Published 05/29/2024

Advancing Moldmaking and Plastics: Trends in 3D Printing, Automation and Sustainability

NPE 2024 showcased the latest trends and technologies in innovation, efficiency and sustainability for moldmakers and molders, featuring advancements in 3D printing, automation, design and virtual reality/augmented reality/artificial intelligence.

Christina Fuges

Editorial Director, MoldMaking Technology

5 Product Innovation Areas Noted by Mold-Building Attendees

Tooling, Mold Design and Maintenance: The Plastek Group is focused on reverse engineering, 3D printing and conformal cooling design, M.R. Mold is advancing LSR tooling, and Westminster Tool continues to develop and use Mantle technology for metal-3D printed tooling. Xact Metal is collaborating with Dlyte's dry electropolishing technology to achieve optimal surface finishes for 3D-printed tooling; Hermle introduced a hybrid machine that combines cold spray technology with traditional machining, International Mold Steel offers HTC metal powder for enhanced moldmaking capabilities and Uddeholm showcased its Corrax tool steel powder optimized for 3D printing (read about the partnership with Xact Metal). Then there are innovations in mold design and maintenance by companies Accede Mold’s servo display in the Mold-Masters’ booth, DME with its two-piece-design collapsible core that enables each segment to open and close independently, ensuring virtually no stress on either segment and companies introducing products that simplify maintenance and installation, such as CUMSA's new cylinder for controlling pre-opening movements in molds.
Precision and Quality: Companies highlighted advancements in precision and quality, like Incoe Corp.'s dynamic localized mold temperature control technology using targeted heat pulses, Husky's servo-controlled injection system that permits more precise melt control right in the gate and Mold-Masters hot runner temperature controller design that eliminates conventional mold thermocouple and power cables and replaces them with a single, lightweight cable connecting the mold to the control head unit.
Advanced Materials: There was a focus on advanced materials, with companies like Ellwood Specialty Metals showcasing high-temperature aluminum plates and Uddeholm USA showcasing an ESR mold steel.
Enhanced Data Collection and Monitoring: Companies like Progressive Components demonstrated a cloud-based system for mold monitoring and asset management and Hasco promoted precise tracking of injection mold inventory for improved production planning.
Sustainability: There is still a strong emphasis on sustainability, with several companies offering solutions that promote environmental sustainability, such as Top Grade Molds' co-injection mold technology, Oerlikon HRSflow's multi-cavity line for low shot weights, that offers fast cycle time, high production volume, processing of PCR compounds and biopolymers and Witosa's 3D printed hot runner nozzle and hardened steel energy blocker for reducing time and costs. This also includes companies like Cold Jet and Cool Clean Technologies, offering dry ice cleaning solutions for more sustainable and no-touch surface preparation.

3D Printing

The overwhelming interest from mold builders who attended NPE was in 3D printing (3DP). It is clear from the 3DP companies exhibiting that this technology has transitioned from initial excitement to a phase of maturity and acceptance as it has become more justifiable to implement. Companies have learned to effectively integrate 3D printing into their operations, solving real problems and proving the technology's value and reliability. This broader adoption spans multiple industries where 3DP is used for creating complex geometries and multi-material tooling components.

Efficient Engineering and Expertise

Advancements in engineering were evident as well. Companies are using imaging and augmented reality technologies in their operations, suggesting a trend towards digitalization and enhanced visualization in moldmaking. For example, enhanced automation and use of Virtual Reality (VR), Augmented Reality (AR) and Artificial Intelligence (AI) to improve 3D mold design and maintenance to streamline workflows, reduce errors, increase productivity and improve mold design accuracy. AR and VR technologies are answering the call for a skilled workforce trained for emerging job roles as well by providing immersive training experiences. These engineering advancements also include developments in mold component and hot runner technology to improve control, precision and efficiency as well as to increase overall part design freedom and speed to market.

Data Monitoring

Data-driven decision-making and AI are reshaping mold manufacturing. The integration of cloud-based mold monitoring, AI-driven automation and data analytics is becoming standard practice, driving significant improvements in operational efficiency and quality. Monitoring systems provide real-time insights, enabling predictive maintenance and optimized performance via cloud-based systems for comprehensive asset management.

Sustainability and Efficiency

Sustainability remains a focus, with companies focusing on how their products and processes contribute to a more sustainable economy, such as by using bio resins, employing co-injection molding and lightweighting via mold designs that reduce material usage while maintaining strength and quality. For example, hot runner technology is being designed to address the specific requirements of bio resins, reflecting a broader trend towards sustainability in materials.

Training and Education

The industry continues to emphasize training and education to ensure a skilled workforce for the future with a focus on mentoring programs to transfer knowledge and develop future engineering talent. Collaborative programs with technical education institutions and eLearning initiatives are critical components of this effort. Programs designed to attract, train and retain talent are essential. Companies are leveraging eLearning for sustainability training and to bridge knowledge gaps while also establishing partnerships with educational institutions to help align curricula with industry needs, preparing students for careers in moldmaking.

These technologies and trends are just a few I was able to observe during my very busy week at NPE that are helping to reshape mold manufacturing. The MMT team is working on following up on many of these trends in future content to do our part in helping to advance moldmaking.