ReelView Fishing faced an electronics obstacle in the development of its new technology for underwater video. Additive manufacturing for moldmaking enabled the speed necessary to iterate to a solution.

Machines constructed from polymer concrete typically have six to ten times the damping characteristics over machines constructed from cast iron. Polymer concrete also has excellent mechanical and thermal characteristics. The drive train should consist of digital drive technology for optimum acceleration and deacceleration. This technology provides the CNC control with the ability to perform a high degree of contouring accuracy encompassed with excellent dynamics capabilities. These characteristics will help minimize cutting tool wear.

Flood coolants are traditionally used throughout the machining process to help disperse heat and remove chips from the work area and the cutting tool. Hard milling often generates a tremendous amount of heat over conventional machining. This heat transferred into the chip and the use of flood coolant during hard milling causes the coolant to vaporize as it hits the hot chips. The use of coolants also can create thermal instability with the tool. Therefore, flood coolants are not commonly used in hard milling. To help displace chips during the cutting process, compressed air is used. Additionally, a combination of oil/mist is often selected. The addition of oil helps reduce friction, therefore increasing tool life and surface finish. When using oil/mist, an oil/mist extraction unit should be integrated into the machine tool to help remove the oil from the air.

Spindle Another important aspect of the machine is its spindle. The spindle should be a vector-controlled motorized spindle. Vector-controlled spindles provide a great deal of flexibility, offering high torque at low rpms and maximum power for large speed range. The HSK interface between the tool holder and spindle should be used. This will provide minimal runout and excellent balancing at high speeds. Hybrid-ceramic bearing in the construction of the spindle will offer some excellent benefits including increased spindle stiffness, accuracy and temperature stability.

Join MoldMaking Technology Editorial Director Christina Fuges as she discovers the benefits of eLearning, including promoting sustainability in moldmaking by reducing travel, minimizing waste and enhancing global workforce accessibility.

The need for data to track information and the history of the mold-building process is ever-increasing, and mold component solutions can help.

PTXPO 2025 is a comprehensive showcase of cutting-edge technologies and innovations within the plastics molding industry. Join fellow molders, moldmakers, brand owners, OEMs and their full suite of suppliers in Rosemont, IL for three days of non-stop networking, education and business development opportunities.

Critical Cleaning Hands-on Workshop Do it; learn it! The one-day workshop teaches how cleaning and cleanliness testing work. By participating in hands-on exercises of techniques for cleaning and cleanliness verification, attendees gain the understanding and knowledge to make practical, effective, and sustainable manufacturing decisions. While exercises are supplemented by demonstrations and tutorials, the workshop is not death by PowerPoint! Topics include aqueous, solvent, and “non-chemical” cleaning, including cleaning chemicals and cleaning processes (spray, ultrasonics, cyclic nucleation, in-line, batch). Most manufactured product and product contact surfaces require cleaning during (and sometimes after) manufacture and assembly.  Examples of areas where effective cleaning is essential include: metal fabrication, product assembly, optics, electronics, microelectronics, wafer fab, medical devices, aerospace/aeronautics, military, and additive manufacturing. WHAT DO YOU CALL CLEANING? There are many different terms for cleaning. Cleaning Precision Cleaning Critical Cleaning Safety/Critical Cleaning Surface Prep for Finishing Technical Cleanliness Residue Removal WHO WILL BENEFIT FROM THE WORKSHOP If you or your company fabricates, finishes, maintains or repairs product or product contact surfaces (like reaction vessels), this workshop is time well-spent. If you sell chemicals or cleaning equipment, this workshop will help you better understand and optimize the market for your products. Examples include: Manufacturing Engineers Product Designers Managers Sales and Marketing Managers Facilities Personnel Assemblers, operators Process Technicians Quality Control Personnel Regulatory Affairs Experts (industry, military, and government) Safety/environmental professionals​ ​ Participants will receive a PDF Certificate of Completion with continuing education credits from Sam Houston State University.

