Published 9/23/2024

Precision Meets Innovation at IMTS 2024

After attending IMTS, it's clear that the integration of advanced technologies is ready to enhance precision, efficiency and automation in mold manufacturing processes. It’s a massive event, so here’s a glimpse of what the MMT team experienced firsthand.

Christina Fuges

Editorial Director, MoldMaking Technology

IMTS 2024: Precision and INnovation

IMTS offered a mix of proven technology and newer innovations, but the main focus was on getting more done faster, cutting costs and addressing the ongoing labor challenges.

MMT Editorial Director Christina Fuges was once again a guest on IMTS TV Shop Talk with AMT Director, Sales & Membership Bill Herman to discuss all things moldmaking.

Makino's shock tower trade show display workpiece highlighting the many complex features and surfaces of mold machining.

Cimatron’s latest mold design software update emphasizes digital connectivity.

YCM explained the technology behind its machines’ superior precision, rigidity and reliability to MMT Editorial Director Christina Fuges and Associate Editor Fiona Lawler.

A complex mold core demonstrating the precision and accuracy of YCM Alliance machines and Open Mind Technologies’ hyperMILL CAM software.

Heidenhain’s TNC7 CNC control platform offers advanced collision protection.

Belmont Equipment & Technologies showcased its three-step process for manufacturing graphite electrodes for cutting tool process improvement.

The SV12P and SG12 sinker EDMs from MC Machinery / Mitsubishi EDM minimize electrical consumption and eliminate the uncertainty in estimating machining time.

Erowa automated systems and cells for assembly & test, material removal, lifting and positioning, pallet changers, robot tooling/grippers, workpiece handling, loading and feeding.

Makino focused on five-axis machining, EDM, automation and small-footprint machine tools.

System 3R autonomous mobile robots help achieve light-out manufacturing.

Verisurf machine tool probing and inspection fast and easy. Users can program and operate their CNC machines like a CMM.

Iscar’s BLP series three-flute fully effective 240° ball nose endmills carrying double-sided inserts. Designed for roughing, semi finishing and finishing at high feed rates.

Hexagon’s Manufacturing Intelligence division’s HxGN Machine Trainer uses digital twins to support upskilling and empowering workers.

Hexagon’s portable measuring arms allow mold builders to take measurements directly in the manufacturing environment, where process improvements are the most beneficial.

NSK America’s ultra-precise, high-speed electric and pneumatic spindles and micro grinding tools.

LaserStar’s 4101 Series Laser Cleaning System is a backpack laser cleaning system made for hi-speed direct part cleaning in an easy to handle package. Works on molds.

I could not resist … F1 baby! Go Haas!

Last but not least, industry trade events are a great way to make new friends.

Advanced Machining

At the forefront of the show were advanced machining centers, with a significant focus on five-axis capabilities. Exhibitors like DN Solutions, Mitsui Seiki and Grob Systems demonstrated machines that excel in machining complex shapes and curved surfaces in a single setup. The DVF 5000 Second Generation from DN Solutions, for example, offers faster speeds and a larger work envelope, ideal for the intricate geometries common in mold production.

These advanced centers are not just about speed and precision; they're also addressing the industry's need for space-efficient solutions. Compact, high-performance machines were all over the place, offering moldmakers the ability to enhance their capabilities without expanding their shop floor.

Automation and Smart Manufacturing

Automation was a central theme, with exhibitors like System 3R, Hurco and Hermle showcasing solutions that enable unattended operations and easy scalability. The WorkPartner 1+ from System 3R, for example, offers flexible automation for milling, EDM and laser micromachining, allowing shops to start small and expand as needed.

Collaborative robots (cobots) and automated work handling systems were featured across the show floor, designed to address workforce shortages and increase throughput. These solutions are particularly valuable for moldmakers looking to optimize their operations and reduce labor costs.

