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Injection Molding Innovation and Emerging Technologies Conference

Date(s): 
Jun 18 2014 to Jun 19 2014
Location: 
Burke Center

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REGISTER NOW for the Innovation and Emerging Plastics Technologies Conference

June 18-19, 2014

Price of the Conference:

SPE Member Rate: $375.00
Non-Member Rate: $485.00

 

Penn State Erie, The Behrend College, is again hosting this highly successful conference. Come learn from industry experts. There will be half-hour presentations in the mornings, with three concurrent sessions on injection molding technology, materials technology, and executive/management practices. The afternoons will feature a choice of three-hour tutorials, with many including a hands-on component. A networking session will be held after the tutorials on June 18 and will feature a pig roast.

 

Keynote Speaker: William R. Carteaux, President and CEO of SPI: The Plastics Industry Trade Association will present 'The State of the Industry'.

 

William Carteaux picture

SPI President Bill Carteaux began his tenure at the association in February 2005. He came to SPI from Demag Plastics Group, where he was named president and chief executive officer of the Americas and co-executive managing director of the global business in 2002. Carteaux previously served as the company's executive vice president. Prior to joining Demag, Carteaux spent eight years with Autojectors, a manufacturer of vertical injection molding machines, including four years as its president. He had been actively involved as an SPI member, taking on numerous leadership roles for more than 15 years. While a member, Carteaux served as chair of SPI's Equipment Council, the NPE Finance Committee and the NPE Operations Committee. He was vice-chairman elect of SPI when he assumed his current position. Carteaux has an MBA from Indiana Wesleyan University and a BS from Purdue, where he has received several awards since graduating. He currently serves on the Board of Directors for the Council of Manufacturing Associations at the National Association of Manufacturers and is Director General of the Council of International Plastics Association Directors (CIPAD).

 

Agenda

Half Hour Presentations

Three Hour Tutorials

Conference Sponsors

 

 

Agenda:

Wednesday, June 18, 2014
 

7:45 am                       Registration & Continental Breakfast/Visit Exhibits
8:15 am

Welcome and Program Overview, Burke 180

Brad Johnson, Conference Chair

Ralph Ford, Director of Engineering

9:15 am David Kusuma, VP of Product Development and R & D, Tupperware Brands Corporation, Building a Culture of Innovation in the Development of Plastic Products

John Snawerdt, Moldex3D, Enhancing Product Quality via Conformal Cooling Design

Jay Whalen, Sabic, Thermally Conductive Polymers for LED Lighting and Coil Wound Devices

9:50 am Steve Spanoudis , Motorola Solutions, 3-D Printing and the Plastics Industry:  Threat, Niche, or Opportunity? Jim Bott, Incoe,   Understanding and Correcting Flow Hesitation Marks Edson Ito, Celanese, Latest Innovations in Vectra LCP LDS Technology for Antennas and High Density Circuitry
10:25 am Lou Young, Director of New Business Development – Tooling & Manufacturing, Linear Mold & Engineering, DMLS Conformal Cooling Tool Inserts, When They Make Sense

Matt Jaworski, Autodesk, Simulation Advances in Injection-Compression and Compression Molding

Mike Sepe, Michael P. Sepe, LLC, Rapid Characterization of Long-term Mechanical Performance in Polymers
11:00 am

John Ward, Arburg, A New Paradigm in Additive Manufacturing

David Okonski, GM Research & Development Center, A Moldflow Validation Study: Material Properties Versus Simulation Accuracy Alicyn Rhoades, Penn State Erie, Detection of Crystal-Crystal Transitions to Elucidate Localized Thermal History in Nylon 6,6 Injection Molded Samples
11:35 am Ken Kisloski, Delta Sales/HunterLab, A Cost Savings Strategy for Color Measurement of Plastics John Beaumont, President, Beaumont Technologies Inc, New Method for Characterizing the Injection Moldability of Plastic Materials Ian Menego, Bayer MaterialScience LLC, Material Properties and Their Influence on Molding Productivity and Efficiency of Medical Resins
12:05 pm Lunch & Visit Exhibits
2:00 pm Tutorials:
  Process Set-Up & Documentation
  Reducing Lead-Times using a Systematic Mold Qualification Method
  Integrated Product Development
  Material Selection Overview
  Introduction to MuCell
  Improve Your Negotiation Skills
  Executive Overview of Validation for Plastics Processors
5:00 – 7:00 pm

