2024 Moldmaking Insights: A Year in Review Part 1

Ejector Pin Selection Guide

This guide provides insight into making informed decisions to optimize mold performance and longevity. Ejector pins, critical components of a mold’s ejection system, vary in material, treatment and coating based on the application. Selecting the right ejector pin requires balancing these characteristics, considering factors like part size, shape complexity and mold temperatures. Common materials include H13 steel, stainless steel, copper alloys and high-speed M2 steel. Each material offers unique benefits like strength, wear resistance, hot hardness and corrosion resistance, making them suitable for different molding applications. Surface treatments, such as nitriding or chrome plating, further enhance pin performance by improving wear resistance and durability. Read the complete article online at: https://short.moldmakingtechnology.com/ejector-pin-selection

Modular Tooling Systems Enable Versatility in Hole-Drilling Operations

Moldmakers now have efficient, adaptable drilling tools to meet the precision and depth requirements of various mold components. Drilling operations in moldmaking are diverse, ranging from simple screw-threaded holes to deep coolant channels. This article highlights that this variety necessitates a range of specialized tools, including traditional solid carbide drills and modern indexable systems, which enhance versatility and reduce tooling costs. Precision alignment holes benefit from multi-flute drills that eliminate secondary boring, while deep holes for cooling are improved by indexable gundrills. These modular systems reduce resharpening and inventory costs while improving productivity. Read the complete article online at: https://short.moldmakingtechnology.com/modular-tooling-system

Dynamic Tool Corporation – Creating the Team to Move Moldmaking Into the Future

This article shares the story of MoldMaking Technology’s 2024 Leadtime Leader winning shop with more than 40 years of offering precision tooling, emphasizing education, mentoring and innovation. Company ownership and dedicated employees worked together to gather the information necessary to showcase why they took the title – from the company’s commitment to excellence, integrity, safety and customer service, as well as inspiring growth and quality in manufacturing. The article also highlights their innovative engineering, design and development solutions for optimizing the production of plastic components and products. They also discuss the team that makes it all happen, both now and in the future. Read the complete article online at: https://short.moldmakingtechnology.com/LLA24-Dynamic-Tool

Hot Runner Truths, Myths and Overlooked Areas

This article provides a user-centric view of hot runner benefits and complexities. Hot runners offer significant advantages for injection molding, such as reducing cycle time and eliminating cold runners and sprue. Although they increase mold complexity and upfront costs, these systems provide long-term benefits, especially in high-volume or high-cost resin applications. Key to their performance are components like thermocouples, which regulate temperature and tip designs, which affect color changes and fill pressures. Advanced designs and better controllers have reduced issues, although challenges like drooling, sprue sticking and gate vestige persist. Addressing these requires understanding orifice sizes and cooling needs. Read the complete article online at: https://short.moldmakingtechnology.com/Hot-runners-truths-myths

Tackling a Mold Designer Shortage

The moldmaking industry faces a significant challenge: a growing shortage of skilled mold designers and engineers. This article highlights a survey conducted by MoldMaking Technology, revealing that while many shops have maintained or increased their number of mold designers over the past five years, the supply still lags behind the industry’s needs. Key concerns include the declining availability of mold design expertise, potential shortages within five years, and dissatisfaction with on-the-job training. To address this, the industry must prioritize targeted education and innovative approaches. Collaboration between businesses and educational institutions is critical to ensuring a sustainable workforce for the future of mold design and engineering. Read the complete article online at: https://short.moldmakingtechnology.com/mold-design-shortage

How to Maintain Heaters, Thermocouples, Valve Gates and Controls

This article reviews proper procedures and advancements to streamline hot runner system maintenance. Hot runner maintenance has significantly improved with the introduction of threaded nozzles, reducing the risk of leaks and other issues. Although toolmakers initially found threaded systems harder to maintain due to thread damage, advancements in thread design and coatings have mitigated these concerns. Proper support for hot halves is crucial to prevent deflection under cavity pressure. Disassembling hot runners requires careful attention to avoid thread damage, especially for less experienced personnel. Thermocouples and heaters must be handled correctly, with proper labeling and monitoring to ensure accurate temperatures. Valve gates add complexity but can run efficiently with regular maintenance. Read the complete article online at: https://short.moldmakingtechnology.com/Maintaining-heaters               

Dynamic Tool Corp. Wins MoldMaking Technology’s 2024 Leadtime Leader Award

The Leadtime Leader Award, established in 2003, recognizes excellence and innovation in mold manufacturing, beyond just short delivery times. Dynamic Tool Corp. (DTC) won the 2024 award for their dedication to growth, integrity and customer focus. Their achievements include repeat business from top molders and OEMs, delivering molds with up to 512 cavities and investing in engineering resources and advanced technologies. They emphasize craftsmanship, team collaboration and education, integrating quality assurance into automated machining processes. Their sales team, composed of engineers, ensures a customer-focused experience. DTC also shares educational content to promote industry best practices, solidifying their reputation for precision and efficiency. Read the complete article online at: https://short.moldmakingtechnology.com/dynamic-lla