First-Time IMTS Experience

By Fiona Lawler, Associate Editor

Attending my first IMTS with the MMT team gave me the chance to explore a variety of products, equipment and services that will benefit moldmakers while engaging with industry experts.

While at the show, I observed the following key trends as well as technologies that are impacting the moldmaking industry.

Automation
Precision and Advanced Machining
Software Solutions
Process Optimization
3D Printing
Inspection/Measurement Solutions

When asking exhibitors about what’s hot on the show floor, the most common answer received was automation. I saw an abundance of booths exhibiting different automation solutions to improve moldmaking processes in terms of time and cost reductions. Automation helps reduce the time it takes to get from design to prototype. Examples that I saw on the show floor that come to mind are cobots, robotic arms and automated tool changers.

As far as precision and advanced machining, there’s a lot of tried and true and new technology out there. Precision and advanced machining is critical in moldmaking as these enable the best accuracy possible to ensure costly mistakes are not made. On the show floor, I saw examples of this in machines with five-axis abilities at exhibitor booths like Kitamura, Grob Systems and Takumi. Five-axis capabilities enable moldmakers to work at quicker speeds while retaining accuracy.

Software solutions were not lacking on the show floor. Whether it be CAD/CAM solutions, new AI features or VR training, one thing is evident: these options offer moldmakers solutions to the workforce shortage the industry is facing.

A trend that struck me as particularly fascinating was that of process optimization. The idea that before a mold can be made, there often needs to be many changes to optimize the process. Whether you are a supplier or molder, a concrete process is always necessary. Quality checks for process and planning ahead saves time, money and efforts in the long run. While visiting Belmont Equipment & Technologies, they described their process in going into their customers shops and smoothing out any kinks before they even begin implementing their services. Key steps in this consultative process include: Visiting the customer in-person to assess process and facility capabilities, ascertaining where improvements need to be made before any concrete steps are taken, active communication with the customer and keeping a detailed log/list of progress.

3D printing remains impactful on the manufacturing world, and moldmakers continue to find ways to utilize additive manufacturing (AM) technology to streamline production processes. Whether it be for quick prototyping, injection molding or creating molds with intricate geometric structures, AM provides solutions that are worth exploring.

Last but not least, I noticed a ton of inspection/measurement equipment and software solutions on the show floor. From hand-held scanners to ensure mold cavities are on par, to software that enables tons of CAD capabilities, its clear there is a large focus on these quality control systems.

Software Advancements

CAD/CAM software saw significant advancements, with AI-driven features taking center stage. Siemens Digital Industries Software introduced NX X Manufacturing, while Autodesk showcased its Fusion software with 1,500 improvements for three- and five-axis CAM programming of molds. Cimatron announced the release of Cimatron 2025 enabling improved modeling and electrode design for the moldmaking industry via CAM enhancements, moldmaking capabilities, efficiency updates and an emphasis on digital connectivity.

Open Mind Technologies' hyperMILL 2024 introduced new features like deep-hole drilling CAM strategy and improved rest machining, addressing specific challenges in mold manufacturing. The integration of Manufacturing Execution Systems (MES), such as Tebis ProLeiS, further emphasized the industry's move towards comprehensive digital solutions that can automate job scheduling, inventory management and quality control checks.

These software solutions offer AI-driven programming tools and advanced machining strategies that can significantly reduce programming time and optimize toolpaths.

Additive Manufacturing

The integration of additive manufacturing into traditional moldmaking processes was also evident. MC Machinery's Mitsubishi AZ600 wire laser metal 3D printer showcased how welding wire can be used as feedstock for creating high-quality 3D structures, opening new possibilities for rapid prototyping and short-run production in mold and die work.

Hybrid manufacturing solutions that combine additive and subtractive processes were also highlighted, offering moldmakers new ways to create complex geometries and conformal cooling channels that can significantly improve mold performance and cycle times.

