Use these links to jump to a specific morning session abstract below.
Conformal Cooling Review for Injection Molding: Additive Manufacturing, Brazing, Bonding, and Caps & Closures Applications, William Sames, HTS International
Advanced Mold Conformal Cooling can be used to better regulate the temperature of molds, reducing cycle time, increasing geometric accuracy, and reducing or eliminating several processing challenges, such as cold slugs and stringing at the gate. Conformal cooling can be achieved through various methods: Powder Bed Fusion, Brazing, Bonding, and Groove-Milling and O-Rings. These methods are reviewed in this talk, and case studies for Caps & Closures Applications are presented. Additionally, applications to bio-plastics, such as PLA, and sustainability are discussed.
Still on Hold? How to Change Part Cooling Time into Production Time., Wayne Daniel, Canon Virginia
As a global manufacturer, Canon understands that injection molders face unique challenges. Long part cooling times and mold changeover downtime are common barriers to productivity for many operations. To address these challenges in its own factory, Canon developed a system that allows an operator to run two different molds on a single molding machine. In certain instances, use of the system results in up to double machine capacity, increases production flexibility, and almost eliminates mold changeover downtime. Canon members will introduce the Shuttle Mold System, present some of its ideal use cases, and explain how it can meaningfully impact operational productivity.
Introduction to LSR Tooling Technology, Dana King, Kipe Molds
Thermoplastic molding and LSR molding are both injection molding processes that appear to be the same. As we look closer however, it is clear that the differences between these two materials drives some very important differences in tooling features. I will discuss how the properties of LSR create a need for some very specific tooling features injection molds. I also will compare some common tooling features for thermoplastic molds with features in LSR molds. Finally, as we move into the future, expect to see more two component molding applications, which combine a plastic substrate and an LSR overmold. We will discuss issues and limitation to two thermoplastic and LSR two component molding.
Advancements in Dosing System Technology, Bob Pelletier, Elmet
- Data Acquisition using OPC-UA/ Euromap 82.3
- Air removal via vacuum degassing during the automated drum-change procedure
- Closed-loop additive control for critical functional additives
- Premium connectivity for remote technical support via internet connection
- Technical videos showing disassembly and assembly procedures for the processing unit and piston pumps
Defect Prevention Using DoE and Autonomous Optimization, Eric Gerber, SigmaSoft
Attendees will learn about defect prevention technology that helps reduce the product development time while achieving high quality on a LSR part. The approach to optimize the process and reduce potential defects will be shown using the embedded DoE and Autonomous optimization technology. The part used in the presentation has a high flow length and thin walls that makes gate location selection challenging to achieve a robust process. DoE and Autonomous Optimization provide the flexibility to analyze multiple designs and make it easy when it comes to decisions pertaining geometrical/ processing variables that will affect the final part quality.
Multi-Component Molding with LSR, Trevor Pruden, Arburg
Multi-component molding with silicone requires different approaches depending on the application. Whether the plan is to over-mold a thermoplastic or silicone substrate, be it in a regular machine or even in micro molding application, different methods can present both opportunities and challenges. This presentation will cover different methods through application examples. Reciprocating screws as well as plungers can be solutions that can play a part in different applications; method of feeding can be just as important. It is valuable to know where the limitations and challenges are in order to select the right technology for the application at hand.
ZEROPLAST - Plastic-Free Products Produced with Plastic Machinery - Why Not?, Brent Strawbridge, Wittmann Battenfeld
Sustainability is a big focus in the industry today, and many plastics processors are currently seeking or soon will have to seek eco-friendly material alternatives that are profitable and conform to this new trend.
In this presentation, we will review the special features of a 100% new and innovative bio-based material that can be processed on an injection molding machine. We also will go into detail about the machine and process requirements, as well as the applications and industries this technology is perfect for.
Disruptive Innovation with Multilayer Packaging, Dan Falla, Shell Polymers
Inter and intra material substitution along with disruptive innovation continue to change the packaging world. The development of multilayer coextrusion lines have facilitated the transition from rigid containers to flexible packaging. Monolayer lines are being replaced with three, five, nine, and even eleven layers; each layer having a distinctive function. In this presentation, the market dynamics are discussed along with an understanding of the function of each of the layers relative to cost and performance.
