Molding

2012

Vital Technologies for Business Success in a Changing Global Market
January 22-25
Hilton Miami Downtown

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CONFERENCE SESSIONS

MONDAY, January 23, 2012

Session 1: Emerging Molding Technologies

Session 2: Micromolding: Emerging Trends

Session 3: Molding Specialty Materials

TUESDAY, January 24, 2012

Session 4: Advances in Medical Molding

Session 5: Advances in LSR Molding

WEDNESDAY, January 25, 2012

Session 5: Advances in LSR Molding (cont.)

Session 6: Energy Management, Sustainability, Green Molding

CONFERENCE AGENDA

Click on a lecture title to view the abstract.

Sunday, January 22, 2012

1:30pm: Registration and Check-in

2:00 - 5:00pm: WORKSHOP: Energy Optimization in Molding Operations
Instructor: Sean Golzarian, Husky

7:30pm: Cheese & Wine Reception



Monday, January 23, 2012

8:00am Continental Breakfast


Session 1: Emerging Molding Technologies

8:30am

NYPRO'S KEY NOTE ADDRESS
Speaker: Mr. Michael P. McGee, Director of Technology, Nypro Inc.
9:15am HIGHLY INTEGRATED NOVEL MOLDING PROCESSES Kragl Joachim, Engel
9:45am AUTOMATION SOLUTIONS FOR IMPROVED PRODUCTIVITY Uwe Haupt, Arburg
10:15am COFFEE BREAK
10:45am IN-LINE AUTOMATION AND INSPECTION VERSUS BULK PRODUCTION, STORAGE AND DOWN STREAM ASSEMBLY Lisa Mauro, Waldorf Technik
11:15am ONLINE PROCESS OPTIMIZATION AND CONTROL FOR INJECTION MOLDING Dan Hazen, Product Manager, MKS Instruments
11:45am WASTE ELIMINATION IN MEDICAL MOLDING
Sean Golzarian, Husky
12:15pm THREE DIMENSIONAL SIMULATION OF INJECTION COMPRESSION MOLDING OF PLASTIC OPTICS Shen-Teng Hu¹, Hsian-Sen Chiu¹, Wen-Hsien Yang¹, and Rong-Yeu Chang²
1. CoreTech System (Moldex3D) Co., Ltd., ChuPei City, Hsinchu, Taiwan
2. Dept. of Chemical Engineering, National Tsing-Hua University, HsinChu, Taiwan
12:45am LUNCH BREAK (on your own)

HIGHLY INTEGRATED NOVEL MOLDING PROCESSES

Kragl Joachim, Engel

This presentation will provide an overview of several new processes which represent a high level of functional integration accomplished directly during the molding process in the machine. Organomelt is a process where a fiber re-enforced thermoplastic sheet is heated, preformed and over molded in a single process within the injection molding machine. The final part is also trimmed in the cell & allows the production of net shape parts out of a thermoplastic system versus currently used sheet metal & insert molded parts. Besides the tremendous weight savings without reducing mechanical properties, advantages include the creation of a single material part that can be easily recycled. Joinmelt is a process, where to parts are hot gas welded inside the molding machine, creating a weld line quality that cannot be achieved with hot plate or friction welding. Smart Foils (capacitive films), allow for touch pad like functionality integrated into an injection molded part. The capacitive functions remain even when underneath several layers of decorative coverings (wood, film, textiles). All three technologies are explained in detail with current applications.

AUTOMATION SOLUTIONS FOR IMPROVED PRODUCTIVITY

Uwe Haupt, Arburg

Parts can be molded using various equipment. This paper will describe the benefits of Automation. It will also show that different automation equipment will give different results. Based on three different strategies to mold the same part with the same mold using different equipment the potential savings and improvements will be shown. An example calculation will proof that some more money spent up-front could pay back in astonishing fast times. The advantages of each of the three solutions will be laid out and discussed.

