214665-DEC 2013.pdf
52
DECEMBER 2013 VOLUME 16 / NUMBER 12 DESIGN / BUILD / REPAIR Designing and Building Molds with Unique Material Requirements PG 8. FEATURES For Better Mold Venting, Start with the Metal PG 24. Gain Process Control with a Specialized Hot Runner Temperature Controller PG 27. CASE STUDY Business Booms with Micro-Laser Welding PG 18.
Transcript of 214665-DEC 2013.pdf
DECEMBER 2013
VOLUME 16 / NUMBER 12
DESIGN / BU ILD / REPAIR
Designing and Building Molds
with Unique Material
Requirements PG 8.
FEATURES
For Better Mold Venting,
Start with the Metal PG 24.
Gain Process Control
with a Specialized Hot Runner
Temperature Controller PG 27.
CASE STUDY
Business Booms
with Micro-Laser Welding PG 18.
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PublisherClaude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Metalworking Group PublisherTravis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Editorial DirectorChristina M. Fuges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Senior EditorMatt Danford . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Economics EditorBill Wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Managing Editor
El McKenzie . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
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Advertising Production ManagerBecky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Moldmaking Technology (ISSN 1098-3198) is published monthly and copyright © 2013 by Gardner Business Media Inc. 6915 Valley Ave., Cincinnati, OH 45244-3029. Telephone: (513) 527-8800. Printed in U.S.A. Periodicals postage paid at Cincinnati, OH and additional mailing offces. All rights reserved.
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The information presented in this edition of Moldmaking Technology is believed to be accurate. In applying recommendations, however, you should exercise care and normal pre-cautions to prevent personal injury and damage to facilities or products. In no case can the authors or the publisher accept responsibility for personal injury or damages which may occur in working with methods and/or materials presented herein, nor can the publisher assume responsibility for the validity of claims or performance of items appearing in editorial pre-sentations or advertisements in this publication. Contact information is provided to enable interested parties to conduct further inquiry into specifc products or services.
2 MoldMaking Technology December 2013
6915 Valley Avenue Cincinnati OH 45244-3029P 513-527-8800Fax 513-527-8801 gardnerweb.com moldmakingtechnology.com
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Contents
4 MoldMaking Technology December 2013
Features
24 Mold ComponentsFor Better Mold Venting, Start with the Metal
Selecting the right material for specific mold components can help prevent a number of costly issues.
27 Hot RunnersGain Process Control with a Specialized Hot Runner
Temperature Controller
Hot runner systems present unique thermal situations that require specialized temperature control for manifolds and nozzles.
30 Mold Maintenance/RepairIn the Trenches: The Obvious Next Step in Minimizing
Press Downtime
A look at crib notes on press operation for mold repair personnel.
33 Industry OutlookSigns of Growth
A survey of North American tool shops indicates that the industry is growing, but so is the competition for new business and talented workers.
36 Supply Chain Management2013 Automotive Vendor Tooling Study
The results of this industry survey set the stage for suggested practices and strategies to help the entire vendor tooling value stream.
Departments
6 From the Editor: Is it Your Turn to be in the Spotlight?
6 WhatÕs New on MMT Online: Leadtime Leader Awards
8 New Business Opportunities: Expanding Mold Types
10 Your Business: RTI Justification
12 Mold Business Index
14 Profile: Creative Blow Mold Tooling
18 Case Study: Mold Repair
20 Case Study: Machining
40 Product Focus
45 MoldMaking Marketplace
46 End Market Report: Medical and Automotive
47 Ad Index
48 TIP: Cutting Tools
ON THE COVER
Image courtesy of Westminster Tool and Westminster Solutions.
This four-cavity SPI Class 101 injection mold features four mechanical
cams and a subgated hot to cold runner arrangement fed by a
four-drop hot runner system. See related story on page 8.
Images above courtesy of (left to right) Makino, DME Company and Orycon Hot Runner
Systems.
1. Expert AdviceExperts recommend that at least 10 percent of the cavity area be made of a porous sintered metal to ensure proper venting.PG. 24.
2. Zero InHot runner controllers that are model-predictive and not proportional-inte-gral-derivative allow users to zero in on the require-ments of the hot runner system more readily.PG. 27.
3. Time to InvestIn the past year, 50 percent of mold shops have invested in new software and 73 percent in new equipment, and more than 80 percent intend to invest the same or more next year. PG. 33.
4. Go DirectDirect sourcing means the OEM contracts with the tooling sup-plier directly and basically circumvents the Tier 1 supplier.PG. 36.
5. Custom-madeCustom-matched cutting for specifc operations can increase cutting data by as much as 20 percent. This can mean a full 15-percent reduction in total component costs.PG. 48.
December 2013 Volume 16 / Number 12
272420
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1213 MMT DEPT--Contents.indd 4 11/18/2013 8:59:05 AM
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THIS MONTH ON moldmakingtechnology.com
From the Editor
6 MoldMaking Technology December 2013
Is it Your Turn to be in
the Spotlight?
Enter the 2014 Leadtime Leader Awards competition and find out.
Christina M. Fuges
Editorial Director
MoldMaking Technology’s Leadtime Leader Awards
were created to honor North American mold manu-
facturers who best demonstrate overall innovation,
efficiency, quality and commitment within their
moldmaking operations. By taking the time to gather
the information about your shop necessary to enter
this competition, you will develop a concrete docu-
ment that details your shop’s achievements, business
levels and future plans—and that’s just for starters. If
you want to know what this award really means, read
what our 2013 winners said about their participation.
“Often we are so focused on the day-to-day activities of running a business
that we don’t think much about all of the things that we’ve done over the
years to create and sustain a successful business. In retrospect, filling out the
questionnaire forced us to consider all the various components of our success,
including the adoption and implementation of new technologies; customer
service; continual education, training and cross-training of employees; our
sales/marketing efforts; and involvement in our industry in ways that help to
make it better and stronger. We believe that receipt of the Leadtime Leader
Award is recognition from our peers of a ‘job well done,’ and we want to thank
everyone involved in the process.”—Jerry Seidelman, Tech Mold Inc., Winner
“The entire Micro Mold team is proud and extremely honored to have been
named the 2013 Leadtime Leader: Honorable Mention. We found the process
to be an introspective one, which yielded valuable insights into the internal
day-to-day operations at Micro Mold that we have subsequently incorporated
into our strategic plan as we seek to continue to improve upon our position
within the tooling and plastics industry.” Ryan Katen, Micro Mold, Honorable
Mention
Give your shop the chance to gain industry recognition and credibility,
attract new customers, boost morale, distinguish itself as an industry leader,
and realize business growth by entering our annual awards.
Any shop performing moldmaking operations is eligible, and all application
submissions will be considered. The rewards include a feature cover story
on your shop with a video; a complimentary 10 × 10-foot booth and two
full conference registrations for the amerimold expo (amerimoldexpo.
com) and an ad program in Plastics Technology magazine (ptonline.com) to
market products and services to more than 25,500 molding subscribers at
more than 11,600 molding facilities.
Enter today! Go to moldmakingtechnology.com/awards/register.cfm.
Follow MMT on: Follow @MMTMag
MMT ZONE: Leadtime Leader Awardsmoldmakingtechnology.com/articles/ leadtime-leader-awardsMoldMaking Technology created the Leadtime Leader Awards to honor North American mold manufacturers who best dem-onstrate overall innovation, efficiency, quality and commitment within their moldmaking operations, while raising the bar in terms of mold engineering, building, repair and management.
BROWSE PAST LEADTIME LEADER FEATURES
• 2013, Tech Mold Inc.: A Triple Threat! A three-division approach, technology innovation and a grow-your-own skilled workforce enables this mold manufacturer to balance the entire moldmaking process.
• 2013, Micro Mold Co.: Partnerships Push the Limits This mold manufacturer exceeds expectations with a team mentality that sees customers, its sister molding company and industry associations as true partners.
• 2012, Industrial Molds Group: Thinking Outside of the Box This shop makes extensive investment in equipment, tech-nology and its employees, and has an innovative approach to its mold manufacturing process.
• 2012, M&M Tool and Mold: Niche Manufacturing Sustains Profitability This shop survived and thrived through an acquisition, during a recession, with an emphasis on lean principles and automation.
• 2011, United Tool & Mold Inc.: Charging Forward with Unique Mold Repair Niche A niche specialty in mold repair, three plants in the south-eastern part of the U.S. and the acquisition of a Korean/Chinese mold manufacturer helped this shop thrive.
• 2011, Mold-Tech Inc.: Technology-Driven, Detail-Oriented Precision Injection Mold Provider. This shop zeroed in on manufacturing complex, close- tolerance, precision injection molds with strict attention to detail combined with superior customer service.
• 2011, MSI Mold Builders: Redefining Mold Manufacturing with Incremental Approval Approach Unwavering employee dedication and team-driven principles are key to this shop delivering customers high-quality molds.
• 2011, JMMS: Constant Reinvention Results in Growth, Success This toolmaker possesses the ability to evolve and adapt to a changing business environment.
VIDEO: Take a Tour of Our 2013 Leadtime Leadersshort.moldmakingtechnology.com/ 2013lla
1213 MMT DEPT--Editorial.indd 6 11/18/2013 8:59:16 AM
™
Stainless
From left to right:
Bill Kushmaul - President, Tech Mold
John Teenstra - Planning/Outside Resources, Tech Mold
Perry Wilkes - Western Sales Manager, Edro Engineering, Inc.
Renee DeKoning - Inside Sales Manager, Edro Engineering, Inc.
EDRO Engineering and Specialty Steels, Inc.Call: 1-800-368-EDRO
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work. Edro built the custom mold base with unmatched workmanship
and exceptional accuracy, allowing us to assemble our cavities, cores, and
other components with ease. We also appreciate that Edro uses RoyAlloy™,
the best stainless mold base steel available.”
Bill Kushmaul
President
Tech Mold - Tempe, AZ
RoyAlloy™ Stainless is covered under Patents 6,045,633 and 6,358,334
0912 Edro.indd 1 7/30/12 12:52 PM
8 MoldMaking Technology December 2013
New Business Opportunities
Designing and Building Molds
for Aerospace Requirements
The aerospace industry has some unique requirements for
many of its plastic components, primarily because the
polymers used for them are typically high-temperature, and
glass-fiber and carbon-filled engineering thermoplastics. A
supplier of molds and molded/machined components for
this industry must understand that the conventional mold
design approach does not accommodate the thermal expan-
sion challenges typically associated with these materials.
“The high temperatures required to mold many of the
materials mean that normal fits, clearances and interlocking
features typically found in conventional injection molds
won’t work,” explains Mark Ypsilantis, vice president
of marketing and sales of Westminster Tool, a Plainfield,
Conn.-based mold manufacturer with molding capabilities
for mold tryouts and short production runs.
With more than a decade of history working with the aero-
space industry, Westminster Tool understands the require-
ments for molding components in the types of materials
needed to withstand the high heats in aircraft engines. Typical
materials for which Westminster designs molds for aerospace
customers include PEEK, PBT, LCP, PAI (Torlon), PEI (Ultem)
and PPA, among others. Additionally, Westminster is a Solvay-
certified processor of Torlon that understands its properties
and the nuances involved in designing and building molds for
this material, as well as
in molding it.
“The approach to
designing a mold for
parts in a material like
Torlon or Ultem has
to be very different,”
Ypsilantis says. “Keeping
in mind the thermal
expansion that a mold
undergoes with the
extremely high molding
temperatures, shutoffs
need to be very robust.
For example, determin-
ing the thermal expansion of a mechanical action is critical to
optimal mold functionality over the long term.”
Venting these tools is extremely critical, and setting them up
so they can be easily cleaned is also important, because they tend
to gas up and get extremely dirty, requiring more maintenance.
Gates for these molds are typically post-machined. “Not always,
but definitely with some of the low-flow materials such as Torlon,
we’ll machine an oversize fan gate into the part,” Ypsilantis says.
“It really depends on the size of the part. If it’s a small part, you
can sometimes get away with a gate that de-gates automatically.”
There are many instances in which a net shape part cannot be
produced as it can with conventional thermoplastics. “There are
dimensional challenges in combination with the material charac-
teristics,” Ypsilantis explains. “In some cases, we build the mold to
produce the features that are repeatable and machine the other
features. We make a Torlon part for one customer in which we
injection-mold a rectangular part and then machine the features.”
Westminster Tool has invested heavily in R&D to develop
customized fixtures and tooling to machine the parts that
require these added features that cannot be molded in. “We’ve
taken our moldmaking competency and applied it to machin-
ing workholding fixtures, as well as developed tooling to more
efficiently cut that material,” Ypsilantis says. “For example, we
contend with large gates by developing customized fixturing
and tooling in-house for efficient handling of these engineered,
filled materials. They are very abrasive, and as we’re machining
these parts, we’re creating shapes. That means we need an exact
method of holding them to maintain the high quality the aero-
space industry expects.”
FOR MORE INFORMATION:
Westminster Tool and Westminster Solutions / 860-564-6966
[email protected] / westminstertool.com
This single-cavity mold sits in a state-of-the-art 110-ton Toyo all-electric
injection molding machine located in Westminster’s Technology Center. The
material is a high-temperature, engineered thermoplastic. Westminster ther-
mally controls this mold with a high-temperature pressurized water system. A
scientifc molding process is being developed for this production mold as part
of its validation sequence.
Imag
es c
ourt
esy
of W
estm
inst
er T
ool.