Precision Meets Innovation at IMTS 2024

The MMT team attended IMTS 2024 and shares some key advancements in moldmaking, emphasizing automation, precision machining and digital integration. With a focus on increasing efficiency, exhibitors showcased five-axis machining centers, AI-driven CAM software and additive manufacturing solutions. Collaborative robots, automated systems and smart manufacturing technologies were featured to address labor shortages and reduce costs. Innovations in EDM, cutting tools and quality control systems were also prominent. Sustainability and workforce training were emphasized through energy-efficient machines and virtual training tools. Overall, IMTS 2024 demonstrated that embracing advanced technology is crucial for moldmakers to enhance productivity, precision and competitiveness in a rapidly evolving industry. Read the complete article online at: https://short.moldmakingtechnology.com/IMTS-recap

The Critical Role of Management Representatives in ISO 9001

A Management Representative (MR) plays a critical role in an ISO 9001 quality management system (QMS), overseeing the implementation, maintenance and effectiveness of quality processes. The article explains how the MR ensures compliance with customer requirements, coordinates internal audits and promotes awareness throughout the organization. Although ISO 9001:2015 no longer mandates an MR, appointing one remains beneficial for managing QMS processes and facilitating communication. For small businesses, an MR helps ensure consistent quality, enhances productivity, and demonstrates a commitment to industry standards. However, the MR should support, not replace, top management’s involvement in the QMS. Read the complete article online at: https://short.moldmakingtechnology.com/management-rep-ISO

Father/Daughter Team Takes Mold Business into the Future

BA Die Mold Inc. celebrated 56 years in the moldmaking industry, led by founder Alan Petrucci and his daughter, Francine, who is president. In this profile, Alan reflects on the company's resilience, attributing its success to skilled employees, innovative unscrewing technologies and a commitment to high-quality mold manufacturing. Memorable milestones include building their plant and earning patents for complex mold systems. Francine shares her vision for the future, emphasizing employee development, leveraging new technologies like 3D printing and maintaining strong customer relationships. As Francine takes the helm, Alan plans to retire at 85, confident in the company's continued strength and legacy. Read the complete article online at: https://short.moldmakingtechnology.com/father-daughter-mold-biz

Integrated CAD/CAM Streamlines Electrode Manufacture, Improves Quality

The case study shares how PTI Engineered Plastics, a Michigan-based custom injection molder, streamlined its electrode design and manufacturing process using Cimatron's integrated CAD/CAM software. The company's 35-person toolroom recently completed a complex EV charging plug prototype in just 5 weeks, a project that previously would have taken 10-12 weeks. Using Cimatron's Quick Electrode feature, PTI automated many repetitive functions in electrode design and programming, significantly reducing manual work. The software's user-friendly interface allows operators of varying skill levels to create complex electrodes efficiently. This implementation helped PTI shift from producing 800 simpler tools annually to under 300 higher-quality, more complex tools, while improving overall manufacturing efficiency and business performance. Read the complete article online at: https://short.moldmakingtechnology.com/integrated-CAD-CAM

Confronting the Mold Design Talent Drought

This post shares industry feedback on the critical shortage of skilled mold designers facing the industry as we approach 2030, with only 0.7% of workers satisfied with their on-the-job training. Key challenges include declining apprenticeship programs, reduced vocational education options and difficulty finding qualified instructors. While some initiatives are emerging, the industry needs a comprehensive solution. This requires changing the public perception of manufacturing careers, rebuilding educational programs, strengthening industry-education partnerships and addressing training costs. Industry leaders emphasize that waiting for government intervention isn't enough—companies must take active roles in developing talent pipelines and modernizing training approaches. Read the complete article online at: https://short.moldmakingtechnology.com/design-talent-drought

Understanding Diamond Compounds

Professionals in mold and die polishing frequently turn to diamond compounds for final or mirror-finishing applications. This tip explains the four main categories of these compounds. Versatile compounds offer consistent particle distribution and wide thermal processing range using synthetic diamonds. Premium compounds use natural diamonds for optimal cutting and finishing. Economical compounds provide a cost-effective option with synthetic diamonds for general use. Fast-cutting compounds blend both natural and synthetic diamonds for quick, superior finishes. All varieties are engineered for precision finishing, with different concentrations and grades available to match specific application requirements and surface finish needs. Read the complete article online at: https://short.moldmakingtechnology.com/diamond-compounds