Concurrent sessions on injection molding technology, materials technology, and executive/management practices.
Sustainable In-House Recycling Solutions, Joe Platek, ACS Group
Learn to properly size a granulator for mechanical recycling, with a focus on in-house recycling in injection molding operation, how changes in your application can impact granulator sizing and how optimizing this process can support your sustainability efforts. Gain valuable insights to enhance efficiency and reduce waste in your recycling processes, all while contributing to a more sustainable production cycle.
Optimize Your Blending Operations: Achieve Peak Efficiency, Michael Tuchalski, ACS Group
Are inefficiencies in your blending process costing you time and money? Join us for an insightful presentation where we’ll explore common challenges in blending operations and demonstrate how AEC’s advanced equipment, combined with the powerful data capabilities of MiVue, can transform your production efficiency. From understanding basic blending limitations to leveraging real-time data for improved accountability and performance, this session will equip you with the knowledge to optimize your operations. Don’t miss out on learning how to elevate your operations to the next level!
Crystallization Kinetics and Polymorphism in PA66/616T Blends: Influence of chain mobility and temperature, Xiaoshi Zhang, Penn State Behrend
This study investigates the crystallization kinetics of polyamide 66 (PA66) blended with an amorphous polyphthalamide random copolymer, 6I6T, in a temperature range relevant to injection molding conditions. Blends were prepared with three different weight contents of 6I6T: 10 wt%, 20 wt%, and 30 wt%. Additionally, two types of 6I6T with different molecular weights were utilized to understand their effects on the crystallization behavior of PA66. Our findings reveal that the addition of the amorphous copolymer significantly slows down the crystallization rate of PA66. Interestingly, the polymorphism of PA66, characterized by the formation of mesophase and α-phase structures, is not greatly affected by the presence of 6I6T. However, the molecular weight of 6I6T plays a crucial role in the crystallization kinetics within the mesophase region, while its impact on the α-phase formation remains negligible. Thermal characterization was conducted using fast scanning calorimetry and rotational rheometry to evaluate the crystallization kinetics and chain mobility. The reasons leading to the drastic differences in crystallization kinetics of the blends in the mesophase region will be discussed in detail.
Introducing Regrind into your Molding Process, Thomas Dunn, Wittmann
With the rising cost and shortage of raw materials and tighter demands for product consistency, many processors struggle with blending their resin recipes. Accurately reintroducing regrind into the final product is more important than ever, driven by environmental mandates and cost savings. In this presentation, WITTMANN will review how to introduce regrind to your process and important key factors that you should know.
Primary Topics:
- How does regrind differ from virgin material
- Sources of regrind and regrind quality
- Determining max regrind percentage
- Best practices for reintroducing regrind
- Effects of an inconsistent mix
- Adjusting IMM parameters for small variations in the mix
Portable CMM’s for Shop Floor Quality Control, Randy Biebel, Faro
This study explores the application of a portable coordinate measuring machine (CMM) for rapid and flexible quality control in manufacturing. Portable CMMs offer significant advantages over traditional fixed CMMs, particularly in their ability to perform on-site inspections of large or complex components, reduce setup times, and improve overall production efficiency. This presentation outlines the methodology employed, including the selection of appropriate measurement strategies, data acquisition techniques, and analysis methods. Results demonstrate the effectiveness of portable CMMs in verifying dimensional accuracy, identifying deviations from design specifications, and facilitating real-time process adjustments, ultimately contributing to enhanced product quality and reduced manufacturing costs.
Electric versus Servo-Hydraulic for Thermoplastic Molding, Bill Saunders, Boy Machines
This presentation will compare molding with electric versus servo hydraulic. The intent is to lay out the pros and cons and differences between the two machines. A discussion will be made concerning the differences in power consumption, cost and process repeatability.
Innovation and variety are key to success in product development and plastics, Wayne Daniel, Canon
What does a “Camera Company” know about recycling and material development? More than you might think. From closed-loop manufacturing processes to bio-based material development using silk and lignin, Canon Virginia is working to reshape expectations for responsible manufacturing and drive innovation for future product lines. With decades of experience in manufacturing across multiple industries, Canon understands that more than one approach is often needed to ensure success.