A plastic component made of Ultem
is inspected on Westminster’s OGP Smart-
Scope Flash 250 vision inspection system.
1213 MMT DEPT--New Business Opportunities.indd 8 11/18/2013 9:00:06 AM
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Find out more at: www.walter-tools.com
1213 Walter.indd 1 10/28/13 1:41 PM
Your Business
10 MoldMaking Technology December 2013
By Ryan Pohl
In October’s article, we introduced some of the common
Related Technical Instruction (RTI) classes that can be benefi-
cial when built into an apprenticeship program for the mold-
making industry. Here, we will continue with a brief justifica-
tion for additional RTI classes.
Applied Metallurgy: We use the word “applied” because
metallurgy is hard to put into context if the class becomes too
concerned with molecular structure and how it relates to a
material’s readings on a stress/strain curve.
Metallurgy can be a fascinating topic if it covers the areas
that are relevant to machining and moldmaking. Its study
can be extremely helpful if the discussion remains focused
on mechanical properties, heat treatment and the effects of
alloying, etc.
Introduction to Manual Machining: For years, educa-
tors and shopfloor managers have debated the relevance of
teaching manual machining along with CNC machining, as
opposed to teaching solely
CNC machining. I have held
programs in each format,
and the apprentices who
have experience on manual
machines always end up out-
performing the apprentices
who do not.
Manual machining involves
the senses. You can hear
the cut, feel the cut, see the cut and even smell the cut. This
teaches the apprentice valuable lessons about tool life, cutting
pressures, chip evacuation and more. Creating a program that
involves direct manual machining knowledge/skill develop-
ment is strongly recommended.
Communication and Leadership: The value of a class or a
number of classes that cover and practice effective communica-
tion and leadership principles, specifically for the shop floor,
cannot be underestimated. Making complex plastic molds is a
team-oriented exercise.
For example, a consultant who works in the stamping die
industry is often called upon to help companies solve com-
plex production problems. He reports that most of the time
he only needs to facilitate a safe communication environment,
which helps the company’s employees solve the problem
themselves. These types of classes have the power to unlock
the innovative potential of your workers.
Mold Designing and Building: No apprenticeship program
would be complete without a comprehensive list of plastic
mold designing and building classes that are relevant to the
specific job description of the apprentice.
Every apprentice should have some formal classes on mold
design. However, if an apprentice is only going to program
and operate a CNC machine, he may not need as much mold
design instruction as an apprentice moldmaker. On the other
hand, an apprentice designer will need as much entry-level to
advanced mold design instruction as possible.
In February’s series installment, we will continue to exam-
ine the remaining RTI that a company should consider for its
apprenticeship training. We will also begin to explore meth-
ods of RTI delivery.
CONTRIBUTOR
Ryan Pohl is president of Expert Technical Training.
FOR MORE INFORMATION:
Expert Tech / 616-785-5733
[email protected] / expert-technical.com
Creating a program that
involves direct manual
machining knowledge/skill
development is strongly
recommended.
Finding, Training & Retaining Employees
PART 7 OF A SERIES
Related Technical Instruction Justification
1213 MMT DEPT--Your Business.indd 10 11/18/2013 9:01:26 AM
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MoldMaking Business Index
12 MoldMaking Technology December 2013
believe that once we get past these deba-
cles, the pace of economic expansion will
accelerate. However, it is far from clear
when, or even if, that will occur.
Taking a closer look at the categories,
New Orders was 50.7. This is just barely
into positive territory, but it stopped
a two-month run of declining orders.
Production came in at 54.1, which indi-
cates that work levels increased at a
strong rate. With new orders higher, we
should expect improvement in backlogs.
Coming in at 45.9, Backlog is near its
peak. Employment is 50.7, which means
that there was a small rise in moldmak-
ers’ payrolls. Prices received were mod-
estly lower again at 49.0. The upward
momentum in materials prices acceler-
ated again as Material Prices registered 62.3. Supplier delivery
times continued their recent trend of gradual expansion with
a 54.8. The pace of decline in offshore orders moderated a bit
as the Exports escalated to 47.1.
Total MBI for October 2013: 50.6
Our latest survey of the North American moldmaking industry
indicates that overall activity levels improved in October when
compared with the previous month. This halted a three-month
trend downward. The MoldMaking Business Index (MBI)
for October 2013 is 50.6. The latest index value is a 2.3-point
increase from the September value of 48.2 and a 0.2-point
increase from the 50.4 value posted in October 2012.
With the October rise back to just above the 50 line, our
index has fully recovered from a couple of weaker months in
late summer and has moved back to the range where it has
been for most of this year. The overall trend throughout 2013
for the MBI has been flat-to-down, and the October reading
certainly continued this trend.
While the North American mold industry is holding its own,
other segments of the industrial sector are performing quite
well. The ISM Manufacturing Index followed up the strong
showing in September with another small gain in October to
a solid 56.4. Demand for autos has moderated in recent weeks,
but the long-term trend upward remains intact.
Just as it has been for the past several months, the primary
reason for the sluggish pace of growth in the economy is the
uncertainty stemming from problems in Washington. The
economic fundamentals at the present time are actually quite
encouraging. The Federal Government is no longer shut down,
but rather than actually solve the problem, Congress just
pushed it down the road another three months. As I have said
before, if our nation’s fiscal issues are not resolved in an expe-
ditious and somewhat graceful manner, the effects on the U.S.
economy will be negative. The problems with Obamacare are
also generating a lot of uncertainty in the private sector. I still
While the recent government shutdown and ongoing political wrangling about
the federal budget and Obamacare have done little to bolster Americans’ conf-
dence, the impact on the manufacturing sector has been minimal so far. Recent
indicators suggest that the overall manufacturing sector is still expanding, and
the plastics industry is one of the real bright spots. Total U.S. output of plastics
products escalated by 6 percent in the third quarter when compared with the
same quarter last year. The good news for suppliers to the plastics industry is
that production of plastics parts has been growing by at least 6 percent for well
over a year and a half. Yet despite this extended period of robust growth, the
capacity utilization rate for the industry remains stuck at just below 75 percent.
If output continues to expand, then very soon the utilization rate will have to
rise, as will demand for new molds, tooling and equipment.
Sub-Indices Oct Sept Change Direction Rate Trend
New Orders 50.7 48.4 2.3 Increasing From Decrease 1
Production 54.1 52.0 2.1 Increasing Faster 2
Backlog 45.9 40.0 5.9 Contracting Slower 18
Employment 50.7 50.0 0.7 Increasing Faster 10
Exports 47.1 45.3 1.8 Decreasing Slower 16
Supplier Deliveries 54.8 53.6 1.2 Longer Faster 2
Material Prices 62.3 61.8 0.5 Rising Faster 22
Prices Received 49.0 48.8 0.2 Declining Slower 3
Future Expectations 69.2 69.0 0.2 Improving Faster 22
MoldMaking Business Index 50.6 48.2 2.4 Increasing From Decrease 1
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3/12
2/12
1/12
12/11
2/13
MoldMaking Business Index
3/134/135/136/13
8/13
7/13
10/13
9/13
1213 MMT DEPT--MBI.indd 12 11/18/2013 3:05:59 PM
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Profle
14 MoldMaking Technology December 2013
Staying One Step Ahead
of Customer Needs
By Christina M. Fuges
The key to optimal customer support for any mold manufac-
turer is doing more—from upfront design engineering during
the initial stages of product development to emergency mold
repair services. And this is exactly the business model Kansas
City-area blow moldmaker Creative Blow Mold Tooling
offers to stay ahead of its customers’ needs.
Creative began building this model in 1984 when the
company was established to design, manufacture, repair
and reverse-engineer blow-mold tooling for the plastic con-
tainer industry. Today, the company’s plant in Lee’s Summit,
Missouri accommodates mold manufacturing for wheel,
shuttle, injection stretch blow mold and reciprocating screw
platforms. This provides the necessary flexibility for the com-
pany to meet its customers’ diverse and changing needs, and
also helps to maximize Creative’s productivity and manufac-
tur-ing processes.
“In our operations, we couple upfront design efficiencies
with lean manufacturing techniques to maximize through-
put that generates an effective value stream and reduces lead
times. This allows us to meet our customer’s scheduled dead-
lines,” explains Jim Hensiek, director of business development.
The “Doing More” Model
Hensiek believes success comes from being different and
willing to do more for the customer than just building tools,
and that is why Creative invests a significant amount of time
and resources in working with clients on front-end design,
some of which it doesn’t get paid for.
“It’s all about the relationship,” Hensiek says. “We collabo-
rate with customers on a variety of issues, many times before
a project has been approved. Once the tooling is built and
delivered, if a customer needs us on site to assist with run-
off or other issues, we commit our people there the next day.
Staying in touch with our customers, being good listeners
and helping them meet their internal company goals have
earned us their confidence. This ‘trust factor’ is essential to
becoming a preferred vendor in their supply chain.”
With Creative already focused on customer plant produc-
tivity, quick turnaround and communication, the logical
next step in the company’s business model was to initiate a
24-hour emergency blow mold repair service. According to
Hensiek, this means that technicians give immediate atten-
tion to molds when they arrive at the dock via a series of
tests to determine the severity of the damage. This informa-
tion is then communicated to customers and turnaround
time is defined, putting everyone on the same page with
regard to expectations. Once the repair work is complete, the
customer is contacted and the mold is returned to the plant.
The Team
To successfully accomplish Creative’s goals, 35 employees are
split among three shifts that cover 24 hours a day, five days
a week. According to Hensiek, this team approach ensures
that a customer’s product is built right, every time, on time—
shortening the customer’s supply chain.
This team has evolved through an ongoing effort of
recruiting and developing dedicated and knowledgeable peo-
ple to service the customers. Team members possess a long
history on both sides of blow molding: experience in plastic
packaging plant operations, and expertise in mold design and
manufacture. Since this caliber of employee is tough to find,
Creative has focused on local high schools, personal relation-
ships and referrals for these new hires. Once on board, each
employee is quickly oriented to Creative’s processes and
methodologies.
Hensiek says the company strives to live up to its core val-
ues every day. These values include:
• Customer focus. Creative says it is passionate about serving
the needs of its customers, whose success is a key measure of
Creative’s success.
• Teamwork. The company encourages collaboration within
the team as well as with its extended team of customers and
suppliers.
• Respect. Creative says it strives to treat everyone with respect
and dignity, recognizing that innovation comes from consid-
ering unique perspectives.
• Integrity. The company also says it strives to be honest and
ethical in everything it does, without compromise.
Creative Blow Mold Tooling’s facility in Lee’s Summit, Missouri.
Phot
os c
ourt
esy
of C
reat
ive
Blo
w M
old
Tool
ing.
1213 MMT DEPT--Profile.indd 14 11/18/2013 9:00:56 AM
INCOE® Corporation
1740 East Maple Road
Troy, Michigan 48083 USA
T: +1 (248) 616-0220
F: +1 (248) 616-0225
North America | Europe | Asia | South America
Automotive design engineers are tasked with setting new trends in quality and part fi nish everyday. For molders,
having INCOE® as a partner provides the assurance that each system is backed by proven application experience.
We have the right combination of fl exibility, reliability, and processing advantages required to drive your business
forward in this fast paced industry. That’s INCOE® Hot Runner Performance.
INCOE® Hot Runner Systems
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www.incoe.com
1213 Incoe.indd 1 11/8/13 9:23 AM
Profle
16 MoldMaking Technology December 2013
• Excellence. Creative recognizes that, in order to grow, it
must learn, adapt and embrace change through continuous
improvement.
“We treat people the way we want to be treated,” Hensiek
explains. “We foster a team environment where everyone can
express their opinion and be confident that their ideas will
be considered. We have open communication with our team
members as to company performance, new projects in the
pipeline, next quarter outlook and issues of importance within
the business beyond the work performed each day.”
Creative is also fortunate to have close access to community
college training opportunities through which employees can
expand their knowledge base. The Metropolitan Community
College Business and Technology Center in Kansas City offers
a variety of classes in CNC machining, CNC programming,
lean manufacturing, design for Six Sigma, and supply chain
and operations management.
Creative also participates in a consortium of local manufac-
turing companies that commit to hiring students as interns at
the end of each semester. These interns have become a source
of new talent for the company.
“Some of our employees have reached a level of expertise
that qualifies them to teach these same courses, which can be
done adjacent to work schedules,” Hensiek says. Creative also
offers online and e-learning opportunities, including training
through its memberships in the AMBA and NTMA.
FOR MORE INFORMATION:
Creative Blow Mold Tooling / 816-525-4220
[email protected] / creativeblowmold.com
The Technology
Along with a commitment to qual-
ity personnel is a significant com-
mitment by ownership to capital
expenditure investment. In 2009,
Creative increased the size of its
Lee’s Summit facility, adding 10,000
square feet for additional equip-
ment and an expanded inspection
room.
In addition, a blend of 19 vertical
and horizontal machining centers
gives Creative the capacity to take
on short-turn projects. By setting
up and running multiple compo-
nents simultaneously, Creative
is able to eliminate wait time for
completion of certain components
prior to mold assembly and inspec-
tion. The company also stocks cer-
tain new mold components based
on customer demand, reducing the
setup and machine time required to
build a finished part. A new DMG
Mori Seiki vertical high-speed
machining center and an additional
Haas horizontal machining center are two recent additions to
the company’s machine line up. When it comes to software,
Creative’s enterprise resource planning system integrates
SolidWorks, Pro/E and AutoCad for design, and Mastercam for
programming. Shoptech’s E2 helps to manage the production
schedule and job costs.
