Advancing the Mold With New Technologies

Hot Runners

Thermal Simulation Provides Additional Security for Hot Runners

Photo Credit: Hasco

In the future, Hasco Hot Runner, a business unit of Hasco, says it will offer its customers additional security with thermal simulation to meet the challenges of high-performance plastics with ever narrowing processing temperature windows. According to Hasco, thermal irregularities or hot spots are already detected during the design process and can be ideally designed by adjusting the heating curve and optimizing the position of the thermal sensor. As a result, the temperature curve of the manifold can be analyzed, as well as the temperature curve of the plastic in the melt channel. When processing temperature-sensitive plastics in particular, the process reliability and the production quality are significantly increased.

Controller Cart Transports Hot Runner Control Units Closer to the Mold

Photo Credit: Hasco

With the Co-Cart transport trolley offering from Hasco Hot Runner, a business unit of Hasco, external hot runner control units can be positioned safely and optimally right next to the mold. The practical, robust cart offers many advantages, Hasco notes, including optimum ease of operation. The smooth rollers enable the safe transport of any hot runner control unit, and the slip-resistant tabletop and raised edges around the cart’s perimeter ensure that the device can neither slip nor tip over. A plastic box in the lower compartment of the Co-Cart offers storage space for all connecting cables and additional equipment; this prevents transport being blocked by cables hanging down when the cart is being moved.

Industrial HMI Remote Access for Hot Runner Controls

Photo Credit: Fast Heat by Spark Industries

Until now, Fast Heat hot runner controls have been able to be remotely controlled with a VNC Viewer application since the advent of the company’s latest touchscreen HMIs. However, according to the company, this application requires the remote access computer or device to be on the same network, meaning a remote user would have to VPN into that network to connect to a hot runner controller.

Advanced Human Machine Interface Improves Hot Runner Control, Flexibility

Photo Credit: Oerlikon HRSflow

Oerlikon HRSflow has thoroughly revised the software for the control unit of its FLEXflow hot runner systems, with updates to the human machine interface (HMI) 4.0 and access authorizations. 

HMI 4.0 now offers the possibility to control multiple servo motors individually and with specific data, Oerlikon HRSflow says. This also enables the handling of systems with mixed nozzle dimensions. 

Next-Generation Advanced Hot Runner Technology for Precision Molds

Photo Credit: Westfall Technik

Westfall Technik’s MHS Hot Runner systems are designed for reliability and longevity in order to mass produce billions of precision-molded parts. Westfall says its hot runner solutions are designed to withstand a wide range of pressure and temperatures, and are capable of running materials from polypropylene (PP) to polyetheretherketone (PEEK), and polyvinylidene fluoride (PVDF) to bio-absorbable resins, with shot sizes that range from 1 mg to 400 Ibs.

Westfall’s team of hot runner experts are passionate about eliminating cold runners from injection molding applications and have developed several solutions to direct gate complex parts.

Hot Runner Device Professionally Diagnoses Heater, Sensors and Wiring

Photo Credit: Meusburger

The novel profiTEMP TM hot runner diagnosis device by Meusburger US Inc. is particularly designed for electrical testing of heaters and sensors as well as preheating and heating up the hot runner.

The main function of the profiTEMP TM is the MoldCheck, said to be a complete and professional diagnosis of the condition of the heaters and sensors as well as the wiring of a hot runner. No specialist electrical knowledge is required for use. The diagnostic result can be saved as a PDF file on a USB flash drive. 

Valve Gate Nozzle, Stack Mold Innovations Address Thin-Wall Injection Molding

Photo Credit: Oerlikon HRSflow

Oerlikon HRSflow launches the new Xp series of valve gate nozzles for hot runner systems, engineered for thin-wall packaging applications. For similar applications, Oerlikon has also developed a new stack mold solution.

The Xp series is designed to withstand high filling pressures, up to 2,200 bar, in addition to fast injection and cycle times in a stable process, with high part-to-part weight consistency. Ultimately, it is engineered to significantly improve the overall aesthetic of finished parts.