Thermally Conductive Polyamides Enabling New Mobility, Mason Valdisera, Lanxess Corporation
The increasing complexity in automotive applications brings components not only closer to each other but also in closer contact with heat sources. Thermal management and heat dissipation must therefore be more effective in order to meet ever-increasing requirements. In addition, if plastic is able to meet these new thermal targets, it can offer many benefits over metal. Part consolidation, increased functional integration, and density reduction can all be used to reduce the weight and cost of next-generation parts.
Many advances in CAE software enable heat transfer in components to be easily and efficiently analyzed, allowing thermal performance of automotive components to be optimized for thermoplastic materials. Newly developed thermally-conductive polyamides offer improved performance in this area. The presentation will show how combining CAE and material technology can significantly broaden the range of possible applications for thermoplastics in these thermally challenging applications.
When to Consider Acrylic for Medical Applications, Mike Zadrozny, Roehm America
In today’s medical plastics arena, there are many different grades of materials to choose from when designing for medical device, diagnostic, and packaging applications. When it comes to a clear chemical-resistant material, your choices are more limited. Do you need a BPA-free alternative that can resist blood and lipids yet still be clear and sterilizable for your application? Whether you need an impact-resistant grade or one for a diagnostic application, ROEHM offers some of the world’s most advanced medical acrylics. In this presentation we will introduce you to CYROLITE® and CYROLITE MD® for some of your most demanding applications that require a BPA-free, clear, and chemically resistant polymer.
A Sustainable and Economical Way to Color Plastics, Paul Maguire, Riverdale Global
Discussion on how using liquid color in molding can substantially improve sustainability while also saving money with lower energy usage, reduced cycle times, less waste, and more. We also will discuss a new line of additives with a focus on achieving sustainability goals, including increasing PCR content in your finished product.
Additionally, an overview of the latest developments in the field of liquid color technology will be provided.
Leveraging Innovative Materials and Advanced Processing Technologies in Emerging Automotive Lighting and Autonomous Vehicle Applications, Jim Lorenzo, Covestro
As automotive electronics and LED lighting continue to merge, opportunities for creating new innovative illumination and autonomous vehicle (AV) sensing capability within vehicle exterior components, such as headlamps, have emerged. As such, the need for enhanced functionality, cost-savings, light-weighting, and sustainability are all of increasing importance.
A new innovative headlamp concept incorporating a range of enabling technologies, such as multi-shot molding (2K), insert-molded electronics (IME) such as LED module and AV sensors, LiDAR transparency, back-lighting, metal-replacement, hybrid material solutions, and heat-managing polycarbonate materials all will be discussed and demonstrated in a state-of-the-art headlamp prototype.
The enabling technologies also demonstrate opportunities for component consolidation, as well as enhanced recyclability.
How Additive Manufacturing Can Be Complimentary or Disruptive to Traditional Molding Technologies, Alan Guyan, Additive Accelerator
Advances in Additive Manufacturing Technology – 3D Printing are enabling acceleration and disruption in the traditional molding industry. There are questions what role traditional molding technologies will serve in future operations and supply chains of the future. One thing is certain: It will be different. Traditional injection molded parts are continuing to be replaced by more complex part geometries and integrated finish part assembles. With the evolution of the digital age in CAD, FEA, mold flow simulation, and analysis software, and lightweight structures, you may question what the future holds for this industry.
There are a number of benefits and challenges in the early stages of incorporating Additive Manufacturing Technologies into the current supply chain. This presentation will discuss these acceleration benefits, and how they will unlock new innovative product solutions. This presentation will discuss these adoption challenge areas, and what needs to be done in addressing the concerns around cost of implementation, integration capacity, materials, build size, post-processing, and skilled labor. This presentation will address potential solutions and moving towards the future as a hybrid manufacturing model approach.