All of this investment has re-positioned Creative with its
current customers, increasing its capacity to take on more
project opportunities while continuing to meet manufacturing
schedules and project deadlines.
“Now with the additional production capacity and market
confidence in our ability to deliver, we can build new mar-
ket relationships, adding market share in the extrusion blow
molding (EBM) and two-stage injection stretch blow molding
(ISBM) markets,” Hensiek says.
Creative knows that its goals require ongoing investment in
people, technology and processes. The company continues to
be committed to remaining lean and highly productive to meet
customer requirements and compete for new work.
From idea to 3D design development
to high-quality precision molds.
1213 MMT DEPT--Profile.indd 16 11/18/2013 9:01:01 AM
When you talk to people who make what matters, the bottom
line on what matters most to them is just that—the bottom line.
See why, for so many manufacturers, Makino and productivity
are two words for the same thing. Read their stories. Watch their
videos and cutting demos at Makino.com/productivity.
We estimate We’ve seen
a 40 to 60 percent reduction in
cycle times on all jobs moved
to the makino cell.”
“
the machine’s rapid acceleration/
deceleration rates and 0.9-second
tool changes have reduced part
cycle times by 50 percent.”
“
With the makino machining
cell, We replaced five machines
With tWo, While doubling
production capacity and improving
quality and flexibility.”
“
1213 Makino.indd 1 11/8/13 9:35 AM
18 MoldMaking Technology December 2013
Case Study / Mold Repair
Business Booms
with Advanced
Micro-Laser
Welding Capabilities
By Christina M. Fuges
Scott Mesick has been micro-TIG (tungsten inert gas) welding
for the moldmaking industry since 1980. He launched Erie,
Pennsylvania-based Micro Tool Welding (MTW) in 2003 and has
since led the company in its tool and die welding specialization.
MTW is strategically located about equal distances from
Cleveland, Pittsburgh and Buffalo, which enables the company
to quickly serve its tool and die, medical, aerospace and power
generation customers across the country. The 4,400-square-
foot facility has a temperature-controlled environment that
includes micro-TIG and micro-laser welding labs. “Our experi-
ence and knowledge combined with the latest technology has
allowed us to become leaders in the micro-welding industry,”
Mesick says. “We have combined the advanced science of laser
technology with the experience in tool and die repair.”
Laser-focused on Quality and Speed
MTW faced several challenges after it was established, including
reaching into areas that cannot be reached by micro-TIG weld-
ing, being able to apply small weld deposits on aluminum and
copper alloys, and keeping the heat-affect zone (sink) to a min-
imum. Adding micro-laser welding to the company’s capabilities
would help address these challenges. And since MTW is known
for its quick turnaround times—often same-day—Mesick wanted
to add more laser capabilities to serve his customers even faster.Ph
otos
cou
rtes
y of
Mic
ro T
ool
Wel
ding
.
Using the most advanced laser welders has allowed Micro Tool Welding to
achieve minimal to undetectable weld sink and distortion. And, the laser move-
ment is mechanical, making it capable of providing a straight and consistent
weld bead profle. Additionally, these machines offer the ability to weld close to
standing features without damage to surrounding areas; and the laser techni-
cian is able to deposit weld uniformly and accurately.
Mesick visited several laser welder manufacturers before
making his final purchasing decision. “After reading a 2007
case study in MoldMaking Technology on O.R. Laser USA, a
laser welder manufacturer based in Elk Grove Village, Illinois, I
knew its system would best suit my applications.” He immedi-
ately flew to Chicago to visit the company.
“I took a part with me that was almost impossible to micro-
TIG weld and gave it to the technician,” Mesick recalls. “With
no hesitation he took the part and welded it. I was totally
amazed. That is what sold me. It was a super-small insert from
a mold that you had to pick up with tweezers. He had to weld
in a hole in between two standing legs sticking up on the part,
and he had to reach down in this hole. I was totally baffled at
how he could do that—and it took him about 10 minutes.”
Mesick purchased a 200-watt laser welder in 2007 from
O.R. Laser. He also added a 300-watt laser welder in 2010 so
Laser-welded four side walls of the
pocket and re-established the rib on the
I.D. of the hole.
Added 0.080 inch per side
on a copper alloy core.
Laser-welded 0.020+ inch on a
surface that was off location.
VIDEO
Access video
at end of article.
1213 MMT DEPT--Case Study 1--microtool.indd 18 11/18/2013 8:58:23 AM
moldmakingtechnology.com 19
he could weld copper and aluminum alloys more easily. These
machines have been instrumental in helping MTW become a
leader in micro-laser welding.
Due to the increased volume of work the company realized
after the purchase of the 200-watt welder—and the quality,
performance and customer service O.R. Laser provided—MTW
has since purchased two more laser welders.
“Using the most advanced laser welders has allowed us to
achieve minimal to undetectable weld sink and distortion,”
Mesick says. “And the laser movement is mechanical, making it
capable of providing a straight and consistent weld bead pro-
file.” Additionally, Mesick notes that these machines offer the
ability to weld close to standing features without damage to
surrounding areas; and the laser technician is able to deposit
weld uniformly and accurately.
And when it comes to necessary machine service, O.R. Laser
quickly responds, Mesick maintains: “Like anything you own,
there comes a day when some kind of service is needed. O.R.
does whatever it can to service the machines. If I have trouble
and an O.R. technician is available, he will drive or fly to Erie
to fix the machine. I tell him what is wrong, and he has a gen-
eral idea of what it could be. This knowledge enables him to
narrow down the problem and select the appropriate part to
bring with him. Then when he diagnoses the problem on site,
he has the parts on hand to fix it.”
Laser-focused on the Future
Business has exploded since Mesick added the 300-watt
machine, and his experience with micro-TIG welding helped
him pick up the new technology quickly and impart that
knowledge onto his employees.
“I was already working under a microscope, and the wire
that I am using is the same wire,” he explains. “The only thing
that is different is the application: laser light vs. electrode elec-
tricity. It has been easy for me to pass this knowledge onto my
team. The average learning curve is typically less than an hour.
If you are experienced, you can pick it up even quicker. It all
depends on the individual. There are crosshairs when you look
through the lens and you can pinpoint the area that needs to
be welded, and you just lay the wire right down by the cross-
hairs and hit the foot control.” And because the machine is
portable, it can be rolled right up to the part, if necessary.
The faster laser machine allows MTW to turn work around
quicker without sacrificing quality. “Quality is number one to
my customers,” Mesick says. “Speed is their number two con-
cern, and price is third. This machine is high-quality.”
According to Mesick, MTW’s work speaks for itself, and
the fact that 90 percent of the work comes from out of town
is proof. Mesick plans on adding another employee in the
near future as well as another machine, once the economy
is more stable. “It is a big purchase, but a definite one. O.R.
Laser’s equipment has enabled my business to expand and
stay competitive.”
Laser-welded the damaged top of this copper alloy core.
FOR MORE INFORMATION:
O.R. Laser USA / 847-593-5711 / [email protected] / or-laser.com
Micro Tool Welding / 814-833-1711
[email protected] / microtoolwelding.com
VIDEO: Micro Laser Welding and Micro TIG Welding short.moldmakingtechnology.com/mtw
Laser-welded the ribs of a copper alloy core.
1213 MMT DEPT--Case Study 1--microtool.indd 19 11/18/2013 8:58:26 AM
20 MoldMaking Technology December 2013
Case Study / Machining
Investing More
Than Finances
Yields True High-
Performance
Machining
Batesville Tooling & Design is a family-owned company that
prides itself on the manufacture of complex injection molds
for the aerospace, automotive, chemical, defense, medical,
oil, power and transportation industries. Its philosophy on
capital investments is to use each new piece of equipment as
a steppingstone toward future performance enhancements.
After several decades of transitioning from manual to com-
modity CNC machines, the company took its first step into
high-performance machining in 2012 with a Makino F5 vertical
machining center.
Batesville realized that this leap in technology would
require a different type of skill set than its operators were
accustomed to, so the company signed on to attend training
courses hosted by Makino at its Auburn Hills, Michigan,
facility. “Without the
training, we wouldn’t
have known how to prop-
erly use the F5 and all of
its technologies,” explains
Gary Blair, Batesville’s
founder and president.
“The training wasn’t
what I had expected,”
says Dan Blair, a manu-
facturing engineer at Batesville. “I walked into the classroom
thinking that we would run through machine functions
and call it quits. Instead we learned about Makino’s entire
approach to machining, beginning with machine tool con-
struction and all the way through tooling decisions. It was an
eye-opening experience that I took to heart and immediately
applied to our processes after returning home.”
Shrink-ft tooling, combined
with the rigidity and speed
of the F5, has led the
company to a 25- to 50-
percent increase in tool life.
The Blair family, (l to r) Gary Blair, Janice Blair and Dan Blair, stands in
front of the company’s new Makino F5.
VIDEO
Access video
at end of article.
Quality Straight Out of the Machine
One of the first workpieces that Batesville sent through the F5
was a medical mold insert the size of a postage stamp. Prior to
acquiring this machine, the company had to endure long hours
of EDM processing in order to accomplish the desired feature
tolerances and side-wall finishes. Because of the rigidity, accu-
racy and high spindle speed the F5 offers, the company decided
to perform a test run on the machine.
Initially, a 4-mm end mill was used to perform roughing and
semi-finish processes on the workpiece. It was then finished
using a 0.4-mm-diameter end mill. Where completion of the
workpiece once required eight hours of machining and manual
finishing procedures, the company was able to complete the
part on the F5 in just one hour while meeting tolerances of
±0.0005 inch and achieving mirror-like surface finishes.
“After completing the machining process, I inspected the
cavity and could see clear reflections of various features
along the side walls,” Dan Blair says. “I’d never seen finishes
like that straight out of a machine before. We pulled the part
out of the machine complete—minimal secondary processes,
minimal manual finishing. But the most satisfying results
came when our customer shared that it was producing the
best-looking parts they had seen come out of a mold.”
One of the most valued tips that Batesville picked up from
its training at Makino was the appropriate use and applica-
tion of shrink-fit tooling. It reached out to its local Single
Source Technologies (SST) representative and was able to
narrow its selection down to a Haimer shrink-fit machine
1213 MMT DEPT--Case Study 2--batesville.indd 20 11/18/2013 8:58:37 AM
moldmakingtechnology.com 21
and toolholders. After it combined these with the rigidity
and speed of the F5, Batesville witnessed not only improved
workpiece quality but also a 25- to 50-percent increase in tool
life. To ensure unattended accuracy, the company also uses
a Blum laser tool-length measurement system and remote
machine monitoring capability.
“The core-cooled spindle on the F5 does an excellent job of
eliminating thermal growth, allowing us to maintain highly
precise processing over extended run times,” Dan Blair says.
“Whether a process lasts an hour or 10 hours, we meet exact-
ing tolerances every time. As a result, we’re seeing highly
repeatable performance, and perfect blends and matches.
Even in certain rib features, we’re producing better results
than what we could achieve through our EDM technologies.”
Single Setup Saves Time and Serves Customers
With the improved workpiece accuracy and quality achieved
on the F5, Batesville has been able to greatly reduce EDM
processes from many of its applications, performing many of
its operations in just a single setup.
“In our former processes, we would have to design the
electrodes, set up the graphite machine, cut the electrodes,
rough out the workpiece to near-net form, set up the work-
piece on the EDM, burn the detail and then polish
it,” Dan Blair explains. “By running work-pieces
on the F5, we’re capable of completing jobs in just
a single setup, eliminating stack-up errors and
substantially reducing cycle times. In many jobs,
we’re delivering finished workpieces in just 10
percent of our previous times.”
According to Gary Blair, this single-setup
approach has enabled the company to service cus-
tomers in a more efficient manner, while increas-
ing overall profitability by anywhere from 30 to 50
percent.
“Our ability to turn around orders faster has
been paramount to how our customers value the
service we provide,” he notes. “If a customer has a
broken insert, we now have the ability to machine
a new one and ship it to them in a day or less, and
they can then continue their manufacturing pro-
cess with virtually no interruption.”
Taking Care with Technology
Batesville’s newly acquired access to high-perfor-
mance machining capabilities and deep techni-
cal training have helped support the company in
building what it believes matters most—reliable
and well-paying jobs.
“When it comes down to it, we’re all here work-
ing together to build a better life for ourselves
and those we care for,” Gary Blair says. “I believe
the only way that we can accomplish this is by working to the
best our abilities and taking care of our customers’ needs. This
is why we place an emphasis on technology and training.”
In using the F5 to produce this medical mold insert, Batesville removed
all EDM processes, while achieving mirror-like fnishes on the side walls.
Imag
es c
ourt
esy
of M
akin
o.
The core-cooled spindle on
the F5 helps eliminate thermal
growth, allowing Batesville to
maintain precise cutting over
extended run times.
1213 MMT DEPT--Case Study 2--batesville.indd 21 11/18/2013 8:58:49 AM
22 MoldMaking Technology December 2013
Case Study / Machining
He is pleased that Makino shares sim-
ilar goals to Batesville’s: building success
by providing the best possible product
and customer service.
“I toured the Makino facilities in Japan
and Singapore, and learned a lot about
Makino and the principles and values
that drive the company,” Gary Blair says.
“They strive to produce a product that
takes care of their customers.”
According to Dan Blair, Batesville has
applied its training knowledge to all
milling processes on the shop floor, real-
izing varying levels of improvements to
accuracy, quality and tool life across all
equipment.