IN-LINE AUTOMATION AND INSPECTION VERSUS BULK PRODUCTION, STORAGE AND DOWN STREAM ASSEMBLY

Lisa Mauro, Waldorf Technik

This presentation will cover the highlights of in-line automation and inspection compared to bulk production, storage, down stream assembly and packing, including the following:

  • Maintaining possession & orientation of molded parts upon ejection
  • Ability to reject parts using vision inspection, prior to final assembly and pack-out, without interruption in production output
  • 100% Quality Inspection
  • Cavity sorting and it's effects on uptime
  • Minimizing total steps from pellet to package
  • Removal of risk
  • Minimize human interface and total labor

ONLINE PROCESS OPTIMIZATION AND CONTROL FOR INJECTION MOLDING

Dan Hazen, Product Manager, MKS Instruments

This presentation will focus on a new approach for online process optimization and control for injection molders. As the injection molding process is highly complex and multivariate in nature, this new approach will utilize a multivariate technique to allow molders to optimize a process based on multiple quality attributes to ultimately achieve parametric release on their processes. In addition to part quality optimization, this approach also incorporates a number of other extremely valuable parameters for molders, such as energy consumption, material usage, and cycle time, into the optimization to provide additional value and cost savings for molders.

THREE DIMENSIONAL SIMULATION OF INJECTION COMPRESSION MOLDING OF PLASTIC OPTICS

Shen-Teng Hu¹, Hsian-Sen Chiu¹, Wen-Hsien Yang¹, and Rong-Yeu Chang²
1. CoreTech System (Moldex3D) Co., Ltd., ChuPei City, Hsinchu, Taiwan
2. Dept. of Chemical Engineering, National Tsing-Hua University, HsinChu, Taiwan

Injection compression molding (ICM) offers many qualitative advantages for injection-molding plastics, such as less shrinkage and warpage, more uniform packing pressure and less residual stress, and so on. To get a better understanding of ICM, a 3D simulation technology is proposed to analyze the process. In this study, the influence of various process parameters with ICM is performed by using light guide plate models. The cavity pressure distribution with ICM is lower and more uniform than that with conventional injection molding which will have more opportunities result in lower volume shrinkage and get better product quality.

Session 2: Micromolding: Emerging Trends

2:30pm

CHALLENGES AND OPPORTUNITIES IN MICROMOLDING Brian Matachun, Director, Technical Sales, MTD Micro Molding
3:00pm MICRO MOLDING: THE NEXT GENERATION Tom Betts, Wittmann Battenfeld, Inc.
3:30pm THE MACRO SIDE OF MICRO - WHAT YOU NEED TO KNOW TO BE SUCCESSFUL WITH YOUR MICRO MOLDING APPLICATION Markus Lettau, Director of Sales and Application Engineering, Empire Precision Plastics
4:00pm COFFEE BREAK

CHALLENGES AND OPPORTUNITIES IN MICROMOLDING

Brian Matachun, Director, Technical Sales, MTD Micro Molding

The presentation discusses the differences that need to be taken into account when transitioning from Macro parts to Micro parts, such as:

  1. Part Design and Materials
  2. Mold Making
  3. Machine Selection
  4. Part Handling
  5. Inspection

The presentation closes with the opportunities that are emerging in medical as well as electronics.

MICRO MOLDING: THE NEXT GENERATION

Tom Betts, Wittmann Battenfeld, Inc.

A review of the current market will include a review of market segments and the trends seen followed by a review of electric molding machines. Included will be a comparison of the injection process of standard injection molding machines to that of the micro molding machines; with data to support the trend to specialized micro-molding machines. Video clips and slides will be used to further demonstrate how far the technology has come. Additional to the review of micro-molding machines, information will be provided on a complete package of peripheral equipment sized specifically for micro-molding machines.

THE MACRO SIDE OF MICRO - WHAT YOU NEED TO KNOW TO BE SUCCESSFUL WITH YOUR MICRO MOLDING APPLICATION

Markus Lettau, Director of Sales and Application Engineering, Empire Precision Plastics

Micro Molding has been around for many years and there is a tendency for companies to boast about how small they can make a plastic part. However many applications do not require the submicron level of features. The majority of applications that would be considered micro require the applications of "Scientific Molding Techniques" and advanced tool engineering to be successful.

This presentation will explain and demonstrate the aspects of micro molding applications in mass production with strategies and techniques in selecting the appropriate molding machines and tooling to accomplish micro molding on a macro scale.