Optimizing Mold Cooling, Mark Brown, Burger & Brown Engineering
Mold Cooling can represent 80% of a molding cycle and yet mold cooling is often an afterthought. Burger & Brown Engineering has developed Scientific Cooling℠, Intelligent Mold Cooling Revealed, helping folks understand the science behind cooling. Mark Brown will provide an overview of best practices to balance and optimize mold cooling circuits resulting in a more robust and sustainable molding process.
Industrial Applications of Lasers for Marking, Cutting, and Welding Plastics, Ben Campbell MECCO & Robert Morris University
Lasers are useful tools in the manufacturing process for plastic components. They mark, cut, and even join plastic parts. There are numerous considerations when choosing a laser for plastics processing including technical requirements, material response, quality, and safety. This presentation will provide an overview of the best practices for marking plastics with lasers. It also will discuss preliminary research in laser degating of injection molded plastic parts for industrial applications. Lastly, the progress made in using lasers for joining plastics will be presented, including a welding process developed recently which has been used to weld millions of parts for the automotive industry.
When Plastic Design Does Not Align with Manufacturing and Assembly – A Multiple Factor Investigation into Plastic Part Failure, Erik Foltz. The Madison Group
There are well established principles when designing a plastic part that guide engineers and designers to take full advantage of these versatile materials. However, often these design principles are implemented in a silo and do not take manufacturing and assembly into account. This presentation will highlight, through a case study, how disjointed optimization of a plastic part can lead to sub-optimal part performance and failure. Additionally, the presentation can show how utilization of simulation tools, such as injection molding simulation and structural finite element analysis (FEA) can be integrated to help proactivity address these issues and avoid failure by taking a holistic approach to part design and assembly.
Overview of ANSI/PLASTICS B151.1-2017 Safety Requirements for Injection Molding Machines, Mike Ortolano, Absolute Haitian
This presentation provides a brief overview of the regulatory framework, in the U.S., with respect to employers providing a safe work environment for employees as it applies to operations which use plastic injection molding machines. The presentation provides an overview of the most recent ANSI Safety Requirements for Injection Molding Machines (ANSI/PLASTICS B151.1-2017) with a focus on the changes from the previous standard. Attendees will walk away with a better understanding of how the requirements are organized, the information contained in the various sections, and the requirements specifically relating to the use of IMMs, which are particularly important to end users. Finally, the inclusion and importance of Risk Assessment methods in modern safety management will be discussed.
Direct Melt Characterization Method for Optimizing the Injection Molding Process, John Beaumont, Beaumont Technologies Inc. & The American Injection Molding Institute
This talk will present the newest generation moldometer, which has evolved into a multifunctional tool used by designers, molders, and polymer OEMs and suppliers. The direct melt measurement system and software now provides an entirely new approach to predict mold filling pressures without the need for complex computer models. It can also be used by molders as a short cut for setting up their process and for mold designers to investigate gating locations and the influence of wall thickness and melt temperatures on fill pressure. For simulation engineers, the new software can also work hand-in-hand with Autodesk Moldflow® to improve their productivity and accuracy.
Closed Loop Systems for Injection Molding Process Control, Laurentiu Bodica, PRIAMUS
The proportion of biopolymers and recycled plastics will increase significantly, which is why considerably higher process fluctuations can be expected in the future. Adaptive process control seems to be a requirement for molding consistent quality parts.
FILLCONTROL process control system from PRIAMUS automatically adjusts the viscosities of biopolymers and recycled plastics cycle by cycle using a patented process, ensuring that the part quality remains within desired tolerances.
iQ Software Suite – The Future of Total Process Control is Now, Joachim Kragl, Engel
The iQ software suite brings total control and transparency to the molding process via a single HMI and controller on the molding machine. Process, machine and auxiliaries become one unit for utmost process control, documentation, and ease of setup. The presentation will cover an introduction to the world of iQ products and how they help processors to master even the most complex process challenges with ease. iQ products can be either used in combination or individually to improve process quality, which will also be explained with real-world examples.
Case Study: Using Shear Induced Variations as a Solution in Medical Application, Travis Belz, Beaumont Technologies Inc.