“The F5 investment wasn’t merely a
new tool. It was a catalyst for change
that pulled us out of our traditional
practices,” Gary Blair says. “When I
approach a challenge today, I see it as an
opportunity for growth and understand-
ing. I think about the things that we can
do, not what we can’t.”
“We’ve entered the next stage in
our company’s evolution,” Dan Blair
explains. “When it comes to accuracy
and delivery, the difference is night and
day. Between the F5 and our techni-
cal training, we’re exceeding customer
expectations and bidding on new jobs
more competitively than ever.”
VIDEO: High-Performance VMC Offers Mold Shop Speed and Precision short.moldmakingtechnol-ogy.com/bates
By producing workpieces in a single setup, the company is able to serve customers more
effciently, while increasing overall proftability by as much as 50 percent.
FOR MORE INFORMATION:
Batesville Tooling & Design
(662) 563-1663 / btd-inc.net
Makino
(800) 552-3288 / makino.com
1213 MMT DEPT--Case Study 2--batesville.indd 22 11/18/2013 8:58:50 AM
In its 12th year, the Leadtime Leader Awards,
presented by MoldMaking Technology, honors
those outstanding North American mold
manufacturers who best demonstrate overall
innovation, effciency, quality and commitment
within their moldmaking operations while
raising the bar in terms of mold engineering,
building, repair and management.
Nominate Your Shop Today!
”Often we are so focused on the day-to-day activities of running
a business that we don’t think much about all of the things that
we’ve done over the years to create and sustain a successful
business. In retrospect, flling out the Leadtime Leader Award
questionnaire forced us to consider all the various components
of our success including the adoption and implementation of new
technologies, customer service, continual education, training
and cross-training of employees, our sales/marketing efforts, and
involvement in our industry in ways that help to make it better
and stronger. We believe that receipt of the Leadtime Leader
Award is recognition from our peers of a ‘job well done’ and we
want to thank everyone involved in the process.”
Jerry Seidelman, Tech Mold, Inc. — 2013 Leadtime Leader Winner
For complete information, eligibility requirements and nomination forms,
please visit: short.moldmakingtechnology.com/LLA
or contact Editorial Director Christina Fuges at [email protected] or (800) 579-8809
Innovative / Effcient / Quality-Driven / CommittedIf this describes your shop, then you have what it takes to be a leader.
SponSored by:
preSented by:
Winner and Honorable Mention Rewards:
A full cover feature with video on your shop
in MoldMaking Technology magazine and online
Free expanded showroom on MoldMakingTechnology.com
and on PTonline.com
Complimentary 10’ x 10’ booth as well as 2 complimentary
full conference registrations for amerimold 2014 –
June 11-12 at Novi, MI’s Suburban Collection Showplace.
www.amerimoldexpo.com
Winners earn a targeted advertising program in
Plastics Technology magazine (ptonline.com) to market
their products and services to more than 25,000 molding
subscribers at more than 11,600 molding facilities!
• Gain industry recognition and build brand awareness
• Attract new customers
• Boost morale in the shop
• Distinguish your shop as an industry leader
Leadtime Leader.indd 1 9/13/13 12:42 PM
Mold Components
24 MoldMaking Technology December 2013
By Bob Salhaney
As part specifications and complexities continue to
rise, proper mold venting is increasingly critical.
Insufficient venting can lead to burning, shrinking
and other costly issues (not to mention longer cycle times).
Selecting the right material for certain mold components can
go a long way toward preventing these problems.
For example, a porous sintered metal, such as one that is
composed of 25 percent air by volume1, can vent gas without
the need for a separate venting component. As a result, core
pins and plugs made with this material help reduce mold size,
cost and complexity. You can use this material to help your
customers achieve better part cosmetics, while also saving time
and money.
A porous metal eliminates trapped gas in the mold. It is
heat-treated to 30 to 40 HRC with porosity around 20 to 30
percent by volume. A system of interconnected pores with
an average diameter of 7 micron (0.0003 inch) or 20 micron
(0.0008 inch) is dispersed throughout the material. This
porosity is the key to the material’s effectiveness.
When used as a core pin material, the metal eliminates
trapped gas problems that occur in inadequately vented areas
within the mold. It is often difficult to provide adequate vent-
ing in these hard-to-mold areas. Traditional methods of vent-
ing, such as parting-line vents and vent plugs and pins, often
do not provide sufficient surface area to accommodate the
large volumes of gases that can be generated. This material
provides a location-specific method of venting gas in a target-
ed area. Since it is 25 percent air by volume, 1/4 of the surface
area becomes a vent. The larger the surface area of the piece
installed, the greater the venting capacity.
Material Benefits
This method of venting delivers numerous benefits, including
reducing injection pressure as well as substantially reducing
Selecting the right material for specific
mold components can help prevent a
number of costly issues.
For Better Mold Venting,
Start with the Metal
scrap and reject rates. Utilizing a porous
sintered metal for core pins and plugs also
enhances part production in the following
ways:
Prevents burning and shrinkage.
Burning is a condition caused by com-
pressed gases trapped by the flow of
molten resin in a cavity pocket. By using
a porous metal, gases are permitted
to evacuate through the steel to the
outside atmosphere, thus eliminating
the burning condition. Additionally,
air bubbles trapped between the resin
and mold steel surface can cause
shrinkage or sink that shows as a ripple in the otherwise straight
plastic surface. Using a porous metal on the trapped-air side of
the cavity will eliminate shrink in most cases.
Prevents flow and knit lines.
Minimizing or eliminating flow and knit lines is an additional
benefit of using this material. Knit lines occur at points where
resin flows converge after molding around an obstruction or
protrusion within the mold, usually away from the gate area.
There are two primary reasons for this occurrence:
1. The failure of resin to sufficiently fuse due to the tempera-
ture drop it experiences after flowing over long distances.
2. The presence of residual air at the resin flow convergence
point at the cavity obstruction, prohibiting the proper fusion of
the flows.
The permeability of a porous metal prevents defects that arise
from residual gases normally trapped inside the mold cavity.
Also, using this material reduces back pressure and improves
the flow rate, enabling the resin flows to merge while still hot.
Core pins and plugs made
with porous, sintered
metal help reduce mold
size, cost and complexity.
Imag
es c
ourt
esy
of D
ME
Com
pany
.
1213 MMT -- FEATURE 1 -- DME.indd 24 11/18/2013 8:54:59 AM
moldmakingtechnology.com 25
Reduces cycle time.
Because of the reduction in back pressure within the mold, the
plastic fills the cavity faster, thus allowing for a reduction in
temperatures, which shortens cooling and cycle times.
Eliminates short shots.
A short shot is another condition caused by too low of an
injection pressure or trapped gases in pocket areas of the cav-
ity. This results in the part not being completely filled out. A
porous metal reduces back pressure, therefore, less injection
pressure is needed. And because it vents trapped gases, both
causes of short shots are eliminated.
Enhances part appearance.
By using a porous metal in the mold, webbed, ribbed and other
difficult-to-fill, thin-walled designs are greatly enhanced and
cosmetically defined. Molding highly detailed, thin-walled and
aesthetic parts is easily accomplished with the reduced back
pressure and added venting of this material.
metal into the core with an air blow setup helps break the vacu-
um seal and aids the ejector pins in doing their job.
Design Guidelines
While porous metal is ideal for core pins and plugs, there are
some practical guidelines to consider when determining its suit-
ability for various other applications.
Resin type.
Depending on the emissions or gas residue given off during the
molding process, the molder will have to evaluate whether to
use a 7- or 20-micron pore size. Resins such as ABS, polypro-
pylene, soft-type
PVC, polyethylene,
acrylic, polyure-
thane and styrene
work very well with
a 7-micron (0.0003-
inch) pore size.
For low-viscosity
or talc-filled resins,
it may be neces-
sary to have an
automated system reverse the airflow after each shot to purge
the impurities from the pores. Rigid PVC resins, phenolics and
natural rubber resins will work, but only until the corrosive gases
close the pores. This can still be a feasible method if disposable
inserts are used.
The 20-micron (0.0008-inch) pore size will vent about 25 per-
cent more gas than the 7-micron pore size, so, where extreme
venting is needed, a 20-micron pore size is recommended. The
20-micron grade was developed to be used with a milled finish.
When milled properly, this process leaves a pore that is partially
open (about 40 to 50 percent).
Rigid PVC, clear polycarbonate, liquid silicone and foaming
urethanes all are questionable resins to use with this material
and should be avoided.
Proper venting.
Experts recommend that at least 10 percent of the cavity area be
made of a porous sintered metal to ensure proper venting. While
this is not always possible, it is important to remember that the
more square inches of venting that are used in the cavity area, the
lower the back pressure will be in the cavity. However, if the dis-
tance that air has to travel through the material, and ultimately
to the exhaust line, is excessive, then venting capacity will be
compromised.
Thus, the shorter the distance through the metal to the exhaust
line, the better. Due to the larger surface area, the insert will
not require cleaning quite as often as a smaller piece. If a porous
metal is used as a core or cavity half instead of as an insert, there
may not be a need for parting line vents.
LEARN MOREVisit our Mold Components Zone for
more information about mold bases, pins,
ejectors, lifters, bushings, guides and
alignment devices.
Go to moldmakingtechnology.com/zones
for a complete list.
Porosity is the key
to this material’s
effectiveness.
Reduces gloss.
When using a porous metal as a cavity in an injection mold,
the air that would otherwise get trapped between the cavity
and the resin and cause a gloss to show on the part is instead
allowed to escape through the pores, thus leaving a dull matte
finish. This often eliminates the need for costly secondary
spray-painting operations.
Simplifies the tool.
When back pressures, injection pressures and cycle times are
lowered, fewer drops are needed to ensure proper filling of the
cavity. Lowering the number of drops needed simplifies the
design while saving tool costs.
Aids in part ejection.
In many situations, an air poppet is needed to help break the
vacuum from the core in a molded part. Inserting a porous
1213 MMT -- FEATURE 1 -- DME.indd 25 11/18/2013 8:55:05 AM
Mold Components
26 MoldMaking Technology December 2013
CONTRIBUTOR
Bob Salhaney is a product engineer for DME Company with more than 33 years
of experience in developing and applying solutions within the plastics industry.
Cleaning and maintenance.
A porous metal is generally a low-maintenance material, but
proactive cleaning is still needed occasionally. There are two
times cleaning must be performed with this material. The first
is when the tool shop has prepared the insert or cavity. The
material is 25 percent air by volume, and the cutting fluids will
displace the air, thus filling and clogging the pores. After the
permeability has been restored, by either stoning or EDM of
the venting surface, the steel should be placed in an oven at
about 350°F for 2 to 3 hours. This will thin and remove most of
the fluids in the pore structure. Once cooled to room tempera-
ture, the material should be placed in an ultrasonic cleaning
unit built for flammable solvents that is filled with acetone.
Cleaning is also needed after the insert or cavity has been
in operation and a film—a thin layer of mold release agent,
resin residue, shop oil or any other contaminate—has partially
or totally blocked the air flow. In addition to these cleaning
methods, it may be necessary to use air pressure to back-flush
the porous metal inserts with acetone in order to thoroughly
clean them. However, waterlines should not be run through
a porous material, since they are difficult to seal and will rust
the material.
Additionally, polymers with flame retardants will require
more frequent cleaning. This is where the reverse blow-back
capability is ideal, as reverse air flow will happen with each cycle
of the mold to assist in keeping the porous metal clean.
Summary
The unique properties of a porous sintered metal make it an ideal
material to use in core pins and plugs. By preventing wasted or
burned materials during a part’s production, moldmakers can
help their customers achieve better part aesthetics, while also sav-
ing time and money. This material helps vent the unwanted gases
that build up inside a mold and lead to imperfections. As a result,
core pins and plugs made with a porous metal can help molders
prevent burning and shrinkage as well as flow and knit lines, all
while reducing cycle times and enhancing part appearance.
1 DME Company manufactures a line of core pins and plugs made of Porcerax II called Vortex.
FOR MORE INFORMATION:
DME Company / [email protected] / dme.net
1213 MMT -- FEATURE 1 -- DME.indd 26 11/18/2013 8:55:12 AM
moldmakingtechnology.com 27
By Sal Benenati
Gain Process Control with a
Specialized Hot Runner
Temperature Controller
Typically, a hot runner system refers to the heated mani-
fold and nozzles that go into a mold; in reality, the con-
troller, once it is coupled with the mold, also becomes
an integral part of the system. When it comes to successful
mold operation, the controller’s performance is just as critical
a factor as the mold components’ performance.
Accurate and responsive temperature control is essential, as
the best manifold system in the world is not going to do the
job all by itself, and obviously a great controller without a good
manifold system is not going to
be of much use.
Consider specialized tempera-
ture controllers for manifolds
and nozzles because of the very
unique thermal siutation a hot
runner system presents. For
example, the manifold needs to
be kept at fairly elevated tem-
peratures, while the mold with
which it is in contact needs to
be cooled. General-purpose con-
trollers, which may be adequate
to control the temperature of a press barrel, are not going to
work well in the dynamic environment of a hot runner system.
In order to control both sides (heating and cooling) and
optimize the entire system’s performance, there is great value
in finding suppliers who manufacture both controllers and
manifold systems.
Hot runner systems present unique
thermal situations that require
specialized temperature control
for manifolds and nozzles.
