Photo credit, from top left, clockwise: Xact Metal, Tungaloy, Mitutoyo America Corp. and Husky Technologies
Mold manufacturing is an industry that is vast and varied, and so are the challenges that come with it. A single product or service does not provide an industry-wide solution. Because this is the case, MoldMaking Technology’s monthly tech roundups showcase different products and services that provide solutions across the industry.
This month’s roundup features a little bit of, well, everything. There’s hot runners, cutting tools, mold materials, mold components and more. We could list them all, but it would take longer for readers to get to the good part: the products themselves.
To check out tech roundups from months prior, please browse the “New Tech” section of the MoldMaking Technology website, or look up “Technology Roundup” in the homepage Search bar. For more information on a product featured below, click on the title link for the respective product.
Altair Partners With Simcon to Deliver Molding Simulation Platform
The addition of Simcon’s advanced simulation technology will give Altair customers a broader, more powerful set of virtual injection molding tools that integrate with other simulation-guided product design tools such as structural solvers, thermal solvers, crash testing software and metrology software.
Simcon’s software suite bolsters Altair’s existing polymer engineering offerings – which already includes materials data, CAE workflow and manufacturing solutions – and will help Altair customers drive the digital transformation of the plastics engineering value chain. By adding Simcon, Altair says it now boasts the most complete set of plastics engineering solutions and expertise.
Mold and Die Focused Software Tackles Process Optimization, Usability, New Technology
Cimatron, a CAD/CAM software supplier for the mold and die industry, has announced the release of its mold and die focused product, Cimatron V16. After an intensive period of industrial beta testing, Cimatron V16 is now available for general distribution.
Version 16 is said to be a substantial release introducing many new features in all areas of the product including a clean new UI and increased automation for faster mold design, electrode creation and NC programming. In addition, the continued emphasis on solutions for toolmakers includes powerful functionality for die addendum surfaces, mesh manipulation and drafting detailing, according to Cimatron.
Metal 3D Printing Series Introduces Industrial Speed, Performance for Mold Production
Aiming to bring affordable metal 3D printing to small- to medium-sized companies and decentralize metal 3D printing, Xact Metal announces the launch of the XM300G series of affordable mid-size metal 3D printers.
According to Juan Mario Gomez, CEO of Xact Metal, the XM300G series is ideal for printing high quantities or large parts where print speed is critical. Based on the XM200G multi-laser printer platform, Gomez adds that the series is another example of how Xact Metal continues to combine the requirements of metal powder-bed fusion and advanced technology for high-performance additive manufacturing (AM).
Metal 3D Printing Technology Targeting Moldmaking is Launched
Mantle Inc. announces the commercial launch of its metal 3D printing technology for toolmaking, simplifying the way mold tool components are made, and accelerating how manufacturers make molded parts.
Mantle’s system includes its patented TrueShape technology and P-200 printer. This hybrid system is built on a CNC platform and integrates printing and machining to produce parts with the accuracy and surface finish required for tools
Boring Head Tool Extension Achieves More Precise Holemaking
Holemaking and finishing cutting tools manufacturer Allied Machine and Engineering continues to expand the Wohlhaupter boring tool product line with the launch of the 420 (410) series fine boring heads, as well as the expansion of the 465 (464) series. Both the 420 (410) and 465 (464) digital boring heads are equipped with a 3ETech docking port for easy digital diameter adjustments.
Offered as one of the world’s smallest digital fine boring tool with a peripheral cutting edge, the unbalanced 420 (410) series has a diameter range of 0.787-1.142" (20-29 mm). The 465 (464) boring heads feature automatic self-balancing and bore diameters from 1.142-8.071" (29-205 mm).
Profile Milling Cutter Delivers Precision Machining, Optimized Tool Life for Molds
Walter USA introduces the Xtra·tec XT M5460, a new profile milling cutter that delivers maximum precision, tool life and surface quality in precise machining of freeform surfaces and deep cavities such as molds.
The Xtra·tec XT M5460 has been specially designed for difficult materials, particularly for hard machining of steels up to 63 HRC. Alongside the geometries of Walter’s P3201 and P3204 indexable inserts, the company is now offering these inserts in its newest grade, WHH15X, for hard machining. In field tests, the M5460 with this latest grade reportedly achieved increases in tool life of up to 500%. The profile milling cutter is said to be effective in steels (ISO P), cast iron (ISO K), stainless steel (ISO M) and hard materials (ISO H). In addition to mold and die making, the product also offers advantages for the aerospace and energy industries.
Indexable Milling Cutters for Semi-Finishing of 3D Surfaces
Tungaloy’s new AddForceBarrel indexable profile milling cutters feature barrel-shaped cutting edges that are designed for efficient semi-finish machining of 3D surfaces.
Based on the design of the TungMeister barrel shape milling head series, which were developed for efficient finish profiling of 3D surfaces such as complex dies and turbomachinery components in five-axis milling operations, Tungaloy’s AddForceBarrel offer an indexable insert solution.
