EAB Insight: 3D Printing, Maintenance, Efficiency, Training

 

Murphy Forsyth, MMT EAB member and Zero Tolerance general manager and processing engineer shares her top article picks. Source | Zero Tolerance

Murphy Forsyth is the injection molding general manager at Zero Tolerance, a rapidly growing plastic injection mold machine shop located in Clinton Township, Michigan.

The company is known for pushing the boundaries of moldmaking and molding through teamwork and innovative technology, which enables it to make on-the-fly adjustments.

Featured Content

Overcoming Pain Points in Moldmaking with AI READ MORE

Your Guide to Smarter, Faster Mold Design READ MORE

How is an Aluminum Mold Energy-Efficient? READ MORE

Murphy joined Zero Tolerance in 2017, where she quickly mastered the art of moldmaking, significantly expanded the company's social media presence to over 30,000 followers and excelled in mold processing and trials.

Here, she kicks off this year’s EAB series by sharing her five favorite MoldMaking Technology articles over the past year, along with key takeaways.

1. In "Hybrid" FIM Process, 3D Printing Complements Injection Molding

Alpine Advanced Materials used a desktop 3D printer and the freeform injection molding process to reduce prototype tooling production time and cost for its customers.

FIM, or Freeform Injection Molding, is a manufacturing process originally developed by Addifab. This innovative technique combines the methods of 3D printing and injection molding to create molded parts. Moldmakers are increasingly seeing this technology featured in the media.

As a molder, I am accustomed to working with aluminum or steel tools to produce parts. I've observed that the time required to create these tools can be substantial, ranging from three to six months to design and manufacture each component. It can also take anywhere from four to seven weeks or sometimes somewhere in between.

The use of 3D printing for cavities and cores is on the rise. This technology enables overnight printing of internal cavity and core blocks, which can then be placed into a speed base the following morning to run prototype injection-molded parts.

Processing these tools requires different key steps because the pressures, temperatures and viscosity of the 3D-printed cavity and core blocks are critical factors. At Zero Tolerance, we will be implementing 3D printing for both plastic and steel cavities and cores!

2. How to Clean and Maintain Molds with Intricate Conformal Cooling Channels

A water-based, eco-friendly plastic mold cleaning system helps Rankine-Hinman Manufacturing restore flow rates and avoid big-ticket failures on complex and costly molds.

I was unaware that a device existed to clean the cooling channels in molds. The shift from repair to prevention caught my attention. Particularly with complex and expensive molds, I can see how implementing a device like this in a shop would be beneficial.

3. 3D Printed Manufacturing Aids Improve Molding Efficiency

Moldmakers and molders turn to 3D printing for end-of-arm tools, fixtures for increased safety and functionality, lower cost and faster turnaround times.

I chose this article because it relates to our work! Since we designed and 3D printed the original molding "claw" we have created many more for other tools where we do insert molding, as well as for customers who require low-volume insert molding. I have seen firsthand how this approach significantly improves efficiency and accuracy in molded parts.

Rather than investing in a costly robot for end-of-arm tooling, we looked for a way to enhance our processes. Initially, our cycle times were over 50 seconds, depending on the operator during each shift. Today, our average cycle time is just 22 seconds, enabling us to complete production orders in half the time. Using 3D printing to enhance our molding department is a smart solution that doesn’t require spending over $100,000 on a robot right from the start. Every insert tool we regularly use here is equipped with a 3D-printed molding claw, all produced on the Markforged X7 Onyx.

While I am not a business owner, my colleague and the President of Zero Tolerance, Steve Michon is, and this has been an excellent solution tailored specifically for our shop. I highly encourage others to implement innovative ideas in their own work environments.

4. Thoughts on VR's Immersive, Interactive Mold Design Training

A virtual reality (VR) application transforms training from passive to active learning by immersing users in a dynamic virtual space.

Kruse Analysis and Training’s virtual training classes are in-depth and extremely helpful for those looking to understand how molds work and the molding process. I have applied what I learned from Kruse in my own processing. It's great to see that this training stays ahead of the times by incorporating AI and molding simulations, which is beneficial for visual learners like myself. If I ever need to train another mold processor, I will definitely have them complete the Kruse training and visit Milacron's plant in Batavia, Ohio.

5. Complex Mold, Versatile Piece of Engineering Enhances Golf

A complex, one-cavity injection mold changed the game for the design and functionality of an innovative golf accessory.

I love the Kid Caddie! This is my favorite article because it provides a wholesome perspective on the impact of Zero Tolerance policies. We take someone’s invention and bring it to life through the process of moldmaking. Every stage of this journey is exciting for a new product owner. People invest their hearts and dreams into their products and being able to help our customers realize their ideas is the most rewarding aspect of being a moldmaker (or mold processor).