Molding Views · president of SPI, and Rob Neilley, IMM editor, gave interesting keynote addresses on two of the days. The conference included a plant tour of Rehrig––Pacific’s

Fall 2008 Page 1 SPE Injection Molding Division

Molding ViewsMolding ViewsMolding ViewsMolding ViewsMolding ViewsBrought to you by the Injection Molding Division

of the Society of Plastics Engineers

Embracing the Perfect Storm and Repositioning Ourselves

IN THIS ISSUE:

Disclaimer: The editorial content published in this newsletter is the sole responsibility of the authors. The Injection Molding Division publishes thiscontent for the use and benefit of its members, but is not responsible for the accuracy or validity of editorial content contributed by various sources.

No. 77, Fall 2008

Continued on page 3

There is no doubt that plastics engineers are facing and embracing a perfect storm—the loss of home equity and retirement savings, the likelihood of a deepening global recession,worries about job security, energy and environmental issues, and a spiraling downturn ofthe economy that even the governments, central banks, and finance ministers worldwidecan not stop. It is anticipated that unemployment rates will continue to rise and the dauntingchallenges facing the industry and our members will be very significant. So what should wedo to weather through this period of turbulence? There are many answers depending onwhom you ask, with no shortage of advice from the media, family, friends, colleagues, andeven presidential and local election candidates. Sometimes, however, the true answersmay lie within your heart.

Chair’s Message 1IMD Leadership 2Committee Reports 2Feature Article: Engineering Jobs 4Ask The Experts (IM, Hot Runners, and CAE) 5Reader Comments 7, 10Featured Technology: MeltFlipper 11Conference: Molding 2009 13Call For Papers 14IMD Best Paper 15

Experimental Study on the Energy Efficiencyof Different Screw Designs for IM

Feature Article: Partners in Education 19IMD Best Student Paper 20

Investigation of Comparative StressDistributions in Thermoforming Versus IM

Featured Product: Learn-on-Demand 22

Feature Article: 23Injection Moulding Process BenefitsBoth Process and Moulded Part

Sponsorship Opportunities 26Conference: SAMTMP 2008 27Student Activities Report 27Molding Corner: AGA-PGT, Inc. 28On The Road: Milwaukee MiniTec 30Feature Article: SPE’s New Website 31SPE & Industry Event Calendar 33SPE Webinars 34BOD Meeting Minutes 35New IMD Members and Companies 37Membership Application 38Sponsors in this Issue 39Publisher’s Message 39

Chair’s Message

Personally, I would like to suggest a few things for our members. First, we can embrace the continuing trend ofglobalization and try to capitalize on it by upgrading our job skills. Whether we like it or not, the trend of globalizationis likely to continue. We need to appreciate the benefits of globalization that enable the reduction of product costsand time to market. Of course, we should not lose sight of the potential impacts on our businesses and jobprospectives. Try to become a professional capable of performing tasks with partners from around the globe andbe able to solve problems or design products and conduct operations from the “system” level. If possible, gain anunderstanding of and respect for cultural variations across various parts of the world. This would be a great time tolearn a new language! You may want to look for opportunities to retrain yourself through distance learning programsif you can’t afford to go back to school, or through government-sponsored vocational programs, if you can’t affordregular tuition.

Lih-Sheng (Tom) TurngProfessor, UW-Madison


IMD Leadership

DIVISION OFFICERS

IMD ChairLih-Sheng (Tom) TurngUniv. of Wisconsin–[email protected]

Chair-Elect, Alt. TreasurerDave [email protected]

Past Chair,Executive Committee LiasonHoa PhamLyondell [email protected]

Secretary,Student Activities ChairWalt SmithXaloy, [email protected]

Technical DirectorPeter GrelleDow [email protected]

TreasurerJim [email protected]

BOARD OF DIRECTORS

Awards ChairJim [email protected]

Communications Chair,Website ChairLee Filbert, [email protected]

Councilor, Reception ChairJack Dispenza,Design [email protected]

Education ChairPat Gorton, [email protected]

Engineer of Year AwardChairKishor MehtaPlascon Associates, [email protected]

Historian, Fellows &Honored Service AwardsChairLarry SchmidtLR Schmidt [email protected]

Membership ChairNick Fountas, [email protected]

Nominations ChairDon AllenPhillips Chemical [email protected]

TPC ’09Brad Johnson, Penn State [email protected]

Past SecretaryLarry CosmaPerformance [email protected]

Board MemberJan Stevens, [email protected]

Board MemberMichael Uhrain, [email protected]

Board MemberRaymond McKee, [email protected]

Board MemberMal Murthy, Doss [email protected]

New Board MemberErik FoltzThe Madison [email protected]

New Board MemberAdam KramschusterUniv. of Wisconsin–[email protected]

New Board MemberSusan MontgomeryPriamus Sys. Tech., [email protected]

CONTRIBUTORS

Newsletter Publisher,SponsorshipChris LaceyUniv. of Wisconsin–[email protected]

IMD Leadership

Committee Reports

ANTEC 2009 Update by Brad Johnson

The year 2009 will be the first year ever that SPE’s ANTEC and SPI’s NPE will be held at the same time andplace, combining the world’s largest technical conference for the plastics industry with the largest trade show in theUnited States. ANTEC runs Monday, June 22nd, through Wednesday, June 24th, while NPE will last the entireweek. Just about everybody who is anybody in the plastics industry will attend this conference. This will be a greatopportunity for you and your organization to showcase what you are doing in the arena of injection molding.

In addition, I would like to invite you to present a paper at ANTEC. There are two formats that can be presented:technical and commercial. Please visit http://www.4spe.org/antec-2009-call-papers to find more information, includinga template which is very helpful when planning and writing your entry. See page 14 for more details.

I would also like to know if you have any ideas about special sessions or topics that you would like to seepresented. Please contact Brad Johnson ([email protected]), the IMD ANTEC 2009 Technical Program Chair, withyour ideas. With your help, we can make this event better than ever!

Technical Program Committee Report by Peter Grelle

The SPE IMD co-sponsored the “Injection Molding: Innovation and Emerging Technologies Conference” onJune 10, 2008 in Erie, Pennsylvania. One hundred people registered for the conference. Bill Carteaux, thepresident of SPI, and Rob Neilley, IMM editor, gave interesting keynote addresses on two of the days. Theconference included a plant tour of Rehrig––Pacific’s Erie operation one evening. The presentations fromindustry and the faculty tutorials were all well-received. In 2009, the conference will take a one year hiatus due tothe NPE in Chicago, Illinois.

The 2009 ANTEC paper review committee will meet on December 13, 2008, in Orlando, Florida. Thecommittee will consist of Brad Johnson, Dave Karpinski, Jan Stevens, and Pete Grelle.


Chair’s Message

Continued from page 1

Chair’s Message - Cont -

Second, we should all strive to live within our means and make sure that we have enough savings for a rainyday. Part of today’s problems stems from our unsustainable culture of consumerism and negative saving rates.From our own financial decisions to corporate management, we need to build a safety net for unexpected needs oremergencies. It may be a perfect time to re-access our investment strategies and take into account the timing of ourretirement. We mustn’t let panic or fear blind our judgment in favor of overlooking the fundamentals. As our lifeexpectancy increases, we may be able to work longer if we choose.

Third, we should prioritize our prospective on life and understand that sometimes happiness may be right infront of us. Studies have found that while money might seem to “buy” happiness initially, it won’t last long. Truehappiness and a meaningful life come from the support and understanding of our family and friends, especially intough times. We work hard to earn wealth and status, but we can not trade them in for health, which we as humanshave a tendency to take for granted. Thus, taking care of our health and focusing on the rich and meaningful partsof our lives may pay more dividends in the long term than any amount of money.

The State of the Division

IMD Chair Professor Turng receives the SPE Pinnacle-GoldAward from then SPE President, Dr. Vicki Flaris, at the ANTEC2008 Banquet.

In this issue, you will find many articles, reports,and announcements that highlight the various activitiesand programs of the Injection Molding Division.Following our great tradition, which won us the SPEGold Level Pinnacle Award at ANTEC 2008, thedivision is actively involved in developing varioustechnical programs (e.g., Milwaukee MiniTec, page 30),and sponsoring SPE scholarships (visit the SPEFoundation Web site at www.4spe.org/spe-foundation), and relevant conferences (e.g., SAMTMP2008, page 27, and Molding 2009, page 13). The IMDis proud to be a sponsor of the SAMTMP 2008 to beheld in Beijing, China, November 15-17, 2008. As partof our goal to expand membership worldwide, we hopeto meet many new members from our presence in Asia.These activities aid in meeting the charter of the SPEIMD as well as strengthening its position within SPE.Five new Board members have been appointed sinceANTEC 2008 to help in these efforts and more newvolunteers continue to join us. We value feedback andparticipation from our current and prospective membersand encourage you all to join us in these various activitiesand in recognizing members with distinguished serviceand contributions to the molding community. Please donot hesitate to contact us (see the contact informationon page 2) if you have any questions, suggestions,comments, or candidates for nomination.

Lih-Sheng (Tom) TurngChair, 2008-2009

Want to be a Reporter forthe IMD Newsletter?

When you attend a molding event such as aconference, exhibit, or trade show, you can share yourexperience with thousands of IMD members. The IMDNewsletter features the column “Things On The Road”to provide members with an opportunity to contribute tothe IMD community. We also welcome informativefeature articles by our readers.

Send your review or summary to Chris Lacey([email protected]) and see it published in the nextnewsletter!


Feature Article

Engineering Jobs Are Prestigiousby Lih-Sheng (Tom) Turng

According to the results of a Harris Interactive survey of 1,010 adults(surveyed July 8-13, 2008), and published on the front page of USA TODAY(Snapshot on Monday, August 25, 2008), the profession of Engineer rankedfirst in terms of prestige, and furthermore, had the biggest percentage-pointincrease from 2007 to 2008, surpassing other coveted professions such asactor, architect, journalist, union leader, and banker (see chart below).

This further confirms the esteemed status of engineers, who actually applyscientific and engineering principles, combining those skills with creativity,workmanship, innovation, and hard work to produce tangible goods andcreate wealth that are sustainable and real. IMD members, you deserve thisrecognition! Keep up the good work!