Laser Sensor Provides Rapid, Accurate Measurements
Hexagon’s Manufacturing Intelligence division announced the HP-L-10.10, a non-contact laser sensor for CMMs that offers manufacturers the ability to perform dimensional measurements at comparable accuracy to tactile probing and rapidly inspect almost any surface.
The HP-L-10.10 sensor uses Hexagon’s latest cross-platform laser line scanning technology to offer similar repeatability and performance compared to tactile measurements executed on the same CMM. It can reportedly measure 600,000 individual points per second with a probing form error of 8 μm, rapidly capturing a complete high-resolution digital representation of a part that is valid for both surface and detailed feature inspection. The HP-L-10.10 is said to be seven times faster than its predecessor and introduces high-precision scanning.
All-in-One CNC System Advances Speed, Accuracy, Operability for Moldmakers
Mitutoyo America Corp. announces the release of the RTX Roundtracer Extreme, an all-in-one measuring system that integrates roundness, contour and surface roughness measurement functions on a single platform to save moldmakers time and improve productivity. The advanced CNC machine is said to utilize speed, accuracy and operability at the highest level to measure a wide variety of workpieces with various geometries, such as camshafts and bearings.
Ceramic Deburring, Deflashing Tools Take Into Consideration Difficult Materials, Operator Safety
Boride Engineered Abrasives introduces a new series of safe and easy-to-use ceramic deburring and deflashing tools. The Work Finisher Tool, for example, is ideal for deburring and chamfering non-ferrous metals such as copper, aluminum and brass products and excels on ultra-hard resins like glass fiber, carbon fiber and talc-filled plastics while reportedly eliminating the fear of cutting hands and fingers, or damaging the molded part in the process. Nunc imperdiet gravida mauris.
Second-Generation Control Algorithm Elevates Mold Controller Performance
Husky Technologies, a technology provider, announces the launch of a second-generation control algorithm for its line of Altanium mold controllers. The Advanced Reasoning Technology (ART 2.0) software delivers greater speed, accuracy, precision and repeatability compared to today’s existing temperature control systems, the company claims.
ART 2.0 incorporates advanced auto-tuning and heat-up strategies which deliver higher out-of-the-box performance. It is said to consistently deliver high accuracy and control precision, significantly reducing variability in the molding process shot after shot and mold after mold. According to Husky Technologies, test results show that ART 2.0 delivers up to 42% faster heat-up times with 30% less energy use.
Optimized Hot Runner Systems for PCR Compounds
Oerlikon HRSflow has developed special hot runner solutions for post-consumer recycled (PCR) compounds. Their application prospects are demonstrated by two examples — a fruit crate and a garbage can for composting organic household waste. With these environmentally friendly projects, which were implemented together with various partners, Oerlikon HRSflow underlines its commitment to the circular economy.
Conformal Cooled Sprue Bushings Line Expanded
PCS Company has expanded its Conformal Cooled Sprue Bushings product line, which is designed to reduce cycle times for injection molders by enabling faster cooling of plastic sprues. Provided as direct retrofits to the common U (3/4" diameter) and B (1" diameter) series sprue bushings, the products are available in 8 (Model U) and 12 (Model B) standard sizes. PCS can also provide custom sized bushings for specific applications. These bushings are constructed of stainless steel for corrosion resistance and longevity.
Previously available in 1/2" radius sizes, PCS has added the 3/4" radius size options for both the U and B Series bushings.
Hot Edge Gate Nozzles Creat Clean Gate Vestiges, Reduces Tip Wear
Melt Design Inc. (MDi), an innovator in the manufacture of hot runner systems and components for the injection molding industry, designed its Power Point Hot Edge Gate Nozzles to deliver multiple advantages for injection molders, chief of which is said to be excellent gate vestige. Another benefit? The nozzle tip will never wear out, the company claims.
Power Point Edge Gate Nozzles are ideal for molding fast-cycling, high-volume production parts such as thin-wall packaging applications and medical goods like pipettes, syringes and personal hygiene products.
Support Pillar With Clearance Hold and Thread Maximizes Mold Design Freedom
Hasco introduces the newly designed support pillars Z571/ with clearance hole and thread, giving designers maximum freedom in mold design when high injection molding pressures have to be absorbed. As a result, “mold breathing” is effectively reduced.
Support pillars serve to support mold plates and intermediate plates in order to bridge large gaps between the mold risers. Depending on the size of the injection molding tool, any deflection when filling the cavities can lead to major problems. Suitable support pillars are able to increase mold rigidity and prevent deflection of the mold parting surface.
Self-Venting Mold Steel for Defect Prevention
Photo Credit: Molder's World
Quality assurance always begins with the end product in mind, so planning for quality in the design of a mold should always be the first step. One consideration is eliminating trapped gas in a mold using Vortex self-venting mold steel offered by Molder’s World. According to the company, complex parts, especially for medical, aerospace and automotive industries, typically have intricate details that are “difficult to fill,” largely resulting from said trapped gas getting in the way inside the mold cavity.
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