The Controller Breakdown
Hot runner controllers that are model-predictive and not pro-
portional-integral-derivative (PID) allow users to zero in on the
requirements of the hot runner system more readily, and without
the trial and error of the conventional PID routine. The difference
is that PID responds to parameters that are preset by the manu-
facturer and, in certain situations, by the user, based on expected
zone conditions. However, conditions within the same hot runner
system may differ substantially from one point to another.
For instance, a manifold zone and a nozzle zone will behave
completely different from one another, and if the same control
parameters are used for both, the result is going to be less than
desirable in one or the other. If one tries to make a universal
PID setting, the result may be a compromise in performance for
both zones.
By contrast, model-predictive controllers sample the zone for
current load (watts), response time and the rate of temperature
rise, in addition to other conditions, and then use an algorithm
to predict how and when to apply power in order to get the
required results. Also, adjustment to the control parameters is
constantly occurring during operation to compensate for factors
For the continued
accuracy of any
controller, it is very
important to keep
the circuitry clean
and properly cooled.
Hot Runners
Heat generated by internal circuits is transferred to the controller housing.
Pho
tos
cour
tesy
of
Ory
con
Ho
t R
unne
r Sy
stem
s.
1213 MMT -- FEATURE 2 -- Orycon.indd 27 11/18/2013 8:55:58 AM
Hot Runners
28 MoldMaking Technology December 2013
such as changes in set-point or mold tem-
perature. With tight gate vestige require-
ments and demanding engineering materi-
als becoming more and more common,
model-predictive controllers can help solve
many processing problems.
Keeping it Clean and Cool
For the continued accuracy of any control-
ler, it is very important to keep the circuitry
clean and properly cooled. This may prove
difficult to achieve on an injection molding
shop floor. Even in shops where the product
is food-related and everyone wears hair nets,
dust and other contaminants can accumu-
late on the internal electronic components
of hot runner controller cabinets.
Thick layers of dust and sometimes even
cobwebs can be found in most controllers
that use circulating fans to cool the cir-
cuits. Dust, tiny plastic particles, lint and
a variety of mist types can be drawn into A controller cabinet with a structural heat sink requires no fans and is easily kept clean.
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1213 MMT -- FEATURE 2 -- Orycon.indd 28 11/18/2013 8:56:11 AM
moldmakingtechnology.com 29
CONTRIBUTOR
Sal Benenati is chief operating offcer of Orycon Hot Runner Systems. He has
been awarded several patents over the past 30 years for controller, manifold
and nozzle innovations.
FOR MORE INFORMATION:
Orycon Hot Runner Systems
732-922-2400 / [email protected] / orycon.com
the controllers by the fans and trapped by the electronic com-
ponents that protrude from the boards inside. Once these
particles stick to the components, they create a textured sur-
face that makes it easier for more particles to get trapped and
accumulate, forming insulating layers over the components.
Semiconductors
and other compo-
nents are affected
by temperature,
and circuit per-
formance under
a blanket of dust
is not the same
as in free air.
For this reason,
higher-accuracy models use static cooling rather than fans.
Heat sinks are employed as an integral part of the controller
housing (or mainframe), and since there is no air circulating
internally to carry contaminants, the electronic components
are kept clean and at peak efficiency.
It is critical to establish a maintenance program that
includes vacuuming the internal surfaces of all controllers
that use fans. The schedule may vary according to the degree
of free-floating dust in the shop, however, if at some point
the dust is not removed, accuracy will be affected, and even-
tually units may fail altogether.
The static cooling type of controller can be cleaned by
simply wiping off any visible dust from the cabinet’s exter-
nal heat sink. The units are designed to keep potential con-
taminants away from sensitive areas, so circuit performance
is not affected and the “other half” of your hot runner system
keeps working at peak performance for much longer.
LEARN MOREVisit our Hot Runners Zone for more
information on hot halves, nozzles,
gates and temperature controllers.
Go to moldmakingtechnology.com/zones
for a complete list.
1213 MMT -- FEATURE 2 -- Orycon.indd 29 11/18/2013 8:56:17 AM
Mold Maintenance/Repair
30 MoldMaking Technology December 2013
By James Bourne
When I make a press call, I usually think of one more
item to add to the stock on hand: a multimeter,
15-amp fuses, a small assortment of roll pins for
lifter heads, etc. All of these items support the same purpose:
to reduce press downtime.
This makes the next suggestion to further the agenda of
minimizing downtime obvious: Train mold technicians the
rudiments of press operation, at
a minimum. What good does it
do to race to the “scene of the
accident,” make a speedy repair,
and then wait 10 or 15 minutes
for a mold setter or process
technician to come along and
start the press up again?
Generally, mold repair tech-
nicians (at least in my experi-
ence) are the highest-paid
hourly employees at a molding
facility. So now, not only is the company losing money on
press time, but also one of the highest-paid employees is wait-
ing around not being productive.
(By the way, walking away from a repair is not usually a
good idea. It’s one thing if you’ve just replaced a broken water
fitting, but if you were in the press addressing a part-defect
issue, it’s always good practice to stay and verify your work. If
the repair was not effective, there will be even more lost time
waiting for your return.)
Following is an example of instructions I initially prepared
for myself and then shared with others in my department:
A look at crib notes on press
operation for mold repair personnel.
The instructions
outline the process
for getting the mold
back on auto-cycle,
no barrel-purging
required.
IN THE TRENCHES
The Obvious
Next Step
in Minimizing
Press Downtime
Imag
es c
ourt
esy
of J
ames
Bou
rne.
Operating Instructions
1. Robot controller (Yushin). Turn the screen on by pressing the button next to the power button. Depress Cycle Stop NOT Start/Stop.
2. Do not open the door until the robot has completed its cycle and is in the home position.
3. Depress the Manual Mode button on the machine control panel.
4. Move the sled away from the sprue (2 to 3 inches).
5. Turn off the pump motor.
6. Open the door and LOTO.
START-UP
1. Remove LOTO.
2. Start the pump motor (the button to the left of pump stop).
3. Move the sled forward.
4. Press the Single Cycle mode button.
5. Press the Cycle Start button after the mold clamps up.
6. Press the Continuous Cycle button.
7. Robot controller. Hit the Auto button and wait for the screen to change.
8. Hit Start/Stop.
1213 MMT -- FEATURE 3 -- SRG.indd 30 11/18/2013 8:56:30 AM
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1213 CUMA.indd 1 11/4/13 1:16 PM
Mold Maintenance/Repair
32 MoldMaking Technology December 2013
CONTRIBUTOR
James Bourne is a tool repair supervisor and freelance writer.
FOR MORE INFORMATION:
James Bourne / 573-701-9123 / [email protected]
• Don’t just take notes.
• When you are being coached through the process,
insist that you be allowed to push the buttons.
• Go through the process several times, take notes,
then go through it following your notes with an
observer (a silent observer).
• Be thorough, specific and detailed.
• Take pictures.
• Make it “Press Operation for Dummies.”
Because there can
be several different
scenarios given your
particular setup—
the length of time
the press has been
idle, the specific
repair verification
needed and so
on—I recommend
you start with the most generic scenario, then build on it as
technicians develop some comfort level with press operation.
It can be intimidating to push “Cycle Start” without panicking,
wondering if you left a stone sitting on the die-lock.
Almost all of our presses are outfitted with robotic demold-
ing and degating. Most of our in-press repairs are “quickies,”
and our most-common resin is fairly forgiving when it comes to
residence time in the barrel, so the repair instructions outline
the process for getting the mold back on auto-cycle, no barrel-
purging required.
Once the repair notes are verified for accuracy, it’s simple to
format them in an Excel document and add circles and arrows.
Visual aides are always an effective means of education. Print the
instruction pages in color and put them in a sheet protector in a
notebook that also has some blank sheets for taking notes at the
next press call. Depending on your mix of presses, this may be
a lengthy process, but in time your manual should be complete
and should start paying you back for your efforts.
LEARN MOREVisit our Mold Maintenance and Repair
Zone for more information on a mold
tryout, welding, cleaning and retroftting.
Go to moldmakingtechnology.com/zones
for a complete list.
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• CMM-level accuracy
• Excels in the harshest machine conditions
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1213 MMT -- FEATURE 3 -- SRG.indd 32 11/18/2013 8:56:36 AM
moldmakingtechnology.com 33
Industry Outlook
If online surveys could capture facial expressions, a recent
survey of tool shop executives would probably show a good
number of smiling faces, albeit cautiously optimistic ones.
According to the 370 tooling professionals who participated
in a North America tool shop survey1, business is exhibiting
clear signs of growth. And while the survey shows that
this growth is far from being challenge-free, any tool shop
executive will welcome these challenges over the experience
of a downturn. Figu
res
cour
tesy
of
Cim
atro
n.
1-2 3-4 5-6 7-8 9-10
35%
22%
17% 18%
7%
Number of quotes won out of every 10 quotes provided.
FIGURE 1
Signs of GROWTH
A survey of North American
tool shops indicates that the
industry is growing, but so is the
competition for new business
and talented workers.
Demand and Competition Growing
One indicator of growing demand is the number of quotes
issued by tool shops. Close to half of the survey respondents
(49 percent) saw an increase in the number of quotes they
issued in the past year, while only 13 percent issued fewer
quotes than the previous year.
Tool shops are not only issuing more quotes; many are also
getting paid better for their work. Forty-six percent of the
respondents believe the price of tooling has increased in the
past five years, while 26 percent think prices went down.
Not surprisingly, the growing demand has spurred tougher
competition. Forty-five percent of the respondents say com-
petition today is stronger than it was five years ago, and 35
percent say they win only one to two quotes out of every 10
they provide. Forty-eight percent believe the primary reason
for losing to the competition is price (Figure 1).
No. 1 Challenge
With the growing demand comes the industry’s most burning
question: Who will do the work? More than half of the tool
shops surveyed have increased their number of employees
in the past two years, and as many as 31 percent of the shops
have increased their workforce by more than 25 percent
throughout that period.
Hiring additional qualified employees is the first step survey
respondents say they would take in order to make their busi-
nesses more successful. Seventy-three percent of the tool shops
that participated in the survey expect to hire additional employ-
ees in the coming year. Close to a third (29 percent) expect to
hire three to six people, and 15 percent plan to hire seven or
more new employees in the coming year.
moldmakingtechnology.com 33
1213 MMT -- FEATURE 4 -- Cimatron.indd 33 11/18/2013 8:56:51 AM
Industry Outlook
34 MoldMaking Technology December 2013
bad perception about manufac-
turing jobs,” says Keith Gerber,
owner and president at Hoosier
Pattern (Decatur, Indiana).
“People think a machine shop
means a dirty environment and
low pay. It’s quite the oppo-
site. The shops are clean and
equipped with the latest tech-
nology. Employees are highly
trained, highly skilled and well-
paid.”
The first step in drawing in
young workers is changing this
perception. Gerber is doing
more than just talk. “I’m try-
ing to set up meetings with
the local high schools to bring
the counselors and teachers
out here so they can see it with
their own eyes.”
Hoosier Pattern also has set
up an apprenticeship program
that brings in high school grad-
uates to teach them the trade.
After five years in the program,
apprentices have logged 10,000
hours of on-the-job training,
while also earning credit hours
at a technical school. “Rather
than finishing college with
huge debt and no occupational
skills, our apprentices get a
raise every quarter and gradu-
ate with no debt and with high-
ly sought-after technical skills,”
Gerber says.
Other shops are taking
similar steps. Industrial Mold &
Machine (Twinsburg, Ohio) is
equipping employees with iPad
tablets and applying innovative
social networking technologies
to bridge the gap between generations and speed up knowl-
edge transfer to apprentices.
Vocational institutions and technology vendors also are
doing their share in the effort to train new workers. Starting
this year, students at the McCann Vocational Regional High
School in North Adams, Massachusetts, have the opportunity
to gain hands-on experience with CAD/CAM software, thanks
to the donation of $900,000 worth of software licenses from
Cimatron.
At the same time, it is worth noting that 58 percent of the
survey participants have been employed in the tooling indus-
try for more than 20 years, and 26 percent have been in the
industry more than 10 years. With few new workers joining
the industry, it is no wonder that finding qualified workers is
the No. 1 challenge cited by survey respondents (Figure 2).
When it comes to passing the moldmaking torch, decades
of a shrinking job pool have driven many away from the
manufacturing sector, especially young workers. “There is a
Finding Qualified Workers
Finding New Business
Overseas Competition
Keeping Up With New Technology
Local Competition
Other
54%
16%
14%
8%
3%
4%
Top tool-shop challenges.
Plans for equipment and software investment (next 12 months vs. past 12 months).
FIGURE 2
More The Same Less
FIGURE 3
41%
29%
42%
52%
17%19%
1213 MMT -- FEATURE 4 -- Cimatron.indd 34 11/18/2013 8:56:57 AM
moldmakingtechnology.com 35
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Technologies at 877-228-2884 or visit
singlesourcetech.com.
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“We are preparing
our students to be
significant contribu-
tors to the manu-
facturing economy,”
says James Brosnan,
superintendent of
Northern Berkshire
Regional School District. “Manufacturing today is all about
speed, so training students on software that enables them
to be more productive is a real asset to them, to their future
employees and to the industry.”
The Path to Productivity
Close to half (44 percent) of the survey participants say
their delivery times have gone down over the past two years,
while only 22 percent say they have increased. Sixty-two
percent of the respondents delivered more than 90 percent
of their jobs on time.