MultiPin Actuator Supports Multiple Valve Gate Nozzle Interconnections

Photo Credit: INCOE

For valve gate applications in which multiple nozzles have to be positioned in the most confined space, and need to be opened and closed simultaneously, hot runner manufacturer INCOE has developed the new pneumatic MultiPin valve gate actuator in two sizes.

Based on its proven pneumatic (PE) units and designed for the (Slim) DF 5 and (Slim) DF 8 nozzle series, the MultiPin actuators are said to support the interconnection of up to four valve gate nozzles with cylindrical valve pin tip (ZTT). The product also features a quick coupling, which has been developed for easier maintenance and assembly. With a single set screw, all valve pins can reliably be locked or released simultaneously, to enable dismantling of the actuator housing, for example, without having to remove the valve pins from the nozzles.

Hot Edge Gate Nozzles Create Clean Gate Vestiges, Reduces Tip Wear

Photo Credit: Melt Design Inc.

Melt Design Inc. (MDi), an innovator in the manufacture of hot runner systems and components for the injection molding industry, designed its Power Point Hot Edge Gate Nozzles to deliver multiple advantages for injection molders, chief of which is said to be excellent gate vestige. Another benefit? The nozzle tip will never wear out, the company claims.

Power Point Edge Gate Nozzles are ideal for molding fast-cycling, high-volume production parts such as thin-wall packaging applications and medical goods like pipettes, syringes and personal hygiene products.

Nozzle Leak Detector Helps Avoid Costly Repairs, Downtime

Nozzle Leak Detector. Photo Credit: PCS Company

PCS Company has introduced the Nozzle Leak Detector (NLD) to help molders detect plastic leakage between the mold and the machine nozzle, preventing costly downtime and repairs. Caused by cracked nozzle tips, misaligned nozzles, plugged gates and other issues, nozzle leaks are a common problem that can cause time-consuming maintenance and repairs, resulting in lost productivity.

The NLD mounts directly onto the machine nozzle with a clamp and features a sensor that plugs into an alarm box. When the sensor detects a leak, the NLD sounds an alarm and triggers a visual alarm light. Input and output receptacles enable connection to the molding machine, which can be directed to stop the molding cycle immediately once a leak is detected. 

Full-Featured Controller Launches for Small Hot Runner Applications

Photo Credit: PCS Company

PCS Company introduces its new TC50 hot runner temperature controller line, featuring two models for 6 or 12 zones of control. The TC50’s standard features include self-diagnostics, mold memory, zone slaving, leak detection and injection press connectivity for I/O functions, among others.

Cost-Effective Hot Runner Leak Detection

Photo Credit: Airtect, Plastixs

Airtect plastic leak detection systems, distributed in the U.S. and Canada by Plastixs, is said to offer cost-effective solutions for detecting plastic leaks in hot runner molds early and preventing them from damaging the entire hot runner system. Often, the mold can be repaired and back into production in one day, the company notes, versus replacements and cleaning in the event of catastrophic damage which requires special ovens to burn off the plastic residue, a process that can take three to five weeks.

Sequential Valve Gate Controller Made More Intuitive for Moldmakers

Photo Credit: Orycon Hot Runner Systems

Orycon Hot Runner Systems announces enhancements to its Model T-700 hydraulic sequential valve gate controller which reportedly make it more intuitive and user friendly for moldmakers.

The T-700 features a 10" touchscreen with high-resolution graphics and is available in models from 8 to 24 zones. Trip points for opening and closing the valve gates can be entered by sliding markers across the screen, Orycon notes, or by entering the desired timing or position via a pop-up keypad.

Thin Heating Cartridges Offered in Miniature Formats

Photo Credit: Hotset America

Thermodynamics specialist Hotset America Corp. presents its high-performance heating cartridges in miniature format for hot runner systems. With a diameter of only 1/8" (3.1 mm), the hotrod type HHP is said to take up no more space than a matchstick. Just as important is its heating performance, which, depending on the application, can reach up to 750°C, according to the company. As a result, the ultra-thin cartridge is highly recommend for technical applications in which high temperatures have to be applied and generated in a target-oriented, highly accurate manner in restricted spaces.