Although all of the components of the circle are important, the machine tool component is, by far, the most significant. The machine must be designed for hard milling and have some of the same characteristics found in a HSM center. The base construction and the individual components of the machine such as the drive train, the spindle and the CNC control, etc., must be capable of handling all the demands of hard milling. The base construction of the machine must be extremely rigid and have a high degree of damping abilities. These characteristics are commonly found in machines constructed from polymer concrete (see Figure 2).

This webinar will provide an overview of new developments in hot runners, controllers, mold components, predesigned molds, process monitoring and mold maintenance equipment. These advancements are designed with the goals of lowering scrap rates, optimizing process temperatures and managing energy consumption. The solutions also aim to support productivity and may contribute to extending the operational lifespan of tooling equipment. Agenda: Innovative undercut and thread-forming components Predesign mold bases and plate control Melt delivery and control solutions Process monitoring and maintenance

Sustainable, productivity-boosting innovations for moldmakers, including stress relief, traceability and cooling solutions.

Poorly developed models also are a common problem. Typically, how a model is created is going to dictate what machining techniques are used. If machining strategies are not considered during the development of the model, then the programmer may not be able to use certain toolpath strategies. Without these considerations, hard milling a cavity or core may not always be suitable without modifying the model. Some of the important requirements of the CAM system are shown in Figure 8.

Diamond compounds, with their varied grades, colors and base options, provide a comprehensive solution for mold builders in need of precise and superior polishing across diverse materials and applications.

There are many resources for hard milling. The supplier or OEM should be your first choice. For example, a cutting tool representative will be able to assist in selecting the correct feeds and speeds for a particular cutting material. Many work directly with machine tool builders for adequate testing of their tools. Manufacturers of tool holders commonly work with builders to share and gather information regarding equipment performance. This also holds true for CAD/CAM developers who commonly work closely with machine tool builders testing new machining strategies and sharing ideas on new and improve machining methods. Training must be on a continuous basis.

One of the common problems associated with CAD/CAM programming is the model. Many companies import data from other systems using a variety of importing tools. In particular, job shops may deal with various clients, who are using a variety of different CAD systems. In this case, a file transfer format needs to be defined to transfer geometry data from the client CAD system to the CAM system. In order to avoid time-consuming repairs of the model, it is very important to select the proper file format for a data transfer. Some CAM systems offer special interface options to directly read in file formats from other CAM systems. When data is imported, problems can pop up. These problems range from missing trimmed surfaces to bad solid models causing numerous headaches for creating efficient toolpaths. These problems need to be fixed before developing toolpaths.

The selection of cutting tools should be short with short flute lengths along with a helix angle of approximately thirty degrees. A thirty-degree helix has proven to be optimal for chip flow and dispersal of heat. The parent carbide substrate should also be considered. Only fine or ultrafine grain sintered carbides should be used. Sintered hard carbide is a composite material based on powder metallurgy. A binder (usually cobalt) is used to bond carbide particles. Tungsten-, titanium-, tantal- or niobcarbide are the most used elements and provide the required hardness at high temperatures and wear resistance. With a reduction of the grain size of the carbide particles to about 0.5 to 0.6fm, the edge strength can be further increased, while the tendency to adhesion can be reduced. For larger hardened cavities and cores, a selection of inserted cutting tools should be considered. Carbide inserts are less expensive than end mills and by rotating the insert, insert life can be extended. However, these tools are not typically designed for high spindle speeds and runout can be significant. There is also a significant safety risk if improper handling occurs.

These humble but essential fasteners used in injection molds are known by various names and used for a number of purposes.

Unique sensor and patent-pending algorithm of the Amper machine analytics system measures current draw to quickly and inexpensively inform manufacturers which machines are down and why.

In ISO 9001 quality management systems, the Management Representative (MR) plays a crucial role. While the 2015 version of ISO 9001 no longer mandates this position, having a trusted management member serve as an MR remains vital for streamlining operations and maintaining quality standards.

Tips for tasks ranging from reducing risk in part design and taking advantage of five-axis machining to refining cutting tool performance and reducing wear with guiding and centering systems.