Cutting Tool Innovations

High-performance cutting tools designed specifically for moldmaking applications were plentiful. Iscar's Mill-4-Feed high-feed milling tools and TOWA's CBN end mills stood out for their ability to machine hardened steels and complex geometries efficiently. These tools promise extended tool life, enhanced cutting speeds and improved surface finishes – all critical factors in mold production.

EDM Technology

EDM technology continues to evolve, with exhibitors like Belmont and MC

MoldMaker Takeaways from IMTS

Five-Axis CNC Machine: In-machine inspection with photo checks and crash protection has advanced rapidly.
3D Printing: New applications and materials in both metal and resin printing are now more affordable, inspiring new implementation ideas.
Robotics: Robots and cobots play a major role in shop integration.
Industry Collaboration: The value of exchanging ideas; left the show with insights that wouldn’t have surfaced otherwise.

-Steve Michon, Zero Tolerance LLC

3D Printing: Xact Metal’s 3D printing of cavity and core blocks for injection molds.
CMM Accuracy: Hexagon CMM impressed with its accuracy and ease of use for checking dimensions on electrodes, molded parts, and inserts.
Precision Machining: YCM machined a small block with incredible detail. The rims on the Bronco model gave a relatable perspective.

-Murphy Forsyth, Zero Tolerance LLC

Inventory Management: Henel's system optimizes floor space and boosts productivity through better inventory control.
Machine Metrics: Industry 4.0 advancements, such as real-time data storage, OEE management and AI adjustments for efficiency.
Multitasking Machines: Soraluce SAD combines milling, turning and finishing processes, reducing lead times within a compact footprint.

-Dennis Goggin, NextGen Mold Technologies

Electropolishing: Gpainnova's system (DLyte) claims to produce a diamond finish quickly.
On-Machine Inspection: Discussed closed-loop feedback for CNCs to compensate for cutter wear.
Submersible Rotary Indexer: Hermann Schmidt's new indexer for wire EDMs automates a traditionally manual process, aiding in workforce changes.

-Chris Hanes, Micro Mold Co., Inc.

Automation: Increasing automation for CNC operations indicates alignment with current trends.
Performance Tracking: Monitoring runtime, uptime and throughput for optimized performance.
AI Integration: Exploring how AI could benefit business applications.
Consistent Tech: No major changes in cutters and machines; the focus remains on 3D printing.

-Brian Bendig, Cavalier Tool & Mfg

Additive Manufacturing: Improved speed, affordability and variety in machines.
3D Printing Sector: Busy with diverse materials and software solutions.
Technology Visits: Explored offerings from United Grinding, Makino and laser engraving vendors for comparisons.

-Emilo Piedra, Intralox

Palletizing: Planning to implement Midaco's technology in a milling cell.
Inspection: High interest in OGP brand upgrades and troubleshooting with Renishaw on CMM probes.
Vision Inspection: Hexagon's advancements in CMM profile measurements.
Laser Engraving: Reviewing Keyence’s latest technology for potential use.

-Chris Howard, Production Mold Shop, Intralox Metal Fabrication

AI: From quoting to programming, our industry is on the brink of a huge revolution.
3D Printing: It appears to be stabilizing, meaning the technology is basically the same from company to company. Now it comes down to what type and machine configuration fits your customer’s needs.
Cloud NC / Cam Assist: Not AI. However, it is adding digital automation to CAM programming. As this evolves and adds five-axis capability, this has the potential to help bridge the talent gap we are experiencing.

-Louie Fields, Decatur Mold

Latest in 3D Technology: Exploring new technologies with the potential for market penetration.
Software Improvements: Enhancing efficiencies through pre-staging, setup and in-process optimizations aimed at streamlining the entire manufacturing workflow.
Advances in Wire and EDM Technologies: Expanding capabilities, especially as we extend our reach into Mexico.

-John Heinrikson, The Plastek Group

Machinery showcasing machines with enhanced capabilities for complex geometries and fine detail work. The integration of AI and adaptive control in EDM machines, as seen in MC Machinery's SV12P and SG12 sinker EDMs, promises to further improve precision and reduce operator intervention.

