NPE 2000: Show demonstrations and highlights

One of the great things about NPE is the enormous range of machinery in action on the floor. Molding machines, robots, hoppers, dryers, moldmaking equipment, and software are put through their paces for your scrutiny. It's a marvelous opportunity to compare machinery, equipment, and services head to head, in one location. To help you sort through the options, we asked exhibitors to tell us what machines they're bringing to the show and what technologies they'll be featuring. Following is a review of the answers we got back. We've identified a series of major equipment categories and described what manufacturers are featuring at NPE. Unfortunately, some exhibitors were less than forthcoming about their specific plans (or missed our deadlines), so we encourage you to consult the Buyer's Guide in the June 2000 issue of IMM for a thorough list of exhibitors sorted by more than 100 product categories.

Electrifying!
The expansion, growth, and increased use of partially and all-electric molding machines is no secret. Electric machines outnumbered hydraulics at IPF '99 in Japan last year, and a similar trend is expected at NPE. Virtually every leading-edge machinery manufacturer has one variety or another. Here's your chance to compare in action the all-servo, the servo injection/mechanical clamp, or the servo clamp/hydraulic injection varieties. Each brings something different to the party. As far as we know, you can see dozens of electrics in action here-from the smallest, Battenfeld's 5-tonner, to the biggest, Ube's 1550-ton machine, which will accompany an 1100-tonner as well. Nissei, for example, will bring nine electrics, ranging from a 7-ton tabletop to a 275-ton model; the electrics will be demonstrating micromolding, high-speed molding, vertical insert molding, and multimaterial or overmolding. Some of the models have servomotors that use no belt; some have belt drives. Niigata will have four all-electrics, from 55 to 385 tons, in its exhibit. Toshiba is bringing seven all-electric (and one hydraulic) machines, ranging from 20 to 390 tons. At Krauss-Maffei you'll find a 660-ton, two-platen, C Series press that uses a new HPS electric screw drive. It's molding PP medical vials in a 32-cavity tool. The hybrid Mega TE F 610/6434 machine in the Sandretto booth will be molding 5-gal containers. Sumitomo is introducing two new all-electrics, including the SE185, which will micromold 1-cu-mm bobbins. Ferromatik Milacron is debuting a large all-electric, the 935-ton Powerline, and the new Roboshot i Series all-electrics, ranging from 17 to 385 tons, molding pipe fittings at the show. Mitsubishi (MHI) is running its new ME all-electric machine, which features larger platen and increased tiebar distances. Be sure to stop by JSW, which is introducing two new all-electric horizontal machines and one electric vertical press. Demag's 250-ton high-speed Ergotech El-Exis S, with accumulators, will run a 24-cavity mold, while the new El-Exis E (standard) will mold polycarbonate lenses in 10 seconds. 

Multimaterial molding
Multimaterial molding demos are often among the most interesting and entertaining to see at a show, and there will be no shortage of viewing opportunities at NPE. There's one demonstration we think you will want to specially note. Have you ever seen glass overmolded with a thermoset? Mir will mold BMC polyester over a 6-inch glass ashtray inserted in a mold specially designed to compensate for any irregularities in the glass. The process takes advantage of recent advances in BMC formulation that offer improved surface finish, thinner sections, and shorter cycle times. 

Some of the overmolding applications you'll see involve switching parts from one press to another; others use rotary molds. YK Seiki is demonstrating the rotary mold type. Curious about the tool? A moldmaker displaying molds for overmolding glass is Soarmoldes, although we don't believe it's the same mold that Mir is using. There are several other multimaterial demos to see as well. Demag will demonstrate its Gram process for two-component molding; the technology is all in the mold, which is constructed with two parallel parting lines, one behind the other. Three-component molding is featured at Battenfeld. Unless it sells the press at Italy's Plast show in May, Presma is bringing and running the Roto HSP/2/BIC, a 10-station coinjection machine that uses four 62-mm screws in two injection groups. Ferromatik Milacron is demonstrating its Monosandwich process on a Maxima two-platen press; the machine injects a virgin skin around a core of recyclate. Also in the Milacron booth you'll find the German-built K-Tec 155 with an 8x8 turntable mold producing perfume sprayer caps with a PP substrate and an elastomer cover. At Krauss-Maffei, an elastomer will be molded over an ABS substrate on a 192-ton multicomponent, dual-platen, C Series machine. Netstal plans to mold a cup with a PP substrate overmolded with elastomer on a SynErgy 2C press. Also, stop at Arburg to see more two-component molding, as well as at Engel, which is running two materials on a 300-ton tiebarless machine. Not only are there lots of machinery and materials people with multimaterial molding on their minds, some molders (ATP) and moldmakers (Foboha) that specialize in this technology are prepared to discuss it with you as well. 