Pig Roast & Networking Reception (beverages sponsored by Beaumont Technologies)

 

Thursday, June 19, 2014

7:45  am                            Registration & Continental Breakfast /Exhibits
8:30 am Keynote:  William R. Carteaux, President and CEO, SPI: The Plastics Industry Trade Association, The State of the Plastics Industry
9:30 am Mark Hanaway, VP, Tech Molded Plastics, Inc. - Processor of the Year: How auditing your culture and your systems produces marketable value! Bob Reese, RJG Inc., A Comparison of Velocity to Pressure Transfer Control Strategies for Injection Molding Dana King, Kipe Mold, Selection of Mold Gates, Parting Lines and Vents for Silicone Molding
10:05 am Mike Zacharias, President, Extreme Tool & Engineering & Cosmos Tooling Solutions Ltd., View from the Tool Room B. Patrick Smith, EVPand CEO, Maguire International, Vacuum Drying:  The New Standard for Drying Polymers Matt Proske, VP, SIGMA Plastic Services, LSR Technology: Materials, Process, & Production
10:40 am Laurie Harbour, President & CEO, Harbour Results Inc., What Studies Show for Tooling

Paul Boettger, Technoject, Raising Molded Article Quality Standards in Valve Gating

Susan Montgomery, President, PRIAMUS System Technologies, Quality Control: From Inside of the Mold
11:15 am TBD Chuck Morgan, Conair, Advances in Resin Handling, Preconditioning and Communications Joachim Kragl, Engel, Thick Wall Lenses in Record Cycle Times - A Reality with Multi Layer Molding
11:50 am Mary Scheibel, Principal and Founder, Trefoil Group,  When Supply & Demand Don’t Align: Winning the Talent Game Chuck Azzopardi, HMM Solutions Inc, Better Processing with Highly-Engineered Machine Nozzles Tom Betts, Wittmann Battenfeld, Stack the Business in your Favor
12:20 pm Lunch & Visit Exhibits    
1:45 pm Tutorials:
  Injection Molding Troubleshooting
  Application of DMA and other Thermal Analysis Techniques
  Liquid Silicone Rubber Molding Overview
  Application of Mold Filling Analysis
  Micro Molding Technology
  Project Management Basics
  Robots for Molding
4:45 pm Penn State Creamery Ice Cream & Prize Drawings

 

Half-Hour Presentations:

David Kusuma, VP of Product Development and R & D, Tupperware Brands Corporation, Building a Culture of Innovation in the Development of Plastic Products

When many consumers think of plastic, Tupperware comes to mind. Thanks to the company's direct sales strategy, the famously kitschy Tupperware parties that were popular in the 1950s and still go on today; perhaps no plastic brand occupies a bigger place in American pop culture. But Tupperware's design team is not stuck in the past. This talk will discuss some of the ways that the company's innovation continues.

 

Steve Spanoudis , Motorola Solutions, 3-D Printing and the Plastics Industry:  Threat, Niche, or Opportunity?

In the past few years, 3-D Printing technologies have seen increased visibility in the news media and growing interest among public and private equity investors. This attention has increased even further with the creation of NAMII, the National Additive Manufacturing Innovation Institute. As the 3-D Printing industry expands, how is it likely to impact more established sectors of the plastics industry?  Should a typical processor view this industry as a threat to their livelihood, an opportunity for growth, a useful tool, or merely a fad, with only niche applications in the real world of production? Recent developments, which include multi-material and multi-color technologies, direct printing of optics, major investment by aerospace companies, and the emergence of an open-source community, may all have some bearing on the future. This presentation will look specifically at 3-D Printing and its inroads into the molding industry, covering the evolution of materials, processes, and business models.

 

Lou Young, Director of New Business Development – Tooling & Manufacturing, Linear Mold & Engineering, DMLS Conformal Cooling Tool Inserts, When They Make Sense

As an early adopter of DMLS, Linear has developed a specialty niche of building conformal cooling lines to complement its mold manufacturing business.  Conformal water lines address the limitations of traditional machining.  This DMLS technology excels in cases in which part designs have varying wall thicknesses, tight dimensional tolerances and challenging mold geometry.  This permits even cooling and prevents warp, sinks and other quality problems.   The benefits of DMLS and conformal cooled inserts include increased flexibility in water line designs, significant cycle-time reductions, minimized scrap, widened process window, noted quality improvements, and better access to hard-to-reach areas.