Session 3: Molding Specialty Materials
4:30pm INFLUENCE OF THE FILLER PREMAGNETIZATION IN HOT RUNNER ON ITS ORIENTABILITY DURING INJECTION MOLDING OF MULTI POLAR SmCo-MAGNETS Aleksander Gardocki, Dietmar Drummer, Institute of Polymer Technology, Erlangen, Germany
5:00pm SUCCESSFUL INJECTION MOLDING OF HIGH TEMPERATURE, AMORPHOUS THERMOPLASTIC MATERIALS Andrew May, Lead Project Engineer, SABIC Innovative Plastics
5:30pm POWDER METAL INJECTION MOLDING William F. Thorne, Product marketing Specialist, BASF
6:00pm Cheese & Wine Reception

INFLUENCE OF THE FILLER PREMAGNETIZATION IN HOT RUNNER ON ITS ORIENTABILITY DURING INJECTION MOLDING OF MULTI POLAR SmCo-MAGNETS

Aleksander Gardocki, Dietmar Drummer, Institute of Polymer Technology, Erlangen, Germany

Polymer bonded magnets with a multi polar structure can be cost effectively produced by injection molding of polymers with magnetic fillers. The permanent magnets are incorporated inside the injection tool to orient and magnetize the fillers during injection molding. The orientability of the magnetic fillers with high magnetizing and demagnetizing field e. g. Samarium Cobalt (SmCo) is very poor so their use for production of multi polar magnets with fine multi polar structure is limited. This paper deals with the method for the production of multi-polar SmCo-magnets that incorporates premagnetization of the magnetic filler in the hot runner system.

SUCCESSFUL INJECTION MOLDING OF HIGH TEMPERATURE, AMORPHOUS THERMOPLASTIC MATERIALS

Andrew May, Lead Project Engineer, SABIC Innovative Plastics

Injection molding high temperature, amorphous thermoplastic materials can be a challenging proposition. Often times, these high performance polymers are used in harsh environments and in demanding applications. This combination can be intimidating.

This presentation examines some of the common pitfalls that can sabotage a project before it gets off the ground along with suggestions for successfully molding a high temperature material into the intended article.

Real-world examples are presented that show the ease at which these materials can be processed and will instill confidence in specifying high performance polymers for your most demanding applications.

POWDER METAL INJECTION MOLDING

William F. Thorne, Product marketing Specialist, BASF

Powder injection molding (PIM) is comprised of two material groups. These groups are commonly referred to as metal injection molding (MIM) and ceramic injection molding (CIM). The metal fabrication market has been dominated by costly processes such as machining and investment die casting for higher strength metal systems. The use of high tonnage compaction presses led to the growth of press and sinter applications reducing the cost associated with high volume manufacturing markets. However, the final density was reduced significantly and the complexity of the geometry was quite limited. In the 1980s work began to mix fine metal powder with a polymer to allow a complex metal geometry to be formed via injection molding. Over the past 15 years these formulations have been developed with advanced binder systems to create a billion dollar market with 15% annual growth.

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Tuesday, January 24, 2012

8:00am Continental Breakfast

Session 4: Advances in Medical Molding

8:30am

Business Perspective Keynote Lecture: CAN WE COMPETE? Bill Wood, Mountaintop Economics & Research
9:15am STATE OF THE ART ADDITIONS TO MOLDING MACHINES FOR MEDICAL APPLICATIONS Juergen Giesow PhD, Arburg
9:30am LSR MICROMOLDING FOR MEDICAL MARKETS Jeff LeFan, Saint-Gobain Performance Plastics
10:15am COFFEE BREAK
10:30am REDUCING TOOL CONDITIONING TIME IN MEDICAL MOLDING Gary Chastain, RJG
11:00am QUALIFICATION OF NEW MATERIALS FOR MEDICAL APPLICATIONS AND VALIDATION EXPECTATION Anand Agrawal, CareFusion

BUSINESS PERSPECTIVE: CAN WE COMPETE?

