semi-crystalline materials. Aliphatic nylons such as nylon 6 and nylon 66, and semi-crystalline polyesters such as PBT and PET, form the next tier on the performance ladder, with Tgs of 131-194°F (55-90°C) and melting points of 437-500°F (225-260°C).

These schools and local industry are working together to close the workforce gap in the plastics industry by offering hefty plastics curricula and training programs for degree-seeking students as well as current plastics employees looking to upskill.

Three of the profiled materials—PP, nylon 6 and nylon 66—are materials with glass-transition temperatures below the temperature range shown in the graph. The PP, with a Tg of approximately 0°C, will show only a marginal increase in crystallinity at higher mold temperatures, while crystallization time increases significantly, slowing the cycle time. The nylons, with Tgs of 65-70°C, will reach “full” crystallization using mold temperatures of 90-100°C, and it is evident that in this temperature range the crystallization time is essentially constant. As it rises above this point, the crystallization time slowly increases, once again extending cycle time.

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).

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.

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.

Successfully starting or restarting an injection molding machine is less about ticking boxes on a rote checklist and more about individually assessing each processing scenario and its unique variables.

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

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

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

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

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.

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

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.

In this collection of content, we provide expert advice on welding from some of the leading authorities in the field, with tips on such matters as controls, as well as insights on how to solve common problems in welding.

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

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

The aim of this presentation is to guide you through the factors and the numbers that will help you determine if a robot is a smart investment for your application. Agenda: Why are you considering automation? What problems are you trying to solve? How and why automation can help Crunch the numbers and determine the ROI

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.

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.

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.

Second-ever PTXPO will feature a robust education program on flexible film, with more technical programming in the works.

“Because errors discovered after we have sourced our metal tooling are expensive and time-consuming to fix, freeform injection molding allows us to replace the binary ‘invest-before-you-can-test’ paradigm of metal tooling with a gradual migration from prototyping that promotes a much higher decision quality, along with lower costs, shorter lead times — and happier development teams,” Staal says.

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.

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

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

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

SPT Vilecon, a development and manufacturing services provider in the medical device and pharmaceutical industries, has implemented a prototyping process that de-risks and accelerates the development process by going directly to a representative, injection molded part. Without creating a steel tool. The process is Nexa3D’s freeform injection molding technology (FIM), which uses additive manufacturing to create single-use, dissolvable injection molds.

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.

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.

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.

The mold and part are then placed in Nexa3D’s xWASH-FIM device. In the washing chamber, the resin is dissolved in solvent, leaving the finished part behind. Besides getting to an injection molded part more quickly, the process also removes some geometric constraints on molding that can require additional tooling in other situations. Unlike a traditional mold, a dissolvable mold does not have to release the part after injection.

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

Processors are often expected to compensate for ill-advised decisions made earlier in the product-development process. In the case of shrinkage, one of the most common ‘fixes’ is to simply reduce the mold temperature.

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

According to SPT Vilecon CEO Bjarne Andersen, FIM saves customers both time and money. By getting testing done faster and on prototypes made with the right materials, Vilecon can get a design to a “fast fail” or to market sooner — whichever the case may be — thus shortening the time before a product starts generating revenue.

Generally, higher performance in polymers is associated with the ability of a material to withstand exposure to elevated temperatures. In semi-crystalline polymers, two important transitions characterize this capability: The glass-transition temperature (Tg) and the melting point (Tm). Polypropylene, which we discussed at the end of the last article, is generally considered to be a commodity material with a Tg that is subambient, near 0°C, and a Tm for most grades at 320-329°F (160-165°C).

The PET evaluated here is a non-nucleated material, so the behavior documented here is not typical of the highly filled semi-crystalline grades used for injection molding. The MXD6 is one of the partially aromatic nylons that we have been referring to. These materials, and others like them, such as PPS and PEEK, display a much different behavior than the polypropylene and the aliphatic nylons. With these materials, the rate of crystallization decreases significantly once the mold temperature declines below a certain point that is related to the Tg of the polymer. The effect is considerable.

As we go up the performance scale to SPS, PPS, partially aromatic nylons—sometimes referred to as PPA, and very high-performance materials such as PEEK, the stakes get higher. These materials have Tg’s that exceed the boiling point of water (230-302°F). Therefore, maintaining mold temperatures high enough to allow these materials to crystallize to a satisfactory level requires the use of pressurized water, oil or electric cartridges. Not all processors are willing to adopt these technologies. But at this high-performance level, the consequences of failing to achieve the mold temperatures required to promote adequate crystallinity become especially severe.

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

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

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

“xMOLD is unique in enabling us to manage complex part features with ease, as we can simply dissolve the mold elements that will normally require high-cost steel mold elements like sliders or collapsible cores,“ says Lasse Staal, director of freeform injection molding at Nexa3D.

Figure 1: This shows the behavior of test specimens molded using the four different mold temperatures noted in the legend. The different levels of crystallinity that the polymer was able to achieve at these various mold temperatures are evident from the response of each sample.

A development and manufacturing service provider is using dissolvable molds to build injection molded silicone prototypes.

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.