Cutting Tools Although hard milling uses many aspects of HSM, the selection of appropriate cutting tools is most important in hard milling. Furthermore, cutting tools are a significant cost factor in both hard milling and HSM; making a good choice can help save money. One of the main contributing factors of hard milling failure is the cutting tool. Many companies tend to skimp on selecting high-quality cutting tools, opting for less than adequate tools. To ensure that quality tools are selected, it is best to select an OEM who specializes in tools for hard milling or offers a well-defined product line for hard milling. The OEM should have technical staff on hand to assist in selecting the appropriate cutting tool for a particular hardened material and cutting strategy.

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Essential tools and resources to support mold builders in making critical strategic decisions about doing business in Mexico.

Presentations will cover 3D printing for mold tooling, material innovation, product development, bridge production and full-scale, high-volume additive manufacturing.

CAD/CAM Falling in line, the CAD/CAM system is another equally important component. Today's CAD/CAM systems have greatly advanced over the years, providing a wide variety of system tools and capabilities. Furthermore, development continues to grow at an outstanding pace. However, not all of today's systems are created equal and it is important to realize that there are still many systems that do not have the built-in tools or strategies to create toolpaths for hard milling or HSM.

Programming errors have a tendency to be less forgiving when conventional machining techniques and softer materials are used. With hard milling and HSM, programming error will no doubt have severe consequences if not caught in time. Cutting tools can easily be broken; tool holders, fixtures and even the machine can be damaged costing hundreds to thousands of dollars. Personal safety also can be at risk. To ensure programming errors are caught before they happen, the CNC code should be thoroughly reviewed for errors. Most CAD/CAM systems incorporate some type of toolpath verification or toolpath simulation within their software. Unfortunately, many of them only view the intermediate file rather than the posted NC code or the C/L toolpath file where errors can occur. Therefore, care should be taken to ensure that the posted NC code is reviewed for errors. If your CAD/CAM system does not have the tools to view or simulate the NC code directly, there are numerous software packages on the market that will. These products can range from a few hundreds dollars to several thousands of dollars but they will save you many major problems by eliminating potential crashes and safety issues at the machine.

Continuing within the circle, tool-holders play an important role in hard milling. Because hard milling requires a large range of rpms-from low rpms for a roughing application to high rpm for HSM-only the HSK interface between the toolholder and spindle interface should be used. This will provide a very rigid and balanced tooling setup over the ISO taper interface. The advantages of HSK over taper tooling are illustrated in Figure 3.

Hydraulic expansion toolholders also provide ease of use as well as high clamping forces and minimal runout, which will provide extended cutting tool life. However, hydraulic tooling can be expensive and bulky to use. Similar to collect chucks, hydraulic tooling is an excellent choice for roughing and semifinishing operations. For finishing those hardened cavities and cores with a high degree of accuracy and quality, power and heat-shrink toolholders provide excellent characteristics. Figure 5 outlines the pros and cons between all four systems. Today, all systems are commonly available from most tooling suppliers.

On June 25-27, 2024, RAPID + TCT returned to the West Coast for the first time in nearly a decade! The three-day event featured the latest in 3D-printing technology from the industry’s leading product and service providers, a full schedule of speakers including a keynote series, and over 125 hours of educational content. The expansive show floor showcased over 400 exhibiting companies’ latest advancements. And next year? It will be even better! Start planning your trip to Detroit, MI to experience North America’s largest additive manufacturing and industrial 3D printing event in 2025!

Join MoldMaking Technology Editorial Director Christina Fuges as she discovers the benefits of eLearning, including promoting sustainability in moldmaking by reducing travel, minimizing waste and enhancing global workforce accessibility.

Report analyzes moldmaking trends, pricing, labor shortages, capital costs, competitiveness strategies and construction spending challenges.

Proper cooling is crucial in molding, yet often overlooked. Discover proper cooling methods to prevent defects and improve efficiency.