0 2 4 6 8 10

Engineer

Actor

Architect

Journalist

Union Leader

Banker

2007-2008 Jobs Rising in Prestige

0 10 20 30 40

Engineer

Actor

Architect

Journalist

Union Leader

Banker

2008 Job Prestige Rating

Automatic balancing of hot runner molds

Advanced cavity pressure & cavity temperature sensors

Real-time material viscosity measurement

Automatic transfer to holding pressure

- Reduce dimensional deviation

- Achieve individual and overall part weight savings

Increase Productivity with Priamus Control

Systems


Question:Thanks from so many of us on your insight into

molding issues. I have two questions. I have a 4-cavityhot runner mold (LLDPE) making a medical squeezetube. It is 1/2" diameter at the hot tip and 4" long.Should I be using 60 degree chilled water or warmwater for the mold? My problem is that I am bendingthe moving side cores which are 52 R resulting in a thinside wall and some backfill at the parting line. Ventingis adequate but not excellent. Also, should I be injectingfast or slow? I am injecting onto a flat core. ~RobertLowe, BL Plastics Inc.

Answer:First the venting. If it is "adequate," it is likely not

good enough. All of the trapped air, gases, and volatilesneed to have an easy egress from the cavity. This is thesimplest and least expensive fix that will provide themaximum benefit to filling the cavity.

As for the mold surface temperature: A warmersurface will, in theory, allow plastic to flow further andwith less pressure. It would be better if you measurethe mold surface temperature rather than the chiller watertemperature. A simple molding test could be the bestmethod to determine the best mold surface temperature.

Starting with your present 60-degree water and usingyour existing molding parameters, adjust the cushion(or lack of cushion) to yield a part about 90% full.Increase the mold temperate in 10 degree increments,trying 80, 90, or even 100 degrees, and then observethe results. You will find a point that the part fills easierand/or completely. Evaluate the cycle time ramificationsand choose the most beneficial mold surface temperatureversus cycle time and part quality.

As for injection speed, common wisdom today isthat a faster speed will allow the cavity to fill with less

Injection Molding Questions

Ask The Experts

pressure. Again a simple test is the best way to provethe best filling speed for an existing mold. Start with aslow speed and gradually increase it (being careful notto over pack the mold) while observing core deflection.These results will allow you to determine the best injectionspeed for your mold.

While doing these experiments observe fill patternson your particular part (not having a sample makes it alittle difficult to understand the core deflection). Visualizehow a second gate on the opposite side would allowmaterial to enter and help stabilize the core. A largenumber of parts with slender core ratios (length-to-diameter ratios of over 5 to 1) will exhibit core deflectionwhen gated on only one side, with plastic materialimpinging on the slender core.

The solution to core deflection is typically a gate onthe top center where material can flow and surroundthe core adding stability or a double gate arrangement.Recent studies have indicated that some cores deflectin the packing stage and really are not a result of fillingwhere, in many instances, low pressures are observed.Each case is unique and some core movement ordeflection is dependent on how the core is anchored(insertion, fit, and concept), the mold material itself, andthe direction of plastic impinging on the core.

You did not mention the mold material used foryour core. Extensive testing has shown that material withhigher rates of thermal conductivity can allow the moldsurface temperature to be evaluated for ease of injectionand yet will cool the part more evenly to maintain oreven reduce your molding cycle. Copper alloys areexcellent for this application. Typically NiSiCr copperalloys are used in medical applications and many have athin, dense chrome plating applied. Additionally, tungstencarbide has a very high thermal conductivity, exceedingthat of typical tool steels.

Bob Dealey, owner and president ofDealey’s Mold Engineering, Inc.answers your questions aboutinjection molding. Bob has over 30years of experience in plasticsinjection-molding design, tooling, andprocessing. Reach Bob by email [email protected].


Ask The Experts

Question:Secondly, I have a stationary sticking problem

with 3/4" long parts, again in LLDPE. Thestationary side is ribbed. Should this side be highlypolished or sand blasted? In blow molding, the sandblasted surface releases better. ~Robert Lowe, BLPlastics Inc.

Answer:If the part has aesthetic finish requirements on the

surfaces that are creating the resistance to release, thatfinish must be applied to the mold. Without knowingany more about your application, I would suggest thatyou consider an SPI B-1 or B-2 finish. A skilled moldpolisher must install this finish in the direction of partrelease (draw). Where I’ve seen highly polishedsurfaces release well, it is more often a combination ofdraft on the cavity and ejection method than the highpolish that is responsible for lower release and/orejection forces. Sand blasted surfaces do break thevacuum better, if that is the reason that the part issticking to the core. Other than the vacuum releaseaspect, the sand blast surface will, in theory, create

Question:What causes hot runner systems to leak and

how can the leakage be prevented?

Answer:This is one of the great mysteries of operating hot

runner systems. If you have been one of the few whohave never experienced a hot runner leak, countyourself lucky. If you use hot runner systems longenough, you will eventually experience a leak. Theunfortunate problem is that most times you don’t realizea material breach has occurred until the system stops

Hot Runner QuestionsTerry Schwenk, owner and presi-dent of Process & Design Tech-nologies, LLC, answers your hotrunner questions. Terry has over 34years of experience in the plasticsindustry, and more then 22 years inhot runner technology specifically.Email your questions to Terry [email protected]

working or you see material coming out of the electricalbox. This, in my opinion, is the worst thing that canhappen to a hot runner system because the time it takesto find the leak and the effort to analyze what happenedcan be very costly. If you have a tool running and youknow a leak has occurred, before you shut down thetool try to do a color change and run a few shots throughthe system. This can be very helpful in determining wherethe leak is coming from.

Leakages can be categorized into three major areas:mechanical, electrical, or thermal. Knowing this can helpanalyze the problem. In addition, it is important tounderstand that a leak can NOT occur unless thefollowing three items are present: (1) heat, (2) pressure,and (3) a leak path. If you take away heat the materialsolidifies and stops flowing. Take away pressure andthe material viscosity will prevent it from flowing. Takeaway a leak path and the material has no place to go.

Most material leakages occur due to a design flawor improper installation. But analyzing and trying to findthe source of the leak can be monstrous. Design flaws

higher initial injection or release forces and compoundthe ejection problem.

Please let us know how you make out and/or if youneed more information. Undoubtedly many of thedivision members and readers have encountered similarsituations and could provide their thoughts. The greatthing I’ve found about professionals in the injectionmolding industry is a willingness to help a fellow molder.

If you need more assistance, please send a digitalpicture of the part, core, gate arrangement, and mold, alongwith test results from the above recommendations, andeither I or other readers will try to offer more suggestions.


Ask The ExpertsAsk The Experts

can range from a missed dimension to an incorrecttolerance on the print. Improper installation can rangefrom poor machining, poor surface finish, a programmingerror, not holding tolerance, improper assembly, wiring,or a loose screw or seal. In the case of the nozzle seals,the seals contact the cavity steel creating an interferencefit, thus closing off a leak path. When seals get damagedby over heating, or are dinged during installation, theireffectiveness is compromised. The success of the sealis dependant on having full contact with the cavity blocknot only from a mechanical seal standpoint but also froma thermal standpoint. When the seal contacts the cavityblock it gives up some of its heat making it cooler. But ifthe seal is loose in the bore it not only creates a leakpath, it remains hot and the material doesn’t solidify.

If there is no design flaw or improper installation,processing conditions may be the problem. Controllingthe temperature of the hot runner system and the moldplates surrounding the system is critical. When thesystem or mold is heated thermal expansion takes placeand controlling that expansion is essential to maintainingthe integrity of the system and mold base. Carbon steelsexpand at a rate of 0.0000063 inches per degreeFahrenheit per inch. Thus, a piece of steel measuring10 inches in length heated to 100 F over ambienttemperature will expand 0.0063 inches. A hot runnermanifold 10 inches in length heated to 470 F will expand0.0252 inches. If the system or mold base is over heated,or the water wasn’t turned on, this can affect the matingof the surfaces. Components that are not seatedproperly due to excessive thermal expansion will createa leak path. Once a leak path has been established,even if you turn the water back on, the damage willhave already been done and the system will leak.Additional processing issues can be as simple as notfollowing proper startup or shut down procedures.These procedures can change depending on the type oftool being processed, such as a single face tool versus astack mold, or a multi-component versus an insert mold.

Paying attention to the hot runner supplier’srecommendations will avoid most issues. Paying closeattention to the installation and integration of the hotrunner system will prevent leakage from occurring. Inaddition, having well trained processing personnel willavoid leakages when a mistake is made.

Reader Comments From Previous Issues

Regarding injection molding plastisol fishinglures (Spring 2008), Caspar Van Spaendonck ofPhilips Consumer Lifestyle, the Netherlands, had thisto say. You might check on the dough mouldingcompound (DMC) for moulding. This is glass fiberreinforced polyester resin for injection moulding. A longtime ago, Philips made speaker housings out of thismaterial, but these days, the back doors of small carsare moulded of this material. See: http://www.composite.com.au/compounds.html#2

Polyurethane clear coat moulding is a process ofcuring the resin in the tool. A source is: http://www.kraussmaffei.com/index.php?itid=317&content_news_detail=4219&back_cont_id=229

By the way, you were right on the barrel: Do notuse the normal screw and barrel used for thermoplasticmaterial. A special barrel must be used!


CAE QuestionsJohn Ralston, operations andengineering manager of BeaumontTechnologies, Inc., answers yourquestions about flow simulation.John has over 18 years of CAEexperience using various flowsimulation packages. Reach John [email protected] with asubject line of “SPE and CAE.”

Question:I did a mold filling simulation on a new part and

mold design to ensure that we had enough pressureavailable to fill the part. However, the analysisunder-predicted the pressures by 20% and now I amon the verge of being pressure limited. I have to goback and rework the mold or find a molding machinewith more available pressure. Is this a commonproblem with CAE? Why is the analysis predictionso different from the actual results?

true at the end of the filling phase. Profiles on the machinewill most likely require less pressure than the constantvelocity that is typically used for most CAE flowsimulation analyses.

Machine Switchover. If the machine switch-overto pressure control is close to the point where the cavityis completely filled, then it is possible that the cavity willexperience hydrostatic conditions. This will be evidentthrough a rapid rise in cavity and machine pressures. Inmulti-cavity molds, these pressure spikes can also occurdue to filling imbalances. For example, the machine maybe set to switch-over when 95% of the shot has beeninjected. But if an imbalance exists, some cavities maybe full while others are only 60% full. The full cavitieswill see a significant pressure spike again due to thehydrostatic pressure conditions. Be sure to comparethe switch-over point used in the analysis to what is seton the machine.

Accounting for Screw Conveyance and MachineNozzle Losses. Many CAE analysts do not model themachine nozzle geometry, nor do they consider the pressurerequired to move the ram. If the nozzle geometry is notaccounted for, then the pressure loss through themachine nozzle and screw conveyance losses need tobe added to the analysis results for a more accuratepressure prediction. As a rule of thumb, add 10% to25% of the pressure achieved in the analysis to accountfor these losses. This rule of thumb range is certainlyaffected by the design of the nozzle (shut-off nozzle,extended nozzle, diameters and length of the nozzleincluding the orifice size, etc.), so be aware of yournozzle’s design and its impact on pressure loss.

