A 360-degree look at resin conveying systems: types, operation, economics, design, installation, components and controls.
This Knowledge Center provides an overview of resin moisture and the drying process, including information on the best drying practices for your manufacturing facility. Mold Designs
Everything you need to know about plastics compounding technology—from feeding solutions to application profiles and expert advice.
Combat the skilled labor shortage using this comprehensive resource to train your own plastics processing experts.
Deep dive into the basics of blending versus dosing, controls, maintenance, process integration and more.
This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.
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 price initiatives for PE and PVC were underway, resin prices had rollover potential for first two months of 2024, perhaps with the exception of PET.
Flat-to-downward trajectory for at least this month.
A mixed bag, though prices likely to be down if not flat for all this month.
Trajectory is generally flat-to-down for all commodity resins.
Flat-to-down trajectory underway for fourth quarter for commodity resins.
Generally, a bottoming-out appears to be the projected pricing trajectory.
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.
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.
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.
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.
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.
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.
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.
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.
Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.
A unique amorphous PHA has been shown to enhance the mechanical performance and accelerate the biodegradation of other compostable polymers PLA in blown film.
Oak Ridge National Laboratory's Sustainable Manufacturing Technologies Group helps industrial partners tackle the sustainability challenges presented by fiber-reinforced composite materials.
The first task in moisture measurement is to purchase an instrument that is based on sound fundamentals. Then, before it goes into use, method development must be undertaken for all polymers that are going to be processed in the plant.
From pre-show coverage to post-show coverage — with at the show coverage in between — you can rely on Plastics Technology to keep you informed on all things related to NPE2024.
Like December 2022, the December 2023 index represents increased activity following dips in November.
A development and manufacturing service provider is using dissolvable molds to build injection molded silicone prototypes.
If a printed tool only has a finite number of shots in it, why waste any of them on process development?
Follow these best practices to minimize loss of time, material and labor during color changes in molding containers from bottles to jerrycans. The authors explore what this means for each step of the process, from raw-material infeed to handling and reprocessing tails and trim.
I’m looking for a few good molders to help trial a new screw design, and share data and results for a future article to prove the benefits of a melt uniformity screw.
While price initiatives for PE and PVC were underway, resin prices had rollover potential for first two months of 2024, perhaps with the exception of PET.
Topping five other entries in voting by fellow molders, the Ultradent team talks about their Hot Shots sweep.
Serendipitous Learning Opportunities at PTXPO Underscore the Value of Being Present.
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.
Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.
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.
Shibaura discusses the upcoming Plastics Technology Expo (PTXPO) March 28-30
A collaboration between show organizer PLASTICS, recycler CPR and size reduction experts WEIMA and Conair will seek to recover and recycle 100% of the parts produced at the show.
Competition will invite participants to help reshape life cycle management in plastics.
Sign up to attend North America’s leading trade show for plastics.
Offerings range from recycled, biobased, biodegradable and monomaterial structures that enhance recyclability to additives that are more efficient, sustainable and safer to use.
Ahead of the first NPE since 2018, PLASTICS announced that its triennial show will stay in Orlando and early May for ’27, ’30 and ’33.
New features of NPE2024 aim to “bring the whole plastics ecosystem together to innovate, collaborate and share findings.”
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.
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.
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.
As self-imposed and government-issued sustainability mandates approach, injection molders reimagine their operations.
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.
Get your clicking finger in shape and sign up for all that we have in store for you in 2023.
Molding 2023 to take place Aug. 29-30 in Minnesota; Extrusion 2023 slated for Oct. 10-12 in Indiana.