 

John Ward, Arburg, A New Paradigm in Additive Manufacturing

Unlike conventional additive manufacturing techniques, with ARBURG Plastic Freeforming (AKF) standard granulates are melted as in the injection moulding process. The freeformer produces layer by layer from minuscule droplets.  The discharge unit with nozzle remains stationary, while the component carrier moves.

 

John Snawerdt, Moldex3D, Enhancing Product Quality via Conformal Cooling Design

Conformal cooling has two major advantages in injection molding: (1) to improve cycle time and (2) to enhance product quality. Laser sintering is the major manufacturing method for building conformal cooling channels. To better estimate its ROI, the use of scientific tools is necessary. The two real cases has demonstrated the positive effects of conformal cooling channels in reducing sink marks, warpage, and cooling time and that CAE technology can effectively simulate these benefits. 

 

Jim Bott, Incoe,   Understanding and Correcting Flow Hesitation Marks

Material flow hesitation marks on parts molded by all open gating, and more puzzling; Sequential gating continues to be a challenge to the plastics industry, particularly automotive. Creating scrap due to poor part aesthetics or plating failure.  The presentation will  explain the filling phenomenon causing these undesirable results, then the solution.

 

Matt Jaworski, Autodesk, Simulation Advances in Injection-Compression and Compression Molding

Current trends in the industry like light weighting and nominal wall thickness reduction are pushing manufacturing to the limits of injection molding pressure capabilities. The benefits offered with injection compression and compression molding are real attractive for both thermoplastic and thermoset materials. See the latest advances in simulation with examples that will help you digitally prototype many alternatives with design, material and process conditions.

 

David Okonski, GM Research & Development Center, A Moldflow Validation Study: Material Properties Versus Simulation Accuracy

The usefulness of thermoplastic injection-molding simulation is influenced by many simulation inputs - such as the modeling of part geometry, mesh type and density, mathematical solution, process settings, and plastic material properties both as melt and as solid. Since 2008, much progress has been made with regards to meshing capability and to having robust solution algorithms, but the material properties data file still remains as a weak link in the simulation process. This paper reviews the results of a validation study that focused on the influence of the material properties data file on the precision and accuracy of Moldflow 2012.

 

John Beaumont, President, Beaumont Technologies Inc, New Method for Characterizing the Injection Moldability of Plastic Materials

The Therma-flo™ Moldometer is the first melt characterization method developed specifically for evaluating how a plastic material will behave in an injection mold. The new method bridges the gap between commonly used isothermal extrusion based test methods ( MFI & rheometers) and injection molding simulation. The accompanying software is very intuitive to operate and can be used to look at the relative pressure required for a material to mold through a user specified wall thickness at a given melt temperature and flow rate. Multiple materials can easily be contrasted at the same time. In addition to providing an improved method for characterizing the injection moldability of a melt, the new moldometer has yielded unique insight into a plastic materials behavior.

 

Mike Sepe, Michael P. Sepe, LLC, Rapid Characterization of Long-term Mechanical Performance in Polymers

The increasing use of polymers in performance critical applications requires a more precise understanding of material properties as a function of time, temperature, and stress. While some long-term performance data for polymers exists, it is often not available for the particular grade of interest and developing the needed data in real time is cost prohibitive and time consuming. This presentation will review techniques that can provide predictions of long-term performance based on results derived from short-term tests. These results can be used to shorten development times without sacrificing precision. They can also be used to improve the accuracy of FEA modeling.

 

Jay Whalen, Sabic, Thermally Conductive Polymers for LED Lighting and Coil Wound Devices

Applications involving LED’s and Coil Wound Devices require management of heat in order for the application to survive.  LED’s require heat dissipation in order to prolong life expectance of the LED itself, while coil wound devices require heat dissipation to maintain power, improve response time and longevity.  Being able to impart thermal properties to a thermoplastic material has allowed these compounds to enter areas predominately occupied by metals, potting agents and encapsulation compounds; while at the same time providing designers part integration, component downsizing and design freedom through injection molding.  This presentation explores the advantages these compounds bring to the LED and coil wound device markets.

 

Edson Ito, Celanese, Latest Innovations in Vectra LCP LDS Technology for Antennas and High Density Circuitry

The rapid global growth and demand for wireless communication and need for more functionality in portable devices have created a need for advanced high performance polymers to meet new antenna and sensors requirements.  This presentation discusses performance of new laser direct structuring LCP grades and developmental grades with improved mechanical and thermal properties as well as dielectric properties engineered to meet new challenges of increased functionality of sensors and reduction in antenna size.

