Tuesday, December 11, 2018
All News
Mold Performance: Tap Into the Power of Data Collection
September 26, 2017
Collecting core data in a transparent way allows molders to drill into the true cost of tooling issues and develop real goals to keep production flowing. As part of MoldTrax training, operators are shown how documentation can be used to identify and troubleshoot mold issues by observing defect patterns and trends. Scheduled vs. unscheduled mold
HRSflow Opens Service Center in Mexico
September 26, 2017
Local spare-parts service. After opening a state-of-the-art hot-runner manufacturing plant in Byron Center, Mich., last year (see Nov. ’15 Starting Up), HRSflow of Italy has established a service center in Queretaro, Mexico, in cooperation with WCS. It will provide 24-hr spare-parts service to all of Mexico. +52 (1) 442 38 62 975 • email
One Place to Hang Out at K
September 26, 2017
If You Thirst for More Than Technology I gather it’s something of a K Show tradition: Near the end of a hard day at the world’s biggest plastics trade fair, those in the know (and maybe a journalist with an interview appointment) repair to a quiet upstairs lounge at the booth of Gammaflux, the venerable hot-runner controls source (since
Novel Hot-Runner Technology Borrows From Flat-Die Extrusion
September 26, 2017
Nozzles with a wide slit fill at lower temperature and pressure. At this month’s K 2016 show in Dusseldorf, Austrian moldmaker Haidlmair will introduce a new hot-runner technology that combines the know-how of its injection moldmaking business with that of its extrusion flat-die business, called EMO. The new FDU (Flat Die Unit)
Block Cavities and Keep Molding
September 26, 2017
AN ‘EXTREME’ EXAMPLE To illustrate the procedure using these control techniques, a trial was conducted at our sister company, Synventive Molding Solutions, in its lab in Peabody, Mass., using a four-cavity direct valve-gated mold (Fig. 4). In the first set of trials, automatic hot-runner balancing and switchover from injection to
INJECTION MOLDING: Hot-Runner Enhancements Ease Processing & Maintenance
September 26, 2017
Three new hot-runner components are available from HRSflow of Italy (offices in Byron Center, Mich., and Windsor, Ont.). First is the new Three-Layer Tip, a nozzle tip made of three materials, with no coating. One of the materials is a copper bushing inside the flow channel to improve thermal conductivity. It’s said to provide
Barnes Group to Acquire Gammaflux
September 26, 2017
Hot-runner controls supplier joins a stable of prominent names in hot-runner, controls, and tooling. Adding to its growing stable of plastics injection molding and tooling-related companies, Barnes Group Inc., Bristol, Conn., has signed a definitive agreement to buy privately held Gammaflux L.P., a leading supplier of hot-runner
Incoe Recognized for Workplace Safety
September 26, 2017
Amerisure Insurance acknowledges hot runner supplier. Hot runner supplier Incoe Corporation, Troy, Mich., has received a safety award for “Outstanding Safety Performance and Continuous Improvement” from Amerisure Insurance Company for the years 2015–2016. “Receiving this award validates the commitment we’ve put
Hot Runners & 3D-Printed Molds Headlined at K Show
September 26, 2017
The FDU is still developmental and is currently available only with Haidlmair molds. The company hopes to make it fully commercial this year. It is also working on an FDU 2.0 version for 2017 that will leave less gate vestige and have faster cycles. In other hot-runner news, Gunther Hot Runner Systems, Inc. (U.S. office in Hoffmann Estates, Ill.)
Injection Molding: Differentiated Power Distribution Give Hot Runner Nozzles a Uniform Temperature
September 26, 2017
Interchangeable nozzle tips make different types of gating possible. New Product Post: 8/24/2017 The smartFILL single nozzle hot runner temperature nozzles feature an array of interchangeable tips to take on different gating scenarios and materials.  Austrian standard mold components supplier Meusburger Georg GmbH & Co. KG (Wolfurt;
Injection Molding: New Compact Hot-Runner Nozzles Debut at Fakuma Show
September 26, 2017
At next month’s Fakuma show in Friedrichshafen, Germany, HRSflow of Italy (U.S. office in Byron Center, Mich.) will show off a new family of screw-in hot-runner nozzles for small, delicate parts such as loudspeaker grilles and for reverse gating from the ejector side. Thanks to a space-saving heating system,
HEATING/COOLING: Lower Temperature Range for Portable Chillers
September 26, 2017
Expansion of temperature control line extends chilling range lower. New Product Post: 5/5/2017 Mokon, Buffalo, N.Y. has expanded its Iceman SC Series of portable chillers, adding the ASL and WSL lines. The ASL and WSL offer a fluid temperature range of 5°F to 30°F (-15°C to -1°C) and a capacity of 1½ to 7½ tons. The
HEATING/COOLING: Compact Mold Temperature Controller Gets Smaller, Lighter
September 26, 2017
New series is 27% lighter and has a 23% smaller footprint. New Product Post: 5/5/2017 Matsui’s new MC5 mold temperature controllers reportedly reach temperature settings quickly, allowing molders can start processing sooner. The controllers are available in 12 different models, with the MC5-G1 series hot-water controllers sold in 25-, 55- and
Chiller Sets New Benchmarks For Energy Efficiency, Tight Control
September 26, 2017
Here are more details on what is heralded as “the most efficient industrial process chiller on the market,” first discussed briefly in last month’s Keeping Up section. Jochen Naujokat, president of Delta T Systems, Richfield, Wis., and Rick Holzhauer, the firm’s chief mechanical engineer, previewed this development
TOOLING: 3D Printed Mold Inserts With Conformal Cooling
September 26, 2017
The DME brand of Milacron Holdings Corp., Madison Heights, Mich., has partnered with Linear AMS (a Moog Company), Livonia, Mich., to offer metal 3D-printed molds with conformal cooling. Unlike conventional cooling with straight, gun-drilled cooling channels, conformal cooling can employ complex arrangements of curved and
The Next Game-Changing Technology in Tools and Dies
September 26, 2017
The first conformal-cooled tools entered the European market 25 years ago; a new conference aims to determine what the next 25 years could hold. Blog Post: 4/18/2017 Robert Beard, P.E., Honored Fellow SPE Guest Blogger and President, Robert A. Beard & Associates Inc. Last year, I achieved 50 years of continuous membership in the Society of
Heating/Cooling: New Central Cooling Pump Sets Features Variable Frequency Drives, New Control
September 26, 2017
Pumps automatically equalize pressure depending on process cooling demands, including number of machines, process pressures and flow rates. New Product Post: 8/24/2017 The Frigel Aquagel GPV central cooling pump sets follows up on the GPP line, adding variable frequency drives and Frigel’s 3PR control.  Italian process cooling
Materials: Cycle Time: Science vs. Rules of Thumb—Part 2
September 26, 2017
In June’s column, I discussed the often-cited connection between the deflection temperature under load (DTUL) for a given material and the appropriate temperature at which a part molded from that material can be ejected from the mold without exhibiting excessive distortion while cooling the rest of the way down to room temperature. Not
Thermal Care Names New Director, Sales & Marketing
September 26, 2017
Specialist in process cooling adds former Grainger exec. Thermal Care, Niles, Ill., a division of IPEG, has named Brad Regillio director of sales and marketing for the company, which specializes in process cooling equipment. Regillio’s most recently worked for W.W. Grainger, where he was director of global sales and
More Examples of Advanced Chilling Technology
September 26, 2017
Now three chiller makers use variable-speed condensers to save energy. Last month, we reported in a Close Up article on a new line of small portable chillers due to hit the market in July from Delta T Systems, Richfield, Wis., that is said to embody a unique collection of technologies and features that provide significant energy
Glass-Filled Nylon 6 and PBT in Two-Part Top Steering Wheel Column Module Housing.
September 26, 2017
BASF’s Ultradur PBT and Ultramid nylon 6 featured in new BMW 3 to 7 series of cars with rear-wheel drive. The new BMW 3 to 7 series of vehicles with rear-wheel drive from the BMW Group features a nylon 6 and two PBT resins from BASF, Florham Park, N.J., in the top column module that connects the steering wheel with the control
Albis Plastics Starts Up New Compounding Plant
September 26, 2017
Prime technical compounds are now being manufactured by Albis in the U.S. Albis Plastics GmbH, (U.S. office in Duncan, S.C) via its subsidiary Albis Plastics Corp. has begun to manufacture prime technical compounds under the Alcom (including PC, ABS, and ABS/PC) and the broad range of customized engineered Altech brands at their new
Conventus Polymers Now Distributes LG Engineering Thermoplastics
September 26, 2017
The agreement covers a broad range of compounded materials in LG Chem’s product portfolio. Distributor of high-performance engineering thermoplastics Conventus Polymers LLC, Parsippany, N.J., is now a distributor in the U.S. and Canada for the extensive line of engineering thermoplastics of Korea’s LG Chem. The agreement covers a broad
New Ionomer Decorative Effects Using Hot Stamping
September 26, 2017
DuPont collaboration with Kurz Group leads to golden or metallized effects. A collaborative R&D effort between DuPont Performance Polymers, Wilmington, Del. and the Kurz Group (U.S. office in Charlotte, N.C.), a renowned innovator in hot stamping and cold transfer technology, has led to the “beautifying” of products made of the
How to Prevent Stress Whitening in PP Copolymers
September 26, 2017
A look at causes, detection, and prevention. Interior automotive components such as instrument panels are typical applications where stress whitening is a concern. Whitening or blush occurs on the part surface after impact or deformation. There are many factors to consider when seeking a robust solution to stress whitening. Light is scattered
Cycle Time: Science vs. Rules of Thumb—Part 4
September 26, 2017
While laboratory tests are helpful in determining how polymers behave, you must remember the fundamental differences between laboratory measurements and the real world of plastic processing. Let’s examine semi-crystalline polymers here. Plots of elastic modulus as a function of temperature for five different grades of nylon 6. Predictably,
Harvey Impact Delays Startup of Some New Ethylene Capacity
September 26, 2017
While several plants have restarted or are in restart mode, logistics continue to be an issue, though improvement there is also underway. Check out the latest post-Harvey analyses on availability of some key feedstocks and resins from IHS Markit with PetroChemWire (PCW) weighing in. ● Ethylene: Around 10% of U.S. ethylene production remains
Resin Prices Rise in Mid-September
September 26, 2017
Harvey helps push up PP, PE, PS, PVC and PET pricing. By mid-September, unlike the previous month at that point, it was clear that prices of all commodity thermoplastics were firm-to-up and the post-Hurricane Harvey impact was central to this movement. This, according to the latest weekly PetroChemWire (PCW) reports on PP, PE, PS, PVC and PET, as
Leading-Edge Molding Technology Installed at ORNL
September 26, 2017
Roctool’s induction-powered heating/cooling equipment to further development of composites. France’s Roctool (RocTool Inc. Charlotte, N.C) has installed its leading-edge composites molding technology at Oak Ridge National Laboratory (ORNL). A developer of mold heating and cooling technologies, Roctool installed its large double-zone
Two-Stage Injection Meets Molder’s Need for High Precision
September 26, 2017
Fixed screw and plunger with no check ring hold tolerances of millionths of an inch. Molding these acrylic level vials requires holding tolerances of a few millionths of an inch, with a very narrow process window. The two-stage screw/plunger system on Empire’s Sodick presses eliminates the reciprocating screw and the need for a check valve,
INJECTION MOLDING: Multi-Shot In-Mold Assembly Swaps Out TPE for LSR
September 26, 2017
Special cold-sprue bushing and third LSR-specific injection unit create finished, sealed automotive duct in 55 seconds. New Product Post: 9/21/2016 Building off a concept which had previous iterations displayed at NPE2012 and NPE2015, French mold maker Georges Pernoud (U.S. office in Detroit) has added over molding of an LSR gasket on its Multitube
What Is the Right Plastics Joining Process for You? Part 1
September 26, 2017
Changing demands, advancing technology and a process-neutral approach to plastics joining for under-the-hood automotive parts. It has been over 25 years since polyamide was used in place of cast aluminum for the first time in a mass-production, air intake manifold in the U.S. Since then, replacing metal components with plastics in automotive
How to Solve Common Ultrasonic Welding Problems
September 26, 2017
Another remedy is to look at equipment that operates on a higher frequency, perhaps 30 or 40 kHz, provided the tooling required by the application is available for use at this frequency. Higher-frequency equipment produces lower amplitude output, but compensates by resonating at a higher frequency. Thus, higher- frequency welders are considered
WELDING: RFID-Coded Weld Tools for Medical Devices
September 26, 2017
Two new features that ensure significant production security when changing welding tools in the assembly of plastic medical devices and other plastic assemblies are now being offered by Hermmann Ultrasonics, Bartlett, Ill.. Both features, showcased at MD&M West 2017 (Feb. 7-9, Anaheim, Ca.), can be easily integrated into the company’s
WELDING: All-Electric, Next-Generation Spin Welder
September 26, 2017
Dukane’s new Servo Weld Plus comes with Melt-Match technology. New Product Post: 12/15/2016 Servo Weld Plus with Melt-Match technology applies servomotors for greater accuracy. A next-generation spin welder from Dukane, St. Charles, Ill., is an all-electric press system that uses two servomotors to provide precise control and accuracy
Welding Pre-hardened 40 Rockwell Material
September 26, 2017
Key tips help ensure safe shop welding practices when using pre-hardened 40 Rockwell material.Article Post: 9/1/2017 Contributed by Paul W. Britton Images courtesy of PCS Company. Pre-hardened 40 Rockwell material is an alternative option to a pre-hardened P20 mold steel. It offers uniform hardness distribution through its center but requires
Molder Gets Hermetic Seal, High Yield with Servo Welder
September 26, 2017
Supplier of power protection systems avoids redesign of molds by replacing pneumatic ultrasonic welder. Yield of this SEL PC reset fault indicator was increased substantially by replacing a pneumatic unit with a servo welder. SEL’s new Dukane iQ Series servo-controlled ultrasonic welding system is integrated into a robotic cell. Previous
What Is the Right Plastics Joining Process for You: Part 3—Coolant Manifold Case Study
September 26, 2017
What is the most appropriate plastics joining solution for a 30% glass-filled nylon coolant manifold? To illustrate the process of determining the most appropriate plastics joining solution for a particular application, consider the coolant manifold shown in Fig. 10 above. Assume for a moment that the part shape has yet to be finalized and that the
What Is the Right Plastics Joining Process for You: Part 2—Available Technologies
September 26, 2017
The four primary joining technologies—vibration, clean vibration, infrared, hot-gas/convection—offer different benefits and challenges for different applications. Vibration welding uses heat energy generated when one part is held stationary while the other part is moved in a linear, back-and-forth motion. The heat generated initiates a
Polymer Resources: Compounding's 'Small Big Guy'
September 26, 2017
This compounder combines a service-first, small-company mindset with the technical might of larger companies to carve a niche in engineering plastics. For Scott Anderson, Polymer Resources’ COO, this compounder’s service-first mindset and ability to tailor resins to highly specific requirements give it a competitive edge in the market.
Additives: Polyolefin Discoloration
September 26, 2017
There’s a growing demand for PE films with lower initial color and improved color stability, as well as better retention of physical properties. New stabilizer systems address these and similar concerns for molded PE and PP parts. BASF Plastic Additives’ Rick King (center), with scientist II Katiah Anderton (right) and associate
TESTING: New Software Boosts Surface Analyzer's Capabilities
September 26, 2017
Cincinnati-based BTG Labs  has introduced the new Archer software that further enhances the capabilities of its Surface Analyst SA3001. First launched in 2014, this was the first fully self-contained instrument for non-destructive testing of a part’s surface conditions on the shop floor. Designed to quickly and easily test whether a
The Need for Generalists: Part 4
September 26, 2017
When I started my first test lab in 1986, I was the first and only employee. This was an invaluable experience because it meant that I fulfilled all the functions required in the lab. Setting up the equipment, learning the software, establishing the test methods, making samples, running the tests, analyzing the data, writing the reports, and
TESTING: Advanced DSC/TGA Thermal Analyzer
September 26, 2017
A new differential scanning calorimeter and thermogravimetric analyzer (DSC/TGA) from TA Instruments, New Castle, Del., is said to deliver ‘unprecedented’ performance in sensitivity, baseline stability, temperature and atmosphere control. The Discovery SDT 650 is reportedly the first simultaneous DSC/TGA to incorporate TA’s most
TESTING: Laser Scanner for Complex Parts
September 26, 2017
A hand-held scanner that incorporates blue laser technology, ultra-fast frame rate, specially developed Nikon optics and the ability to measure the most challenging materials has been introduced by Nikon Metrology, Inc., Brighton, Mich., Said to represent a new generation of scanners, the ModelMaker H120 scanner is said to be ideal for use in the
TESTING: Haze Meter for Plastic Films
September 26, 2017
A new instrument that promises fast and accurate measurement of the optical quality of plastic films and other transparent materials is newly available from Paul N. Gardner Co. (GARDC0), Pompano Beach, Fla. The new Novo-Haze TX haze meter reportedly measures total transmission and haze according to ASTM D1003 (CIE, C), the key standard used in most
TESTING: High-Pressure TGA Benchtop for High-Performance Plastics
September 26, 2017
What is said to be the first ‘benchtop’ high-pressure TGA system has been launched by TA Instruments, New Castle, Del. At the core of the new Discovery HP-TGA750 is a patented ultra-high resolution magnetic suspension balance, and new temperature control system that combined produces the most sensitive and accurate results. Its magnetic
DECORATING: High-Speed Inkjet Printer for Cables
September 26, 2017
The latest high-speed continuous inkjet printer from Paul Leibinger (U.S. office in East Troy, Wis.) will debut at K 2016.  Jet3up Rapid reportedly allows cables to be marked immediately after extrusion at up to 1000 m/min (60 km/h). The inkjet coder is said to achieve never-before-seen speeds when marking and coding other plastic
Dramatic New Potential for Circuitry Printed on Plastics
September 26, 2017
Novel nano-silver and nano-copper inks reduce costs and complexity, while opening up new applications. Printed circuitry on thin film with nanoparticle ink. Direct digital printing of conductive inks onto molded plastic makes cellphone antennas more simply than by co-molding and laser direct structuring (LDS). Previous Next Printed circuit boards
Rubbery, Velvety, Silky: Properties of Coated Auto Plastic Parts
September 26, 2017
HapticMapping is an objective approach for determining the haptic properties of PUR-coated plastics. The coating of interior automotive plastic components to improve appearance, physical properties and to impart the unique soft feel also referred to as haptic feel, has been taking place for some time. However, a key challenge in developing haptic