Correct Mold and Melt Temps. In addition to theinjection rate, the mold and melt temperatures used inthe analysis must also be conveyed to the processor sothat those temperatures are used in the process. Highmold and melt temperatures will lower the viscosity anddecrease the actual pressure. The melt temperature usedin the analysis is NOT the barrel or nozzle settings. Thebest way to measure the melt temperature is with an airshot and a hand held pyrometer (we recommendfollowing RJG’s 30/30 melt test). The mold temperaturespecified in the analysis is the temperature at the plastic–metal interface, NOT the temperature of the coolant or

Answer:We see many instances where the flow analysis

simulation program’s pressure results do not matchclosely with the actual injection molding process. Thereare several reasons on why this could happen. First youneed to determine if it is a problem caused by softwarelimitations or an error related to the comparison of theactual injection molding process. In order to determinethe cause of why the pressure prediction is not the sameas the actual molding, we recommend the followingtrouble shooting steps.

STEP 1. First you need to determine if the analysistruly reflects what is being molded. Here are somecommon items to review when setting up an analysis toreplicate an injection molding process.

Comparison of Analysis vs. Machine Setup.Simulations allow the user to specify an injection timeor polymer flow rate, while injection molding machinesnormally have an injection profile. Profiles may rampup from a slow rate to full velocity and then slope downagain prior to the end of the filling phase. Even if themolding machine is programmed to have a constantvelocity, the ram will not move at a constant speed asthe ram can not instantly change velocities. The same is

Ask The ExpertsAsk The Experts


Ask The Experts

the setting on your thermolator. The coolant temperaturewill typically be lower than the temperature at the plastic–metal interface. It should also be noted that if you didnot run a cooling analysis, the CAE software assumesperfect uniform cooling—which in most cases does notreplicate the true molding process.

STEP 2. Once you have verified that you are closelyreplicating the molding process, the next step is to verifythe analysis inputs. Major areas of concern with settingup an analysis include the following.

Analysis Selection. There are multiple solutionplatforms that can be used for a filling analysis.Depending upon the software vendor, these couldinclude 2D, Midplane (2 ½ D), Dual Domain, Hybrid3D, and Full 3D methods. The decision to use aparticular solution method is complex and based on thescope of the problem, part complexity, and the degreeof accuracy required. Choosing a wrong solutionplatform may cause inaccurate results. You should askquestions of your CAE analyst or supplier to verify thatyour problem can be solved effectively and efficientlywith the chosen solution platform.

Inaccurate Modeling. Ensure that the entire feedsystem is modeled, including the sprue, runner system,and gates. This applies for hot and cold runner systems,or hybrid systems (hot-to-cold). There is a pressureloss associated with any channel that the melt flowsthrough, with the feed system contributing significantportions of the total pressure loss.

Material Characterization. This is an area wherea lot of variation could be introduced. CAE analysiscalculations for flow, temperature, and pressure arehighly dependant upon proper material characterization.In most cases, the material database supplied with theCAE software is limited, which presents a problem whenperforming an analysis for your specific job. Tocompound the problem, even if you find the exactmaterial, supplier, and grade in the database, the datamay not be valid for several reasons.

For example, improper rheological characterizationor the use of generic family data (Generic PVT) mayinaccurately represent your specific material’s rheology.Single point thermal conductivity or specific heat valuesverses tabulated data may also cause problems. Thebest way to ensure proper results is to have the material

tested based on your analysis requirements. Thedrawback with material testing for each project wouldbe added expense and time required. Another optionwould be to run verification analyses concurrently withthe actual analysis. This can be accomplished byanalyzing an existing mold or through the use ofproprietary methods such as Veri-flo™ services(contact Beaumont Technologies, Inc. for moreinformation).

SUMMARY. As you can see, there are many vari-ables that can contribute to inaccurate results with CAEflow analysis programs. We discussed the major sourcesfor error, but there are certainly others to consider. Thekey to obtaining the best results is to understand theinjection molding process, how it relates to flow analysissimulation, and the limitations and assumptions made inthe code. If you are outsourcing flow simulation, doyour homework and find a CAE consulting source thatunderstands these issues and can react appropriately,providing you with the best results available with today’stechnology. The key to making simulation successful ishaving someone with the ability to interpret the results,not just the ability to make pretty pictures.


Reader CommentsFrom Previous Issues

Regarding a copolymer withan orange peel surface finish(Summer 2008 ), Caspar VanSpaendonck of Philips ConsumerLifestyle, the Netherlands, had thisto say. Having some experiencewith Asian tooling, it might be thatthe polishing of the tool was donetoo hastily. When polishing steelwith too high speed and pressure(over polishing), an orange peeleffect can appear. See this link forASSAB / Uddeholm polishingguidelines (orange peel problemsare mentioned on page 8): http://www.buau.com.au/english/fi les/POLISHING-ENGLISH_950901.pdf

1) Are three flow fronts colliding? Especially ina flat area with no pins or other ventingpossibilities, the air will be trapped. In theworst case, it will burn. This is a tool/gatingproblem. If you are lucky with a shut-off hotrunner, you can try sequential opening of therunner nozzles to move the colliding flowfronts.

Regarding bubbles in a clear polycarbonate part (Spring 2008), Caspar Van Spaendonck of PhilipsConsumer Lifestyle, the Netherlands, had this to say. I appreciated your article on PC moulding; it was practical,helpful, and to the point. Allow me to share some experience on the air inclusions. If the bubble consistentlyappears in the same location, ask yourself the following questions.

2) Is there a weldline after a hole? In cases where notvented or poorly vented air is dragged along, ventingthe pin will help.

3) Is the bubble at the end of the flow where the partcannot be easily packed? Here we have a realproblem with PC. A combination of difficulty flowingand over packing near the gate can cause excessivestress. If the gate does not freeze too early, a specialpacking pressure profile might be the solution.

Ask The Experts


An Example of MeltFlipper Technology:Performance Evaluation of an 8 Cavity PVC Medical Parts

The image below shows the two distinct flow groups of an 8 cavity geometrically balanced mold. Flow groupsare made up of a group of cavities that receive the same melt properties with or without the patented BeaumonthTechology MeltFlipper melt rotation technology used by Integrity Plastics for this evaluation. The inside fourcavities make up flow group 1 (red) and the outside four cavities make up flow group 2 (blue). Any variationbetween these flow groups is caused by shear. These shear variations can be addressed using MeltFlipper technology.Variations within these flow groups are classified as steel imbalances. Steel imbalances can be caused by differencesin runner size, wall thickness variations, cold slug issues, venting, gate diameters, etc. MeltFlipper technologycannot resolve steel variations.

Featured Technology

5 Step Software Results

Short shot samples were analyzed using the Beaumont 5 Step Software to determine the root cause of imbalancein the medical PVC part mold. Shown below is the steel variation for the two flow groups. Flow group 1 shows a2.1% steel variation (due mainly to cavity 6). Flow group 2 shows a 4.6% steel variation (due mainly to cavity 5).

1

5 6

2 3

7

4

8


Steel imbalances are caused by differences inthe physical steel dimensions. Small differences inrunner and gate diameters can have a large effecton the filling balance. Shown below is the pressuredrop equation highlighting the impact that the channelradius (r) has since it is raised to the 4th power.

Shear imbalances are caused by shearing the material through the machine nozzle and the runner system.MeltFlipper technology provided uniform filling by managing and distributing the high sheared laminates to all thecavities. By using the MeltFlipper technology, Integrity Plastics was able to improve the filling balance and enablethe cavities to receive identical melt properties. The MeltFlipper technology has the potential to increase theprocess window with improved dimensional consistency. Other benefits include a potential for decreased scrap,lower injection pressures, and faster mold commissioning.

Featured Technology

Cavity 5 and 6 are both the lightest cavities intheir respective flow groups. Consequently, theseparts are fed by the same secondary runner whichshould be checked for consistency to the otherrunners. The difference between the flow groupsevaluates the amount of shear imbalance. The shearimbalance determined from the short shot sampleswas 8.1%.



Call For Papers


Abstract

New advances in screw designs and mixing sectionshave allowed processors to advantage of new resins,higher production rates, and improved product quality.With new material formulations, and increased energycost it is paramount that the machine utilize the totalenergy input in the most efficient manner. This paperwill present data on the melting performance of a newinjection screw design with a unique flight geometry thatmaximizes the conductive melting mechanism (low shear)in the screw channel. A comparison is made betweenthe total energy required for melting, pumping and mixingcharacteristics between a standard General purposescrew, barrier screw and a new Variable Barrier EnergyTransfer screw (VBET) (12).

Background

Injection molding is the most widely used plasticforming process in the industry today. The cost of eachpart produced depends on a number of factors includingresin, cycle time, total energy input and scrap rate just toname a few. In general, the lowest cost per part willoccur at the highest production rate and the lowest energyusage. The majority of the energy required to fully meltthe resin is dictated by the screw design selected.

Viscous energy dissipation via shearing in single screwextrusion has been the subject of intensive study overthe last forty years. It is well documented in the literaturethat the polymer pellets start to melt after 2 to 4 diametersfrom the hopper and are compacted into what is knownas a “solid bed”, as shown by Figure 1. The initial meltingmechanism of a tightly compacted solid bed is mainly byrubbing on the hot barrel surface as it rotates with thescrew and by conductive heating from the barrel heaters(1). As the melt film between the solid bed and the barrelincreases, heat is generated from viscous shear heating,which dominates the melting of the polymer. Inconventional screws, viscous shear heating is the principlesource of energy to melt the polymer (2).

More modern screw designs utilize a barrier flight asshown in Figure 2. As the melt film is wiped off thebarrel surface by the main flight, the melt is deposited

Experimental Study on the Energy Efficiency of DifferentScrew Designs for Injection Molding

Jeff A. Myers: BARR Inc., Onsted, MIMark Ruberg 1, Ritch Waterfield 1, Mark Elsass1, Steve Kelsay1: Milacron Inc, Batavia, OH

into a separate melt channel. A barrier flight divides thesolid and melt channel such that the clearance over thebarrier flight will only allow melt to enter into this channel.The main function of a barrier flight is to separate themelted polymer from the solid bed and keep the solidbed from becoming unstable and prematurely breakingup. By continuously removing the melt film over thebarrier flight, the solid bed surface remains intact. Thisallows for a greater solid bed surface area on the barrelwall to keep the viscous energy dissipation via shearingas high as possible. In addition, since the melt filmthickness over the barrier flight is small, the shear energyis also high. It is believed that this type of phase separationwill increase the melting rates as compared to non-barriertype screws. However, since approximately 90% of thepolymer is melted by the high shear in the barrier section,the melt temperatures are correspondingly higher, whichis undesirable in many applications.