 

Alicyn Rhoades, Penn State Erie, Detection of Crystal-Crystal Transitions to Elucidate Localized Thermal History in Nylon 6,6 Injection Molded Samples

The semi-crystalline microstructure of nylon 6/6 is directly related to the shear and thermal history of the material. Injection molding freezes in a set microstructure distribution through the thickness of a quenched sample. The relationship between the amorphous and crystalline domains in nylon 6/6 injection molded samples was explored using DMA, Flash DSC and FTIR analysis. The rate of injection during molding was shown to have the most significant effect on final microstructure distribution through the part thickness. Areas within the test geometries were analyzed to determine if the microstructure had formed at conditions above or below the Brill transition temperature, providing insight to the condition of localized polymer melt just prior to quenching.

 

Ken Kisloski, Delta Sales/HunterLab, A Cost Savings Strategy for Color Measurement of Plastics

Proper measurement procedure of plastic pellets versus finished part.  Description of the instrument method employed in order to insure cost savings for the molder of critical colored parts.

 

Mark Hanaway, VP, Tech Molded Plastics, Inc. - Processor of the Year: How auditing your culture and your systems produces marketable value!

PlasticsNews named Tech Molded Plastics, Inc. as the Processor of the Year at its’ Executive Forum held February 2014. The award is sponsored by the Society of the Plastics Industry. Judges evaluated candidates for the award on seven criteria: financial performance, quality, customer relations, employee relations, environmental performance, industry/public service and technological innovation. Although Tech has been recognized by industry peers as a processing leader in the technical world of precision molded plastics, the process of auditing your company culture, community investment, and performance systems can produce valuable recognition for your people.

 

Ian Menego, Bayer MaterialScience LLC, Material Properties and Their Influence on Molding Productivity and Efficiency of Medical Resins

The processability of three medical grade engineering resins was studied in terms of how their physical properties influenced their cycle times.  The variability of molded parts and the energy necessary to process each resin was also investigated in this study.

 

Mike Zacharias, President, Extreme Tool & Engineering & Cosmos Tooling Solutions Ltd., View from the Tool Room

From his company that is based in Michigan’s Upper Peninsula, Zacharias will discuss his perspective of reshoring and how toolmakers can be innovative and competitive. As president and largest shareholder of Cosmos Tooling Solutions Ltd., with a location in Shaogguan City, Guangdong Province, China, he also will cover the pressures and challenges of providing export tooling from China to the United States now versus six years ago.

 

Laurie Harbour, President & CEO, Harbour Results Inc., What Studies Show for Tooling

In its 2013 Vendor Tooling Study, one key topic analyzed by Harbour Results was the use of a low-cost country strategy as well as re-shoring. Taking insight from the analysis, Harbour will discuss the difficulties foreign companies face when moving businesses to the U.S., the impending capacity shortage that has re-shoring implications and, more importantly what this means for plastics processors.

 

Mary Scheibel, Principal and Founder, Trefoil Group,  When Supply & Demand Don’t Align: Winning the Talent Game

Plastics manufacturers know firsthand both the prevalence of and the disruption caused by the widening skills gap. The issue has made national news and drawn political concern in almost every region. Accordingly, numerous national and regional initiatives have emerged, which have helped create vital public, private and government partnerships to begin to address the issue.  But are manufacturers themselves doing enough to attract the talent they need to thrive?  The average plastics engineering technology graduate has more than one job offer when leaving college. At the same time, your best talent may be under pursuit by your competitors, and the experienced people you are trying to attract are increasingly scarce. To win, you must become a destination employer, one that can compete against the largest, most prestigious companies in the industry and your region – regardless of size.  The good news: Smart people want to work for smart companies doing amazing things. This presentation will offer insights on the ways manufacturers can tell their story and position themselves more attractively to recruits, while simultaneously building a reputation as a company who is up to something that prospective employees and customers alike want to be part of.

 

Bob Reese, RJG Inc., A Comparison of Velocity to Pressure Transfer Control Strategies for Injection Molding

Injection molders commonly use a position setting to control switchover. As in-mold sensors have become more widespread, using them to control switchover ensures more consistent part quality than machine-based control. Herein we explore several control strategies applied to an array of different mold configurations and materials. We evaluate each method's ability to minimize in-cavity variation when material viscosity changes. The results provide the molder with information for choosing a control strategy appropriate to each application.