Key technologies — such as multicolor molding, film molding and PUR overmolding for both exterior and interior applications — are at the forefront of this transformation. Join this webinar to explore the vast potential of eMobility in molding large components — including those with fiber reinforcements — thereby driving the need for large injection molding cells with a clamping force of up to 11,000 tons. You will also gain insight into Engel's innovative two-stage process, a solution for future recycling processes. This webinar will provide an in-depth overview of challenging applications, production concepts and best practices, including: BMW iX front panel production cell Smart rear panels concept based on IMD and 2C molding Sustainability concepts based on two-stage process Large tonnage equipment for battery moldings
In today's manufacturing environment, robust processes that meet strict industry and regulatory standards are essential. With the advent of servo-driven ultrasonic welding technology, enhancing product quality and maintaining consistency has become remarkably effortless. Discover the fundamentals of ultrasonic welding, delve into vital components within these systems, explore how servo-driven ultrasonic welding enhances weld quality via advanced control features and gain insights into optimizing your assemblies for welding in these high-performing machines. Join Dukane to unlock the potential of ultrasonic welding in modern manufacturing for plastic devices and components. Agenda: Fundamentals of ultrasonic welding Key components in an ultrasonic welding system Using servo-driven ultrasonic systems to control your welding process Designing your parts and components for servo-controlled ultrasonic welding
This webinar will help you make informed decisions to confirm the equipment access stairs in your facility are OSHA compliant and meet the highest standards of safety and ergonomics. Agenda: Identifying opportunities to increase safety in the work place Utilizing space saving stairways Ensuring code compliance for equipment access
4.0, EUROMAP, OPC, OLE, QC, DSN, SQL, VNC, MES, ERP, FTP, CMS, SPI — are you confused by all buzzwords being tossed around in the plastics industry? Not convinced the data collection is necessary? Or are you unsure of how it could be implemented and improve your molding processes? Wittmann has been on the cutting edge of the data collection push for nearly 20 years. In this webinar, take a step back from the idea of the manufacturing facility of the future and discuss what you can do today to improve your process. Using readily-available technology, Wittmann can help reduce downtime, limit scrap and wasted material, and predict required maintenance. Let the experts at Wittmann help you understand: what data can be collected, what that data can be used for, what systems are used, and how to implement them. Agenda: Demystifying the terminology Tracking the material flow and lot information through the material handling system The data available from various auxiliary equipment, such as: dryers, blenders, mold temperature controls and robots Automating the process through changes in the data collected at the machines during production Adding visualization to increase productivity
Learn how targeted, modular, dosing and blending solutions — covering powders, granules, regrinds and liquids — provide plastics processors of all kinds with best-in-class accurate dosing while delivering significant raw material savings and ensuring highest quality. Agenda: Introduction to Movacolor Blending in plastics applications Movacolor feeding and dosing technology Hybrid blending to combine high material throughput and dosing accuracy
This presentation will explore the in-situ polyurethane (PU) overmolding of injection-molded and composite parts, allowing for direct out-of-mold class "A" surfaces. KraussMaffei will review the process and equipment required. It will also discuss tooling types currently available for PU systems for this process. KraussMaffei will compare the pros and cons of this technology over currently-available coating and painting systems. Agenda: Introduction and evolution of the ColorForm technology Overview of the ColorForm process Equipment required Tooling and PU systems Benefits of the system compared to typical spray-applied coatings Pros and cons of the technology
The global plastics industry has been navigating through what is arguably the most volatile period in decades. Unprecedented amounts of new production capacity are scheduled to start in North America, Europe, and China in the near term and compete for demand during a period of economic challenges. How will trade flows shift? Will this lead to regional cost disparities and rationalization? Energy transition and sustainability targets continue transforming the plastics market and increasing the competitive landscape. As the market evolves, what impact will new technology, policy, regulation, the growing role of chemicals versus fuel and other factors have on industry restructuring and business models? At GPS 2024, leading global experts will come together to discuss pivotal impacts and initiatives shaping the plastics industry. Join us and participants from across the globe to gain the latest insight and deep analysis as you connect with your peers and industry professionals. This year’s conference will explore the theme Disruptive Global Dynamics Reshaping Plastics and include a full day workshop focused on the Global Plastics Business and Plastics Transition to Circularity, 1.5 days of expert content and numerous networking functions.