Recognizing the inherent problems and limitations ofbarrier type screws, the solid/melt mixing type screwwas developed (1). This principle differs from the barrierdesigns in that the metering section is divided into twoequal subchannels by a secondary flight. The solid bedis intentionally broken up at the end of the melting sectionto allow some solids to enter the mixing section. Theclearance of the secondary flight is much greater thanthe clearance of the barrier flight on a barrier screw,allowing unmelted pellets to pass through. The depth ofone subchannel decreases while the depth of the otherincreases, forcing the melt to flow over the secondaryflight at relatively low shear rates, as shown by Figure 4.Solid bed fragments mixed in the melt are broken intoindividual pellets by passing over the secondary flight.The pellets are continually mixed with the melt promotingheat transfer by conduction from the melt to the pellets.Since the viscous energy dissipation via shearing in solid/melt mixing screws is low and the primary meltingmechanism is by conduction, the melt temperature isreduced (3).

The goal of this work is to evaluate the total energyrequirements for the molding machine with three differentscrew designs and make a comparison on theperformance and energy each screw required at differentmolding conditions.

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Material

The resin used for this study was a standard injectiongrade High Density Polyethylene (HDPE), Fortiflex T50-500 grade. The melt flow rate (MFR) of the resin was6.5 g/10 min (190 0C, 2.16 Kg). All tests were performedusing 100% virgin natural pellets.

Equipment

The experiments were performed on a Milacron MM-550 (4) injection machine with the specifications listed inTable 1. The barrel was fitted with standard Ceramicheater bands. The total kW per zone is listed in Table 2.

The General purpose (GP) and Barrier screw thatwere evaluated are typical designs supplied by themachine manufacture.

The GP screw had a 100mm constant lead-length anda primary flight clearance of 0.10mm. It had a 12-diameter feed section that was 12.70mm deep, a 5-diameter constant taper transition section, and a 5-diameter constant depth meter section that was 4.70mmdeep.

The Barrier screw had a 9.4-diameter feed sectionthat was 14.50mm deep with a 100mm lead-length, 8.0diameter barrier section with a 125mm lead-length, anda 2.6 diameter constant depth meter section that was5.33mm deep. The feed and metering section were singleflighted and the barrier section was designed with a meltand solid channel as shown in Figure 2. The clearanceover the barrier flight had a constant depth of 0.51mm.The barrier screw had a 2.0 diameter spiral mixing sectionat the discharge end.

The VBET solid/melt mixing design had a lead-lengthof 120.7mm and a primary flight clearance of 0.10mm.It had a 6.0 diameter feed section that was 19.0mm deep.The constant taper transition section was 6.4 diameterslong with a starting depth of 19.0mm and ending at 7.6mmdepth. The solid/melt mixing section was 6.9 diameterslong with a starting depth of 7.6mm and exit depth of6.9mm. Within the mixing section the channel depthvaried between 3.8mm and 12.7mm. As shown in Figure4, the depth and length of the undercut flight variedthrough the length of the mixing section. The startingdepth of the first peak was 3.8mm and the ending depthwas 2.5mm. The period of these oscillations was out ofphase for the two channels. The constant depth metersection was 1.3 diameters long at 6.9mm deep. Thedischarge end of the screw had a 1.0 diameter slottedmixing section. This screw design will be referred to asthe Mixing screw in the rest of the paper.

The barrel heater zones and screw motor wereconnected to a data acquisition systems which allowedthe total power to be recorded for each test. A meterwas installed on the main power supply which recordedthe total machine power required for the duration of eachtest. To investigate the total energy input for each screw,the molding parameters were held constant throughoutthe test and are listed in Table 3. Data was recorded forfifty consecutive shots once the machine was at steadystate.

Results and Discussion

The screw Recovery Rate (g/sec) is shown in Figure5. The Mixing screw had an 18% higher rate comparedto the GP design and a 15% higher rate compared to theBarrier design at 150 rpm. The melt temperature wasmeasured using a hand held pyrometer after the lastconsecutive shot in each test. The maximum dischargetemperature at 75 and 150 rpm is shown in Figure 6. Thedischarge temperatures for the Mixing Screw were 14to 12 oC lower than the Barrier design at 75 and 150 rpmrespectively. The melt quality for the Barrier and Mixingscrew showed no sings of unmelt. The melt quality ofthe GP design showed evidence of unmelts at 75 and150 rpm. At 150 rpm, unmelted pellets were more evidentin the purging and the molded part. This data is consistentwith the low discharge temperature with the GP design.

The specific energy inputted by the screw is shownin Figure 8. The Mixing screw used 6 to 12 % less energycompared to the GP and Barrier design. The varyingdepths in the solid/melt section of the Mixing screwallowed energy from the screw to be used moreeffectively. Shear energy inputted to the resin in theshallow channel regions was readily transferred to thecooler solids in the deep channel.

The total energy required, Et , to produce a single partis calculated from the following relationship:

E t = P t /RM ; kW/kg (1)

RM = 3.66*W t /CT ; kg/hr (2)

Where Pt is the total machine power in kW. RM is themachine specific rate in kg/hr, which is a function of thecycle time. Wt is the part weight in grams, and CT is thetotal cycle time in seconds. The results at 75 and 150rpm are listed in Figure 9. The Mixing screw required1.6 to 2.6% less energy per molded part compared tothe Barrier and GP design. The actual value would behigher if scrap rates and are included in the calculation.

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Conclusions

Machine efficiency is an important aspect in themolding process. The data clearly shows that screwdesign plays an important role in the total energy requiredto produce a molded part. The results of our tests suggestthat a design that maximizes conductive melting as theprimary melting mechanism requires less energy per partthan a GP or Barrier design. Data from a subsequenttest indicated that the Mixing screw is able to produce amore uniform melt temperature distribution and improvedmixing which can also improve the overall machineefficiency.

References

1. C.I Chung, Extrusion of Polymer, Hanser, (2000).2. J.A. Myers, R.A.Barr, SPE-ANTEC Tech. Papers,

48,154 (2002)3. T.A. Hogan, M.A. Spalding, E.K. Kim, R.A. Barr,

J.A. Myers, SPE ANTEC Tech. Papers, 180, 490(2003)

4. Milacron Inc. Plastic Technologies Batavia, OH5. “ET” Registered Trademark of Robert BARR Inc.6. C.I. Chung and R.A. Barr, SPE ANTEC Tech.

Papers, 29, 168 (1983).7. C.I. Chung and R.A. Barr, U.S. Patent 4,405,239.8. T.A. Plumley, M.A. Spalding, J. Dooley, and K.S.

Hyun, SPE ANTEC Tech. Papers, 40, 324 (1994).9. S.A. Somers, M.A. Spalding, J. Dooley, and K.S.

Hyun, SPE ANTEC Tech. Papers, 41, 222, (1995).10. B.A. Salamon, M.A. Spalding, J.R. Powers, M.

Serrano, W.C. Sumner, S.A. Somers, and R.B. Peters,R.B., Plast. Eng., 57, 4, 52 (2001).

11. R.A. Barr, U.S. Patent 6,599,004 (2001).

Key Words:

Solid Melt/Mix, Conductive Melting, VBET.

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Figure 1. Conventional screw channel flow.

Figure 2. Barrier screw channel flow.

Figure 3. Solid/melt mixing channel flow.

Figure 4. Schematic of VBET section.

Zone kW per zone Zone -1-Feed end 11.5

Zone-2 11.5 Zone-3 11.5 Zone-4 19.0 Total 53.50

Injection Capacity, Max G.P. Styrene , kg 2.98

Screw Diameter, mm 100 L/D 22:1

Maximum Screw Stroke, mm 400 Electric Screw Motor, kW 75

Maximum Screw, rpm 200 Number of Heater Zones 5

Total Heating Capacity, kW 53.8

Table 1. Machine specifications.

Table 2. Heater zone specifications.


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Screw Speed, rpm 75, 150 Back Pressure, Bar 6.2 Feed Throat, o C 60 Zone-1, o C 229 Zone-2, o C 229 Zone-3, o C 229 Zone-4, o C 229 Nozzle, o C 229 Screw Stroke, mm 183 Cycle Time, sec 22.0, 18.0

Table 3. Molding conditions.

Figure 5. Screw recovery rate.

Figure 6. Discharge temperature.

Figure 7. Screw motor power required.

Figure 8. Specific energy inputted by the screw.

Figure 9. Total machine energy required per molded part.


Partners in EducationBy Mike Thomas, Milwaukee SPE

Milwaukee SPE is delighted to announce that this year’s Ticona grants will be awarded to two deserving studentson March 17, 2009, during Milwaukee SPE’s Annual Education Career Night. Ticona and Milwaukee SPE will begintheir 12th year presenting these joint financial grants. With a shared goal of the education of our customers, employees,members, communities, and public and private schools and universities, Ticona and SPE Milwaukee have workedseamlessly over the years to recruit and reward deserving recipients of this prestigious award. Ticona is alwayslooking for polymer, engineering, and manufacturing talent from Midwestern Universities, and the partnership betweenTicona and Milwaukee SPE seeks to further the placement of qualified individuals with Ticona, thus keeping talent inthe Midwest.

Mike Thomas, a former employee of 32 years with Ticona and current member ofMilwaukee SPE, has directed this joint financial grant from SPE Milwaukee’s side forthe last 12 years. Originally started with Ticona’s Pat Hughes in 1995, Mike continuedthe program with Jack Grates and, more recently, with Clay Linstid. Clay visited Milwaukeein February 2007 to personally present the grant to Scott Winkelmann of UW-Milwaukee.Clay also worked with Gail Bristol of SPE National on joint educational programs. It iswith great regret that I inform you that Clay passed away unexpectedly on June 29, 2008.He is sorely missed by everyone who knew him. Vivek Jain of Ticona has taken over forClay in coordinating Ticona’s educational programming in 2008 and 2009. Ticona’sgenerosity and commitment to the students and professionals in the plastics industry overthe years has not gone unnoticed.

Ticona, which is part of Celanese Corporation, is a global company of material scientists, design engineers,technical support experts, account managers, and customer service representatives dedicated to helping companiesachieve their goals in the use of engineering resins. They are a world leader in materials such as acetal polymers,liquid crystal polymers, long fiber reinforced thermoplastics, and ultrahigh molecular weight polyethylene. They holdstrong positions across their broad portfolio of other thermoplastics as well. Ticona has about 1,800 employees inpolymer production, compounding plants, and laboratory and design centers throughout the world. Their productsserve designers and engineers in a number of key markets, including automotive, appliance components, informationtechnology, consumer and recreational products, industrial, medical and health, and many others. They are dedicatedto the principles of responsible care, including care for the health and safety of their customers, employees, andneighbors, as well as the environment overall.