 

B. Patrick Smith, EVPand CEO, Maguire International, Vacuum Drying:  The New Standard for Drying Polymers

Vacuum drying is not new to the plastics industry having been used by polymer producers since the early 70s.  What is new is the Vertical Batch Dryer that makes vacuum drying affordable by all processors.  Vacuum drying lowers the boiling point of water to make the drying process 6 times faster.  Vacuum drying does not use desiccant to dry materials.  With no desiccant to be regenerated vacuum drying consumes 60% less energy.  Fast drying also substantially reduces the risk of degradation during the drying process.

 

Paul Boettger, Technoject,  Raising Molded Article Quality Standards in Valve Gating

 Valve gate systems are being used more frequently for today’s applications because the gate diameter can be chosen to be larger, thereby reducing the shearing in the gate area. Additional benefits include the high quality gates as well as an optimized flow of the melt. This is attributed to the fact that, in contrast to applications without shut-off needles, the melt stream doesn’t have to flow through one, two or three small holes in the nozzle tip. If you observe a transparent plastic part under polarized light, there are, depending on the type of plastic, to a greater or lesser extent pronounced visible flow lines. These flow lines are caused by the splitting of the melt flow in the nozzle tip. The flow lines produce tension in the plastic part, reduce the consistency and, especially in colored plastics or plastics coated with glitter, mar the appearance of the article’s surface.  The flow lines are less, but still present with a conventional valve gate system. This presentation will high-light some of these problems and discuss new hot runner designs in which the molten plastic will at no point in time split and the flow lines, which are caused by the needle, will not even appear. These new developments open up new possibilities for direct valve gating challenging resins requiring extremely high optical and mechanical properties.

 

Chuck Morgan, Conair, Advances in Resin Handling, Preconditioning and Communications

Recent years have delivered a new level of performance expectations to auxiliary equipment for the entire plastics industry.  As a result, new equipment designs have emerged that combine advanced output, a reduction of energy consumption, lower maintenance and a significant jump in the sophistication of communications within and between resin conveying, drying and blending equipment.  This presentation will provide an overview to these advancements and why many processors are urgent to upgrade and allow themselves and their operations to do much more with much less.

 

Chuck Azzopardi, HMM Solutions Inc, Better Processing with Highly-Engineered Machine Nozzles

In today's global manufacturing environment, molders are looking to optimize their injection molding processes in every way possible. Highly-Engineered Machine Nozzles can improve the injection molding process in a variety of ways.  One way molders can maximize the productivity of their molding operations is by minimizing downtime that occurs due to poor processing or failure of the mold. Minimizing the clogging of gates and/or hot runner tips due to foreign material or contamination in the melt stream is perhaps the most obvious and readily cost effective way that Machine Nozzle Filters improve productivity on plant floors. The cost to take a mold out of operation, re-schedule molding operations, disassemble the mold and repair or replace damaged tips or gates - just once - is commonly greater than the cost of the Nozzle Filter itself.  Molders using additives at the injection molding press, such as colorants, commonly employ Mixing Nozzles, which improve the dispersion and mixing of additives, which can improve molded part quality, while simultaneously reducing the volume of additives used. However, it is important that a high-quality Mixing Nozzle that minimizes shear and pressures drop be utilized.  Finally, Shut-Off Nozzles can minimize drool in molding operations where the injection molding press is frequently disengaged from the mold, such as in many 2-Shot Molding applications. Again, choice of a high-quality Shut-Off Nozzle is important to ensure that unnecessary complexity and cost is not introduced into the molding operation.  High-quality Machine Nozzles improve the efficiency of molding operations, while reducing overall costs of materials and downtime. Highly-Engineered Machine Nozzles, using new technologies, offer significantly improved performance, including lower pressure drops and enhanced ease-of-use. Molders are taking a fresh look at these new technologies to see how they improve molding operations.

 

Dana King, Kipe Mold, Selection of Mold Gates, Parting Lines and Vents for Silicone Molding

Information from Sigmasoft flow simulation and actual data from Priamus in-mold sensors  will be used to show basic principles for molding LSR.   In addition, how the concepts of LSR rheology can be applied to mold design considerations critical to the performance and functionality of silicone molds such as location of gates, parting lines and vents will be discussed. 

