Precision Meets Innovation at IMTS 2024

The message to moldmakers is clear: embrace technological advancements! The MMT team was on-site at IMTS to uncover what’s new and what works when it comes to metal-cutting technology for mold manufacturing.

The International Manufacturing Technology Show (IMTS) 2024 in Chicago earlier this month has once again proven to be an important event for the moldmaking industry, showcasing products, equipment and services set to redefine our approach to precision manufacturing. As the MMT team walked the bustling show floor, it became clear that the future of moldmaking is smart, connected and more efficient.

The event highlighted how integrating cutting-edge technology, maximizing flexibility, embracing automation and using advanced control systems can position mold builders to capitalize on new business opportunities, achieve lights-out capabilities and lower operational costs.

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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.

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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.

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

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.