Their global reach, extensive product portfolio, and engineering and science capabilities enable them to work withtheir customers at any stage of the process—be it an early concept or in the full production stage—anywhere in theworld. Ticona’s goal is simple: To meet the customer’s design and engineering challenges and exceed the customer’sexpectations of technical expertise and support.

For more information, visit Ticona’s website (www.ticona.com) and Milwaukee SPE (www.milwaukeespe.org).These two fantastic organizations are committed to maintaining their leadership position in the plastics industry. Along term relationship is vital to our success.

Feature Article


Investigation of Comparative Stress Distributions inThermoforming Versus Injection MoldingThomas W. Shoaf, Department of Industrial Studies

University of Wisconsin-Platteville, Platteville, WI 53818

Abstract

The comparison of stress distributions has beeninvestigated in thermoformed and injection molded partsof a similar design. Injection molding is traditionallypreferred for automotive applications because of its abilityto create parts with minimal internal stress. However, inrecent years because of potential cost reductions,thermoformed parts are often being substituted. MatroxInspector has been used to evaluate internal stress createdby both processes. Results show a difference in thecomparative stress distributions of similar parts that isdependent on location.

Introduction

A product’s strengths and weaknesses are oftendependent on how it is processed. Because of its abilityto produce a nearly stress free part, the preferredtechnique for processing plastics for use in automobileshas been injection molding. Whenever the designparameters of a product allow, thermoforming is beingconsidered as a viable processing alternative. This canpotentially reduce the cost and processing times ofproduction. Because of these savings manymanufacturers have switched from injection molded tothermoformed parts.

The differences between the thermoformingtechnique and injection molding technique can createdifferent stress distributions in identical parts that areinherent to each individual process. Research has shownthat these stresses are the result of changes in theequilibrium position of atoms and the distortion of valenceangles in the molecular chains as well as from changesin the distances between segments in the molecules [1].

High levels of stress in a plastic have the potential toadversely affect a final product. This can manifest itselfin the form of reduced optical characteristics, postprocessing warpage, and premature, or unexpected,failure of a part [3]. These stresses can also leave aplastic open to chemical attack, reducing the lifespan ofa part. It is because of this that the focus of this study isthe comparative stress distributions created by theinjection molding technique versus those of thethermoforming technique.

Experimental Procedure

In this study, two injection molded parts with differentdesigns were prepared; the first part being a clearPlexiglas faceplate and the second being a common, clearplastic cup. Using the injection molded parts as atemplate, two male molds were produced in order to beable to form a nearly identical thermoformed part.

Clear sheets of PET (polyethylene terephthalate)were heated in a thermoformer at 550 degrees Fahrenheitfor 19 seconds then vacuum formed around the moldsfor 14 seconds. The subsequent thermoformed parts werethen hand cut from their sheets.

Several of each injection molded and thermoformedparts were then separately subjected to a polarized lightand viewed through a polarizing film. This caused brightbands of colors, created by the bending of light, to formas shown in Fig 1. These bands of color indicate areasof stress in the part. A Panasonic Lumix DMC-FZ5 wasthen used to take photographs of the areas which wereto be analyzed.

Each of the injection molded and comparativethermoformed parts had an area designated for analysis.For the face plates the area for analysis was the flatface area away from the injection site, otherwise knownas the gate. The analysis area on the plastic cups wason the bottom of the cup at the injection site.

To quantify the stresses in the areas of analysis, thephotographs were loaded into Matrox Inspector; acomputer program designed for photographic analysiswhich, hereafter, will be referred to as photographicanalysis software (PAS). A blob analysis, with thresholdat 140, was then performed to indicate areas of stress inthe plastic, as shown in fig. 4. The results from the blobanalysis where then recorded and averaged.

Results and Discussion

A PAS blob analysis was used to quantitate the areasof stress in the test areas. A blob analysis works bysegmenting objects in an image from a background, aswell as from each other, using a variety of thresholdoperations. The PAS then counts and labels thesegmented objects. For each test area the threshold wasset to count only the highest concentrations of colored

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bands produced by the polarizing film; effectivelyindicating and counting the areas of stress.

Analysis of the injection molded and thermoformedfaceplates revealed 16 and 184 average areas of stressrespectively, as shown in Fig 2. The stress in the injectionmolded part can be explained by the molding conditions.If the part cools too quickly from the melt, frozen-instresses may be quite high due to differential shrinkage[2]. Even so, most of the plastic is able to relax duringcooling, relieving the majority of the internal stress. This,however, is not the case for the high levels of stress inthe thermoformed parts, which are a result of the heatingand stretching inherent to the thermoforming process.

When running a blob analysis on the injection moldedand thermoformed cups the PAS respectively indicated87 and 78 average areas of stress as shown in Fig 3.The high level of stress in the injection molded cup isdue to the fact the area of analysis on the cup was nearthe plastic injection location. Flow-induced stresses arisefrom the presence of the shear and normal stressesduring the filling and packing of the polymer in the moldcavity [4]. During the cooling phase, some of thesestresses are frozen in the final product due to incompleterelaxation. This gives the area of injection in the injectionmolded part a similar stress distribution to thethermoformed part.

Comparison of the different stress distributions dueto processing in relation to the analysis areas show lessstress in the injection molded parts away from theinjection area. However, in the thermoformed partsstress distribution was high in both analysis areas.

Conclusion

When comparing the stress distributions of injectionmolded versus thermoformed parts, a number of patternsstart to emerge. First the injection molded parts in generalhave a lower level of internal stress in comparison tothe thermoformed parts. Second, stress in the injectionmolded parts is concentrated around the gate anddissipates as a function of distance, while thethermoformed parts tend to have similar levels of stressthroughout.

The internal stress level in an injection molded partcan be influenced by the injection process itself or byrapid cooling after the initial injection. These can lead tothe creation of an injection molded part that has a stresslevel comparable to that of a thermoformed part. Forthis reason it is important to consider the application ofthe part to be produced before making a choice oftechnique to process it.

If a part needs a relatively low level of internal stress

then injection molding is the best choice of processing.However, for this technique to produce the best part aninvestment needs to be made in the research anddevelopment of the mold to prevent stress form formingduring processing. When the design of a mold allows for itsuse and the internal stress in the part is not a concern thenthermoforming is an often cheaper, viable option.

References

1. G. Menges, A. Dierkes, L. Schmidt, and E. Winkel,SPEANTEC Tech Paper, 300 (1980).

2. H. B. DALY, K. T. NGUYEN, B. SANSCHAGRIN,K. C. COLE, Journal of Injection MoldingTechnology (USA), 2, 59 (1998).

3. H. B. DALY, K. T. NGUYEN, B. SANSCHAGRIN,K. C. COLE, Journal of Injection MoldingTechnology (USA), 2, 78 (1998).

4. J. M. Hoffman, A. Sjong, SPE-ANTEC Tech. Papers,1409 (2006).


Figure 2. PAS indicated average number of stressareas in injection molded faceplates at 16 and 184for the thermoformed faceplates.

Figure 1. Image of the bright bands of colors.


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Figure 3. PAS indicated average number of stress areas in injection molded cup at 87and 78 for thermoformed cup.

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Injection Moulding Process Benefits Both Process and Moulded Partby André Lück, Demag Plastics Group

Injection compression moulding (ICM) and its advantages for machine selection, process design, and part properties have longbeen known. Many injection moulding processes are currently gaining important benefits when combined with injectioncompression moulding. Whether compression is applied sequentially or in parallel with injection, with ICM control for injectionmoulding machines, the possibilities are endless.

Phases of injection compression moulding.Injection compression moulding,sometimes also called injection stampingmoulding, provides many qualitativeadvantages for injection moulding apartfrom reduced material shearing and lessorientation. It also permits reductions ininjection pressure, clamping force, andcycle time. In addition, there tends to bean improved holding pressure effect,which minimises sink marks and warpage.The number of ICM applications isincreasing—for IMD-decorated parts,mechanically stable plastic elements inautomobiles, or exceptionally thin-walledpackaging articles, for optical and foamedparts, as well as for thin parts with a finelytextured surface, or for decorative backinginjection.

The advantages of ICM—ranked indecreasing order of importance—can becategorised as follows.

1. In the ICM process, shrinkage iscompensated not only via the fluidcentre but by compression of themelt as the mould closes. There aretwo advantages: the action of theholding pressure is on a flat surfaceand uniform, and overpacking of thecavity is possible earlier duringinjection. By reducing holding time,this cuts cycle times, removes sinkmarks at points of material accumul-ation or at the end of the flow path,and diminishes clamping forcerequirements.

2. Reduced molecular orientationduring injection into an extendedcavity has a positive effect onwarpage and provides better long-time dimensional accuracy.

3. Improved venting to the mouldenables critical parts to be easierfilled which avoids surface flawsand tends to result in fast injection.

Injection compression moulds call for special engineering design.

Flat-face effect of the hold pressure during injection compressionmoulding is advantageous.

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4. Backing injection reduces stressesin mats or foils to be decorated andultimately, enhances the freedom onusing designs and decors.

5. Material shear in injectioncompression is less so that fibredegradation in the case of long fibrethermoplastics (LFTs) is reducedand mechanical part properties areimproved.

The possible advantages are counter-balanced, however, by the extra costs forthe machine and mould as well asrestrictions in respect of part geometry:

• The IM machine requires anadditional ICM controller, the extracost, by the way, is oftenexaggerated.

• The mould must be physicallyadapted to ICM in order to preventthe melt from penetrating into theparting line. There are a number oftechnical solutions to address thisproblem.

• Undercuts or penetrations acrossthe compression direction areproblematic.

• Parts that are designed withconsiderable depth in the injectiondirection are very difficult to mouldby the ICM process.

Basically, the ICM processes arealways alike and easy to understand sincewhat they add to the injection moulding isonly an additional stroke of the clampingunit:

1. Close mould down to the com-pression gap,

Table 1: Advantages and disadvantages of different mould concepts forinjection compression moulding.

In processing LFTs, Injection compression moulding makes forfavourable fibre orientation.

Applied for optical parts, ICM reduces double refraction.