Bill Wood, Mountaintop Economics & Research

I want to start the dialogue and provide the language, the context, and the forum that will address one simple question, "Can we compete?" No more happy talk, no more politicians, no more analysts selling advertisements. It is my belief that if we are to compete successfully, then we must commit to competing completely. Not just in our place of business, but also in how we operate our households and how we bolster our communities and especially in how we govern ourselves. In a world where one must compete to live, the future will belong to those who live to compete. We look back with great pride to the the national spirit that created Rosie the Riveter, ration cards, and the Greatest Generation. A 21st Century version of this spirit is what we need now. Some will refer to this as "sacrifice." I prefer to think of it as "getting in shape" and "restoring our health and vitality." We are ENTITLED to nothing. We must compete for everything we get. Winning is good for the soul. Let's re-capture the mojo.

We can start this dialogue with a strategic review of the manufacturing sector and the plastics industry. We must know where we are and how we got here. Then I want to identify some of the obstacles that we can see, and mention a few that are not yet visible but may be lurking just over the horizon. We can then discuss the strategies and solutions that will enable us to seize the future. Failure to do so, if that is an option we wish to consider, will likely result in our demise.

STATE OF THE ART ADDITIONS TO MOLDING MACHINES FOR MEDICAL APPLICATIONS

Juergen Giesow PhD, Arburg

What is important in Clean room applications? What can be done to a state of the Art Molding machine to minimize the release of contaminations into the air?

What are the possibilities to help with the validation process through the Software of the machine? How can support equipment be integrated into the machine and why.

What clean room options are available? Classifications as well as molding in our outside of a clean room.

Good Molding practices will be discussed as well.

LSR MICROMOLDING FOR MEDICAL MARKETS

Jeff LeFan, Saint-Gobain Performance Plastics

With less-invasive procedures becoming the new norm, reducing the scale of surgical instrumentation is critical to limiting operating room and patient recovery times. As a result, the medical device community is challenged with delivering innovative designs that provide the same level of precision and functionality in a smaller package. Liquid Silicone Rubber (LSR) injection molding has been taken to the micro-scale, resulting in elastomeric products that can be used independently or produced as an overmold with more rigid materials. This presentation provides a comprehensive overview of the current capabilities of micro-LSR components: advancements in tool manufacturing, a review of current dimensional capabilities of molded components, and downstream process changes affecting part handling and metrology.

REDUCING TOOL CONDITIONING TIME IN MEDICAL MOLDING

Gary Chastain, RJG

Having the correct molding machine to put my new mold is paramount. Often we think: "It fits between tie bars… I have enough shot size…so why am I struggling?" We can focus the set up needed to produce good parts before we ever cut steel. Your solid model and flow analysis provide valuable information to what machine size and performance is needed, but you can't stop there. Machine information from your machine choice must be fed back to the model and flow analysis to complete the recipe. You can know with certainty that you have the right mold in the right machine with the best odds of making the best parts.

QUALIFICATION OF NEW MATERIALS FOR MEDICAL APPLICATIONS AND VALIDATION EXPECTATION

Anand Agrawal, CareFusion

As mold makers and molders for the medical industry we try to survive and thrive in this fiercely competitive business climate, it makes sense to offer their customers the most complete service possible by understanding their requirements. Things that could be avoided before the company invests a lot of money into validating a new material or mold will be discussed in this presentation.

This paper will also provide a detailed description of the steps which will deliver the types of results a validation process is designed for qualifying a new material or an alternate material. Several aspects of process validation for thermoplastic or silicone injection molds and good manufacturing practices will be discussed that probably leads to fewer questions asked by FDA. Conducting a robust IQ/OQ/PQ for a new material will ensure a capable tool and robust process that can run in a production environment for a long time. Development of protocols, identifying the right labs, setting the key goals and establishing the quality requirements ahead of time will be the focus of this presentation for a new or alternate material qualification. Design plans, design review meetings, and change control for documentation of changes to design inputs and outputs, require sound methods for document maintenance.