Presentation topics include:
- Closed-loop recycling process development for high-production environments
- Examples of how Canon is upcycling plastics waste streams
- Canon Virginia’s use case for 100% recycled plastics
- Other sustainability efforts around Bio-based material development
Optimizing Low Constant Pressure Molding through Simulation, Ken Cheng, Moldex3D
This study explores the benefits of simulating low-pressure molding techniques such as iMFLUX and Decoupled 3. By utilizing adjustments within this simulation framework, the molding process can be optimized, resulting in reduced cycle times and fewer defects. Low-pressure molding enables manufacturers to produce larger parts on smaller machines with lower clamp tonnage and pressure requirements. Additionally, this process supports sustainability goals by lowering energy consumption and enabling the use of recycled materials. The paper outlines the general advantages of low-pressure molding and demonstrates how simulation can enhance the process, maximizing its value. It emphasizes the role of virtual sensors in dynamically maintaining constant low pressure. The simulation provides a solid foundation for the process, minimizing setup time and effort by identifying the minimum required injection pressure and determining the ideal process windows for low-pressure operations. These advancements contribute to improved dimensional accuracy and product quality.
Technology and Methods for Improving OEE in the Plastics Industry, Kent Royer, Milacron
In injection molding operations, there is constant pressure to reduce cycle times, costs, and time shortages. We will examine the different variables that can affect OEE (Overall Equipment Effectiveness), the availability of technology, and techniques that can be applied.
Monitoring with Nozzle Pressure Sensors versus Cavity Pressure Sensors, Jeremy Dworshak, 3M
In the realm of injection molding, digital data acquisition is pivotal for ensuring process consistency and product quality. Nozzle body sensors provide critical insights by directly measuring plastic pressure and indirectly gauging resin melt temperature. These metrics are invaluable for assessing the consistency of the injection molding process, often revealing discrepancies not apparent on the HMI displays. However, the molding process complexity changes with multi-cavity tools, where process consistency can vary across cavities. This presentation explores the pending research around the efficacy of in-cavity sensors, hoping to better understand their capability in monitoring and maintaining uniformity in multi-cavity injection molding processes.
A Real User’s Experience in the Advancing Automation Age, John Williams and Shawn Dailey, Plastikos
A “day in the life” from the Manufacturing Team looking at Automation and its impact in our operation. This presentation will discuss the When, Why, What and How to Automate. Case studies will be broken down and lessons learned will be shared.
The When to Automate: Not all automation projects are on new products. Deciding when to automate and how far to automate might be a game changer for your organization.
The Why to Automate: We all hear of the efficiency gains from automation, but what else can I use for my ROI to ensure I’m spending my money wisely?
The What to Automate: Selecting your automation projects and prioritizing them correctly will keep your team motivated and focused.
The How to Automate: Do I just order a robot online? Or is it a cultural thing deeply seated in the organization? Most importantly, what resources are needed to make this all happen?
The Role of Fiber Cross-Section: A Comparative Study on How Flat Fibers Affect Processing and Part Performance, Hunter Beaumont, The Madison Group
The use of discontinuous fiber reinforced composite materials allows designers the opportunity to push the boundaries of plastics applications, allowing for the potential for higher strength and part stiffness at elevated temperatures. However, the addition of fibers introduces two issues that can limit their utility as it relates to manufacturing parts. Those issues include higher material viscosity and increased potential for part warpage. This paper examines how changing glass fiber cross-section from round to rectangular can influence the viscosity, strength, and dimensional stability of injection molded parts. The study presents data not only on the changes in material behavior, but also looks at how the change in the fiber geometry can influence the overall processing of real parts with different gating configurations. The study also includes looking at how the level of fiber loading and part wall thickness can influence the benefits of these changes. All materials tested used the same base polyamide matrix.