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2. Inject and fill cavity 80 to 95%(equivalent to 100% or more of theultimate volume),

3. Sequential or simultaneous com-pression by clamping the mould, and

4. Apply hold pressure, cool, openmould, and eject part.

Compression is effected either by theclosing movement of the mould only or bythe movement of an individual mouldelement that is activated by means of ahydraulic core pull function (“corecompression”). Besides the basicfunctions, it is possible in ICM to use anumber of additional options, for instance,pre-compression and intermediateopening. Pre-compression serves for theforming of materials to be decorated.Intermediate opening may be necessarywhere the mould is initially closedsomewhat more than necessary for ICMin order to prevent jetting and ensurelaminar flow during injection. Intermediateopening may also be helpful in foaming ifit is desired to permit initial distension tothe melt.

ICM controllers come at two levelsof sophistication: (1) sequential ICMcontrol with the process phases takingplace in succession, and (2) simultaneousICM control with the process occurringin parallel with injection as well as pre-compression and intermediate opening.

The options are summarised onDemag screen pages 9 (“compressioncontrol”) and 8 (“pre-compression/intermediate opening”) for the control ofinjection compression. Here, ICM controlis fully integrated in the “flexible machineoperation.” It is an add-on feature that canbe deactivated to serve as a standard IMmachine.

What is often underestimated is thesavings potential on cycle time. Injectioninto an extended cavity and parallelcompression will, as a rule, shorten cycletime by anything from a few tenths of asecond to more than a second. The restof the cycle is identical in the case ofsequential and parallel compression with

In the in-mould decoration process, ICM counteracts creasing.

In decorative backing injection, ICM reduces stresses in the material tobe decorated.

Table 2: Advantages of ICM for various applications.

Feature Article


the press-moulding by means of ICM offeringpotential to reduce holding pressure time. Here again,time savings are possible of a few tenths of a secondor up to several seconds—depending on the type ofpart and material.

Recently, there have been distinct improvementsin mould designs. The trend is for the classical verticalflash face to be replaced by female mould/male plugconcepts or by designs with guided intermediateplates. In some cases, male plug and core com-pression variants have established themselves. Anoverview of the pros and cons of the three mouldvariants is provided in Table 1.

Injection compression by means of the clampingunit of IM machines offers the advantage of asubstantially higher force reservoir compared todesigns with a male plug fitting into a female mould.In contrast to hydraulic two-platen machines, toggleclamping units apply the force uniformly and centrallyto the mould with a distinctly sufficient compressionforce—contrary to a widely held prejudice.

Especially when filling asymmetrically arrangedcavities or cavities with long flow distances, the toggleis advantageous. Thanks to the special kinematicsof the toggle, mould movements can be duplicatedand guided with a very high degree of accuracy nearthe locking range and, consequently, for extremelysmall compression gaps.

Typical examplesIn many currently important applications—such

as IMD components, mechanically stressed LFTparts, thin-walled packaging articles, optical parts,parts made by decorative backing injection, finelytextured surfaces and foamed moulded parts—anICM function will provide technical or economicalbenefits (Table 2).

It is a good plan to decide already at the designstage of the mould whether an ICM function will behelpful for technical, economical or qualitativereasons. It is also important to configure the machinewith the necessary ICM functions and to ensure theICM controller is logically organised and easy tooperate.

About the Author: André Lück, Dipl.-Ing. (FH)for Plastic Engineering, is a Process DevelopmentEngineer in the Research and Process TechnologyCenter of the injection moulding machinemanufacturer Demag Plastics Group in Schwaig,Germany. Contact: [email protected]

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Member Profile

Student Activities ReportBy Walter S. Smith

The Injection Molding Division (IMD) offers a $3000 scholarship that is made annually to a graduate orundergraduate student. Applicants must have experience in the injection molding industry, such as courses taken,research conducted, or jobs held. The scholarship will be awarded through the SPE foundation.

The IMD continues to sponsor the Injection Molding Reception at ANTEC. Many students attend this event.This is a great opportunity for students to network and meet professionals in their chosen career field. Furthermore,the IMD contributes $1000 to the Student Author Travel Fund which aids students in their travel to the variousANTEC cities.

The SPE Foundation 2008 Scholarship brochure/application is available for interested students who will beattending college during the 2008–2009 school year. General foundation scholarships range up to $4000/year.Specific scholarships requiring specific knowledge or background can range up to $7000/year.

SPE offers membership to over 120 student chapters. Learn, network, and educate yourself with the help ofSPE. Get involved in an existing SPE chapter or start your own! For more information on what it takes to start astudent chapter, or to find out what SPE can do for your plastics program, contact Tricia McKnight [email protected].

I strongly recommend that all students get involved. I promise that it will be worth your time and effort.

Student Activities Report


AGA-PGT, Inc. – A World Class Molder and Mold Maker of Plastic Gearsby Mal V. Murthy, Ecogenus Group LLC

Molding Corner

A Bit Of History

In 1944, Helmar Anderson, Edward Bertsche, andClarence Anderson formed the ABA Tool & DieCompany in Manchester, CT, as a metal componentmachine shop dedicated to the supply of precision partsto the aircraft industry, primarily Pratt & Whitney ofnearby East Hartford, CT. The company performedwell and in the early 1950’s, it evolved into amanufacturer of injection molds for the new andburgeoning plastics industry. Circa 1956, DonaldAnderson, Helmar’s son, assumed the presidency ofthe company and brought in his brother Bill, as account-ant and buyer, and his brother Earl, as shop floormanager and maintenance director.

As the plastics industry grew and changed, ABATool & Die moved along with it. In 1961, ABA Tool &Die began to manufacture injection molds specificallyfor the production of plastic gears. Remarkably, manyof those gears are still hard at work today. Thus beganthe ascent of what was once a tool and die machineshop into one of the world’s pioneers and world classmanufacturers of plastic gears and plastic gear injectionmolds.

In what was the first publication devoted exclusivelyto the design of plastic gears (there were manypublications regarding metal gears), William McKinleyand Samuel Pierson collaborated to publish “The ABAPlastics Gearing Design Manual” in 1967.

There are many stories of injection mold makersbeing asked by their customers to “qualify” their moldsby running them on in-house injection molding machines,and ABA was no exception. As you might imagine,production injection molding was not far behind, and in1969, ABA Tool & Die started the Plastics GearingTechnology (PGT) division. It was 23 years later thatthe ABA mold making division officially merged withthe PGT molding division to form ABA-PGT, Inc., an

employee stock ownership (ESOP) company dedicatedto the manufacture of plastic gears and plastic gearinjection molds.

The New Millennium

The newly merged entities enjoyed the fruits of aplastics industry growing by leaps and bounds, as plasticscut into many of the previously sacred domains of cutmetal gears. Boasting lower costs, reduced weight, andless noise, plastics were becoming a gear designerspanacea for correcting problems posed by metal.

But ABA-PGT wasn’t about to stand still and simplygrow as the industry grew. It was, and remains, atechnology-driven enterprise. The company pioneeredanother first: the “lights out” manufacturing of plasticgears in 1996 at a satellite plant in Vernon, CT.

The success of the company presented spacechallenges, as their facility at 1395 Tolland Turnpike—a rather typical old New England mill—becamecramped. With help from the state of Connecticut, ABA-PGT built a state-of-the-art molding and mold makingfacility in a new industrial park in Manchester, CT: a68,000 square foot building that now holds 40 injectionmolding machines and a 30-man tool room.


Molding Corner

Not An Injection Molder of Gears, But A GearMolder

What’s the difference between an injection molderthat occasionally molds gears and a gear molder thatexclusively molds gears? This: Plastic gear quality isdetermined by measurements of concentricity,roundness, involute profile, tooth spacing errors, axialhourglass or taper, helix angle (for helical gears), andsize, arc tooth thickness, and outside and root diameters.A plastic gear molder has invested in specialmeasurement equipment/software and has trainedpersonnel to provide assurance that each lot of parts isconsistent.

It’s The Tool That Makes The Part

ABA-PGT designs the gear molds that it makesand then manufactures that mold to the highest standardsof quality. Alloy steel components hardened to Rockwell“C” 50-62 result in durability that enables the companyto offer a one million cycle service commitment—thebest in the industry. In-house manufactured master-gearquality electrodes properly compensate for mold

Contact:

ABA-PGT, Inc.10 Gear Drive, Manchester, CT 06042Website: www.abapgt.comEmail: [email protected]: (860) 649-4591FAX: (860) 643-7619

shrinkage and spark gap, thus producing a molding-quality finish and avoiding the distortion of post-processing. Add 60 years of expertise across a full staffof tool designers and toolmakers, and you have awinning combination.

“Lights Out” facility in Vernon, Connecticut


MiniTec speakers (from left): Prof. AdamKramschuster, Dr. Maureen Reitman, Prof. Sarah

Gong, and Prof. Lih-Sheng (Tom) Turng.

MiniTec attendees browsed the table-top exhibit.

Milwaukee co-organizers, Prof. Lih-Sheng (Tom)Turng of the SPE IMD, and Mr. Vic Baez of the SPE

Milwaukee section, welcome the attendees.

Over 60 people attended the MiniTec.

Over 60 people attended the SPE MiniTec in Milwaukee, entitled “Emerging Technologies and Materials:Nanotechnology and Biopolymers,” on Tuesday, October 21st, in Milwaukee, Wisconsin. The event was co-organized and co-hosted by Vic Baez, president of SPE Milwaukee, and Lih-Sheng (Tom) Turng, chair of theSPE Injection Molding Division. Sponsors included Nanocor, Dealey’s Mold Engineering, and Sabic InnovativePlastics. Speakers came from both academia and industry, including such prominent names as Tom Hotaling ofNanocor, Maureen Reitman of Exponent Failure Analysis Associates, John Baldus of the Wisconsin Office ofEnergy Independence, Sam Dahman of RTP Company, Ned Bryant of RTP Company, Krishna Pillai of UW-Milwaukee, Tim Osswald of UW-Madison, Bill Hickey of Phillips Plastics Corp., Craig Clemons of the USForest Products Laboratory, Adam Kramschuster of UW-Stout, Sarah Gong of UW-Milwaukee, and Lih-Sheng (Tom) Turng of UW-Madison. The presentations were followed by a networking reception partiallysponsored by Leanne Burton of Great Lakes Calcium.

On The Road

SPE Milwaukee MiniTec: October 21, 2008


Feature Article

SPE’s New Website

By Susan Oderwald

Initial Release

I am pleased to announce that we have launched anew SPE website. This marks an important upgrade toour online presence around the globe. As of now, thenew site includes a series of “under the hood” changesthat will allow it to function more efficiently and bettersupport SPE’s many transactions that now take placeonline.

It also includes a completely new look, feel, andarchitecture. This update was sorely needed to allowmembers to better search and navigate, and to allowSPE to better promote the full range of Society activitiesand events—including events produced independentlyby SPE groups.