Stepping back to our machine tool, builders have incorporated elaborate acceleration and deceleration servo tuning algorithms as well as complex servo lag algorithms (look ahead features) into their controls to enhance motion control. These look ahead or control feedrates by analyzing directional changes within the NC code. The greater the directional change (for example, zero to ninety degrees) the more the control has to slow down to maintain the programmed path. In hard milling, these abrupt changes in toolpath direction create dwells and slow downs, which can have an effect on tool life and surface finish (see Figure 12). Therefore, toolpath quality should be an important feature of your CAM system.

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Identifying specific areas where CAM software can utilize machine capabilities to benefit the user and maximize milling machine potential.

Sustainable, productivity-boosting innovations for moldmakers, including stress relief, traceability and cooling solutions.

The Society of Plastics Engineers’ Mold Technologies division is accepting applications for a $3,000 student scholarship honoring Joseph Prischak and a $5,000 educational grant program.

Discover how to enhance your mold design process with CAD/CAM software specifically tailored for the moldmaking industry. In part two of this webinar series, Cimatron will demonstrate how to intelligently design mold components, such as slides and lifters, using powerful CAD/CAM tools to accelerate the design process. Additionally, it will cover how to avoid errors and ensure design accuracy for ejector pins by checking clearance distances, calculating cutoff heights correctly, and thoroughly documenting all ejector components. Agenda: Slides Lifters Inserts Ejection pins and charts

In ISO 9001 quality management systems, the Management Representative (MR) plays a crucial role. While the 2015 version of ISO 9001 no longer mandates this position, having a trusted management member serve as an MR remains vital for streamlining operations and maintaining quality standards.

Hard milling uses a combination of several key technologies that can be categorized into components. These components are defined as the machine tool, the CAD/CAM system, the tool-holders, the cutting tools and the know-how. To be successful at hard milling, these components must come together in what can be called The Circle of Technology as illustrated in Figure 1. Each component will be examined within the circle so that a clear understanding can be developed to facilitate successful hard milling of small- to medium- sized parts.

Smart sensors and sophisticated process and measurement data management are driving intelligent moldmaking to new heights.

Discover how to enhance your mold design process with the right CAD/CAM tool for parting and cavity design. This webinar will explore CAD/CAM capabilities including how hybrid solid/surface modeling can streamline workflow and improve accuracy. Learn how to confidently tackle parting, runoff, and shutoff, ensuring precision and efficiency in your designs. Agenda: Part analysis QuickSplit techniques Parting and runoff strategies Shutoff solutions

Know-how Finally, proper know-how and training are vital keys to being successful at hard milling. You can have all of the above elements but they are no good to you without a clear understanding of principle processing procedures. Often, an entirely new approach is required to gain the profitable advantages of the hard milling process over conventional milling. The successful employment of the hard milling process is based on specific know-how, advanced knowledge of the basics of the HSM process, choice of appropriate cutting tools, choice of appropriate clamping systems for cutting tools (and parts) and professionalism, using an HSM capable CAD/CAM system.

The titanium-based hard material layers such as TiCN and TiAlN are the most commonly used protection layers for HSM and hard milling cutting tools. The resistance to wear (hardness) is the most important property of TiCN, while TiAlN has a better heat and oxidation resistance property. The OEM may also further enhance the coatings by offering unique blends, perhaps creating a leading edge over coating quality and tool life. Recently, other advances in coatings have entered the market such as proprietary coatings. Commonly called Rainbow coating, it is a proprietary multielement PVD (physical vapor deposit) coating offering a competitive edge over traditional nonpropriety coatings.

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

There have been many exciting developments in high-speed machining relative to machining centers and controls, tooling and CAD/CAM systems.

The cutting tool can be held by several methods. These methods include collet chuck, hydraulic expansion, shrinkfit and power shrinking. The method selected should be determined by the requirements of the machining operation (see Figure 4).

Intralox's integration of the Alpha Laser ALFlak has significantly improved their tool room efficiency when it comes to difficult welds and urgent repairs.