How are shops able to accelerate delivery times while
battling the shortage of qualified employees? Continuous
investment in new equipment and software makes shops
more efficient and productive. Over the past 12 months more
LEARN MOREVisit our CAD/CAM and Other Software
Zone for more information on CAD, CAM,
CAE and data management software.
Go to moldmakingtechnology.com/zones
for a complete list.
than half of the shops surveyed (59 percent) invested in
new software and 73 percent invested in new equipment.
More than 80 percent of the shops say they intend to
invest the same or more in equipment and software dur-
ing the next 12 months (Figure 3).
Looking Forward
So what does the future hold for tool shops? Tool shop
veterans have been around long enough to recognize that
the time to invest in the future is now, while the industry
is on the upswing. They know that investment in technol-
ogy will pay off both in times of growth and when business
tightens up, and that training the next-generation work-
force is a top priority.
1 Conducted by Cimatron.
1213 MMT -- FEATURE 4 -- Cimatron.indd 35 11/18/2013 8:57:05 AM
Supply Chain Management
36 MoldMaking Technology December 2013
Tooling spending by automotive OEMs is expected to
grow to $15.2 billion by 2018, but vendor capacity will be
inadequate to meet this demand, according to a study
of the North American vendor tooling industry.
Harbour Results Inc. (HRI) and the Original Equipment
Suppliers Association (OESA) collaborated on the 2013
Automotive Vendor Tooling Study to provide an understand-
ing of the role of each stakeholder (OEMs, Tier 1 and Tier 2
parts suppliers, and vendor tooling suppliers) in the entire
vendor tooling value stream. This study also served to uncov-
er the root cause of inefficiencies, waste and risks impacting
the supply chain, while identifying best practices and cost-
saving opportunities.
In addition to reviewing the expected future challenges for
the industry associated with capacity shortages, the results
shed light on many of the levers used by OEMs to drive down
the price of individual tools as well as those cost factors that
drive price up, including costs below the surface and processes
that are mostly overlooked by OEMs. The study also shares
best practices and ideas for improvement that may gener-
ate the savings needed to maintain and grow this industry in
North America.
Challenges
In addition to talent and skill shortfalls, there are many other
challenges facing the North American automotive industry.
Off-shoring, for example. Although OEMs are not specifically
Proportion of tooling available for planned vehicle launches.
FIGURE 1
By Laurie Harbour
The results of this industry
survey set the stage for
suggested practices and
strategies that could help
the entire vendor tooling
value stream be more
competitive, have adequate
capacity and reach its
desired success.
2013 Automotive Vendor Tooling Study
requiring that Tier 1 suppliers use off-shore tooling operations,
the fact that the OEMs set unrealistic target prices for tooling
forces many Tier 1 suppliers to use low-cost country sourcing
(LCCS) to meet those target prices.
OEMs believe that the level of LCCS will remain the same
(not increase), primarily due to a few key factors: an over-
all increase in the demand for tools and for more complex
tools, in particular, in North America; dramatically changing
economic factors in China; and timing concerns. OEMs are
demanding lower costs on tools and are expecting them to be
delivered faster, which is generally not possible when tools are
made overseas. The study results found that the actual savings
from LCCS is not as high as most OEMs may believe and that
there is a disconnect between perceived and actual costs.
Payment terms also are one of the major sticking points in
the automotive tooling industry for tool suppliers and Tier 1s.
Eight out of 10 OEMs acknowledge that their standard pay-
ment terms follow PPAP (production part approval process)
or the equivalent, which takes place near the launch of the
vehicle and much later than when the tool was delivered to the
Tier 1. As demand increases and strategies evolve, OEMs real-
ize that to attract and retain the best tool suppliers and obtain
capacity, they must improve payment terms. HRI believes that
there will be an increase in the use of progressive payments
with certain OEMs.
“Transactional waste” impacts pricing, too. Tool suppliers
have increased prices to cover things such as unrealistic prof-
1213 MMT -- FEATURE 5 -- HRI.indd 36 11/18/2013 8:57:20 AM
moldmakingtechnology.com 37
it expectations, capacity impact on pricing, lack of visibility
in long-range planning, program delays, feasibility and devel-
opment, and inability to get paid on time, just to name a few.
Most OEMs and Tier 1 suppliers do not realize that the
amount of quote activity at a tool supplier and the subse-
quent hit rate for those quotes also have a huge effect on
capacity, but this is the nature of the tool supplier’s daily life.
The study revealed that a typical tool supplier has a hit rate
of between 4 and 5 percent on all business it quotes, although
HRI believes many shops would tell you that this number
is actually high and could be more like 2 to 3 percent. As a
result of this poor hit rate, suppliers must quote in excess of
their annualized sales each month just to maintain current
revenue levels. A key reason tooling suppliers have to quote
so often is that they have virtually no insight into the busi-
ness opportunities prior to the request for quotation.
Opportunities
The 2013 study does present opportunities for the vendor
tooling industry in North America over the next 5 to 7 years.
Growth in total OEM tool spending in North America is
forecasted to be $15.2 billion by 2018. This is a 64 percent
increase over current spending. Figure 1 validates this growth
expectation by analyzing the anticipated growth of foreign
OEMs in North America. This chart shows the number of
expected product launches each year out to 2018 (provided by
LMC Automotive) and then plots the percentage of available
tooling for sourcing locally by OEMs. Substantial growth is
expected in particular for European OEMs who are relatively
new to the North American market and have been getting
the majority of their critical tooling primarily from Germany.
Additionally, there are some years that Asian OEMs are
expected to have more demand than the Detroit Three. The
main reason for this shift in mindset for tooling sourcing is
the tremendous complexity and number of automotive mod-
els these foreign companies are now producing.
HRI believes that there are several factors that will make
LCCS and China, in particular, less of an option to meet this
growing tooling demand in North America and around the
globe. The Chinese are working on improving labor produc-
tivity and have made this a new focus over the last couple of
years as labor rates have risen. Yet studies show that, even with
labor efficiency, labor rate increases are outpacing this produc-
tivity and will not reduce the gap. Many other costs in China
are rising as well. The price of energy is up 15 percent; fuel cost
also is up, making transportation more expensive; there are
restraints on the number of new ships being built, and a con-
tainer shortage is expected by 2015, making it more difficult to
ship tools to North America. Additionally, the cost of land in
China is almost double
the global average.
Another reason for the
anticipated growth in the
North American vendor
tooling industry is the
trend of European com-
panies moving their tool
sourcing to the region in
which they are building
vehicles. The economy is
still not good in Europe,
and it remains a high-
cost area in which to
manufacture tools. Many
European companies have
said that North America
is becoming a low-cost
country to them. There
are other regions of the
world that could help
Figu
res
cour
tesy
of
Har
bour
Res
ults
Inc.
FIGURE 2
HRI estimates that OEMs in North America spend
an average of approximately $9.25 billion on
vendor tooling, based on 2012 information. At
2012 vehicle volume levels and North American
tool spending levels, the average North American
vendor tooling content per vehicle was $550.
Key fnding: OEM/Tier 1/tool supplier alignment.
1213 MMT -- FEATURE 5 -- HRI.indd 37 11/18/2013 8:57:26 AM
Supply Chain Management
38 MoldMaking Technology December 2013
LEARN MOREVisit our Business Strategies Zone for
more information on sales and marketing,
global initiatives/strategies, banking
and fnance, workforce development,
and new business opportunities.
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for a complete list.
close the capacity gap in North America for vendor tooling, however they are
small players like Indonesia and Thailand.
Although HRI believes a significant portion of future capacity needs will
be filled by North American tooling suppliers, we acknowledge that they will
not entirely close the gap, and OEMs will continue to utilize some off-shore
resources for tooling. This does open up opportunities for new shops to enter
the market, however, and those opportunities may come from European,
German or Chinese shops that may invest in a new plant on this continent.
Every OEM that participated in
the 2013 Automotive Vendor Tooling
Study indicated that it recognizes the
need for establishing a more collab-
orative relationship with the supply
chain, including with tool suppliers
(Figure 2). Cited reasons include
receiving supplier input into part
design, the optimization of manufac-
turing feasibility, increased robust-
ness of tools and a reduction in cost.
Another benefit of collaboration cited by OEMs is gaining an understanding of
new technologies, new processes, supplier capabilities and capacity.
Some Japanese and domestic OEMs are finding ways to get tool suppliers
involved earlier in the process, with varying degrees of success. There is a defi-
nite relationship between tooling supplier performance and the level of collabo-
ration within any specific supply chain. The primary benefits of a collaborative
relationship include receipt of a high-quality tooling at the best price.
Another major area of true cost opportunity lies in the completeness of tool
data as it comes from the OEMs and Tier 1 suppliers. Completeness of tool
design is tied to the degree of design change—in other words, how big is the
change when it comes to the tool supplier? These two elements are a great por-
tion of the root cause of the problems related to the total cost of tools. If OEMs
FIGURE 3
Sourcing Methods.
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1213 MMT -- FEATURE 5 -- HRI.indd 38 11/18/2013 8:57:30 AM
moldmakingtechnology.com 39
CONTRIBUTOR
Laurie Harbour is president and CEO of Harbour Results Inc. She has more than 25 years of experience in strategic planning, benchmarking, operational assessments, lean manufacturing and performance enhancement. Harbour Results specializes in manufacturing, production operations and asset-inten-sive industries, as well as a number of manufacturing processes, including stamping, tooling, precision machining and plastics processing. Full survey results are available from Harbour Results Inc.
OESA provides a forum for automotive suppliers by addressing issues of com-mon concern through peer group councils. With 450 member companies that have global automotive sales exceeding $300 billion, OESA represents more than 70 percent of North American automotive supplier sales. The group is an affliate of the Motor & Equipment Manufacturers Association.
FOR MORE INFORMATION:
Harbour Results Inc. / 248-629-9331 / harbourresults.com
Original Equipment Suppliers Association (OESA)
248-952-6401 / oesa.org
can get a better handle on this tool data and submit it to the
tool supplier in a much more complete form, and limit the
number of engineering changes, the OEMs can benefit from
substantial savings in overall tool cost.
The projected increase in tooling demand over the next five
years, as well as exponential growth in mass customization
and complexity, mean the total cost for tooling at each OEM
also will be far greater than any has paid in the past and will
want to pay in the future. As a result, most OEMs have set very
aggressive cost-reduction targets for their tooling purchase
teams. These new, aggressive budgets will be very difficult
to meet if the OEMs focus on price levers applied in the past
without working toward greater collaboration with suppliers.
The challenge will be how to meet customer demands and
maintain profit margins in this changing dynamic.
In the past two decades, there has been an increased use at
specific OEMs of another sourcing structure that HRI has clas-
sified as direct buy (Figure 3). In this structure, the OEM actually
establishes its own preferred or required list of tooling suppliers.
Another structure identified through this vendor tooling
study is described as direct sourcing (Figure 3). It involves the
OEM contracting with the tooling supplier directly and basi-
cally circumventing the Tier 1 supplier, increasing the oppor-
tunities for early OEM/tooling supplier collaboration. In many
examples studied by HRI, the tooling supplier was selected
before sourcing of the Tier 1 supplier.
Those OEMs that have trialed direct-sourcing models have
had issues with executing programs, which has led some to
abandon this new structure, at least temporarily. In the tradi-
tional sourcing model, the Tier 1 supplier is responsible for the
program management of the tooling supplier. When OEMs
move to a direct-sourcing model, they
take on this responsibility themselves,
and they can be unprepared for what
“program management” comprehensively
entails.
When it comes to tooling supplier prof-
its, HRI has identified a minimum profit
margin expectation for tooling suppliers
(Figure 4). This includes provisions for
both reinvestment in people and reinvest-
ment in process improvements, including
capital equipment. OEMs that believe this
profit amount is too high are again focus-
ing on the wrong areas. Measures to drive
down tooling-supplier profits are levers
that will not enable OEMs to realize
lower overall costs. The ability of tooling
suppliers to reinvest in their businesses
will determine the long-term successful
reduction in supply-chain costs.
Summary
So, how do OEMs, Tier 1 suppliers and tooling vendors work
together to solve the anticipated capacity gap and reduce
costs while still making a fair profit margin? OEMs must
create a structure in which Tier 1 suppliers and tooling ven-
dors will be encouraged to work together to examine the
“below-the-surface” issues that drive overall costs and will be
rewarded for doing so. Working together to solve problems
and improve part and tool designs may be the only means of
jointly capturing cost-reduction opportunities.
Tool supplier fair proft margin.
FIGURE 4
1213 MMT -- FEATURE 5 -- HRI.indd 39 11/18/2013 8:57:35 AM
Product Focus / Inspection
40 MoldMaking Technology December 2013
Internet-Based Training Focuses on
Coordinate Metrology SoftwareVerisurf University is a training program from Verisurf Software Inc.
designed to help customers, educators and students improve their
knowledge of Verisurf software and coordinate metrology, and their
practical application in a manufacturing environment.
Designed to be an extension of the company’s instructor-led training,
Verisurf University is available 24/7, delivering internet-based video
training through a standard web browser. The curriculum is designed to
provide learners with a strong theoretical and practical understanding of
Verisurf X and includes 12 courses covering the user interface, measure-
ment, alignment, analysis and reporting functions. Learners also can
earn a Certificate of Completion by successfully passing examinations
following each course. A learning management system manages the
learner’s home page and provides quick access to all his or her account
information, history, certificates, personal calendar and courses.