Every three years, leaders from almost every major industry gather at NPE to advance their businesses through innovations in plastics. The largest plastics trade show in the Americas, NPE offers six technology zones, keynote speakers, workshops and opportunities to build partnerships.
The 3D Printing Workshop @ NPE2024 – The Plastics Show, is an immersive, half-day workshop focused on the emerging possibilities for part production via 3D printing and additive manufacturing. Presented by Additive Manufacturing Media, Plastics Technology and MoldMaking Technology, the 3D Printing Workshop will build upon a successful model first introduced at IMTS 2014. Attendees will benefit from a program focused on practical applications of 3D technologies related to plastics processing. This event will conclude with a 3D Printing Industry Reception sponsored by Additive Manufacturing Media.
The Society Plastics Engineers (SPE) Extrusion Division and the SPE Eastern New England Section will co-host the Screw Design Conference-Topcon on June 19-20, 2024 @ UMass Lowell in Lowell, MA. This highly technical program will focus upon screw design principles for single and twin screw extruders with wide ranging topics relating to screw designs for feeding, melting, mixing, venting and pumping plastics products and parts. Areas of focus will include screw designs for melt temperature and gel management, gel minimization, bioplastics, recycled materials and foaming. In addition to the technical sessions, a tour of the UMass Lowel Plastics Processing Laboratories will be integrated into Day 2 of the event. This program is not just for screw designers, but to help anyone responsible for any type of extrusion operation to evaluate existing extrusion equipment; and also to prepare for future projects. Price to attend: Less than $1000! Registrations will be accepted in early 2024. Call for papers – To be considered to give a presentation, please submit a talk title and abstract on or before December 15 to: Technical Chair: Eldridge M. Mount III, e-mail emmount@msn.com Corporate sponsorships - A limited # of corporate sponsorships (15) are available on a 1st come basis. Included is a 6’ tabletop display (must fit on table), denotation in all promotional activities, and 1 no charge registration. To become a sponsor contact: Charlie Martin, Leistritz Extrusion, e-mail cmartin@leistritz-extrusion.com, cell 973-650 3137 General information: A reception on Day 1 and a tabletop display area will allow the attendees to meet and discuss state-of-the-art screw technologies with industry experts. The SPE Extrusion Division will issue a “Screw Design Certificate” to all participants who have attended the program. Students are encouraged to attend and will receive a discounted rate. For additional information contact: Program Chair: Karen Xiao, Macro Engineering, KXiao@macroeng.com
Debuting in 2010, the Parts Cleaning Conference is the leading and most trusted manufacturing and industrial parts cleaning forum focused solely on delivering quality technical information in the specialized field of machined parts cleansing. Providing guidance and training to understand the recognized sets of standards for industrial cleaning, every year the Conference showcases industry experts who present educational sessions on the latest and most pressing topics affecting manufacturing facilities today. Discover all that the 2022 Parts Cleaning Conference has to offer!
Presented by Additive Manufacturing Media, Plastics Technology and MoldMaking Technology, the 3D Printing Workshop at IMTS 2024 is a chance for job shops to learn the emerging possibilities for part production via 3D printing and additive manufacturing. First introduced at IMTS 2014, this workshop has helped hundreds of manufacturing professionals expand their additive capabilities.
There are many things to consider, and paying attention to the details can help avoid machine downtime and higher maintenance costs — and keep the customer happy.
Fig 1: Machine nozzle tip cold slug Photo Credit: Jim Fattori
One primary goal in any three-plate mold design is to minimize the length of all the parting line openings. Three-plate molds have a taller stack height and at least two additional parting lines. Therefore, they require a much longer opening stroke. It’s often necessary to put a three-plate mold into a higher tonnage molding machine only because a higher tonnage machine has the capability for a longer opening stroke.
But larger machines have a higher hourly rate and are often a little slower, which will cut into your profits. Larger machines usually have larger barrels, which could create a material residence time issue, as well as less control of the shot size, which can increase your reject rate. Other than increasing your machine utilization, there is absolutely no benefit to putting an injection mold in a machine larger than is required to fill the cavities and prevent flashing.