This talk will present a real-world case study on a transparent part, which required a flawless cosmetic finish and the ability for it to form a hermetic seal. The issue that arose during molding was a gas-trap and the solution ended up being provided by something we are usually trying to fight to find a solution for, which is shear induced heating and the variations that it causes. This talk will dive into using simulation and design techniques to evaluate the polymer flow through the tool to first diagnose the root cause of the problem, followed by discovering and engineering a solution that most would not recognize.
Data Acquisition and Process Control in Injection Molding - Industry 4.0 in Practice, Szaolcs Horvath
Industry 4.0 is on the verge and going slowly into the molding industry. There are several ways to measure the process parameters such as cavity pressure, machine parameters, or information from auxiliary devices. The idea is simple—collect information from all kind of devices and use them to understand and improve the process. In practice, we can find ourselves confronting different machine brands with different communication protocols. Every injection machine producer offers its own software, but what if there are several machine brands within one factory? Collecting and storing the right information is quite a challenging task and not as easy as it is thought. Data is just a bunch of storage until you find the way that it can help people not to do extra work. Cavity Eye company developed a hardware and software solution for data collection and process control. Every injection machine could be connected independently from the machine brand, manufacturing year, or software version. We are ready to integrate water flow measurement system data and to use any industrial standard sensor with our hardware. Digital or analogue signals, EM63 or OPC/UA protocol, we are able to incorporate and show data in our IoT system. Automated information will be available for the production, managers, process technicians - decisions can be made by facts, not by rumors.
Reducing Variation and Protecting Molds Using In-Cavity Melt Position Sensing, Brad Johnson, Penn State Behrend
Applications of a novel, simple device used to detect the arrival of the melt in the mold cavity will be discussed. Some possible uses for the device include controlling when to transfer from velocity control to pressure control during injection, when to open and close valve gates, and to detect and, possibly, control the cavity balance in a multi-cavity mold.
Rethink Your Tool Launch: Get Better Parts Faster, Kenny Lu, RJG
Rethink traditional material, machine, mold, and process evaluation during a tool launch as we demonstrate new concepts to accelerate time to market and reduce rework. We will reveal our new, cutting edge technical advancements and show you how to combine them with the human element to streamline your launch process and make better parts faster. Get an inside look at how we link the digital roadmap and the latest innovations to your plastic human capital.
Plate Staging for Injection Molds, Jay Fidorra, HASCO
In the courtroom all cases are not open and shut. The same goes for injection molds. Depending on part geometry and features, multiple plate movements may be needed to release the part. Plates can be staged to allow slides to retract, cores to collapse, or ejection to be delayed. This presentation shows the components available to provide this action and the situations where they are required.
Dry Ice Cleaning – Who Needs It?, Steve Wilson, Cold Jet
If the polymers you mold off-gas and foul your cavities and vents; if some of your molded parts need to be deflashed; or you need to clean your molded parts prior to painting – you do. Dry ice is a proven way to help molders be more competitive in a global economy. This presentation discusses the top 5 reasons molders need dry ice. The need to improve quality, increase productivity, extend the asset life of their molds, reduce costs and improve environmental quality and worker safety. The attendee will obtain a working knowledge of the theory and process of how dry ice cleaning works, and how to adapt it to various other cleaning opportunities in their factories. This presentation includes supporting research from several independent studies, along with several industry case studies, pictures, and videos.
- How to extend production runs by cleaning injection molds on-line, at operating temperatures, and extend the asset life of the mold
- How to reduce costs and scrap by eliminating aqueous methods of surface preparation of plastic parts prior to painting
- How to deflash molded plastic parts quickly and effectively without altering part geometries
- A benchmark understanding of the theory and process of how the dry ice cleaning and surface preparation works
Increase Production Efficiency by More Than 50%, by Maximizing Your Output per Sq. Ft. - Reverse Cube / Compact Cube, Martin Müller, FOBOHA
A cube is the most efficient mold technology for manufacturing high volume production runs of complex assembled parts, multicomponent, and even single component parts. The most important aspect of the technology is that processes run in parallel on each side of the cube mold. The FOBOHA Plug ‘n Play Compact Cube fits onto an extension tie bar of each injection molding machine and is also very easy to maintain. The main benefit of the FOBOHA Reverse Cube are two thermally separated cube molds that rotate by 90 degrees in opposite directions. Two or more parts can manufactured and assembled in a single operation. The system has a up to 40% shorter cycle time and requires a much smaller floor space compare to a conventional system.