VR (Virtual Reality) Learning Integrations, Torsten Kruse, Kruse Analysis
In the fast-paced world of mold design and injection molding, precision, speed, and innovation are crucial. To address the skills gap, our groundbreaking Molding Expert VR application transforms engineering education. This immersive VR tool offers interactive training, simulating mold design and production without the risks and costs of physical trials. It shifts from traditional theoretical education to active learning, enhancing problem-solving and technical skills. The VR tool appeals to digital-native engineers, offering scalable, cost-effective training, especially for small-to-medium enterprises. It signifies a transformative leap in mold-making education, empowering engineers and fostering industry innovation and excellence.
Recycling Gold Rush – How to use your “picks and shovels”, Paul Martin, Krauss Maffei
In the context of the polymer recycling industry, the term "picks and shovels" refers to the foundational tools, technologies, or services that support the industry's operations rather than the end products or direct recycling processes. This approach is inspired by the Gold Rush analogy, where those selling the tools often profited more consistently than the miners themselves
Controlled Viscosity Molding, Rick Fitzpatrick, X2F
Most polymer and process engineers view plastics through the lens of conventional extrusion and injection molding. This perspective limits their understanding of polymer behavior, as traditional injection molding relies on high pressure and velocity to shear polymers, reducing viscosity for mold filling. This fixed-input approach overlooks the non-Newtonian nature of polymer melts, where pressure increases viscosity, necessitating large machines and molds and restricting the range of processable thermoplastics.
Controlled Viscosity Molding (CVM) disrupts this paradigm by leveraging the non-Newtonian properties of polymer melts to achieve flow and mold filling through extrusion, using far less pressure and offering superior precision. This counterintuitive, low-velocity method redefines product design, material options, and processing capabilities. By integrating data and algorithms conventional molding processes cannot, CVM delivers a fixed-output process adaptable to any thermoplastic, challenging conventional assumptions and unlocking new potential.
Pack Pressure’s Influence on Gate Freeze Time, Zach Morton, American Injection Molding Institute
An important step in developing a consistent injection molding process is determining the time required for a cavity’s gate to fully solidify. Gate solidification marks the instant at which plastic flow into or out of the mold’s cavities is no longer possible. This moment is commonly referred to as gate seal or gate freeze time. Research will be presented to show the relationship between pack pressure and gate freeze time using the AIM Institute’s process development methodology on a variety of processes, including three materials and four different molds. The investigation will include a brief review of each material’s compressibility and pvT profile. Finally, this presentation will explore how these findings may warrant changes to standard process development methodology.
Pressure Drop Studies…Are Air Shot Pressures Accurate?, David Hoffman, American Injection Molding Institute
Most processors these days are taught to do a Pressure Loss Study as part of their Scientific Molding practices. The main purposes for the study include: 1. determine which sections of the material flow path are consuming the greatest amount of pressure, 2. determine how much pressure is required to fill the mold by subtracting the air shot pressure from the machine’s pressure at transfer, and 3. determine the accuracy of mold filling simulation pressure predictions. Previous research will be summarized that shows errors with the practice of doing pressure loss studies at various steps through the mold. This will build into recent research that now questions the accuracy of the air shot pressure, in particular for materials whose viscosity is pressure sensitive. Studies will be shown that compare the pressure loss both during an air shot and during the molding cycle by incorporating a pressure sensor in the machine nozzle tip. The results will also be compared to Autodesk Moldflow simulation predictions, and how differences in the pressures could be misinterpreted. The research could ultimately call into question the entire practice of performing Pressure Loss Studies for some materials.
Ultrasonic Welding of CYROLITE and other medical plastics, Michael Zadrozny and Andrew Sneeringer, ROHM CYROLITE®
Overview of ultrasonic welding as a versatile fabrication technique for joining various plastic materials to each other, key factors influencing weld strength, weldability of acrylic copolymers to other medical plastics, and key properties of acrylic materials that make them versatile in many medical applications. We have a basic version covering fundamentals and lingo as well as an advanced version that goes through all plus testing that Roehm has had completed in the past.
Troubleshooting Acrylics in Injection Molding, Michael Zadrozny and Andrew Sneeringer, ROHM CYROLITE®
Overview, understanding and eliminating of injection molding defects with acrylics and other clear plastics, top defects and troubleshooting of the process, evaluation of each process step and how it can have a role in process improvements.