Figure 2: Curled three-plate runner Photo Credit: Jim Fattori
When the machine’s clamp decompresses and starts to open, parting line #1A “breaks” a short distance (assuming you use urethane or compression springs). Then parting line Number 2 — which is the main parting line between the cavity and the core, or A and B-plates — usually starts to open. I say usually because on occasion the part may have a lot of surface area, low draft conditions, a textured surface and other factors (such as overpacking) that can cause the molded part to stick firmly in the cavity. So firmly, the parting line between the runner stripper plate and the A-plate continues to open before the cavity and core plates do. And that’s fine.
There are only two parting line opening sequences that really matter: (1) The initial break between the A-plate and the runner stripper plate must be first (as previously discussed); and (2) The parting line between the runner stripper plate and the injection clamp plate cannot start to open until the opening between the runner stripper plate and the A-plate is fully open. Otherwise, the runner may not have enough room to fall freely out of the mold.
The first opening must be between the A-plate and the runner stripper plate.
Figure 3A: Thin stiffening ribs help prevent bending and curling Photo Credit: Jim Fattori
The amount parting line Number 2 needs to open depends on the molded part. It typically needs to be the height of the part, plus the height of the core above the parting line, plus some safe amount for the part to fall freely. Most parts tend to rotate when they are ejected. That rotation can be anywhere between zero degrees and 90 degrees, depending on the center of gravity of the part. The speed at which the molding machine ejects a part can also affect how it falls, as well as how much room is required. It’s a good idea to make this opening stroke a little longer than expected but have a simple method to possibly reduce that amount after the initial sampling, and potentially get you into a smaller molding machine, as well as a slightly reduced cycle time.
Figure 3B: Guideline for sizing stiffening ribs Photo Credit: Jim Fattori
Once you have estimated what the total parting line Number 2 opening should be, that’s when some type of mechanism engages the A-plate and creates, what I call, parting line Number 1B — the full amount of opening between the A-plate and the runner stripper plate.
The amount the parting line between the A-plate and the runner stripper plate needs to be is typically equal to the combined distances of:
Regarding Number 5, the “safe amount” can vary a lot. If the material has a filler in it, such as glass or calcium carbonate, it tends to be rigid and usually will not bend or curl very much when it’s ejected. Unfilled materials and thick runners tend to curl a lot, especially when the runner is not completely solidified when the mold opens, as shown in Figure 2. This can require longer opening strokes for the runner to fall freely.
Figure 4A: A thin runner being retained by the molding machine’s nozzle tip Photo Credit: Westfall Technik
It’s best to use a safe amount of opening, but make it easy to adjust after the first mold sampling. Even if the mold functions fine with the longer stroke — minimizing the amount of stroke afterward can shave a little time off the molding cycle.
It is important for processors to notice the direction the runner curled in Figure 2. It has nothing to do with the geometry of the runner; it is due to the mold cooling. Runners, as well as parts, will warp or curl toward the hotter sides or areas of a mold. Figure 2 is a good example of the runner stripper plate being colder than the A-plate, which is why it curled inward. The amount and direction a runner, or a part, warps can often be influenced by the temperature of the cooling lines in the various plates.
Figure 4B: Adding a center disk to the runner will help it eject Photo Credit: Jim Fattori
To help prevent the amount a runner curls and reduce the required opening distance, a thin stiffening rib can be added as shown in Figure 3A. Figure 3B is a guideline for the size of a stiffening rib.
The runner stripper plate bushing has a 1¼-inch diameter opening in the center. If the cold slug in the machine’s nozzle tip has sufficient force to pull a flexible runner through this opening, as shown in Figure 4A, the runner will not eject. One method to help eliminate this problem is to add a center disc to the runner as shown in Figure 4B.
Flash traps on a runner will dramatically help reduce the amount of mold damage caused by flash, as shown in the before and after pictures in Figure 5.