Second-Generation Control Algorithm Elevates Mold Controller Performance

Altanium family. Photo Credit: Husky Technologies

Husky Technologies, a technology provider, announces the launch of a second-generation control algorithm for its line of Altanium mold controllers. The Advanced Reasoning Technology (ART 2.0) software delivers greater speed, accuracy, precision and repeatability compared to today’s existing temperature control systems, the company claims.

ART 2.0 incorporates advanced auto-tuning and heat-up strategies which deliver higher out-of-the-box performance. It is said to consistently deliver high accuracy and control precision, significantly reducing variability in the molding process shot after shot and mold after mold. According to Husky Technologies, test results show that ART 2.0 delivers up to 42% faster heat-up times with 30% less energy use. 

Mold Components

Flowmeter Enables Accurate Water Volume Measurement, Regulation

Photo Credit: Hasco

Hasco America introduces its new flowmeter Z9905, enabling accurate measurement and regulation of the required volumes of water in cooling systems. This is ideal for moldmakers where, in the course of production, it is frequently necessary for the flow rate of the cooling medium on the injection mold to be read off rapidly and easily so that it can be regulated locally if necessary.

Ejector Pins With Ventilation Surfaces Improve Mold Performance

Photo Credit: Hasco

Hasco America unveils its new ejector pins Z401 with ventilation surfaces to ensure that the air in the cavity can easily escape, improving mold performance. Specific to this product, the extra-long ventilation surfaces extend over a large part of the ejector pins, so the pins can be easily and individually shortened to the desired length.

Round Locating Unit for Flat, Precise Mold Centering

Photo Credit: Hasco

Hasco now offers the round locating unit Z083 for the precise, offset-free centering of injection molding tools and mold inserts. The unit also locks to prevent transversal forces in the mold.

The one-sided DLC-coated locating unit is mounted in the mold via the center axis in order to compensate for differing heat expansion in the two mold halves.

Support Pillar With Clearance Hold and Thread Maximizes Mold Design Freedom

Photo Credit: Hasco

Hasco introduces the newly designed support pillars Z571 with clearance hole and thread, giving designers maximum freedom in mold design when high injection molding pressures have to be absorbed. As a result, “mold breathing” is effectively reduced. 

Support pillars serve to support mold plates and intermediate plates in order to bridge large gaps between the mold risers. Depending on the size of the injection molding tool, any deflection when filling the cavities can lead to major problems. Suitable support pillars are able to increase mold rigidity and prevent deflection of the mold parting surface.

Component Supplier Supports Standard, Custom Solutions for Moldmakers

Photo Credit: Nonnenman Inc.

Component supplier, Nonnenman Inc. has been operating since 2005, supporting and supplying plastics, tool and moldmaking customers in the U.S., Canada and Mexico. The company says it offers an extensive selection of standard products and special solutions, including ejector pins and guide elements as well as temperature control couplings. Special parts can be customized via supplied design data. 

Expansion of Online Moldmaking Catalog Streamlines Mold Component Search and Sourcing

DMS Components has expanded the capabilities of its online moldmaking catalog by adding a part number lookup feature and 3D PDF datasheets. Built by Cadenas PARTsolutions, these new capabilities are said to expand on the existing DMS moldmaking catalog, streamlining the process for design engineers to find and source mold components.

With more than 12,000 moldmaking components available, the DMS product catalog includes pins, ejectors, bushings and locating rings, as well as a wide selection of complementary products and supplies. 

Online Mold Base Configurator for Simplified Mold Base Ordering

PCS Company has released its easy-to-use, three-step online Mold Base Configurator for configuring and ordering high-quality mold bases. Mold builders have access to a range of configurator options including Frames 7.875 x 7.875 –  23.75 x 35.5, A and B plate thickness from 0.875 to 5.875 and #3 and #7 Steel.