The key to solving problems lies in rethinking the process, not just adding technology. For example, an effective automation strategy focuses on removing time and cost from the process. It’s important to define true cost-cutting measures and avoid automating inefficient processes. Consistency in EDM operations is crucial for achieving optimal results.

Measurement and Quality Control

The importance of precise measurement in moldmaking was reflected in the advanced inspection tools on display. Hexagon introduced handheld 3D scanning devices, while Verisurf showcased its Inspection Planner Suite, offering moldmakers powerful yet affordable inspection solutions with full CAD capabilities.

Blum-Novotest's FormControl X measurement software, designed for unmanned operations and robotic integration, highlighted the industry's move towards more automated and precise quality control processes.

Industry 4.0 Integration

The combining of various technologies under the Industry 4.0 umbrella was evident throughout the show. Increased connectivity between machines, software and management systems was a common theme, with real-time monitoring and data analytics taking center stage. This integration allows for unprecedented levels of process optimization and predictive maintenance, crucial for maintaining the high precision demands of moldmaking.

Maintenance and Repair

Solutions for mold maintenance were highlighted as well, including LaserStar's 4101 Series Laser Cleaning System featuring a portable backpack design for versatile indoor and outdoor cleaning. Its precision tackles rust, paint and grease on various materials.

Rocklin Manufacturing's MoldMender Micro Welder also stood out for in-house mold repair. This low-heat, non-arcing device addresses scratches, pinholes and flashing with interlinking spot welds, minimizing heat distortion.

Both technologies highlight portability, on-site use and efficiency, promising streamlined maintenance, reduced downtime and extended asset life.

Training Technology and Courses

Hexagon’s Machine Trainer is transforming workforce training with virtual machines using digital twins. This technology allows machinists and metrology specialists to practice safely without risking expensive equipment. The system replicates real machines, including a 43-inch screen, CNC handwheel, and CMM joystick, providing an authentic experience that helps bridge the manufacturing skills gap. It supports up to three CNC controllers (Fanuc, Heidenhain, Siemens) and simulates 3-axis, 5-axis, and mill-turn machines for versatile training.

Entegris/Poco Materials continues offering free EDM training, now both in-person and online. Their basic program covers EDM processes, materials classification, and graphite selection, while the advanced curriculum addresses complex topics. The six-module online course includes videos, Q&A, and quizzes, resulting in a certificate of completion.

Gesswein’s intensive mold polishing training, led by an instructor with 40+ years of experience, teaches attendees to polish rough EDM surfaces to a mirror A-2 finish.

These offerings underscore the industry’s commitment to skill development, providing accessible, cutting-edge training for professionals at every level.

Sustainability and Efficiency

Energy efficiency and sustainability were not overlooked, with many machine tool builders showcasing energy management features in their CNC machines. Tools and processes designed to reduce cycle times and material waste were also prominent, aligning with the industry's growing focus on sustainable manufacturing practices.

Embracing the Future of Moldmaking

IMTS 2024 painted a clear picture of the future of moldmaking – one where advanced technology, automation and digital integration are not just buzzwords but essential components of a competitive moldmaking operation. The show demonstrated that while the initial investment in these technologies might seem daunting, the potential returns in terms of increased productivity, precision and capability are substantial.

For moldmakers, the message is clear: embrace technological advancements! Whether it's investing in advanced five-axis machining centers, integrating automation solutions, adopting AI-driven CAM software or exploring the possibilities of additive manufacturing, there are numerous paths to enhance your moldmaking capabilities.

As the industry continues to evolve, those who can effectively integrate these technologies into their operations will be best positioned to meet the increasing demands for complex, high-precision molds, faster turnaround times and cost-effective solutions. The future of moldmaking is here, and it's smarter, more efficient and more connected than ever before.