 

Matt Proske, VP, SIGMA Plastic Services, LSR Technology: Materials, Process, & Production

SIGMASOFT® Virtual Injection Molding considers all of the 3D mold components [water cooled cold deck, heated cavities, over-molded inserts, two-shot, thermocouple driven (PI Controller) electrical heaters, and insulation plates], 3D LIM-LSR (Liquid Injection Molding – Liquid Silicone Rubber) runner system with parts, actual molding process, and temperature and curing dependent material properties together in virtual molding machine where multiple consecutive cycles of production can be evaluated. This novel approach provides a detailed view into the potential problem areas of the entire LIM system before the mold is built. Investigating into the root causes of common LIM issues; low viscosity flow behavior, venting/air traps, curing, flashing, mold temperature control, and cycle time will be addressed. Some basic chemistry of LSR materials and their behaviors will also be provided.

 

Susan Montgomery, President, PRIAMUS System Technologies, Quality Control: From Inside of the Mold

During production, even an optimized process can be changing. By controlling two- dimensional plastic conditions from inside of the mold, consistent quality parts can be produced independently from machine to machine. Results achieved by controlling material viscosity (shear stress and shear rate), part compression and part shrinkage for medical and automotive applications will be summarized. In addition, new methods for streamlining costly and time- consuming mold validations based upon this advanced process control technology will be presented.

 

Joachim Kragl, Engel, Thick Wall Lenses in Record Cycle Times - A Reality with Multi Layer Molding

Multi layer lens molding technology allows for a dramatic reduction of cycle time which leads to increased productivity. Especially in LED lighting systems very thick lenses are required, thus extremely long cycle times would result with conventional molding processes. In order to achieve better optical quality or surface feature replication multi layer molding technology can also be combined with variothermal processing technologies offering process relevant advantages. The presentation will provide an overlook at the current state of the technology.

 

Tom Betts, Wittmann Battenfeld, Stack the Business in your Favor

This presentation will look at conventional and multi-material molding process with unique and interesting applications for the more traditional stack tooling concept. Utilizing a convention molding machine with only minor modifications it is possible to achieve significant increases in yield (70-80% range) by incorporating “Tandem” molding technology; a process utilizing stack type molds. Similarly a different spin on two shot molding utilizing stack type molds with a rotating vertical platen separating them. These machines often feature a horizontal clamp with apposing injection units and a rotating mold turning on a vertical axis. Machine construction, mold concepts and requirements will be reviewed in detail. A variety of current applications including glazing, structural components and fabric over-molding will be considered. Video clips and slides will be used to demonstrate the technology.

 

Three-hour Tutorials:

Brad Johnson, Penn State Behrend, Process Set-Up & Documentation

Go through a hands-on process set-up using a proven methodology for setting up an injection molding process on a closed-loop controlled machine. The two stages of this method refer to the injection portion of the set-up, with the first stage controlled by velocity and the second stage controlled by pressure. During this tutorial you will be walked through the steps of the set-up, learn what types of problems to look for along the way, and why the various process settings are made.

 

John Beaumont, Penn State Behrend, & Dave Hoffman, Beaumont Technologies, Reducing Lead-Times using a Systematic Mold Qualification Method

Mold qualification is a daunting task even for the seasoned veteran, partly due to all the "noise" seen during mold startup. This noise makes it difficult to separate out root causes of variations in the process, mold, and part quality data. This workshop will provide attendees with an understanding of fundamental plastic flow principles and teach them how material property variations are occurring naturally within their molds and affecting their mold qualification time. Attendees will then use this understanding to assign “Flow Groups” and “Regions” to any given mold layout so that they can apply root cause analysis to their data (i.e. mold balance analysis, mold maintenance, or part quality). The overall goal of this tutorial is to help attendees learn how to reduce mold lead-times by giving them a systematic approach for isolating the root causes of variations by separating “steel” from “shear-induced” material property variations. Attendees will work with the 5 Step ProcessTM software (from Beaumont) as part of this tutorial.

 

Jason Williams, Penn State Behrend, Integrated Product Development

Product development is no longer a modular, linear process. Current trends in product lifecycle demand a rapid, team-based approach to create dynamic products. This workshop will provide attendees with an overview of this integrated approach to product development and provide an outline they can apply to their own development processes.

 

Gary Smith, Penn State Behrend, Material Selection Overview

Basic polymer fundamentals will be introduced with a strong correlation to structure property relationships. An overview will be given of homopolymers, copolymers, morphology, molecular weight, and viscosity. Structure property relationships based on polymer chemistry (in a non-intimidating way!) will focus on “why” the materials perform like they do. Polymer fundamentals will be incorporated into a product selection process and failure analysis.

