Short Shots: From the industry floor 20723

Liquid silicone multimolding is hot

A “hot” topic in more ways than one—LSR multicomponent molding—drew 150-plus attendees (including our very own contributing editor, Glenn Beall) to Milwaukee, WI in March for an “Info-Tech” sponsored by the Milwaukee section of the SPE. The event featured a number of provocative tabletop displays with the latest products for LSR multimolding from a number of prominent materials and molding systems suppliers, in addition to a delicious buffet-style meal (including bratwurst, naturally).

The event’s highlight was a presentation addressing the major factors involved in LSR multicomponent molding from a specialist in runnerless LSR multicomponent molds—Kurt Manigatter, managing director of Elmet Elastomere Produktions & Dienstleistungs GmbH (Oftering, Austria; www.elmet.com). His U.S. associate Susan A. Patterson, project coordinator of Elmet’s regional rep, Elmet North America Ltd. (Kentland, WI), also was on hand.

Although Manigatter bemoaned the lack of commercially available LSR flow analysis software, he estimates that, nevertheless, LSR molding and multimolding is growing at 8-10% per year. He also hinted that his company plans to build a moldmaking plant stateside soon, possibly in the Midwest. Based on his experiences to date, he offered the following five observations in his presentation:

1. There’s no rule to finding the best method for LSR multicomponent molding.
2. It has to be approached on a product-by-product basis, using analysis and brainstorming.
3. Proper thermal separation of the LSR and the thermoplastic components is a key to success.
4. Determining the proper type of bonding method also is essential.
5. Teamwork between the customer, the materials suppliers, and the moldmaker is also essential. “They all have to be in the same boat and all rowing in the same direction,” Manigatter said.

You can read more about what the exhibitors at the LSR InfoTech had to say at http://www.immnet.com/articles?article=3194.—CK

We can see clearly now

And so did attendees to this year’s Geneva Motor Show. They were treated to the eXasis concept car, the third vehicle to come from a collaboration between Bayer MaterialScience and Rinspeed. The aluminum-framed, insect-shaped car features an all-polycarbonate (Makrolon) body and floor coated with a yellow film. Mecaplex (Switzerland), which specializes in aircraft canopies, manufactured the panels and floor, which together reduce vehicle weight substantially. The 750-kg concept car is powered by a two-cylinder Weber engine that runs on ethanol and produces one-tenth of the CO2 emissions of a typical passenger car. Although not slated for production, the vehicle clearly (excuse the pun) demonstrates the capabilities of polycarbonate in both glazing and body panel uses.—MM

MICRO SHOTS

Management transition at ADAC
An automotive supplier of molded and painted door handles and functional exterior and interior trim parts, ADAC Automotive (Grand Rapids, MI), has shifted its top positions. Ken Hungerford, previously chairman and CEO, will retain his chairmanship and hand off chief executive responsibilities to the current president and former COO, Jim Teets. Executive VP Don Bittner is now COO.—AC

Name change for M2M
In an effort to differentiate the parent company from one of its products, M2M Holdings Inc., which owns Made2Manage ERP software, has changed its name to Consona Corp. (www.consona.com). Made2Manage is now part of the business unit Consona ERP.—AC

New prez at Dow Automotive
Dow Plastics’ business unit in the Asia-Pacific is losing its VP, but Dow Automotive is gaining a new president. That new president is Peter Sykes, who is taking over leadership from George Hamilton, who will head Dow Chemical’s new coatings business. Dow Automotive’s HQ will remain in Auburn Hills, MI, although Sykes intends to work from Dow’s Tokyo offices for the present.—AC

Worldwide water safety

A centerpiece of an exciting new safe water initiative sponsored by a leading humanitarian health care agency—International Aid (Spring Lake, MI; www.internationalaid.org)—is a new, lightweight water filter combining a proven filtration technology called BioSand with an innovative new filter housing designed and molded by Cascade Engineering (Grand Rapids, MI; www.cascadeng.com). International Aid sources say the simplicity and affordability of the new unit has the potential for making a dramatic impact on the global water crisis.

International Aid is responding to a health crisis of enormous proportions. Recent reports note that more than 10 million people—half of them children and teens—die annually from diseases caused by unsafe drinking water. In developing countries, 70% of poor people reportedly lack access to treated water.