Conformal Cooled Sprue Bushings Line Expanded

Photo Credit: PCS Company

PCS Company has expanded its Conformal Cooled Sprue Bushings product line, which is designed to reduce cycle times for injection molders by enabling faster cooling of plastic sprues. Provided as direct retrofits to the common U (3/4" diameter) and B (1" diameter) series sprue bushings, the products are available in 8 (Model U) and 12 (Model B) standard sizes. PCS can also provide custom sized bushings for specific applications. These bushings are constructed of stainless steel for corrosion resistance and longevity.

Precision Custom Core Pins

Photo Credit: Smith Enterprises

Smith Enterprises’ custom core pins expand DedTru systems grinding capacity with dimensional repeatability, accurate tolerances and concentricity within 0.001-0.0002. Ideal for demanding, small-diameter applications such as in medical and electronics, the core pins are suited for high-cavitation molds running 24/7. Consistent dimension control enables simple core pin replacement at required maintenance intervals. 

Guide System Offers Precise Positioning in One System

Photo Credit: Agathon Machine Tools

Agathon Machine Tools continues to highlight its novel Guide System Plus, which performs guiding and centering tasks for the precise positioning of mold halves/mold component using only one system. Ideal for cleanroom, high-precision, micro-injection molding and high-temperature applications, this innovative reinterpretation of existing guiding and centering systems is said to increase planning reliability in production, boost productivity and reduce overall production costs.

By design, each bushing and pillar comes with a freely positioned retaining ring that is adjustable to various plate thicknesses for improved adaptability when repairing or converting tools to newer guide systems. One component can be used in multiple designs.

Gate Cutting Technology Advances Mold Material Separation

Ermanno Balzi introduces its gate cutting technology, which enables separation of the molded part from the cold runner during the mold cycle. This is performed via the axial movement of a cutter, driven by a mini cylinder fed with high-pressure oil. The cut is made with the mold closed at the end of the holding phase while the polymeric material is still hot. 

According to the company, it should be noted that while the term “cut” is used here, the operation is not necessarily a real cut, but a movement of melted material.

Double Rack Lifter Expansion Enhances Undercut Release Capabilities

KR series double rack lifter. Photo Credit: CUMSA

CUMSA has expanded its cooled double rack lifters (KR) series for the release of undercuts with additional available sizes. Targeting difficult-to-cool inserts, the KR lifter maintains the same benefits and features as the DR series, with an internal housing that can incorporate a cooling circuit that connects the mold to a cooling channel.

Mold Materials

Self-Venting Mold Steel for Defect Prevention

Molder’s World Vortex speaker grill inserts. Photo Credit: Molder's World

Quality assurance always begins with the end product in mind, so planning for quality in the design of a mold should always be the first step. One consideration is eliminating trapped gas in a mold using Vortex self-venting mold steel offered by Molder’s World. According to the company, complex parts, especially for medical, aerospace and automotive industries, typically have intricate details that are “difficult to fill,” largely resulting from said trapped gas getting in the way inside the mold cavity.

Vortex self-venting mold steel is a high-tonnage pressed and sintered, porous metal that is heat-treated to 43 HRC with porosity of 25% air by volume. A system of interconnected pores with an average diameter of 7 (0.0003″) microns is dispersed throughout the Vortex material to eliminate trapped gas.

Hot Work Tool Steel Achieves High Thermal Conductivity

Swiss Steel USA highlights its new hot work tool steel, Thermodur 2383 Supercool. Developed by Deutsche Edelstahlwerke (DEW), a member of Swiss Steel Group, the tool steel is said to combine excellent mechanical properties and high wear resistance with high thermal conductivity. This makes it ideally suited for applications in indirect press hardening, die casting and injection molding tools.

Miscellaneous

Mold and Die Focused Software Tackles Process Optimization, Usability, New Technology

CAD enhancements include the ability to create structural ribs from either a 2D or 3D contour. Photo credit: Cimatron

Cimatron, a CAD/CAM software supplier for the mold and die industry, has announced the release of its mold and die focused product, Cimatron V16. After an intensive period of industrial beta testing, Cimatron V16 is now available for general distribution.

