Hallo!

A very big Thank YOU to all whom have used and partook in our services this past year, and to all whom celebrate it a very Happy Thanksgiving.

 

While it has been only a few weeks since returning from the K and a bit of holiday, I have had time to think a bit more of what was observed and this issues share a bit of that with all.

Though this is only a small sample of what was observed, it did appear that many were taking notice by taking pictures, even though in many cases it was stated no photos, technology has allowed all to ignore.

Enjoy, comments welcome, always willing to discuss if you have questions.

As the yearend approaches keep in mind that the only difference between your shop and the next is knowledge and skill set, if we can help let us know.

 

  

Ta

 

Steven

 

  Some short observations at the show....

 

In general some old processes were being shown and some new ways of performing the old process, along with some new things. This is understandable given the advances in technology and control, not only in the primary processing equipment but also within the secondary equipment used in the manufacture of parts. The following are only some of the observations.

Cells:

There seemed to be an emphasis on cell manufacturing which were developed to perform multiple functions both within and external to the tool itself. These involved many robotic functions and also internal functions to the mold.

 

Multiple component molding:

This was evident at many machine manufactures and involves the use of carbon fiber sheet which is than formed, and over-molded with the details. The over molding is usually in a glass fiber filled material that in some cases was continuous (very long) and/or long fiber and short fiber of a high percentage. The steps involved:

1. To place precut sheets into a heater area to heat the sheets to a formable temperature
2. Upon mold open the newly heated sheets are placed into the mold
   1. This upon taking out current product
   2. This may be one or multiple sheets
3. The mold closes and is used as a press (forming) to form, bend the sheet into a shape and at a set time the filled material is injected into the cavity around and onto the formed sheet.
4. In many cases the product is complete at this point
5. In some cases the product is removed and then reheated for another insertion and molding operation.
6. In all cases the end product is produced that is functional and has many features necessary to allow it to be used without any further steps.
7. The overall benefit is weight savings along with a high-strength product.
8. What was shown from the other perspective was the thought process in performing the various functions within a cell.
   1. This involved the use of robots
   2. The end of arm tooling for the robots was multiple and sometimes 4 positions around the end of arm so all the robots had to do were rotate the gripper section and another function could occur.
   3. Allowing one robot to use and change end of arm tooling with the cycle of the cell.
   4. The overall minimization of parts handling and assembling by humans.

The creation of Hollow Parts

Some of the displays showed how to produce a sealed container in a non-blow molding/ rotational molding process, but by injection molding, one display actually inserted a filter into the parts prior to sealing up the unit.

1. The mold was a spin stack with two stacks and the machine was a 3 barrel arrangement.
2. The materials to be injected were a PS, PP and white PP.
3. A filter was inserted into the vial part of the product when the mold opened by a robot
   1. Further the robot removed the previous sealed operations.
   2. Upon mold close the molded parts would be assembled and colored material would be injected into and around the joint area sealing the units.
   3. Also upon mold close the individual pieces for the next operation were manufactured.

Overall it was an interesting and complex tool. Given that the robot entered via the side it could be envisioned that the whole of the molding areas could be sealed for a clean room effect. In discussion with the tool maker it was stated at present they were only placing a filter into 1 of the 4 available cavities at this demonstration. It was showing the concept of hermetically sealing filters in process, so as to demonstrate the capabilities of both the tool making company and the machine manufacture.

 

I should state that though the tool was to run at specified demonstration times there were times when it was not. Upon asking it was found that the tool had only been completed shortly prior to the show.

Other components that were sealed involved two different concepts and production yields.

1. The first involved a billows product using a 2 barrel machine which produced both halves.
   1. One was out of TPE and one was PP
2. At the same time as producing both halves it also sealed the previous shot.
3. This particular tool used a two shot type operation where upon mold open
   1. One half of tool rotated
   2. The robot removed previous shot and removed and placed new parts into position within the tool.
   3. Upon mold close the previous shot was now matched up to be mated/sealed as was the manufacture of the new half parts.
4. Upon ejection a bellows type product was produced thus each shot 4 parts produced complete.

The other sealing process though old used the following process

1. Upon injection both halves were produced
2. The plates slide into a new position
   1. This causes alignment of the 2 halves
   2. This also re-aligns the 3 plate runner
3. Upon second injection a seal is formed around the 2 halves
4. Note that this process has need for injection control which injects different shot size every other shot to manufacture the halves one shot and then to seal them the next shot.
   1. Thus instead of a finished depart every shot there is one every other shot.

The other cell which was of interest was within the micro molding area and used two machines in tandem. While this is not necessary new, (the use of two molding machines to Produced a finished part) as one produces both part halves, the other in this cases assembles the parts from machine one and seals them hermitically with a TPE material in this case. It was all done under controlled air conditions and all parts were visually inspected for quality.

 

Other:

Within other molding processes the use of high-speed robots with arms manufactured out of carbon fiber to reduce weight and inertia, many side entries for the in mold label application and as many as four individual labels inserted per cavity.

In one process of IML the process was used on both side of the molded part.

1. Reel to reel label for ink transfer on B side
2. Placement of touch sensitive film on A side
3. After take out the ink was cured via an UV light and then trimmed completely to produced a finished product for use in an application.

 

The other old new concept presented by many was the concept of heating up the mold surface prior to injection to get a high gloss cosmetically perfect surface, and or to be able to flow the material a far distance.

1. The use of induction heating within the mold
   1. Note that ideally this usage needs to thought of from the get go as retrofits are not easy but might be able to be retrofitted by a 3rd party.
2. The use of mold heaters to heat than to switch to cool upon completion of the injection of plastics into the mold
3. The use of two circuits to achieve the same as 2 above
4. The use of a ceramic heater to heat the surface and fluid to cool
5. The use of heaters in the water passage
   1. In this concept the water flow is stopped via control valves both at inlet and out let
   2. Once flow is stopped the heater turn on creating steam/ superheated water in flow channels
   3. Upon completion of injection the heaters turn off and valves open to allows cooling media to help cool the tool.
6. The use of Co2 to both heat and cool
   1. Note that in multiple discussions on this special piping and or types of steel may be required.

In general all the above are of concern to molders and while many are designed for high volume low cost applications it really comes down to what is necessary to get the job done at the lowest possible price versus yield.

 

06112013

SLSILVEY

 

 

 

 

 

 Do you have opportunities at your plant?