Design to Injected Part in a Single Shift with Ceramic Mold Inserts, Rajeev Kulkarni, Axtra3D
Achieving same-day design-to-injected-part production has long been a goal for product developers, enabling rapid design iterations and low-volume manufacturing. However, producing high-speed, precise, and durable 3D printed injection molding tooling has remained a challenge.
Axtra3D has addressed this with its Hybrid PhotoSynthesis (HPS) process, using the Lumia X1 printer and Forward AM’s Ultracur3D RG 3280 ceramic-filled photopolymer. HPS combines DLP for internal imaging and a laser for external boundaries, achieving SLA-quality finishes at DLP speed and allowing mold printing in 60 to 120 minutes, depending on size and geometry. The precision achieved is within 45 microns, and the mating surfaces are within 20 microns, eliminating the need for any post-machining. Customers have successfully implemented this same-day process - from CAD receipt to mold design, printing, post-processing, and injection molding to produce 30 to 3,000 end-use parts in PP, PE, TPE, TPU, and ABS.
Plastificants – A different sort of plastic, John Pinchek, Piab
Not your typical plastic which use cups or grippers to pick and place, this family of plastics challenges the EOAT maker to come up with something out of the ordinary to manipulate it throughout its forming process from just another plastic to an actual automotive part.
Shrinkage Compensation: When Cavity Size Really Matters, Mason Myers and Trevor Thorwart, Autodesk Moldflow
Accurate prediction and compensation of mold shrinkage is critical for producing high-quality plastic parts. Autodesk Moldflow, a leading simulation software, offers advanced tools for analyzing and predicting mold shrinkage, thus enabling manufacturers to achieve precision in their tool designs. This talk will delve into the principles and methodologies employed by Autodesk Moldflow for mold shrinkage prediction and compensation, highlighting key factors such as material properties, processing conditions, and mold design parameters.
We will explore the software's capabilities in simulating the cooling phase and its impact on shrinkage, as well as the compensation strategies that can be implemented to minimize dimensional deviations. Case studies will be presented to demonstrate the practical application of these techniques, showcasing how Moldflow helps optimize mold design and production processes. Attendees will gain insights into best practices for utilizing Moldflow to enhance part accuracy, reduce production costs, and improve overall product quality.
Unlocking the Potential of Polycarbonate used in Medical Molding, Derrick Hennebicque, Husky
In today's medical device and components manufacturing landscape, we rely on a combination of factors to mold smaller parts with greater precision, satisfying growing demands and higher production levels – within a smaller space.
In this context, polycarbonate has become a popular material for its high impact resistance, thermal resistance, optical clarity, light-weight, and dimensional stability. However, because polycarbonate is an engineering resin, it requires more care and attention in processing than commodity resins. How are leading medical component manufacturers leveraging polycarbonate to meet their production and business objectives? This talk will discuss:
- The properties that make polycarbonate an attractive choice for material selection
- Considerations for part design
- Best practices for processing equipment and functionality, from pellet to final part
- How to troubleshoot defects
- Case studies and examples of success using polycarbonate
How AI-driven control capabilities advance efficiency and quality in the molding environment without overcomplicating its application, Eric Anderson, Absolute Haitian
AI is increasingly being applied and practiced in injection molding to improve efficiency, precision, and cost savings by enabling predictive maintenance, optimizing process parameters, improving energy usage, enhancing quality control and facilitating connectivity between the molding machine and surrounding auxiliary equipment.
The demand for this transformative technology is moderated by the need to keep applications practical for workers to understand, thereby supplementing and amplifying the workforce. Often, molders are concerned about transferring hands-on human control of the process to an artificial intelligence. In addition, increasing the connectivity between digital and physical operations elevates the need for cybersecurity awareness and action to mitigate the risk of a breach or attack.
This presentation describes how Haitian International managed to implement AI technology at a practical level in its Generation 5 control systems without over-complicating the application or forcing customers to pay for extreme features they will rarely, if ever, use.