The Manufacturing Technology Series East, featuring EASTEC in West Springfield, Massachusetts — is at the epicenter of a region that is a traditional manufacturing powerhouse. Historically, more than 700 companies have connected at this event to network, learn from industry experts and explore the latest manufacturing technologies.

Mark the calendar for AMBA Conference 2025, "Breakthrough Innovation," May 7-9, 2025, Grand Rapids, MI. During this industry event, attendees will meet with peers to discuss best practices in business, employee management, technology and more.

In this most recent product roundup, MMT continues to offer a variety of innovative as well as tried-and-true technologies to benefit moldmakers.

Throughout the last few years, hard milling has captured the attention of manufacturers around the world. These manufacturers are typically focused on the mold and die industry where materials such as P20, H13, S7 and others are commonly cut. Traditionally, core and cavities from these materials are manufactured in the hardened state using EDM. Through the years, new technologies have been developed where these materials can be, in most cases, machined directly into hardened material using new toolpath processing techniques in combination with high-speed machining (HSM) techniques to form hard milling. These materials can range from 45 HRc to as hard as 64 HRc.

(see Figure 10). In this simple example, a spiral morph toolpath on the green surface, combined with a true spiral from top to bottom on the red surface, provides a suitable method for machining this part. Toolpath quality is commonly overlooked in a CAM system. Figure 11 represents what appears to be a normal looking toolpath; but upon further evaluation, it is revealed that there are many unnecessary changes in the toolpath direction (see Figure 12).

While the transition from traditional methods to this innovative approach may present initial challenges, the benefits far outweigh the learning curve. Through the NextMold and partner network, Forward AM provides comprehensive support at every stage of the integration process. This ensures a smooth adoption of the technology into company’s operations, including seamless collaboration with molding companies. Forward AM’s commitment is to facilitate this technological transformation, enabling your business to leverage the full potential of 3D-printed mold inserts. Agenda:  Molding with 3D-printed inserts Ultrasim3D Next Mold: Forward AM offering Successful adaption: integration at Beaumont Technologies

Extrusion's general sessions cover best practices, troubleshooting and processing solutions that can help you run your operation and maximize the utilization of your existing assets—as efficiently as possible. ​ Extrusion professionals from the shop floor to the front office are represented at the Extrusion Conference.​ You’ll meet the entire global supply chain: manufacturing managers, supervisors, engineers and technicians, as well as engineers and technical managers at OEMs and other firms.

Alba Enterprises created a mold base to match the needs and pacing of product iteration using mold tooling made via additive manufacturing.

Alba Enterprises created a mold base to match the needs and pacing of product iteration using mold tooling made via additive manufacturing.

Although no system is devoted entirely to hard milling, many that offer HSM capabilities will have the same strategies for hard milling since there is a common relationship between the two technologies. When considering hard milling, strategies that keep the tool in motion should be used for hard milling. This will ensure that the tool is continuously cutting with a constant chip load. This is one of the more desirable conditions to maintain for hard milling. Before further discussion on machining strategies can begin, a careful review of the CAD model is important.

As mentioned earlier, in hard milling it is important to keep the tool in motion avoiding dramatic changes in direction. Therefore, depending on the complexity of the part, multiple toolpath strategies may be required to complete the part. The process of recognizing and separating key areas of the part and applying different toolpath strategies is commonly called modular toolpath programming (MTP). This method of programming is generally used in HSM to maintain high cutting speeds. Similarly, MTP can be used to help keep the tool in motion while avoiding dramatic changes in direction. In its simplest form, Figure 9 illustrates a single parallel finishing toolpath strategy. Although simple, this is not the ideal method for machining this part in its hardened state. If individual part features are recognized and separated, two different strategies can be applied to this part

With a clear understanding of all the components in this Circle of Technology, one will have a better awareness of the tools needed to be successful at hard milling.

Collet chucks are by far the most flexible. In addition to offering maximum flexibility, they are easy to handle, provide excellent shock absorbing characteristics and offer an excellent range of clamping diameters. These are suitable for aggressive roughing and semifinishing of hardened materials.

A combination of lasers, probes and software help moldmakers automate in-process cutting tool and workpiece measurement.