Version 16 is said to be a substantial release introducing many new features in all areas of the product including a clean new UI and increased automation for faster mold design, electrode creation and NC programming. In addition, the continued emphasis on solutions for toolmakers includes powerful functionality for die addendum surfaces, mesh manipulation and drafting detailing, according to Cimatron.

Simulation Software Updates for Smarter Machining, Mold Manufacturing

Photo Credit: CGTech

CGTech announces the latest release of Vericut version 9.3, a software program used for simulating CNC machining, additive and hybrid manufacturing processes. The software operates independently, but also integrates with all leading CAM systems.

Vericut 9.3 focuses on creating “smarter,” more efficient manufacturing processes with features that bring in data around the machine, the tools and the stock to improve simulation and the overall manufacturing workflow, according to the company. Improvements have been made to strengthen the software’s core, including improved collision checking, increasing the limit on axes per subsystem and more. Hundreds of customer-driven changes and improvements have also been addressed in this latest release.

Profile Milling Cutter Delivers Precision Machining, Optimized Tool Life for Molds

Photo Credit: Walter USA

Walter USA introduces the Xtra·tec XT M5460, a new profile milling cutter that delivers maximum precision, tool life and surface quality in precise machining of freeform surfaces and deep cavities such as molds. 

The Xtra·tec XT M5460 has been specially designed for difficult materials, particularly for hard machining of steels up to 63 HRC. Alongside the geometries of Walter’s P3201 and P3204 indexable inserts, the company is now offering these inserts in its newest grade, WHH15X, for hard machining.

Digital Shopfloor Solution Monitors, Prioritizes Production Site Data

Photo Credit: Heidenhain Corp.

Heidenhain’s new PlantMonitor is a digital solution to aid the manufacturing shop floor. PlantMonitor is now available for companies interested in simultaneously monitoring and analyzing production data at multiple sites utilizing machine tools where at least one is equipped with a Heidenhain TNC control/StateMonitor software combination per site. According to the company, this updated product is capable of aggregating the data onto one screen for review. Machine tools using non-Heidenhain controls can also be included and monitored.

Metal 3D Printing Series Introduces Industrial Speed, Performance for Mold Production

Photo Credit: Xact Metal

The XM300G family from Xact Metal is a single-, dual- or quad- independent laser system with 100% overlapping print zones. A large 300- x 300- x 350-mm build volume, upgradable to 300 x 300 x 450 mm, a selection of 400W or 700W fiber lasers and an interchangeable build platform to reduce printing cycle time, makes the XM300G well-suited to support a wide variety of industries — aerospace, automotive and general manufacturing — and AM applications, particularly for customers starting their entry into metal 3D printing, including product development, manufacturing, research, education and producing molds. 

Kitting Cart Enhances Material, Component Handling Capacity

Creform kitting cart with shelves. Photo Credit: Creform

Creform Corp., a manufacturer of products for material handling and commercial use, has designed and built a kitting cart. While it is originally aimed at aerospace manufacturers, it has potential applications for mold builders as well.

The unit, with dimensions of 96" L x 48" W x 63" T and designed to hold up to 600 lb., features a custom five-level shelf section on the left with pullout drawers. Each drawer features a solid surface and a lip around the perimeter to help ensure the product does not move during transit. The right side of the cart has four shelf levels with solid surfaces. The cart has a top shelf that acts as a dust cover as well as for overflow storage if needed.

Metal 3D Printing Technology Targeting Moldmaking Is Launched

Fathom Manufacturing cavity and core inserts as printed with Mantle’s TrueShape metal 3D printing technology (left). Cavity and core inserts after Fathom finished the printed inserts and assembled them in their modular mold system (right). Photo Credit: Mantle Inc.

Mantle Inc. announces the commercial launch of its metal 3D printing technology for toolmaking, simplifying the way mold tool components are made, and accelerating how manufacturers make molded parts. The announcement follows the successful beta testing of the printers at several leading injection molding and moldmaking companies, including Westminster Tool.