Additional courses in development include model-based definition
and inspection, advanced surface analysis and reverse engineering
techniques. For companies with more specialized learning needs,
Verisurf University staff members can recommend the best mix of
online and instructor-led course work based on the individual’s or
organization’s objectives.
For more information from Verisurf Software Inc. of
Anaheim, CA, phone 714-970-1683 or visit verisurf.com.
Software Complements
Portable Measurement Applications
Hexagon Metrology’s PC-DMIS Touch Portable measurement software fea-
tures a full-screen interface, advanced multi-touch technology and intuitive
inspection routines designed to complement portable measurement applica-
tions. It is now available with and said to be particularly well-suited to the
company’s Romer measuring arms.
Using high-resolution multi-touch display technology on a tablet PC, users
can physically interact with the software’s guided measurement sequences
and report templates. One-time dimensions are executed through intuitive
automated measurement sequences, while more complex measurement plans
are created by simply following guided sequences and measuring features
directly on the part.
PC-DMIS Touch organizes measurement plan features intuitively using the
“Face” concept for the traditional work plane. The user is guided through mea-
surement processes using a full set of inspection tools such as simple feature
measurement, construction of features or feature sets, 2D and 3D dimensional
reporting, geometric dimensioning and tolerancing configuration, and more.
Each of these tasks follows a consistent, intuitive sequence that the company
says can be quickly learned with minimal training.
For more information from Hexagon Metrology Inc. of
North Kingstown, RI, phone 401-886-2000 or visit
hexagonmetrology.us.
Device Adjusts CMM Adapter Plate to Any Angle
The Cube Squared Plus from Q-Mark is designed so that CMM users can quickly
position adapter plates at virtually any angle. The device’s predecessor, the
Cube Squared, adjusted the adapter plate’s cube to 90 degrees relative to the
CMM’s X and Y axes. The Cube Squared Plus uses an engraved protractor and
a series of ball detents for unlimited axial rotation of the cube to any angle.
The handheld device requires no additional tools. The user simply loosens
the cube on the adapter plate, sets it to the desired angle and retightens it.
The process takes one minute or less to complete, the company says.
For more information from Q-Mark Manufacturing of Rancho
Santa Margarita, CA, phone 949-457-1913 or visit cmms.com.
1213 MMT DEPT--Product Tech Focus.indd 40 11/18/2013 9:00:19 AM
moldmakingtechnology.com 41
CMM Offers Increased Accuracy
With a maximum error of (1.7+3L/1,000) µm, the
Crysta-Apex S coordinate measuring machine
from Mitutoyo America is said to offer a higher
accuracy specification than other CMMs in its
class, increasing the effective measuring range
at a given measurement tolerance.
Extreme rigidity helps the CMM maintain accu-
racy, the company says. The Y-axis guide rail is
integrated into one side of the granite surface
plate. Precision air bearings located on the bottom,
front, rear and upper surfaces of the X-axis slider
minimize vibration and ensure stability, even dur-
ing high-speed, high-acceleration operation.
In addition, the machine’s drive offers maxi-
mum speed of 519 mm/sec. and maximum accel-
eration of 2,309 mm/sec.2, resulting in higher
throughput for greater productivity, and lower
total ownership and operating costs, the com-
pany says.
The Crysta-Apex S also supports a range of
probes that offer increased capabilities, includ-
ing the MPP-310Q scanning probe, which collects
cloud point data at speeds as fast as 120 mm/sec.
Other probes suited for screw-depth, ultra-small-
diameter and non-contact measurement are also
supported.
Software options include GeoPak, a high-func-
tionality, general-purpose measurement program
that is part of the Mitutoyo Controlled Open
System for Modular Operation Support.
For more information from Mitutoyo
America Corp. of Aurora, IL, phone
888-648-8869 or visit mitutoyo.com.
Metrology Line Includes Variety
of Gaging, Inspection ProductsHeidenhain Corporation offers metrology prod-
ucts ranging from in-process fixture inspection
equipment requiring multiple gaging configura-
tions, to 2D and 3D inspection machine encoders
and digital readouts. Gaging and inline process
inspection products include the company’s Specto,
Metro and Acanto series of length gages, which
are designed to provide a high level of repeat-
ability and reproducibility to collect reliable data.
When connected to either Heidenhain’s Gage Chek
ND2100G or the MSE1000 multiplexor, go/no-go
relay signals can be sent directly to a PLC, and data
can be exported cleanly to Excel. These products are suited for inspection processes that require dedicated
fixturing of the manufactured parts and custom applications.
Heidenhain’s piece-part inspection products include the ND series of digital readouts for applications
requiring simple, intuitive dimensional inspection, and the IK 5000 Quadra-Check software/hardware
system for those that require a PC-based solution. This PC-based solution is suited for manual and auto-
mated 2D and 3D measuring tasks, and is said to be particularly useful on multiple-probe-, video- and
touch-probe-based CMMs, as well as optical comparators.
For more information from Heidenhain Corp. of Schaumburg, IL, phone
847-490-1191 or visit heidenhain.us.
• Keep up on the issues affecting mold manufacturing.
• Interact with industry leaders and newcomers alike.
• Share insights, observations, challenges and solutions .
Participate in the
MMT Blog
The MoldMaking Technology
Blog is designed for you, allowing
you to participate in a dialogue
among professionals in the mold
manufacturing industry.
Conversation. Communication. Community.
Join the Discussion!
MoldMakingTechnology.com/Blog
1213 MMT DEPT--Product Tech Focus.indd 41 11/18/2013 9:00:24 AM
Product Focus
42 MoldMaking Technology December 2013
Spindle Choices Enable 5-Axis HMCs
to Machine Variety of MaterialsDesigned for both powerful and high-performance machining, HBZ Trunnion
five-axis horizontal machining centers from Handtmann offer a variety of
spindle types suitable for machining aluminum as well as steel. The series
includes the HBZ TR 80 with turning option, which features an 800-mm table;
the HBZ TR 120 with a 1,200-mm table; and the HBZ TR 160 with a 1,600-mm
table size.
For machining aluminum, the machines use a 125-kW spindle that can
achieve speeds as fast as 30,000 rpm for a high chip removal rate and reduced
machining time. A horizontal machining configuration and large chip conveyor
support the high volume of chips produced.
Rigid tool interfaces allow the use of spindles with high torque for machin-
ing materials like steel. They can be machined on the compact HBZ TR 80 at
as much as 430 Nm torque, while the larger HBZ TR 120 and HBZ TR 160 offer
maximum torque of 1,010 Nm.
According to Handtmann, it is primarily the rigid machine design that
enables the use of the different spindles. Essential components were con-
structed to achieve maximum rigidity at a high table load and under dynamic
conditions. For example, the Z axis uses a welded steel construction because
of the higher E module; the A axis is driven and clamped from both sides; and
the X axis is driven and fitted with upper and lower guideways. These factors,
along with the use of three-point floor mounting, resist the particularly high
feed forces.
The Handtmann Spindle Monitoring System (HSMS) is designed to monitor
and optimize all processes, continuously checking vibration, bearing tempera-
ture, rotation speed, etc. The HSMS also can automatically define optimal feed
values and rotation speeds.
The HMCs can accommodate both Siemens 840D SL and Heidenhain TNC640
controls, and offer a flexible tool range, including large tools for applications
with deep cavities as large as 400 mm on the HBZ TR 80 and as large as 500
mm on the HBZ TR 120 and 160. The tools are held in magazines with various
tool capacities.
For more information from Handtmann CNC Technologies of
East Dundee, IL, phone 847-844-3300 or visit
handtmanncnc.com.
Tool Catalog Available
Tool Alliance’s updated Ultra-Tool 2014 catalog is now available and can be
downloaded from the company’s website, toolalliance.com. A printed version
can be obtained by calling 800-854-2431 or emailing [email protected].
The catalog includes the company’s Monolith end mills, which now are avail-
able within the 323, 365, 355, 395, 330AL and 333AL series.
For more information from Tool Alliance of Huntington Beach,
CA, phone 714-898-9224 or visit toolalliance.com.
Quick-Change Pallet System
Features High Retention ForceThe Schunk Vero-S quick-change pallet system features a patented dual
clamping stroke and an integrated turbo function that provide pull-in force
of as much as 9,000 lbs. This high retention force increases the clamping
system’s rigidity, enabling considerably higher cutting forces; even extremely
high shear forces can be absorbed reliably, the company says. The Vero-S
is designed for increased precision, efficiency and process reliability with
reduced setup in metal cutting and CMM inspection.
The Vero-S uses one or more clamping pins to clamp workpieces, pallets,
clamping stations, existing fixtures and tombstones. Its radial-aligned clamp-
ing slide pulls in the clamping pin and locks it. Exact positioning is accom-
plished via a short taper. Radial location is done via a diamond pin, ensuring
a repeat accuracy of at least 5 microns (0.0002”). Holding forces of as much
as 16,800 lbs can be achieved. A pneumatic pressure of 6 bars (85 psi) is suf-
ficient for opening the module.
The system is completely compatible and interchangeable with Schunk’s
previous pallet systems, and the clamping pins work universally across the
line. Workpieces can be transferred from machine to machine or to a CMM
accurately and seamlessly, the company says.
The module is completely sealed and protected against the penetration of
chips, dust and coolant. An air purge connection is integrated into the standard
module and can also be used for part recognition. The position of the clamping
side can also be monitored via an air purge monitoring system. The module
also is equipped with bottom and lateral air connectors for mounting flexibility.
For more information from Schunk Inc. of Morrisville, NC,
phone 919-572-2705 or visit us.schunk.com.
1213 MMT DEPT--Product Tech Focus.indd 42 11/18/2013 9:00:30 AM
moldmakingtechnology.com 43
HMCs Process Parts in Aluminum, Cast Iron and Carbon SteelSugino Corporation’s Self-Center H15 and H15B horizontal machining centers are designed for high-
precision milling, drilling, tapping and boring of small- to medium-size parts in aluminum, cast iron and
carbon steel.
Both the H15 and H15B HMCs feature BT30 high-pressure, coolant-through spindles with maximum
speeds of 15,000 rpm and 20,000 rpm, respectively. Specifically designed to save space and energy, the
H15 offers a compact 4.5 x 9-ft. (1,375 x 2,750-mm) footprint, while the H15B is even more compact at 3.5 x
9 ft. (1,020 x 2,690 mm). The H15 offers a work area measuring 11.81” x 13.78” x 13.78” (300 x 350 x 350 mm)
and accommodates weights as heavy as 770 lbs (350 kg), while the H15B offers a 7.87” x 7.87” x 7.87” (200
x 200 x 200-mm) work area and accommodates weights as heavy as 1,100 lbs (500 kg).
For more information from Sugino Corp. of Itasca, IL, phone 630-250-8585 or visit
suginocorp.com.
Additive Process Builds Plastic Parts without Molds
Arburg has developed the Arburg Plastic Freeforming (AKF) process and
Freeformer machine to additively manufacture individual plastic parts without
the need for molds or predefined cavities. In this process, 3D CAD files are pro-
cessed directly, standard plastic granulate is melted, droplets are generated
from the liquid melt, and a fully functional component is built up from these
droplets layer by layer.
The AKF process uses conventional plastic granulates rather than prefab-
ricated supplies such as powders or strands that can make the material, the
processing and therefore the parts more expensive. Because the Freeformer
can operate without support structures and therefore produces no waste,
material consumption is reduced and production is more cost-effective, the
company says.
The Freeformer offers conventional material processing that is said to
operate in much the same way as injection molding. The machine is filled with
the plastic granulate, a heated plasticizing cylinder melts the plastic in the
discharge unit, a nozzle uses fast opening and closing movements to produce
the plastic droplets under pressure, and the part is additively built up. The
discharge unit and nozzle remain in a fixed vertical position, while the com-
ponent carrier moves along three
axes. A five-axis version also is
available for applications that do
not require any support structure.
The machine also can be
equipped with two discharge units
to process two different materials
or colors at once. As a result, even
movable, hard-soft combinations
or parts with a special appear-
ance or texture can be produced,
Arburg says.
For more information from
Arburg Inc. of Newington,
CT, phone 860-667-6500
or visit arburg.us.
Injection Unit Adds Multi-Shot Capability to
Single-Material Molding MachinesMold-Masters has added two models, the EM4 and EM2, to its E-Multi line
of portable auxiliary injection units that are designed to easily convert a
single-material press into a multi-material system. The units are said to be
especially suited for shops looking to economically optimize their existing
injection molding machines. The mold-mounted, servo-driven injection units
are portable and compact, and can add multi-shot capability to virtually any
standard molding machine.
A radial mounting option also is available that allows the injection unit to
swing to the non-operator side for mold changes and positioning flexibility.
For more information from Mold-Masters of Georgetown, Ontario,
Canada, phone 905-877-0185 or visit moldmasters.com.
1213 MMT DEPT--Product Tech Focus.indd 43 11/18/2013 9:00:35 AM
Product Focus
44 MoldMaking Technology December 2013
Mold Stone Polishing Catalog Adds ProductsBoride Engineered Abrasives has updated its mold stone polishing supply
catalog to include its newest products, including the Golden Star polishing
stone, Ceramic Super Stone kits, U-LAP 30 profiler, Grande BLH 600 micromo-
tor electric grinder, Wood Stick kit, Premium Purple Mounted Points, Truing
stone, and OptiVisor and accessories.
To request a copy of the catalog, email [email protected].
For more information from Boride Engineered Abrasives
of Traverse City, MI, phone 231-929-2121 or visit
borideabrasives.com.