Session 5: Advances in LSR Molding

11:30am

FACTORS REQUIRED FOR A SUCCESSFUL SILICONE MOLDING PROGRAM Mark Hammond, General Manager, GW Silicones

12:00pm

ADVANCEMENTS IN LSR METERING AND MIXING TECHNOLOGY Craig Lustek, Product Manager, 2KM US Inc

12:30pm

SILICONE OVERMOLDING - ADHERING LSRS TO DIFFICULT SUBSTRATES Steve Spanoudis, Motorola Solutions
1:00pm LUNCH BREAK (on your own)

2:30 - 6:00pm

WORKSHOP: Expert Scientific Molding Instructor: Umberto F. Catignani, Orbital Plastics Consulting

FACTORS REQUIRED FOR A SUCCESSFUL SILICONE MOLDING PROGRAM

Mark Hammond, General Manager, GW Silicones

In order to have complete success for a silicone molding program both the OEM and molding supplier need to work together to fully understand the requirements and needs of each other. Developing the program in the right manor using proper part design, prototype techniques, material selection, tolerances, mold design and production method are vital to success. This presentation will discuss the many factors involved in a silicone program and provide some helpful tips for the OEM when it comes to launching a project.

ADVANCEMENTS IN LSR METERING AND MIXING TECHNOLOGY

Craig Lustek, Product Manager, 2KM US Inc

Since the introduction of Liquid Silicone Rubber, The Metering unit has ensured it will pump the two primary liquid Materials, and maintaining a constant ratio while being released. With different properties of elastomers evolving over the years, Metering and Mixing Pumps have had to expand their capabilities. Large shot applications, micro-molding and variable mixing ratios are just a few of the things advanced technologies can provide. This Presentation will present various solutions for Metering and Mixing equipment for these challenges.

SILICONE OVERMOLDING - ADHERING LSRS TO DIFFICULT SUBSTRATES

Steve Spanoudis, Motorola Solutions

In medical, industrial and other markets, liquid injection molded silicones are used to provide a range of desirable properties. As product designers advocate greater integration in product designs, silicone overmolding can become a significant challenge. Difficult substrates, including metals and metal- plated surfaces can add to the challenge. This presentation reviews methods for achieving adhesion between silicones and substrate materials, and analyzes test results from experiments evaluating materials, molding process conditions, tooling preparation, cleaning methods, and primer coatings.

Outline

  • Overview of elastomers and over-molding adhesion
  • Methods for improving adhesion (physical, chemical)
  • Over-molding metals
  • Tooling and processing for LSR overmolding
  • Achieving high overmolding yields
  • Physical and environmental test results
  • Summary
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Wednesday, January 25, 2012

8:00am Continental Breakfast

Session 5: Advances in LSR Molding (cont.)

8:30am

NEW DEVELOPMENTS FOR LSR MOLDING Juergen Giesow PhD, Arburg
9:00am LSR COLD RUNNER FILL IMBALANCE: CHALLENGES AND SOLUTIONS Dana King, Kipe Molds and Susan E. Montgomery, PRIAMUS System
9:30am CONSIDERING MOLDING LSR? HOW TO CHOOSE THE RIGHT MOLD MAKER Rick Finnie, M.R. Mold & Engineering
10:00am COFFEE BREAK

NEW DEVELOPMENTS FOR LSR MOLDING

Juergen Giesow PhD, Arburg

With the drive to make smaller and smaller parts the demand on the Equipment has changed for Micro molding for LSR, what is new and what is next?

How can modern pressure recording and monitoring features help to secure and also trouble shoot the process?

Status update on 2 shot molding for the LSR industry. Silicone over Silicone and Silicone of Thermoplastic.

LSR COLD RUNNER FILL IMBALANCE: CHALLENGES AND SOLUTIONS

Dana King, Kipe Molds, and Susan E. Montgomery, PRIAMUS System

Fill balance for LSR cold runner molds can be a real challenge. There are ample qualitative observations to surmise that a variety of factors affect fill balance. This paper presents data for a four cavity LSR family development mold which illustrates a strong correlation between fill balance and a variety of independent variables. Using systems based on in-cavity sensing (temperature and pressure), valve gate controls are automatically operated and material viscosity for each cavity is determined.

CONSIDERING MOLDING LSR? HOW TO CHOOSE THE RIGHT MOLD MAKER

Rick Finnie, M.R. Mold & Engineering

Liquid silicone rubber has very distinct qualities. Designing and building molds for LSR cannot be compared to plastic injection molds. Choosing a mold maker who has experience with LSR is imperative. The mold maker you choose must have extensive design experience with LSR, modern equipment and technology. As most projects require creative problem solving, the mold maker must be able to meet this challenge. Having in-house equipment to test and sample the LSR mold prior to shipment is critical in saving you time and money. This paper will explain all that is necessary to find the right mold maker for your LSR project in order to maximize your production process.