A water-based, eco-friendly plastic mold cleaning system helps Rankine-Hinman Manufacturing restore flow rates and avoid big-ticket failures on complex and costly molds.

A discussion with AMT’s Bill Herman during ShopTalk on the big stage at IMTS 2024 highlights moldmaking's unique blend of craft and technology that is driving innovation while its community tackles key challenges.

Identifying specific areas where CAM software can utilize machine capabilities to benefit the user and maximize milling machine potential.

Before toolpaths can be applied, there must be a complete analysis of the part. Not all parts are suitable for hard milling. The specific areas to be machined should be clearly identified, determining the smallest internal radius and largest working depth. A 4:1 ratio of length to tool diameter commonly does not pose any problems. Problems arise when the ratio grows, and careful consideration should be made towards the feasibility of success. When ratios are excessive, experience at hard milling will have an important role in determining how successful one will be. Hard milling with tool diameters as small as 0.005" can be accomplished as long as care is taken to maintain a constant chip load and machining at minimal cutting depths. These depths can commonly range from 0.0002" to 0.0005" on such small tools. Toolpath strategies can now be determined.

CNC Control The performance of the CNC control is critical. A control with maximum block processing rate will ensure that the received data will be handled quickly and efficiently. This data should reside on a hard-drive located on the control. Incorporating numerical algorithm to calculate the velocity profile in the control will assist in smoothing machine motion. Additionally, all servo systems on a CNC machine exhibit a characteristic called servo lag. Servo lag is the actual amount that the machine position trails the position commanded by the control. In hard milling, any motion that is not continuous with the programmed path will create excessive stresses on the tool, causing the possibility of premature failure. Therefore, it is essential that the control have the ability to handle and control servo lag.

Join this webinar where Hexagon will explore how state-of-the-art CAD/CAM technology can drive your business forward. Learn how to optimize tool paths, enhance design accuracy and reduce lead times with advanced simulation. Discover the power of automation and real-time data for continuous improvement. Tailored for mold and die manufacturers, this session offers actionable insights to boost productivity and quality. Don’t miss this opportunity to gain a competitive edge in progressive die manufacturing. Agenda:  Key challenges in progressive die manufacturing Optimizing tool paths Enhancing mold and die design accuracy Reducing lead times with simulation Automating processes for greater efficiency Leveraging real-time data for continuous improvement

When used for conformal cooling in plastic injection, 3D printing opens a wide range of design freedom. This design freedom enables designers to develop highly-efficient thermal regulation networks. However, this blessing also comes at the expense of not only higher manufacturing cost but also higher design cost as the designer could spend weeks to develop optimal cooling channels. This webinar will explore strategies and tools — including SimForm, a front-end thermal simulation app — to help tool designers and tooling managers maximize the benefits of 3D printing while minimizing manufacturing and design costs. Agenda: 3D printing applied to the plastic injection industry 3D printing pros and cons Tools and methods to facilitate the integration of 3D printing

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

A discussion with AMT’s Bill Herman during ShopTalk on the big stage at IMTS 2024 highlights moldmaking's unique blend of craft and technology that is driving innovation while its community tackles key challenges.

For roughing hardened materials, four-flute end mills or higher are recommended. This will provide small chip loads while having the ability to cut at higher feedrates. Additionally, torus end mills are recommended for roughing because the sharp edges of conventional end mills are not sufficiently resistant against the possibilities of vibration and thermal stress when cutting hardened materials.

Hard milling creates a great amount of stress on the tool from high heat and abrasive wear. To help overcome these stresses, coatings must be applied to the cutting tool. These coatings offer a protective layer on the tool, substantially increasing its life. The most common coatings are titanium nitride (TiN), titanium carbon nitride (TiCN), titanium aluminum nitride (TiAlN) and titanium aluminum carbon nitride (TiAlCN); each coating has its benefits (see Figure 6). Coating selection should be made based on individual properties and the OEM may dictate these when selecting a cutting tool. Figure 7 highlights the more important properties related to the coatings.