Improve Your Processing with Novel Hot Runner Technology, Angelo Morra, Haidlmair North America
A look at the technical details of the new FDU hot runner technology with a comparison to current hot runner systems. We will analyze its application on different products and how it brings improvements in processing and part quality.
Perfecting Project and Asset Management Processes to Reduce Costs From the Start, Darrell Witham, Progressive Components
Successful project launches require input and collaboration from stakeholders across all functional areas. From tool design to qualification and production, there are critical aspects that should be focused on, including component specification, validation, mold monitoring /maintenance, and asset tracking. All of these help to ensure a smooth launch and efficient production for the life of your asset.
How Do I Know When I’m Ready to Get a Central Vacuum Conveying System?, Chad Stover, Conair Group
Conair started its business in 1956 selling material conveying solutions and since then has been the leading supplier of motor loaders and receivers. We often hear questions like:
- How do I know when I’m ready to get a central conveying system? Is it strictly based on system size?
- Is it easy for me to make the switch from self-contained motor loaders to a central conveying system?
- What are the benefits of a central vacuum system?
- What do I need to know?
- How do I determine ROI of the tubing, pump, and conveying control?
This presentation will answer all those questions and provide operational tips to each type of loader, to help you make informed decisions today and in the future.
High Precision in Gravimetric Resin Blending, Gene Flockerzi, Moretto
The joining of plastic resins prior to processing, commonly referred to as "blending," is a critical part of molding. The addition of color and processing aid additives along with regrind not only increases the economical use of lower-cost base resins but actually establishes the performance characteristics of the final product.
Many equipment manufacturers offer gravimetric equipment for this common process. But precision consistency is often questionable since there is a wide variety of methods used for the dosing and weighing of each ingredient. Further, acceptable blending performance relies on the blender's ability to thoroughly mix the materials to eliminate product variations. Lastly, to make the blending equipment truly useful to processors, its ability to be readily cleaned and prepared for rapid material changes is crucial for continued molding up-time. Additionally, easy programming and communication integration with other molding processes is crucial for efficiency.
In this presentation, Mr. Flockerzi will outline the specific details of a range of throat mounted (or floor mounted) multi-ingredient blenders that answer these common issues, resulting in highly-controlled blend ratios, easy use by shop personnel, and easy cleaning.
In addition to his detailed outline of the latest technology in blenders details, options for medical compliance, powders, precision dosing, high temperature materials, and static elimination will also be overviewed.
New Generation of moldMIND II – The Digital Cockpit for Injection Molds: Protects Your Mold and Is a Helpful Device for Preventive and Predictive Maintenance, Don Hickel, MÄNNER
Injection molds have their own memory. They never forget anything: High shot volumes, long operating periods, operating errors, downtimes and repairs – they all leave traces behind. The process data and events actually generated directly in the mold provide information about what has happened. moldMIND II captures relevant process data—such as temperature deviations, sensor breakage, downtimes, and pin movement—in real time and records seamlessly for the lifecycle of the mold. The intelligent device generates alarm signals that can be sent to a mobile device for fast reaction. moldMIND II supports maintenance planning and makes it possible to log maintenance. The device is continuously developed so that data is available for proactive predictive maintenance concepts in the future. Equipped with a GPS module, owners and operators of several molds can thus maintain an overview of the exact locations and the operating state of their molds.
Case Study: New Ways for Injected Automotive Applications, Jochen Mitzler, KraussMaffei Technologies
Sub-Content: Usage of circular economy, new technologies, and how digital solutions improve the processes:
- Story from a molded packaging bucket over compounding to an automotive application
- Usage of Decoration processes, Automation and MuCell (reduced weight – better stability)
- Digital Solutions:
- Improved operator comfort: Hot-Runner-Controller (Needle movement) Integration into MC6 (machine controller)
- Tracability of all Circular Data: easyTrace and DataXplorer
- 100% part documentation via QR – Code labeling