As you explore this new site, keep in mind that thearchitecture and layout were engineered by aprofessional web-development firm with the averageSPE member or prospect in mind. The site design wasbased on composite profiles of SPE members and non-members, from both our 2007 member-survey resultsand outside research on how technical people, andengineers specifically, utilize the web as part of theirdaily jobs. The site was NOT designed for people whoare already familiar with the Society. This strategyprotected us from making incorrect assumptions abouthow others might use the site.

Important Upgrades

Most of the site contains the same information andfunctionality of the prior site, but some importantupgrades have been added:

• A MUCH better calendar function that ispervasive throughout the site, and a newgroup forum function to replace the anti-quated AskPIP service. This includes a dis-cussion forum for each Division and SpecialInterest Group.

• Much of the site is accessible to membersthrough a single login mechanism. Animportant exception is the Online TechnicalLibrary. At present, this service is provided bya vendor with whom a unified login is cost-prohibitive. We are moving to a new providerwithin the next six to eight months. The OnlineTechnical Library will be accessible under thesingle login feature after the transition. We arelooking forward to that.

• The new website was designed, from the groundup, with “search engine optimization” in mind(for details, see http://en.wikipedia.org/wiki/Search_engine_optimization). This is an importantadvancement. We anticipate that the site willgain more visibility and usage over time by folkswho had previously not been able to find usonline. Full search engine optimization will takea month or so to complete (all the basics aredone, but a full auditing and testing phase cantake place only in a live environment). The newsite will provide a great deal more statisticalinformation about its usage, which will help usmonitor and change the site over time asdemand dictates.

Group Pages

One especially good thing about the site is that itputs our technical groups—Sections, Divisions, SpecialInterest Groups, and Student Chapters—front andcenter (group pages are housed under the menu“Technical Groups”). An important advancement to theDivision and Special Interest Groups pages is that onlinediscussion boards are posted to and accessible fromgroup pages, in addition to the pages where one canreach the entire discussion board. If you visit thediscussion forum and post a question under“Automotive,” a notification will also appear on the


Automotive Division’s webpage. This redundancy is important because different users of the site will come toinformation in different ways. This site-wide functionality is programmed into our calendar feature as well. Eventsthat are posted to the calendar feature of an individual group’s webpage will be instantaneously populated on theSociety-wide calendar, located throughout the site.

We are, of course, very excited about this new functionality. However, these new features will be useful only ifindividual groups make full use of them. I was a little disappointed to learn that of our 80-plus active Sections,fewer than 25 utilized the old SPE site to promote their activities. I hope that this will change. Given the nature ofsearch engine optimization, it is very likely that outsiders to SPE seeking activities and information on plastics willfind them first through our global site, and only later discover local sites. It is therefore important that all groups,Sections, Divisions, Special Interest Groups, and Student Chapters update the SPE site as much as possible (inaddition to independently-maintained sites).

Technical Challenges

As with all new launches of a site, there will undoubtedly be a few glitches to work through as various supporttechnologies are fully tested and tried in a live environment. The site was optimized for Internet Explorer 7.0 orhigher and Mozilla Firefox 2.0 or higher. If you use another browser, you may see occasional odd spacing.

The Leadership Services area and content for SPE group pages are being moved to the new site. These areascan still be accessed through a legacy version of the previous website, at http://legacy.4spe.org/communities.Membership Chairs and Treasurers should be on the lookout for a separate email with guidance on how to accessmaterials necessary for their operational area. Thank you for your patience as we work to bring these online.

Moving Forward

Your constructive feedback is always welcome, but I don’t want to overwhelm my staff at this particularmoment. If you could please jot down ideas and comments and forward them to us over the next few months, wewill work through them all. If you see glaring errors (broken links, typos, incorrect information on an event, etc.)please forward those immediately to [email protected], and I will distribute them to the appropriate folks. Toassist us in this type of troubleshooting, please copy and paste the link (string at the top of your browser thatspecifies the exact page), so we can locate the problem.

Moving all of our information over to this new system, wireframe, and design was a huge undertaking by ourtechnical staff here at headquarters. I want to thank and applaud everyone for their efforts, with the full understandingthat this is just the beginning. A number of new functions and activities are scheduled to be added to the site over thenext six to twelve months. As you all know, a website is never finished.

As we move into the next phase of website enhancements, we will turn our attention to developing an extranetto facilitate the operational aspects of administering Society activities, including more online tools for SPE groups(document storage, newsletter forms and templates, friendlier access to data downloads, etc.). We look forwardto bringing you these additional features in the near future.

Feature Article


November 2008Plastic Parts Failure Analysis and Product LiabilityNovember 5–6, 2008; Charlotte, North Carolina USA

Die Design Principles for Extrusion of PolymersNovember 5–6, 2008; Charlotte, North Carolina USA

Mold Design & Mold Building FundamentalsNovember 5–6, 2008; Detroit, Michigan USA

Injection Molding: Advanced Concepts & AnalysesNovember 5–7, 2008; Charlotte, North Carolina USA

Snap-Fits, Press-Fits & Welding of PlasticsNovember 7, 2008; Detroit, Michigan USA

Highlights of Thermoplastic Formulation &Compounding

November 10, 2008; College Park, Georgia USA

Blown Film Technology & TroubleshootingNovember 10, 2008; College Park, Georgia USA

Crystallization & Mechanical Behavior of PolymersNovember 10–11, 2008; College Park, Georgia USA

Twin-Screw Extrusion TechnologyNovember 10–11, 2008; College Park, Georgia USA

SPE 2008 New Technology SymposiumNovember 11–12, 2008; Philadelphia, Pennsylvania USA

Practical Applications for Melt Rheologyin Polymer Processing

November 11–12, 2008; College Park, Georgia USA

Purchasing & Quoting of Plastics PartsNovember 12–13, 2008; College Park, Georgia USA

Thermoplastic ElastomersNovember 13, 2008; College Park, Georgia USA

Profile Extrusion Design and Advanced ProcessingNovember 13–14, 2008; College Park, Georgia USA

Fundamentals of Patent Law for Plastics ProfessionalsNovember 14, 2008; College Park, Georgia USA

Principles of Polymer Blending & AlloyingNovember 17, 2008; Toronto, Ontario Canada

Fundamentals of ExtrusionNovember 17–18, 2008; Toronto, Ontario Canada

http://www.4spe.org/conferences-and-events

Blow Molding - Concept to CustomerNovember 17–18, 2008; Toronto, Ontario Canada

Fundamentals of Plastic Materials & ProcessesNovember 19, 2008; Toronto, Ontario Canada

Scientific Processing for Injection MoldingNovember 19, 2008; Toronto, Ontario Canada

December 2008

Euromold ExhibitionDecember 3–6, 2008; Frankfurt, Germany

Modern Toolmaking ConferenceDecember 4, 2008; Frankfurt, Germany

February 2009

Expo Plasticos 2009February 3–5, 2009;

Cintermex, Monterrey, Nuevo Leon, Mexico

SPE International Polyolefins Conference 2009February 22–25, 2009; Houston, Texas USA

GPEC® 2009February 25–27, 2009; Orlando, Florida USA

March 2009

SPE Polymer Nanocomposites ConferenceMarch 2–4, 2009; Bethlehem, Pennsylvania USA

SPE Thermoset ConferenceMarch 4–5, 2009; New Orleans, Louisiana USA

The Failure Analysis & Prevention SIG’s Virtual Conf.March 5–6, 2009; On-line via SPE E-Learning

SPE 30th Industrial ThermoformingSymposium & Workshop

March 8–13, 2009; Dallas, Texas USA

6th European Additives & Colors ConferenceMarch 11–12, 2009; Antwerp, Belgium

Plast ‘09March 24–28, 2009; Milan, Italy

June 2009

ANTEC™ 2009June 22–24, 2009; Chicago, Illinois USA

SPE & Plastics Industry Event Calendar


WebinarsAn SPE e-Live® Webinar is a simple and easy way to view a live presentation from the comfort of your home. Youcan also participate in an SPE webinar along with your colleagues in an office or conference room as well. All youneed is a direct or dial-up Internet connection and a separate phone line to access the teleconference portion of thepresentation. There will be a touchtone polling and question and answer period at the conclusion of the event.Presentations are recorded by the Society of Plastics Engineers for future distribution.Webinars are usually onehour in length (typically 11am to12pm EST). The cost is $99 ($150 for non-members).

http://www.4spe.org/conferences-and-events/webinars

Understanding Bioplastics and PropertyModification With Additives

November 5, 2008

Statistical Process ControlNovember 6, 2008

Developing International StandardsWith ASTM Committee D20

November 13, 2008

Film & Textile Insert Injection Moldings:Applications and Challenges

November 19, 2008

Engineering Design with Polymers andComposites - Part 1

December 3, 2008

Engineering Design with Polymers andComposites - Part 2

December 4, 2008

Utilizing FTIR, DSC, TGA and Ashto Identify Polymer Types

December 10, 2008

Tutorial on Carbon and Environmental Footprintof Bioplastics Using Biocarbon Content and

Life Cycle Assessment (LCA)December 11, 2008

Basic Rubber TechnologyDecember 17, 2008

Plastics Recycling:Processes, Opportunities, and Issues

December 18, 2008

Failure Analysis of Plastic and Rubber Materials- Part 1

January 8, 2009


January 15, 2009


January 22, 2009


January 29, 2009

Closed-Loop Process-Control Systemsfor Injection Molding Based Upon

Melt-Front DetectionFebruary 4, 2009

Container Molding: Never-Ending ChallengesFebruary 11, 2009

Simulation-Driven Product Designin Plastic Packaging

February 19, 2009

The Failure Analysis & Prevention SIG’sVirtual Conference

March 5–6, 2009

Fast-Scan DSCMarch 11, 2009

Closed Loop Control in Laser Weldingof Plastic Components

March 25, 2009

DMA - An Introduction and OverviewApril 15, 2009

SPE & Plastics Industry Event Calendar


Board of Director’s Meeting - October 20, 2008 - Milwaukee, Wisconsin

Chairman: Tom TurngChair-Elect: Dave KarpinskiCouncilor: Jack DispenzaTechnical Dir: Peter GrelleTreasurer: Jim Wenskus / Dave KarpinskiSecretary: Walt Smith

Chairman, Tom Turng:· Meeting called to order at 1:00 pm Central

time.· Roll call taken.

Milwaukee MiniTec, Jack Hill:Discussed Milwaukee MiniTec details.

SPE Presentation, Tricia McKnight:· Talked about recent SPE activities, financial

situation and present assets of SPE, newwebsite, ANTEC 2009, EUROTEC Papers,and other SPE plans for 2009.

Secretary, Walter Smith:· Review minutes of May 4, 2008 meeting.

Motion to accept May 4th minutes made byJack Dispenza and seconded by DaveKarpinski. Motion passed by Board.