The existing filter is constructed from concrete and typically weighs more than 300 lb. International Aid’s new Plastic BioSand Water Filter weighs just 7 lb, so it’s much easier to transport and distribute in rural areas and remote locations. Researchers at the University of North Carolina–Chapel Hill (www.unc.edu) say BioSand technology yields disease reductions of 30-40% among household members, including a particularly vulnerable portion of the population—kids less than five years old.

Injection molded and nonelectric, the new device has neither moving nor replacement parts. It’s engineered to provide clean, safe water at up to about a 12-gal/hr (47-liters/hr) rate and is designed to meet all of a family’s daily water needs, including drinking, bathing, and washing clothes. The Dow Chemical Co. (Midland, MI; www.dow.com) reportedly will fund a new study to test the effectiveness of International Aid and Cascade Engineering’s new injection molded version of the BioSand filter in Ghana, West Africa.—CK

Striving for excellence in teaching

You might call it the training Olympics—an international competition in which several training approaches compete for the gold. At this year’s International German Training Prize 2007 awards (March 2), organized by the Professional Assn. of Sales Promoters & Trainers (BDVT) at Europe’s biggest education trade fair, Didacta, Engel Austria GmbH (www.engelglobal.com) walked away with the gold for its e-Trainer online product. Called a flight simulator for injection molding machines, e-Trainer runs 2-hour, virtual PC training sessions via the Internet that teach skills to machine operators or refresh their knowledge. According to Engel, its product provides comprehensive machine and robot training without the need for a machine onsite.—AC

Dow Corning’s strategy paid off

Seven years ago, silicon-based-materials supplier Dow Corning implemented a plan some called “risky,” which split the company’s offerings into two approaches. The new initiative was an online business called Xiameter (www.xiameter.com) that was designed for customers looking to save money, who ordered in large volumes, knew what they needed and how to use it, and didn’t need extra services or technical support. Dow Corning’s standard business model of labs, scientists, and other advice remained.

Xiameter’s products are made to order, which reduced inventory and associated costs. The result was double-digit sales growth every year since 2002, reduced logistics costs by 60% (a $3.5 million savings), and a combined Dow Corning/Xiameter online sales percentage of 30% in 2006 compared to zero in 2000. ROI came four months after the launch of Xiameter.

“Severe cost pressures made customers more wary and demanding,” says Dow Corning’s CFO and Americas area president J. Donald Sheets. “Fortunately, we recognized that our environment was changing, and we were able to adapt.”—AC

Report: How outsourcers are faring

A recent survey conducted by eyeforprocurement, “2007 Sourcing in Low-Cost Countries Report,” of 185 procurement professionals in manufacturing (66%), retail (1%), and transport and logistics (33%) shows some shifts over the past year. More than half (54%) of the respondents are located in Asia, 32% in North America, 12% in Europe, and 2% in Africa.

Some key comparisons to the 2006 report:

• 54% of respondents cited lower labor costs as their primary reason for sourcing in low-cost countries (vs. 48% last year), while 43% cited lower material costs (vs. 47% last year).

• The biggest obstacles to sourcing in these regions, according to 48% of respondents, are trade regulations, customs, and tariffs (vs. 37% in 2006). However, only 30% of respondents answered this question by citing a poorly developed infrastructure, compared with 48% in 2006.

For the complete report, go to www.eyeforprocurement.com/lccs2007/report.shtml.—AC

First U.S. mechatronics degree in Michigan

If you have a budding automation specialist in your midst, here’s an opportunity for education: Lawrence Technical University (Southfield, MI; www.ltu.edu) is now offering a Master of Science degree in Mechatronic Systems Engineering. To assist with hands-on learning, Kuka Robotics (Clinton Township, MI; www.kukarobotics.com) will provide KR3 robots and Sim Pro simulation software in the university’s new lab, where students will learn robotics programming and application simulation. The robots are being used in graduate-level courses including Analytical and Adaptive Dynamics, Mechanical Design of Mechatronics Systems/Robots, Mechatronic Systems Implementation, and Adaptive Control, as well as an undergraduate course—Introduction to Mechatronics. The program is reportedly the only Masters-level mechatronic systems engineering program in the United States.