VisualCAD/CAM Update Includes Enhanced ModulesThe 2014 version of MecSoft Corporation’s standalone CAD/CAM software
suite, VisualCAD/CAM, includes enhanced and improved VisualMill, VisualTurn,
VisualNest and VisualArt modules. Each of these modules runs integrated
inside the Visual CAD base design tool, and can be bought and licensed
independently.
A free demonstration version of VisualCAD/CAM 2014 can be downloaded
at visualcadcam.com.
For more information from MecSoft Corporation of Irvine, CA,
phone 949-654-8163 or visit mecsoft.com.
Horizontal Boring Mills Offer High RigidityMitsubishi Heavy Industries’ MAF-E Series of table-type horizontal boring mills,
distributed in the U.S. by Yamazen Inc., features a boring spindle diameter
of 150 mm and an 800-mm extendable spindle stroke, said to be the longest
among the same class for medium-size workpiece machining. The mills’ struc-
tural rigidity enables high-speed, high-accuracy machining, Yamazen says. The
main spindle offers motor outputs of 30 kW, a spindle rotation speed of 3,000
rpm and a feed rate of 15 m/min.
For more information from Yamazen Inc. of Schaumburg, IL,
phone 800-882-8558 or visit yamazen.com.
1213 MMT DEPT--Product Tech Focus.indd 44 11/18/2013 9:00:38 AM
moldmakingtechnology.com 45
Precision Laser TechnologyPLT
[email protected] www.PrecisionLaserTech.comTEL 585.458.6208 FAX 585.458.6209
Laser Engraving and Welding Servicesfor Complex Molds
MoldMaking Marketplace
www.imscompany.com
Phone:1-800-537-5375
• Guide and Parting Line Components
•Wear Plates/Strips, Bushings, Pins and Clamps
... and MUCH MORE!
work in progress
Join an engineering or sales team as we continue to grow,
setting new standards and supporting our customers.
To discuss, contact Glenn Starkey at [email protected].
Linkedin.com/in/gLennstarkeypcic | pcic-group.com
Roehr is expanding its engineering/technical support team.
If you’re interested in joining a company that’s having an
industrywide impact, contact Keith Laporte at 978-562-4488.
www.roehrtool.com/careers
FeatureCAM Adds High-Speed Roughing Strategy
Delcam has added the Vortex high-efficiency area clearance strategy to the
latest release of its FeatureCAM feature-based CAM system. The strategy was
developed specifically to gain the maximum benefit from solid carbide tooling,
in particular those designs that can give deeper cuts by using the full flute
length as the cutting surface. It can be used for two- and three-axis roughing,
3+2-axis area clearance, and for rest machining based on stock models or
reference tool paths.
According to Delcam, one fundamental problem with conventional area-
clearance strategies is that the optimum cutting conditions only occur during
a straight-line cut. The Vortex roughing strategy follows the shape of the part
and keeps air moves to a minimum for more efficient machining. Cutting is
undertaken at a more consistent volume-removal rate and feed rate, protect-
ing the machine, and cutting time is shorter.
For more information from Delcam of Salt Lake City, UT,
phone 877-335-2261 or visit delcam.com.
1213 MMT DEPT--Product Tech Focus.indd 45 11/18/2013 9:00:44 AM
46 MoldMaking Technology December 2013
REPORTEnd Market By Bill Wood
FOR MORE INFORMATION:
Bill Wood, MoldMaking Technology’s Economics Editor / Mountaintop Economics & Research Inc.
413-772-6436 / [email protected] / plasticseconomics.com
Output of Medical Supplies and Equipment Still Strong
Trend in Motor Vehicle Assemblies Remains Robust
scenario that seems highly unlikely at the present time), then the impact of
Obamacare on this data will likely start to appear in 2015, about the same time
as the next expected cyclical peak in the data.
8 percent, and Nissan is enjoying a 9-percent gain. The biggest percentage gain
goes to Subaru, which has seen a jump of 28 percent this year. Luxury brands
also are doing well: Porsche sales are up 24 percent, Jaguar receipts are up
19 percent, and Mercedes-Benz and BMW sales show a 13-percent bump.
Medical and Automotive
Dat
a so
urce
: Fed
eral
Res
erve
Boa
rd
Fore
cast
: Mou
ntai
ntop
Eco
nom
ics
& R
esea
rch
Inc.
The total U.S. output of medical equipment and supplies expanded by 4 percent
in the third quarter when compared with the same quarter in 2012. That would
be pretty decent growth for most industries at this stage of the recovery, but
for the medical industry it means that the growth in overall production levels
is decelerating. Total output of these products grew by 6.5 percent for all of
2012, and the rate of expansion was 7 percent through the first half of this year.
Our forecast calls for a gain of at least 6 percent in 2013, but the trend of
gradual deceleration in the growth rate will persist through most of next year.
Our current forecast calls for a rise of 3 percent in 2014. As the chart shows,
this industry follows a cyclical pattern with peaks and troughs timed at about
two years apart. This suggests that the next cyclical peak in the growth rate will
occur in the middle of 2015. The good news is that while the growth rate may
fluctuate on a cyclical basis, the cyclical lows have never been severe, even
during recessions. On average, this industry has grown by a solid 4 percent
per year since 2001.
The long-term demographic trends in the U.S. suggest that this industry will
continue to grow at a solid rate for the foreseeable future. The most significant
factor in the short term will likely be Obamacare. If things go as planned (a
The total number of motor vehicles assembled in the U.S. expanded by 9
percent in the third quarter when compared to the same quarter in 2012. The
auto industry remains on a pace to get to a total of 11 million assemblies for
2013. This would represent a gain of 7 percent over the 2012 total of 10.3 million
units assembled. We expect this uptrend to continue through at least the next
12 months, with the total exceeding 12 million units in 2014. As the chart shows,
that would put the industry back at its pre-recession levels.
The robust uptrend in the assemblies data is due to strong underlying con-
sumer demand. For the year to date, total light vehicle sales are running more
than a percent above the total from a year ago. Sales of light trucks are up
more than 11 percent, while sales of passenger cars are up by nearly 6 percent.
For 2013 as a whole, light vehicle sales are expected to total more than 15.5 mil-
lion units, and there is still plenty of room for growth from here.
The employment data in the U.S. are gradually improving, and the economy
is expected to gain momentum in 2014. This should spur wage growth, which is
a major factor in demand for motor vehicles.
Breaking the sales data out by manufacturer, Ford is garnering large gains in
market share so far this year. Sales for both General Motors and Chrysler are up
over 8 percent, but Ford’s sales figures for the year to date have increased by
more than 12 percent. Total sales for both Toyota and Honda are up by just over Dat
a so
urce
: Fed
eral
Res
erve
Boa
rd
Fore
cast
: Mou
ntai
ntop
Eco
nom
ics
& R
esea
rch
Inc.
12
10
8
6
4
2
0
-2
-42
00
1
20
02
20
03
20
04
20
05
20
06
20
07
20
08
20
09
20
10
20
11
20
12
20
13
12 M
on
th M
ov
ing
Avg
.
Medical Equipment - U.S. Industrial Production
12-Month Growth Rate (Percent)
13
12
11
10
9
8
7
6
5
20
01
20
02
20
03
20
04
20
05
20
06
20
07
20
08
20
09
20
10
20
11
20
12
20
13
12 M
on
th M
ov
ing
Avg
.
U.S. Motor Vehicle Monthly Assemblies
Millions of Units, Annual Rate
1213 MMT DEPT--End Market Report.indd 46 11/18/2013 8:59:28 AM
Ad Index
moldmakingtechnology.com 47
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What machine tool are you looking for?
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Model ResultsEDITORIAL ADVISORY BOARD (EAB)
The EAB enhances the standing of the publication and strengthens its professional
integrity through the active involvement of its members.
Vic Baez, Plastics Technology Manager
Rockwell Automation
Andrew Baker, Operations Manager
Byrne Tool + Design
Tim Bartz, Vice President of Operations
Mold Craft Inc.
John Berg, Group Marketing Director
MGS Manufacturing Group
Wayne M. Hertlein, Program Manager
Wilbert Plastics Services
David Hirt, Tooling Engineer
Ventra Plastics
Tom Lynn, Tooling Engineer, Plastics
General Electric, Appliances & Lighting
Dan Mishek, Managing Director and Co-Owner
Vista Technologies LLC (VistaTek)
Ralph Neufarth, Senior Engineer
Proctor & Gamble, Global Package Development
Tim Peterson, Vice President
Industrial Molds Group
Steve Rotman, President
Ameritech Die & Mold
Michael Walter, President
MET Plastics Inc.
Mike Zacharias, President
Extreme Tool & Engineering/Cosmos
Tooling Solutions
Alba Enterprises Inc. . . . . . . . . . . . . . . . . . . . . . . . . 2
Better Molding Solutions . . . . . . . . . . . . . . . . . . . 45
CAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CUMSA (Comercial de Utiles y Moldes, S.A.) . . . 31
DMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Edro Engineering . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Expert Technical Training . . . . . . . . . . . . . . . . . . . 45
Haas Automation, Inc. . . . . . . . . . . . . . . . . . . . . . . . 11
Hurco Companies, Inc. . . . . . . . . . . . . . . . . . . . . . . . . 1
Hyundai WIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
IMS Industrial Molding Supplies . . . . . . . . . . . . . . 45
Incoe Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Iscar Metals, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
iWarriors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2014 Leadtime Leader Awards . . . . . . . . . . . . . . . 23
Makino . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Mastip, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Mold-Masters Limited . . . . . . . . . . . . . . .Back Cover
Omni Mold Sytems . . . . . . . . . . . .Inside Back Cover
PCS Company . . . . . . . . . . . . . . . . . . . . . . . . . . Insert
Plaspec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Precision Laser Technology . . . . . . . . . . . . . . . . . 45
Progressive Components . . . Inside Front Cover, 45
Renishaw Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Sescoi USA, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Single Source Technologies . . . . . . . . . . . . . . . . . 35
Sumitomo Electric Carbide Inc. . . . . . . . . . . . . . . . 13
TechSpex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Tool Alliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
WALTER USA, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1213 MMT DEPT--Ad Index.indd 47 11/18/2013 8:58:06 AM
TIP
48 MoldMaking Technology December 2013
Release the Entire Potential of Your Machine Tool
Investment
CUTTING TOOLS
By Jeff Rizzie
During the machine tool purchase process, tooling is an
often-overlooked piece of the puzzle; however, by thinking
about the tooling right from the start, shops can cut machine
tool payback time by as much as an entire year. And by
reducing payback time, they can also reduce the time it takes
for a new machine to start making their businesses more
profitable.
Tooling certificates make early tooling planning easier and
more productive. Starting early in the process, the company
works with the machine tool distributor to integrate a tool-
ing package into the machine purchase. After the distribu-
tor orders the tooling certificate for the customer, tooling
company representatives visit the shop to choose, order and
install the tooling products best suited for the application.
There are immediate benefits to this integration. If a buyer
implements a tooling certificate right at the start, he or she
has the right to potentially use it as a tax write-off or a justi-
fication. Also, with a tooling certificate partnership in place,
the machine arrives, the tooling arrives and the customer is
ready to go. Nobody is scrambling to collect old tools that
will work until the new tooling gets ordered and delivered.
It’s a much more seamless process.
In addition to reducing run-off complications and offering
potential tax benefits, wrapping tooling and accessories into
the machine purchase makes for more streamlined financ-
ing and budgeting. Tooling certificates help machine tool
partners and distributors provide added value for their cus-
tomers, while easing the burden of intensive engineering and
application support.
If a company were to spec out every tool and assembly after
a big turnkey purchase, it would have to assign an engineer
to that task for months at a time. Tooling providers can act as
partners to take the load off the existing engineers, enabling
them to concentrate on more machine-tool-specific concerns
such as programming, fixturing, location and robots.
Flexibility is another benefit of integrating tooling pur-
chases. The distributor can order the machine, get it spec-
ed and order the tooling certificate without having to spec
exactly what tool the company plans to purchase at that
particular moment. As machine delivery nears and the shop
decides on tooling, the distributor can start ordering based
on that new information.
A common misconception is that company size is a deter-
rent to pursuing tooling certificates. Regardless of headcount,
budget or square footage, pressures are likely the same: lower
costs, global competition, reduced leadtimes, and evermore
complex designs and exotic materials. And, above all, the
company has to deal with the challenge of maintaining a
competitive edge and generating the fastest possible return
on its investment. A tooling certificate is aimed at alleviating
all of these stresses.
By looking at the real numbers, a shop will quickly see
a whole new world of opportunities. On the surface, tool-
ing accounts for a mere 3 percent of total production costs;
however, there is a more important set of numbers. Expert
tooling can provide the power to run a machine to its full
potential and beyond. Custom-matched cutting for specific
operations can increase cutting data by as much as 20 per-
cent. This can mean a full 15-percent reduction in total com-
ponent costs.
The math adds up: Making tooling a part of your machine
tool purchase via a tooling certificate can save you time and
money.
FOR MORE INFORMATION:
Sandvik Coromant / 800-726-3845 / sandvik.coromant.com
Imag
e co
urte
sy o
f Sa
ndvi
k C
orom
ant.
Tooling certifcates make early tooling planning easier and more productive.
CUTTING TOOL MANUFACTURER
CONTRIBUTOR
Jeff Rizzie is a machine investment manager for Sandvik Coromant, Market
Area Americas.
1213 MMT DEPT--Tip.indd 48 11/18/2013 9:01:13 AM
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