Smart Hot Runner for Autonomous Sequential Molding, Jeremy Makohn and Dan Ward, Barnes Molding Solutions
This talk presents a comprehensive study on the development and implementation of a smart hotrunner system designed for autonomous complex sequencing applications in injection molding processes involving parts with more than two gates. The system integrates advanced sensor technology for real-time monitoring and precise control, enabling the accurate sensing of the melt front position. This innovative, plug-and-play system is fully wired, with sensors seamlessly integrated into the hotrunner system itself, requiring no additional machining of holes into the cavity. This design significantly reduces the effort required from mold makers, streamlines the setup process, and substantially lowers setup costs. By automatically compensating for viscosity changes in the molten material, particularly in cases of batch changes or PCR processing, the smart hotrunner system ensures consistent quality and efficiency. The autonomous adjustments optimize the flow and distribution of molten material, enhancing both the efficiency and quality of the injection molding process. The integration of such intelligent systems marks a significant advancement in the field, offering substantial improvements in manufacturing precision, operational reliability, and cost-effectiveness. These findings demonstrate the potential of smart hotrunner systems to revolutionize complex sequencing applications, paving the way for more sophisticated and efficient production methodologies.
Advancement in Melt Delivery and Control Systems to help achieve Sustainability and Productivity Objectives, Lisa van der Vorst, Mold-Masters Ltd.
Learn how the latest in hot runner, auxiliary injection and control systems have helped to drive increased productivity in various applications and their critical role to successfully support applications involving processing Bio-Resins and Post Consumer Recycled (PCR) materials.
Introducing Nitrogen and Carbon Dioxide to Molding Machine, Kohei Shinohara, Sodick
Sodick’s advanced molding technologies (NRPs and INFELT-V) focus on precision, contamination reduction, improved flow properties, and energy and material efficiency, making them ideal for high-performance and complex molding challenges using Nitrogen and Carbon Dioxide inert gas.
Lightweighting of Plastic Injection Mold Inserts, Scott Kraemer, Xact Metal
For too long, we have tried to adopt 3d metal printing into mold making. However, it has not been thought through. It has been a combination of old-world brick making and then adding conformal cooling and calling it additive. While that is true, it is not taking full advantage of what the technology can offer. In some cases, the adoption of just adding conformal cooling is the best option. But to truly think differently, you need to rethink how you “could” do it. Why not infill with lattice structure? Or why not make them hollow? You could still add conformal cooling or just flood the lattice work with water. Why not learn what we can and take this technology to the next level? Listen as we explore the world of lightweighting mold inserts and experience what the future of mold making can be.
Improving Part Quality: Key Design and Manufacturing Factors, Eric Gerber, SigmaSoft
A presentation that explores the key challenges in mold development. It will cover part design, gate location determination, cooling and ejection strategies, and essential process parameters to ensure parts meet specifications.
Additionally, it will address concerns about shrinkage and warpage, guide you in selecting the right machine, and consider any special requirements.
Innovative Hybrid Molding Concepts for Cost-efficient Manufacturing of Multi-Material/Functional Components, Saeed Farahani, Clemson University
Advanced multi-material structures are known for their superior characteristics due to the synergy of different materials. However, the multi-stage and high cost of their manufacturing processes are the main drawbacks in expanding their application in cost-effective industries such as automotive. To counter these challenges, hybrid manufacturing approaches can be utilized to overcome limitations associated with earlier technologies, while adapting themselves to incorporate new materials and unique features. Moreover, hybrid manufacturing increases the complexity and technical requirements of the system, thereby making product imitation difficult. Motivated by the aforementioned aspects, several innovative hybrid molding concepts have recently been developed by our research group on the intersection of plastic injection molding process with forming, foaming, and additive manufacturing processes, which will be introduced in this presentation. While these concepts were initially proposed to overcome the manufacturing difficulties of multi-material components, the unique design flexibility provided by these integrations hypothesizes such hybrid technologies as a promising pathway towards cost-efficiently manufacturing of composites and multi-material parts while increasing their performance and functionality.