Kuka has also been busy winning awards at the National Robotics Challenge (March 9-10) in Marion, OH. An injection molding cell using a six-axis KR3 robot won the Gold award in its division and the robot was named 2007 Robot of the Year. The robotics team at Ohio Northern University designed, built, and programmed the cell, which made poker chips.—AC

RP co-op adds capacity

Ever heard of “fractional ownership”? Rapid prototyping firm Tangible Express (Springville, UT; www.tangibleexpress.com), the self-proclaimed pioneer in RP fractional ownership, offers this service as a way for companies that need to build prototypes to own part of an SLA or SLS machine, with a corresponding allotment of build time. Tangible hosts and builds the prototypes, and ships them to you.

Given increased demand for these services, which are designed to save the capital outlay of a company purchasing its own RP equipment, Tangible recently ordered 10 more RP systems from 3D Systems Corp. (Rock Hill, SC; www.3dsystems.com). The order includes six Viper Pro SLA systems, three Sinterstation HiQ HS SLS systems, and one Viper SLA system. It also enables Tangible to build prototypes in two more materials: Accura Bluestone and DSM Somos 11120.

“This order . . . allows us to offer our users a turnaround time unheard of in the industry,” says Tangible president and COO Alex Linde. The company’s founder and CEO David McInnis adds, “Our goal is to set a new industry standard by beginning owners’ builds within hours instead of the current industry practice, which is days.”

More recently, Tangible Express has made a broader agreement with 3D Systems that, in the words of a Tangible spokesman, widens what Tangible can offer even small design shops to “any machine that any fractional owner wants, and prototypes in virtually every material available.”—AC

Online Six Sigma training

An affordable Six Sigma process-improving, training, testing, and coaching program trademarked MindPro is now available online in a virtual classroom with a certified coach, or in blended learning models that combine online training with the support of consultants. Developed by Mikel J. Harry, said to be one of the original architects of Six Sigma, the MindPro best practices implementation system is necessary for North American molders to stay globally competitive, according to Hermann Plank, president of TecnoKal LLC (Scottsdale, AZ), a licensed reseller of MindPro.

“Rather than outsourcing, the key lies within each organization to streamline processes, reduce variation and waste, and to create value from within,” Plank says. “A recent lean Six Sigma survey revealed that less than 16% of Six Sigma companies and less than 8% of all respondents are holding true to the rigorous program with the stringent quality goal, structured problem-solving approach, dedicated training, and prioritized projects that are the hallmark of the original Six Sigma philosophies.”

On average, Plank says companies with what he calls “true” Six Sigma produced 40% more savings. In general, he believes the cost of poor quality can still be as high as 25-40% of sales today.

“There is a huge opportunity for improvement and many successful deployments of Six Sigma demonstrate that products and services previously outsourced into low-labor-cost countries could be kept, or brought back into the United States,” Plank says. For more information, call Plank at (480) 704-3273, or visit www.tecnokal.com/MindPro.—CK

Hall of Fame nominations open

Do you have someone in mind who you think should be honored by induction into the Plastics Hall of Fame? Nominations are now being accepted for “individuals who made significant contributions that helped our industry reach the highest level of esteem,” according to the Plastics Academy’s chairman and 2003 inductee John R. Kretzschmar. Nomination forms can be obtained from the Academy office in Leominster, MA (call (978) 537-9529) or from a member of the Academy Board of Directors. Those individuals selected will be honored at Antec 2008 (the Society of Plastics Engineers’ Annual Technical Conference).—AC

Cool Stuff

Wal-Mart’s push toward more eco-friendly packaging has been making headlines in recent months, and at the company’s Sustainable Packaging Exposition in Bentonville, AR in March, AVC Corp. (Torrance, CA; www.avccorp.com) presented a tube design that falls in line with the retail giant’s edicts.