 

Brent Strawbridge & Levi Kishbaugh, Trexel,  Introduction to MuCell

The MuCell process for producing microcellular injection molded parts is accepted as a technology for providing a more dimensionally stable part through a reduction in residual stress with increased productivity over compact molded parts.  However, parts designed for solid injection molding will always be limited in the benefits achieved with microcellular foaming due to industry accepted design constraints resulting from the solid molding process.

A much larger improvement in productivity can be realized by designing parts to take advantage of the unique process enhancements provided by the MuCell process.  This tutorial will discuss the basics of foaming, the MuCell process and design freedom that can be realized through microcellular foaming.  A demonstration of the process will also be carried out in Penn State’s processing lab.

 

Mike Brown, Penn State Behrend, Improve Your Negotiation Skills!

Knowing how to negotiate effectively can help you and your organization succeed.  In this session, you will learn some of the basics of effective negotiation.  You will also have an opportunity to practice what you've learned by taking part in a negotiation exercise. 

 

Sean Tucker, BD,  Executive Overview of Validation for Plastics Processors

This session will focus on the key elements involved with Installation Qualification (IQ), Operational Qualification (OQ), and Performance Qualification (PQ) as applicable to molding operations.  An overview of process development and other requirements to successfully validate the process, after receiving a finalized product design, will be reviewed.

 

Brian Young, Penn State Behrend, Injection Molding Troubleshooting

This tutorial will provide hands-on experience in solving common molding problems in the processing lab. In the classroom, the theory behind the solutions and problem-solving strategies will be discussed.

 

Alicyn Rhoades, Penn State Behrend, Application of DMA and other Thermal Analysis Techniques

Dynamic Mechanical Analysis (DMA) data makes it possible for engineers and designers to understand the important aspects of a plastic material’s behavior over an extended service life.  See the how data is generated and learn about practical applications.  In addition, a number of other thermal analysis techniques will be reviewed.

 

Brad Johnson, Penn State Behrend, Liquid Silicone Rubber Molding Overview

You should be prepared to get your hands dirty (or sticky) as this tutorial will involve making parts on our all-electric liquid silicone rubber (LSR) molding machine. See how the LSR process differs from conventional thermoplastics molding. The steps of a process set-up will be reviewed, as well as some of the features of the LSR feeding and molding equipment.

 

Jon Meckley, Penn State Behrend,  Application of Mold Filling Analysis

This workshop shows the advantages of using mold-filling analysis during the design phase to reduce potential problems and create a more robust design. There will be demonstrations of the use of the software and the methodologies used to solve problems.  How to interpret the results of the simulation will also be discussed.

 

Ken Bush & Bob Koch, Boy Machines, Micro Molding Technology

A demonstration will be given on a 11-ton BOY XS injection molding machine and discuss the subject of Micro Molding Technology including the blending of precision tool building, processing, innovation, and the sprueless molding concept.  The BOY XS will process a single-cavity idle clip with a living hinge using the sprueless method of injecting directly into the cavity.  The tool was built and is provided by Pleasant Precision located in Kenton, Ohio.

 

Diane Parente, Penn State Behrend, Project Management:  Tools, Techniques, and Tricks

This session will focus on both fundamental and more advanced principles of project management.  Additionally, the presenter will provide shortcuts to determining if your project is on time and within budget.  Finally, participants will use tools to handle project implementation.  The entire session will be within the context of a classic project management case.

 

Charlie Clarke & Kyle Andrade, Yushin America, Robots for Molding

This session will begin with a review of some examples of how part removal robots used in molding robots can be used to do much more.  Attendees will then be led through some programming exercises using Yushin’s Flex software, starting with a standard program and showing how it can be modified to take advantage of the full function of the robot.

 

 

Please contact the Office of Community and Workforce Programs for additional information at 814-898-6103.

 

Conference Sponsors:

 

Gold Sponsors:

RJGSigmabeaumontautodeskHarmacmaguiremoldexPlastics newsPTASPE

 

Silver Sponsors:

Kistler PriamusPort Erie PlasticsTech ToolTrexelYushinKiperoutsisextreme  haitiancaleneseLindeIncoesingle temp

Event Contact Name: 
Carleen Orlando
Event Contact Email: 
Phone: 
(814) 898-6103
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