Session 6: Energy Management, Sustainability, Green Molding
10:30am A PIONEERING 'GREEN' MOLDER ROADMAP TO PROFITS Bob Bechtold, President, Harbec
11:00am ENERGY SAVINGS & MOLDING COSTS - WHAT CAN RETROFIT MOTOR SPEED CONTROL ACHIEVE FOR YOUR INJECTION MOLDERS? Fred Pratt, CCS Technology
11:30am GREEN ENERGY STRATEGIES FOR PROFITABLE INJECTION MOLDING Markus Lettau, Director of Sales and Application Engineering, Empire Precision Plastics
12:00pm BIOPLASTICS - ENGINEERED FOR INJECTION MOLDING Christoph Lohr, FKuR Kunststoff GmbH
12:30pm CONFERENCE ADJOURNMENT

A PIONEERING 'GREEN' MOLDER ROADMAP TO PROFITS

Bob Bechtold, President, Harbec

The purpose of this presentation is to demonstrate that being a sustainable business does not have to cost more, but in fact can save money and help to control business costs. Contrary to popular belief, it is not more expensive to be 'green' or environmentally responsible. In fact, actual practices and events which are being used at Harbec will be reported on to demonstrate real environmental and economic opportunities that can exist. It is Harbec's mission to be a continually growing and profitable leader in the manufacture of prototypes, custom machining, high tolerance tooling and quality injection-molded parts, while striving for sustainability and true corporate social responsibility.

ENERGY SAVINGS & MOLDING COSTS - WHAT CAN RETROFIT MOTOR SPEED CONTROL ACHIEVE FOR YOUR INJECTION MOLDERS?

Fred Pratt, CCS Technology

All hydraulic injection molding machine will benefit from a retrofit system installed to regulate motor speeds and save energy; it's probably the most important energy-saving investment a molder can make. Many USA molders harbor great cost reduction potential, with very attractive rebate programs to make such energy saving projects not just a desirable goal but a business necessity. What you need to know is how much energy saving can be expected, what will be the costs, which systems work well & reliably, and which ones do not.

This presentation covers all the issues from an experienced world leader in the design and retrofit of frequency inverter (variable speed drive) systems for energy savings on injection molding machines, based in USA and headquarters in UK.

GREEN ENERGY STRATEGIES FOR PROFITABLE INJECTION MOLDING

Markus Lettau, Director of Sales and Application Engineering, Empire Precision Plastics

Globalization has brought forth increasing competition for Injection Molding Companies. Competing against companies in regions of the world where energy costs are low can be a challenge. Often times high energy costs can consume low margins on molding and make it difficult to be profitable for some areas of the world. Find out strategies to save energy in the injection molding operation.

Even in areas where energy costs are reasonably low there is a movement by many large corporations to trim their carbon footprint. This is passed down to vendors such as injection molders and can influence their selection criteria.

This presentation will demonstrate ways in which injection molders can improve their energy efficiency and become green.

BIOPLASTICS - ENGINEERED FOR INJECTION MOLDING

Christoph Lohr, FKuR Kunststoff GmbH

The processing of Bioplastics using injection molding may be considered more challenging than with regular plastics. But Bioplastics already reach into quite demanding applications like consumer electronics and household appliances processed via injection molding. The best choice of Bioplastics combined with customer friendly processing support enables you to mold almost every rigid part.

Using the slogan "Plastics - made by nature!" FKuR Kunststoff GmbH was incorporated in 2003. In cooperation with Fraunhofer UMSICHT, Oberhausen, FKuR Kunststoff GmbH has developed a wide range of biodegradable plastics primarily made from natural resources. Recently FKuR enlarged their R&D effort for injection molding resins with great success. Important knowledge about the improvement of the formulations, the tooling and processing conditions was gained. This experience was used to develop optimized grades for the injection molding process (p.e. higher MVR, improved flow behavior). Bioplastics are a well-known and accepted raw material for film applications since some years. Nowadays Bioplastics enter more and more applications other than packaging.

To underline the quality and process ability of our materials we will show case stories as well as samples for rigid parts (e.g. electronic devices).

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