Conveying: The Underrated Utility Powering Plastics Manufacturing, Nick Paradiso, Paradiso
In plastics manufacturing, power, water, and compressed air are recognized as essential utilities—but what about resin conveying? Often overlooked, resin conveying systems are critical for ensuring efficient, safe, and automated material handling. In this presentation, we’ll explore why conveying is the backbone of plastics processing, how Conair’s industry-leading technology simplifies material flow, and how our innovations—such as Conveying with Optimizer, Wave Conveying, and the SmartFLX control—empower our processors to excel in a highly competitive space. We’ll also discuss how Conair’s expertise, unmatched service, and commitment to R&D keep us at the forefront of innovation. Join us as we highlight why resin conveying is not just a utility—it’s a game changer for our processors.
Two-Stage Process: The most environmentally friendly way to recycle, Lukas Neunzig, Engel
The 2-stage process developed by ENGEL is an innovative solution designed to enhance the efficiency and sustainability of plastics recycling. This process divides the traditional injection molding procedure into two distinct stages: plasticization and injection. By separating these stages, the system allows for effective filtration and degassing of the melt, which significantly reduces contamination and volatile organic compounds. This results in improved product quality with fewer defects and enhanced mechanical properties. Additionally, the 2-stage process offers substantial energy savings and a reduction in CO2 emissions, making it an environmentally friendly choice. It is particularly beneficial for processing recycled materials, as it shortens the recycling chain from flake to finished product, thereby reducing costs, and improving overall efficiency.
Invisible Weld Lines: Direct-Flo Hot Runner Systems with Heat-INject™ Technology, Matthew Robb, INCOE
Hot Runner System technology advancements allow increased freedom and flexibility in the Mold Design, solve complex Runner and Gating Applications, and improve Molding Process challenges. Part and Process optimization can be achieved with Heat-INject: a dynamic localized cavity surface temperature control technology. INCOE will showcase new technologies and case-study applications: Heat-INject, SoftGate, and SealFit Direct-Flo Systems.
Faster Product and Process Development with Real-Time Chemical Intelligence, Christoph Pielen, Anton Paar
In polymer processing, meeting quality standards while optimizing development time and minimizing waste is a constant challenge. Traditionally, quality assessments have relied on offline, retrospective analysis, leading to long optimization cycles and high resource consumption. Blending polymers is crucial for achieving the right mechanical, optical, and thermal properties. However, maintaining the correct composition throughout the process isn’t always easy. Errors in dosing, mixing, or material handling can lead to inconsistent products and costly batch failures. By integrating the Cora 5001 Raman Analyzer into lab extruders, we can now track chemical and compositional changes in real time. This not only allows for immediate corrective actions but also improves overall process control, consistency, and product quality. Real-time, in situ chemical intelligence enables faster, more efficient product and process development, and allows quick, evidence-based responses to quality control. The integrated monitoring capability of the Cora 5001 bringing us one step closer to smarter, more sustainable manufacturing and opens new possibilities for real-time, in-situ monitoring of polymer composition during extrusion. In this talk, we explain the experimental setup, show how we used Raman signals to track PC/PMMA ratios, and discuss how this technology enables faster feedback, better formulations, and more reliable polymer production.
Unlocking Innovation with Hot Runner Systems: Compact Solutions, Paul Boettger, Technoject
We'll explore how these compact, high-performance solutions are being applied in industries like medical devices, electronics, packaging and beyond. Learn how Heitec's technology can improve efficiency and precision in small-size applications, and how it can benefit your production processes. Heitec’s unique nozzle and manifold designs including miniature valve gate nozzles, compact edge gate designs and slim diameter nozzles lead to compact molds and better processing for small molded articles.
Precision Cleaning for Plastics Manufacturing: Understanding Dry Ice Blasting, Mike Henderson, Cold Jet
Join Cold Jet at our conference session to discover the significant advantages of dry ice blasting for cleaning within the Plastics industry. This presentation will detail how Cold Jet's innovative dry ice blasting technology offers an efficient, high-quality, and sustainable solution for companies aiming to optimize their manufacturing processes. Learn how this non-abrasive method effectively removes residues, mold-release agents, and contaminants from crucial equipment like molds and extruders without the risk of damage associated with traditional abrasive or chemical cleaning. Cold Jet will explain the science behind dry ice blasting, highlighting its non-toxic nature and residue-free operation, and underscore the importance of selecting the right equipment to achieve superior results in maintaining product quality and operational efficiency.