· Board roster was circulated for updates andapprovals.

Financial Report, Jim Wenskus/Dave Karpinski:July 1, 2008 – September 30, 2008

· The IMD SPE rebate was $4,468.96.· Newsletter sponsorships payments were

$1310.00.· Interest and dividends were $129.02 for a total

of $42,216.61 of available funds.· Expenses were $531.51 for an ending balance

of $41,685.10.

Financial Audit, Larry Cosma/Walt Smith:Skipped. (This information is in the IMD bylaws).

Councilor Report, Jack Dispenza:The SPE Councilor Committee meeting took placeon Saturday, October 18, 2008.

· Color and Appearance and CAD are the twodivisions returning their rebate to SPE.

· Talk about giving our SPE rebate back to SPEin the winter meeting in Orlando?

· Action item: Jack to submit completeCouncilor’s report to the IMD Board.

Chair Elect Report, Pinnacle Award, DaveKarpinski:

· There will be no newsletter awards givenanymore.

· The 2008–2009 Section/Goals & Plans mustbe submitted by November 15th.

· Council and Sections/Divisions CommitteeMeetings: Jack Dispenza to verify attendanceto 2007–2008 Council and Sections/DivisionsCommittee meetings.

· Membership: Nick Fountas to verify if theIMD is in compliance. Prospective membersinformation to be sent to SPE.

· Technical Programming: Collect informationon recent Topcon activities with non-SPEorganizations.

· Communication: IMD to improve SPEheadquarters database accuracy. IMD BoardMembers to verify evidence of compliance.

· Membership: Develop and implement at leastone new service that offers member value.IMB Board members to verify evidence ofcompliance.

Technical Director, Peter Grelle:Technical Programs Update

· ANTEC 2009 paper review, December 13th,Brad Johnson, Pete Grelle, Dave Karpinski,and Jan Stevens at the Florida Mall Hotel inOrlando, Florida. 104 Abstracts submitted.Papers due November 14, 2008. The Matrixmeeting is scheduled for December 15, 2008.

· Penn State Erie Conference, Brad Johnson:June 10–12, 2008, 100 attendees.

· Milwaukee IM MiniTec, Tom Turng: 60attendees.

· Coming TopCon and MiniTech schedulingdiscussed.

· Molding 2009 & SAMTMP 2008 sponsorshipdiscussed.

· Drawing for attending Molding 2009: two IMDboard members or guests will win thisdrawing.

John Ratzliff (Our IMD SPE liaison):Seeking IMD members to speak at trade shows inChina on various technical topics.

Fellows & HSM Committee, Larry Schmidt:Larry requested candidate names for HSM and

Board of Director Meeting Minutes


Fellow from existing board members. Nominationforms for the following two IMD Board membershave been completed and forwarded to SPEheadquarters:

· Robert A. Beard – Honored ServiceMember

· Shia-Chung Chen – Fellow

BOD Terms & IMD History, Larry Schmidt:· Action Item: Existing Board members to

send Larry an e-mail stating your dates ofservice on the IMD Board. Larry also needsbest paper award history.

· Action Item: Walt Smith to send Larryanother disc containing IMD Board historyand IMD information.

European Update, Jan Stevens:No update given at this time.

Membership Report, Nick Fountas:· Below are the SPE/IMD membership

numbers as of May 2008:– 4,932 IMD members, both primary

and secondary; down 6.2% fromyear prior.

– 18,501 SPE primary members; down5.9% from year prior.

· A new IMD brochure has been developed torecruit new members to the IMD and will bedistributed at ANTEC, Topcons, MiniTecs,and third party conferences.

· Action Item: Nick to submit updatedMembership report to the IMD Board.

Communications Committee Report,Lee Filbert/Chris Lacey:

· Chris went over sponsors to the IMDnewsletter, both new and lapsed sponsors.

· Need more sponsors for the newsletter.· Action item: Walt Smith needs to get Fall

IMD Board meeting minutes to Chris Laceyby Monday 10/27/08 for inclusion in the Fall/Winter newsletter.

· It was suggested that the IMD Board offera 10% discount upon IMD sponsorshiprenewal for the newsletter.

Website Committee, Lee Filbert:· Lee put forth pricing proposals for the

website construction. Three websitedevelopment bids were shown, including

Nelix ($5250), Scott Watson ($3800), and AceraTechnologies ($999).

· Raymond Mckee, Nick Fountas, and Pat Gortonwill serve on website committee with Lee.

Discussion about Education Committee and ChairCandidate, Tom Turng:

· Pat Gorton will serve as committee chair for theEducation Committee.

· Susan Montgomery will serve on this committee.

Nominations Committee, Don Allen:· Don Allen will be working with Tom Turng and

Larry Schmidt on the dates of service for boardmembers.

Student Activities, Walt Smith:· Action Item: Tom Turng to contact Leslie Kiel

concerning rooms for IMD board meeting andStudent Reception room at ANTEC 2009.

· IMD will sponsor the Injection MoldingReception at ANTEC 2009 for $7500.

· IMD will contribute $1000 to the Student AuthorTravel Fund.

· IMD will sponsor an annual $3000 scholarship toa graduate or undergraduate student.

New Business, Tom Turng:· New IMD Board members: Tom Turng

appointed three new members to the IMDBoard for the remainder of the term effectiveOctober 20, 2008, up to ANTEC 2009.

· The new IMD Board members are Susan E.Montgomery, Erik Foltz, and AdamKramschuster.

· Action Item: Tom to talk to Mal Murthy aboutbeing an emeritus member to the IMD Board.

Old Business, All IMD Members:· Next IMD Board meeting will be on either

January 23, 2009, or February 6, 2009, inOrlando, Florida.

· Tom went over action items from May 4, 2008board meeting.

· Mike Uhrain can not be TPC in 2011 because ofprior commitments in Germany. The board needsto find another volunteer for the 2011 TPC.

· Eric Foltz volunteered to help Nick Fountas onthe Membership Committee.

· Motion by Pete Grelle at 5:01 PM Central timeto adjourn meeting. Motion passed by boardmembers.

BOD Minutes - Cont -


Board of Directors Meeting Min-

Nicolae AbrudeanTony AcunaRenita J. AndersonDavid ArenconAndrei BelooussovMorton D Bohn IVDave BrimbleWayne T. ComeauRosendo CordovaMike ErvinJim Fleming Jr.John GaidosRuben Gonzalez-Nunez,Ph.D.Keith HagueJeff HammondRaleigh J. HarnessMickael HavelMark Hawkins

The IMD welcomes 73 new members from around the world.David JobMark G. KurtzwegAl W. LeidingerGreg LetendreEd MackessyDavid W. MagnusonAdrian MinesKen NelsonAl NortonBill PattonAnil PittaJack PollittAndre Preissler Sr.Margaret ReeberWon-gil Gil RyimDave W. SmithMark SmithPeter ThorpeRobert W. Tymcio

New Members

Mark VliemRalph WhitneyClifton C. WillisWilliam Chi Wai WongJohn L. AndersonDavid A BagliaCaprice BlackYann CallyCary D ColtonJohn CorreiaSteve CowenEd GrabowskiDustin HahnLen HarveySebastian HessnerAlan HickokFritz KlaiberJeffrey P. LeFan

Steven LubowinskiRobert M. MaierAlex MayesMason MyersAndreas NuessRichard OlesSteve ParkerFlorian PetzoldJulio RiveraTom ScheckAndreas SchreiberLarry SlettenMark W. SnyderKevin StonemanCorey TraceyRichard VaughanMike VaughnAlexander Willer

The IMD also welcomes 56 companies and organizations that haverecently expanded their membership in the Injection Molding Division.

A.C Dispensing Equipment Inc.ACT Fastening SolutionsArkema Inc.Armstrong Mold Corp.BD BiosciencesBeaumont TechnologiesBrett Martin Ltd.Centre Catala Del PlasticCINCHCompressor Products InternationalCovidienDickten Masch Plastics LLCDouglas Corp.EcoWater Systems LLCElster Amco WaterEM LyonEngplasticosEurotherm Inc.FiSA North America, Inc.GAF Material Inc.

Greene, Tweed & Co.Heubach GmbHHydroHoist Marine GroupIKV RWTH AachenImerys Performance Minerals N.A.Imtech Design MoldflowSimulationInfiltrator Systems Inc.Institute of Plastics ProcessingCIKVLewis Pipe Co. IncLyondellBasell IndustriesM Vliem & Associates LLCMabeMoldionNatech Plastics IncPiper’s CroftPlasti-Co Equipment Co.Progressive ComponentsPSG Plastic Service Group Inc.

Qingdao Blue Ocean New HighTech Co. Ltd.

Reckitt BenckiserRowa Group USASafetySyringes Inc.SIGMA Plastic Services Inc.Sinostar Ltd.Square D Co.Tacony ManufacturingTec Products Inc.Tri-Craft Inc.U. AucklandUniversidad De GuadalajaraVanguard Search GroupVision Plastics Inc.Wilsonart InternationalWittmann Inc.Worldwide DispensersXaloy Inc.


Membership Application


Chris LaceyNewsletter Publisher

1513 University Ave.Madison, WI 53523T: 608-263-5963F: [email protected]

Dear Readers,I hope you’ve enjoyed the

fall edition of the SPE IMDnewsletter. This issue has a“Featured Technology” column.Would you like to showcaseone of your technologies or letothers know about a technologythat has made a difference inyour life? If so, please send mean email for consideration in ournext issue.

The success of the Ask theExpert columns continues togrow with the addition of JohnRalston of Beaumont Tech-

BEAUMONT 12(www.BeaumontInc.com)

D-M-E 10(www.DME.net)

DEALEY’S MOLD 5ENGINEERING(www.DealeyME.com)

INCOE 7(www.Incoe.com)

PRIAMUS 4(www.Priamus.com)

PROCESS & DESIGN 6TECHNOLOGIES(www.ProcessDesignTech.com)

XALOY 9(www.Xaloy.com

nologies, here to answer your CAE questions.Do you have an idea for making this newletter

even better? Then what are you waiting for? Pleaseemail me with your suggestions.

Last but not least, we invite you to take advantageof our sponsorship opportunities. It’s a great way toreach over 5000 individuals in the injection moldingindustry! Don’t have an ad? With your images and text,I can help design one for you (see the Dealey’s MoldEngineering and Priamus ads as examples). Sponsorshipdetails can be found on page 26.

Sponsors Publisher

http://www.4spe.org/conferences/antec-2009

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http://www.plasticsindustry.org/

Documents

Molding Views · president of SPI, and Rob Neilley, IMM editor, gave interesting keynote addresses on two of the days. The conference included a plant tour of Rehrig––Pacific’s