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

New designs of medical device components demand a higher level of testing and scrutiny due to the critical nature of their uses and the potential consequences of failure. In health care settings, a malfunctioning device can have life-threatening implications. Rigorous testing is essential to de-risk new designs by ensuring that components function safely and effectively. For this testing to provide meaningful results, the parts need to be representative of production parts. Investment in a steel production tool can be a risky decision point for a product developer, putting leaders in the position of committing to a design that may later need to be changed based on verification and validation test results.

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

It is unfortunate that some suppliers of high-performance semi-crystalline materials tell molders that full crystallization is only important if the part is intended for use at temperatures above the glass transition. This is not at all true, something we will address in a later article.

Plastics processors are finding applications for 3D printing around the plant and across the supply chain. Here are 8 examples to look for at NPE2024.

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.

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

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.

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.

Figure 2: As this graph indicates, knowledge of the specific polymer being processed is crucial to understanding the impact of changing the mold temperature.

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.’

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.

Learn about sustainable scrap reprocessing—this resource offers a deep dive into everything from granulator types and options, to service tips, videos and technical articles.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Starting in molding in 1993 and clocking in for nearly every job on the floor over the intervening decades, I’ve seen all sides of the hiring, training and retention process in the industry. Here are my thoughts on how to keep your most important asset — your people.

According to Staal, the same characteristics that make FIM a good solution for medical device development also make it a good choice for other highly regulated industries, such as aerospace and automotive.

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

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.

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.

Unlike PP and polyethylene, which can be run at relatively low mold temperatures, these engineering polymers require higher mold temperatures to achieve their ideal structure. It is with these materials that the temptation to turn down the mold temperature can become problematic for part performance.

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

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.

The flexibility, biocompatibility and stability of silicone make it an essential material for medical device components. However, these components can be challenging to prototype. Thermoset materials such as silicone cannot be melted and built up the way a thermoplastic material can be. There are ways of printing silicone parts, but the results are not as precise and not comparable to injection molded parts. Precision is especially important for medical device assemblies, such as those made by SPT Vilecon.

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.

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.

Semi-crystalline polymers exhibit a significant decline in modulus as they pass through the glass transition. When polyamides (nylons) are filled with this level of glass fiber it is expected that the material will retain approximately 50 percent of its room-temperature modulus above the Tg. This is exactly what is observed for the specimen molded at the highest mold temperature. The samples molded at the lower mold temperatures exhibit progressively larger modulus reductions as the mold temperatures used to produce the samples decline. At the lowest mold temperature, the modulus decline is nearly 75 percent. This will have implications for long-term performance characteristics such as creep resistance and fatigue resistance, even at temperatures below the glass transition.

New system automatically cleans mold-cooling lines—including conformal channels—removing rust and calcium, among other deposits, while simultaneously testing for leaks, measuring flow rate and applying rust inhibitor.

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.

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

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

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.

The maker of plastics processing equipment has placed a machine and an injection molding expert in NIAR’s ATLAS lab in Wichita, Kansas, to help molding, composites and aerospace take off.

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

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.

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.

Michael Sepe is an independent, global materials and processing consultant whose company, Michael P. Sepe LLC, is based in Sedona, Arizona. He has more than 40 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.

The FIM process starts with a 3D printed mold, its design is the inverse of the desired part and printed from Nexa3D’s xMOLD resin. Once the mold has been printed and assembled, it is placed in a mold base in the injection molding machine. The mold base may be a simple metal plate or a more elaborate master unit die, depending on the application. Material is injected into the cavity to form the part, and the cavity and part are ejected from the mold base to cool. The tooling is compatible with standard injection molding machines, and no special modifications are required.

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 our next article, we will look at a semi-crystalline polymer that does not follow the rule that maintaining a mold temperature above the Tg is the only requirement for achieving appropriate crystallinity.

Figure 1 shows the behavior of test specimens molded using the four different mold temperatures noted in the legend: 135°, 194°, 257° and 318°F (57°, 90°, 125°, and 159°C). The material partially aromatic nylon (PPA) reinforced with 35-percent glass fiber. Specimens from each sample group were tested using dynamic mechanical analysis (DMA) to evaluate the temperature-dependent behavior of the material. This is provided as a plot of the elastic modulus of the material as a function of temperature. The different levels of crystallinity that the polymer was able to achieve at these various mold temperatures are evident from the response of each sample.

Implementing a production monitoring system as the foundation of a ‘smart factory’ is about integrating people with new technology as much as it is about integrating machines and computers. Here are tips from a company that has gone through the process.

It is not a coincidence that the dividing line between the properly crystallized sample and the ones that fall short is the glass transition temperature of the polymer being molded. Maintaining a temperature above the Tg provides the molecular mobility needed to form crystals. Figure 2 shows the relationship between mold temperature and the rate of crystallization for various materials.

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

Using a mold temperature above a polymer’s Tg ensures a degree of crystallinity high enough to provide for dimensional stability, even if the part must be used at elevated temperatures. But POM is an exception. Why?

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

This is part four of an eleven-part series focused on the most important job of a processor. To read the rest of this series, click these links: