Level Up Your Moldmaking With AI

This article explores how AI-based feature detection is revolutionizing mold design and manufacturing by automating complex, repetitive tasks and accelerating CAD/CAM workflows. Trained on over 100,000 part models, the AI “learns” to recognize and classify features such as pockets and holes, color-coding them for seamless transition into automated machining. By reducing manual programming and errors, AI allows skilled moldmakers to focus on higher-level innovation. The piece emphasizes a human-AI partnership, where expert validation ensures accuracy and continual learning. Looking ahead, AI promises to automate mold assemblies, electrode design and generative layouts, defining the future of intelligent moldmaking.

MMT Chats: One Moldmaker’s Mission Empowers Veterans

This MMT Chats episode features Don Starkey, moldmaking veteran and chairman of Progressive Components, who helps lead iWarriors — a volunteer-run nonprofit providing iPads to wounded veterans for connection, recovery and independence.

Founded in 2011 by moldmakers Tim and Kim Bartz, iWarriors has since gifted over 1,100 iPads to veterans coping with PTSD and traumatic brain injuries. Starkey and Progressive ensure every dollar raised through golf outings and merchandise goes directly to recipients. Beyond technology, the program fosters community, empowerment and hope, bridging veterans to family, education and essential services while keeping a powerful moldmaking mission alive.

What Is Design for Manufacturing? Part 1 of 4

This article explains the principles and best practices of Design for Manufacturing (DFM), the process of designing parts and products for easier, lower-cost production without compromising quality. It emphasizes conducting DFM early in the design phase with input from engineers, designers, mold builders and suppliers to identify inefficiencies and prevent costly changes later. The piece outlines key considerations for design, material selection, environment and compliance, along with 10 proven DFM principles that reduce part count, standardize components and simplify assembly. Ultimately, effective DFM ensures optimized, manufacturable designs that balance performance, cost and production efficiency across the entire product lifecycle.

Machine Sizing and Specification for Optimal Mold Performance, Part 1

This article outlines seven key guidelines for ensuring a new or existing injection mold fits properly and operates efficiently within the molding machine.

Focusing on the clamp system, Part 1 of this two-part series covers essential considerations such as tie bar spacing, stroke and shut height, mounting alignment, locating ring size, clamp tonnage calculation, platen rigidity and dry cycle speed. Proper configuration of these parameters prevents mold damage, flash and premature wear while enabling consistent, high-quality part production. Ultimately, optimizing the mold-machine interface is critical to achieving reliable performance, full production speed and extended mold life.

Too Old for the Form, Too Good to Ignore

This piece profiles Andrea Gruber, a PhD candidate at UMass Lowell specializing in thermal interface phenomena in precision injection molding. Named 2024 Teaching Assistant of the Year, she has developed comprehensive expertise across the entire mold development process — from design and simulation to machining and molding.

Her research addresses heat transfer at mold-polymer interfaces, bridging simulation tools with hands-on manufacturing. Andrea mentored student teams through complex mold engineering projects and emphasizes viewing moldmaking as a systems-level design challenge. The article includes her insights on transitioning from academia to industry, highlighting her commitment to bridging laboratory research with practical shop floor applications.

Real-Time Mold Monitoring Boosts Molding Efficiency and Cost Savings

ProPlastics, founded in 2021 by Dan McMahon in Sidney, Ohio, built its manufacturing operation around technology from inception. Operating nine presses with a young workforce averaging 30 years old, the company implemented SensFlo's FloControl monitoring system to optimize production.

The system uses IoT devices and automatic mold identification to track real-time process parameters, sending alerts when deviations occur. Results include over 100 minutes of daily time savings from eliminating manual data collection, improved quality control, and enhanced operator performance tracking. The technology enables precise cycle time monitoring and predictive maintenance, with setup requiring just five minutes per machine, demonstrating how modern manufacturers leverage advanced monitoring for competitive advantage.

Strategic Mold Venting

This article from the Emphasizing the Basics series by industry veteran Dennis Czubin focuses on the critical role of venting in mold design. Czubin explains how improper or inadequate venting causes common molding defects — such as burning, weak weld lines and short shots — and outlines best practices for designing, cutting and maintaining vents. He compares traditional and vacuum venting methods, warns against relying on “natural” venting and stresses verifying vent depths and monitoring wear over time.

Drawing on decades of experience, Czubin underscores that precise venting design directly impacts mold performance, part quality and overall production efficiency in plastics manufacturing.

30 Under 30: The Next Generation Reshaping Moldmaking

MoldMaking Technology’s “30 Under 30: The Next Generation Reshaping Moldmaking” highlights young professionals driving innovation and progress in the moldmaking industry.

These under-30 honorees represent diverse backgrounds and roles — from CNC machinists and engineers to managers and marketers — all contributing fresh ideas, technical skills and leadership. Many entered the trade with little experience but advanced quickly through adaptability and continuous learning. They are helping shops modernize with automation, software and improved processes while mentoring peers and promoting manufacturing careers. This program recognizes their impact and showcases the evolving, opportunity-rich future of moldmaking.

The Overlooked Solution to Manufacturing's Skills Gap

This piece argues that manufacturing should actively recruit experienced professionals over 50 who left the industry during economic downturns, rather than focusing solely on developing young talent. Using materials engineer Robert Scavuzzo as an example, the article highlights how downsizing between 1,990-2,000 displaced skilled workers whose tribal knowledge could immediately solve current shop floor problems like inefficient cooling and process improvement. These seasoned professionals offer mentorship capabilities and practical expertise that today's facilities desperately need. The author advocates for a balanced workforce strategy incorporating part-time roles, consulting positions and knowledge transfer programs to preserve irreplaceable expertise before retirement-age experts permanently leave, emphasizing experience as essential rather than expensive.

Strategic Mold Cooling – Hot Spots

This article explores practical methods for cooling hard-to-reach hot spots in injection molds that affect cycle time and part quality. It reviews traditional and specialty cooling materials such as copper and tungsten carbide alloys, as well as heat pipes that efficiently transfer heat.

When these methods fall short, the author details creative air-cooling solutions — from external jets to internal air channels, core pins and ejector sleeve designs — to manage localized heat buildup. Emphasizing design-stage planning, the article demonstrates how unconventional cooling approaches can enhance productivity, part appearance and mold longevity in challenging molding applications.

Partnerships Fuel Moldmaker’s Growth in Technology and Training

This profile highlights Versatile Mold and Design, a family-owned precision mold manufacturer now backed by The Heico Companies, combining small-company craftsmanship with large-scale resources. 

Founded in 1998 by Robert Heusser Sr., Versatile specializes in thermoset and thermoplastic tooling, advanced automation and full-service mold manufacturing from design to maintenance. Under President Robert Heusser Jr., the company emphasizes technology investment, apprentice training and international partnerships to reduce lead times and improve efficiency. Recent growth includes lights-out machining, digital collaboration and expansion into medical tooling. Guided by its founder’s customer-first philosophy, Versatile continues to blend innovation, quality and workforce development to drive sustainable growth.

Strategic Mold Cooling: Common Causes of Inadequate Mold Cooling

This article examines common causes of inadequate mold cooling and offers practical solutions to maintain optimal flow and temperature control. Issues such as air locks, starved cooling lines, lime and rust buildup and improperly installed bubblers or baffles can restrict coolant flow and reduce cooling efficiency, leading to longer cycle times and poor part quality. The author shares firsthand experiences and troubleshooting tips, including using restrictors, cleaning techniques and proper manifold setup. Emphasizing consistent maintenance and system checks, the article highlights how even small cooling issues can significantly impact mold performance, productivity and overall part consistency.

Requirements for Automated DFM for Injection Molding

This piece discusses how automated design for manufacturability (DFM) tools are revolutionizing injection molding by enabling engineers to identify and resolve design flaws before production begins.

These AI-powered systems analyze draft angles, wall thickness, undercuts and parting lines using color-coded heat maps and visual markers. By providing instant, pre-quote feedback on part moldability and potential cost impacts, automated DFM tools — combined with human expertise —help designers avoid costly revisions, tooling bottlenecks and production delays. This integrated approach streamlines workflows, reduces manufacturing costs and accelerates time-to-market for injection-molded products, transforming what traditionally took weeks into an instantaneous process.