The EnviroTube’s eco-friendly nature takes on many forms. For one, it uses just one type of plastic to eliminate cross contamination in the recycling stream. It also can be made using alternative materials to PVC. And up to eight-color printing directly on the package obviates the need for a paper insert. The container comes in several designs, including circular, oval, rectangular, and square, and suspends a clamshell or thermoformed tray inside. It’s sealed with injection molded or thermoformed end caps that contain slits in the center to hold the internal tray.—AC

Time to grow for E&O

E&O Tool & Plastics Inc. (www.eoplastics.com) has seen its sales increase, which meant its capacity had to increase, too. The molder/moldmaker recently added five molding machines—250- and 500-ton Toshiba hydraulics and a 300-ton Negri Bossi electric—to its Elk River, MN facility, as well as 120- and 160-ton Negri Bossi electrics to its Monterrey, Mexico operation. E&O runs 41 presses from 40-500 tons and serves a variety of markets, including home improvement, appliances, healthcare, electronics, and transportation.—AC

Micro Medical Murray expands

Medical Murray (North Barrington, IL; www.medicalmurray.com) expanded its micro- and nanomolding capabilities with the recent addition of a 7-ton Sumitomo SE7M all-electric. When combined with its proprietary nanomolding equipment, the new press will extend its medical parts molding range from .0001 cm3 to 5.6 cm³, and its shot sizes from .01g to 5.6g. Medical Murray is a medical device designer and manufacturer that also specializes in nano- to micro-sized parts design engineering and production.—CK

Waste becomes energy

Everyone’s concerned about energy consumption, not only for its long-term effects on the environment, but also more immediately for its impact on the bottom line. A new company called Recycled Energy Development LLC (RED; Westmont, IL) offers a way to mitigate the problem of harmful greenhouse gas emissions and wasted energy by purchasing inefficient power plants and converting them into energy recycling facilities. RED captures waste heat from industrial operations to produce electricity and useful steam, reportedly without burning additional fuel or emitting additional pollution or greenhouse gases. Intrigued? Find out more at www.recycled-energy.com.—AC

Watch your back—thermoforming’s coming

Automotive plastic parts with Class A finishes—they’re molded and painted, right? Not for much longer, according to Ed Gniewek, president and CEO of a major automotive thermoformer, Durakon (Lapeer, MI; www.durakon.com). He says, “We’re breaking the mold.”

For example, Durakon is cost-effectively thermoforming more than 250,000 Class A rocker panels a year for GM’s Buick Lucerne in 14 different colors, including metallics and pearlescents, by using paint films trademarked Soliant Fluorex from Soliant LLC (Lancaster, SC; www.paintfilm.com). It’s also thermoforming paint-filmed rocker panels for the Cadillac STS-V, Saab front-end fascias, and Jeep Liberty Renegade fascias.

Soliant sources say their paint films are creating a new standard for Class A automotive plastic parts with finishes that are more durable than paint and with a more environmentally friendly finishing process.

“OEMs are specifying paint film instead of conventional paint on parts requiring high wear resistance, such as stone guards, rocker panels, fascias, and running boards,” Soliant sources say.—CK

A happy anniversary

Investments in building a new management infrastructure and inmold-cavity pressure-sensing technology have helped a custom molder/moldmaker enter into a celebration of its 40th year in the business with record-breaking sales. ProMold Plastics (Cromwell, CT; www.promoldplastics.com) was founded in 1967 as a one-man tool and die shop by Riccardo Puglielli, an Italian immigrant. His son, Richard Puglielli, is president today.

“When I first became president in the late 1990s, new opportunities for growth were limited,” he says. “Sales over the past few years increased and in 2006 everything finally paid off—we had our best-performing year since I became president.”

ProMold recently invested in the eDart System from RJG Inc. (Traverse City, MI; www.rjginc.com). It has allowed ProMold to continue to improve upon its existing quality assurance program by automatically separating suspect parts from good ones, ensuring that no bad parts are ever shipped to its customers.

It also has invested in some of the best CAD/CAM systems available, including Pro/E, Mastercam, and Cadkey to support its precision moldmaking capabilities. And in support of its molding and insert molding activities, its one-stop-shopping, value-adding secondaries now include pad printing, sonic welding, tapping, drilling, and insert pressing.—CK

Quality kudos to Carris

Send props out to Carris de Mexico (CdM), which earned ISO 9001:2000 certification on March 5. The custom molder and plastic reel manufacturer employs 50 and runs 12 molding machines plus an extruder in its 65,000-ft² facility.—AC

Time to get compliant

Which is more important to you: safety or comfort? A survey conducted by Kimberly-Clark Professional at the National Safety Council (NSC) Congress in November 2006 revealed that many workers fail to don appropriate protective attire because of both poor fit and a feeling of invulnerability. If this is a concern in your organization, as it was with 85% of the survey respondents, you may want to check out the full results at www.kcprofessional.com.—AC