When the molding material is injected into the mold, the flash trap fills and solidifies before the injection pressure starts to significantly build up. That’s what prevents the flash from extending beyond the flash trap. As a bonus, the flash trap helps prevent the runner from curling a little.
Figure 5: Flash traps on runners (left, before; right, after) prolong the life of a mold Photo Credit: Jim Fattori
I like to make the flash trap depth and protruding width about 20% of the runner depth. For example, if the runner depth was ¼ inch, the flash trap would be 0.050 inchdeep and protrude 0.050 inch on either side of the runner. And, yes, flash traps are beneficial on all types of cold runner molds and all types of runner shapes.
Figure 6: Range bolts used to control parting line openings. Left, closed. Right, open Photo Credit: Jim Fattori
There are several methods that can be used to pull the various plates. The more common methods are range bolts, range bars, latch locks and plate locks. For small- to medium-size molds, I like to use range bolts. For larger molds, I like to use external range bars. I tend to avoid any mechanism that uses springs or has components that can wear or require grease. Range bolts and range bars can also have their stroke easily adjusted.
Figure 6 shows range bolts being used for all three parting line openings of a three-plate mold. Whatever method you choose, just make sure the components will not prevent the runner from falling freely out of the mold.
Figure 7: Close up of a range bolt Photo Credit: Jim Fattori
Figure 7 shows some of the finer points about range bolts, such as how they should be mounted in a recessed or counterbored hole 1/32 inch to ¼ inch deep to help resist damage from any lateral loads. They should always have a thermoplastic washer, such as urethane, with a flat steel washer under their heads to absorb shock and dampen the noise. This shock absorption also helps prevent the threads of the bolt from stripping out. Often, the head of the range bolt is inaccessible for maintenance when the mold is in the press.
Figure 8: Range bolt mounted in a telescoping cylinder Photo Credit: Jim Fattori
Machining opposing flats on the range bolt so that a wrench can be used to remove it can be very helpful. Hence the term “wrench flats.” For more detailed information on range bolts, see my June 2019 article.
Sometimes you can’t install a range bolt within a mold that is long enough to obtain the desired parting line opening. In a case like this, you can use a telescoping range bolt, such as in Figure 8. This design uses a standard range bolt mounted inside a floating cylinder. The cylinder has a shoulder on the end to limit the stroke of the assembly.
Figure 9: Range bolt mounted in a telescoping cylinder Photo Credit: Jim Fattori
Other times you don’t have room to install all the range bolts within the mold base. In that case, you can mount a range bolt on the outside of the mold, such as in Figure 9.
Figure 10: A basic range bar Photo Credit: Jim Fattori
An alternative to range bolts are range bars, which are almost always mounted externally. They are a little noisier, unless you incorporate some type of snubbing feature, but they are very simple and effective. The most basic design is shown in Figure 10.
Figure 11: A telescoping range bar Photo Credit: Jim Fattori
A telescoping design is shown in Figure 11. And a design for maximum opening strokes is shown in Figure 12. Notice how a spacer was added to one of the range bars in Figure 12 to reduce the opening stroke after the initial mold sampling.
Figure 12: Range bars for very long opening strokes Photo Credit: Jim Fattori
Figure 13 show an excellent method of achieving a parting line opening stroke that exceeds the stack height of the mold, without the use of the notorious metal chains. It’s the same premise as metal chains, but uses low-stretch, reinforced timing belts — the kind used on servo motors and motorcycles. They are extremely strong and have very high shock resistance.
Figure 13: Timing belts used for pulling mold plates
Another benefit of timing belts is that the belt length, and corresponding opening stroke, can be adjusted in the press in a matter of minutes. I have had success with this little-known design, particularly on very large molds.
About the Author: Jim Fattori is a third-generation injection molder with more than 45 years of molding experience. He is the founder of Injection Mold Consulting LLC. Contact jim@injectionmoldconsulting.com; injectionmoldconsulting.com.
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