Sophisticated assembly
Assembly isn't primarily a downstream operation any more, at least where molders are seeking labor efficiencies. Assembly as a secondary operation within the cell is happening at C.A. Lawton. But assembly in the mold to avoid a secondary operation altogether is the focus of JSW's Die Slide technology-a process introduced several years ago in Japan, but just now available in North America. Here two halves of a solid part are molded simultaneously, then pressed together to mold a hermetically sealed part, such as a manifold. See it in action. Branson will demonstrate laser welding with its IRAM unit, where light passes through to a second surface with an absorbent filler, welding a whole surface simultaneously. Similarly, Bielomatik is introducing the Laser-Tec 200, a laser-based welding system that uses no vibration or heat to achieve a seal.

TXM: Mighty magnesium molding
While you won't be lucky enough to see the TXM process, or thixoforming, at work at NPE (too hazardous for a show floor), the two machinery suppliers are each bringing a machine for static display. Watch for them at JSW and Husky, which license their technology from Thixomat (the company that trademarked the term Thixomolding). Thixotech, a leading TXM molder, will be happy to discuss its take on the process and its burgeoning opportunities in thin-wall and high strength-to-weight-ratio applications. If you haven't seen a TXM part before, check out Raycon, another magnesium molder. At least one moldmaking pair that offers tooling for this specialty is also present: Alpha Mold and Alpha Mold West. You can even talk about the process at Omega Heater, where high-temp heater bands for TXM are on display. 

Micro foaming agents
The structural foam segment has gotten a boost from the recent introduction of MuCell, microcellular technology from Trexel. Indeed, the firm's technology is now widely licensed and will run in several machines. Look for the technology on presses in the Arburg, Engel, and Ferromatik Milacron booths. At Engel you'll find the process running on a 1000-ton tiebarless press; at Ferromatik Milacron it will be on a Magna T 310. Also, visit DuPont, which recently announced MuCell support. Differing slightly from MuCell, but using a similar technology, is a foaming material called Expancel. It uses expandable thermoplastic microspheres that set up under heat and pressure to create closed cell structure. It's used mostly with elastomers and polyurethanes. 

Molds and tooling
While the mold itself is basically unchanged, the materials, methods, and technology used to make and control it are evolving rapidly. Several firms at NPE are showing products aimed at accelerating mold production. Precision Optical Mfg. helps moldmakers go from CAD to steel with its laser-and-powdered-metal Direct Metal Deposition process. Similarly, Extrude Hone's ProMetal process "prints" a polymeric binder onto thin layers of metal to build green mold inserts; these parts are then debound and infiltrated with bronze to make fully dense inserts. Round Mate Systems, Parametric Technology, Makino, and Dynisco HotRunners have joined forces to develop the RUSH (rapid use of shop hours) system. Using it the four companies plan to build a mold each day of the show and then mold parts from it at the close of each day. Visit any of the participating companies to see them perform their part of the moldmaking puzzle. At Caco Pacific you can see the much talked-about Interactive Process Manager, the industry's first controller made exclusively for the mold. 

Logic Corp is demonstrating and conducting seminars on its new incremental cavity ejection (ICE) system, designed to demold parts faster without stress, scuffing, or the aid of mold releases. Finally, looking for on-the-spot estimates on tooling costs? If you bring your CAD file to the show, Project Design Services says it will turn around a tooling quote within 2 hours. 

Soft and softer
The overmolding of TPEs onto harder, more functional substrates has reached a near frenzy. Those looking for softer materials and how to handle them have many options at NPE. Super-soft grades will be introduced at GLS, and Goodyear is introducing an additive in pellet form for polyolefins to enhance the soft feel. There are even those offering granulators especially for reclaiming these super-soft materials: Nissui with a new three-axle grinder for both hard and soft materials, and Harmo-Soken.

Robots and automation
It's always fun at NPE to see what robotics have to offer the molder when it comes to speed, size, and versatility. The K show in Germany in 1998 saw a proliferation of articulated-arm robots. That trend is expected to continue at NPE. Conair will demonstrate a six-axis articulated-arm robot working in a vertical insert molding cell. This year CBW Automation is collaborating with Husky to demo a lid handling system. At Conair you'll also find what is believed to be the largest robot at the show, the PIP 3071, with a 21-ft horizontal beam and vertical stroke of almost 12 ft. It will be paired with a six-axis articulated-arm robot to demonstrate part trimming. You'll find another large robot at Mark 2 Automation, which is showing the ELH Model. The last entrant in the big robot category comes from a relative unknown in the molding industry, Robotic Production Technology. RPT is demonstrating a rail-mounted six-axis unit that measures more than 12 ft wide and carries up to 154 lb. 

A very popular attraction at the K show was the robot controller virtual reality show that Wittmann Robot & Automation brought. It will be at NPE and is a worth a short wait in line. For something a little different, check out the Wittmann and Star Automation robots running in the Krauss-Maffei booth that are dropping parts behind the moving platen, but within the machine frame. The robots are mounted on the fixed platen and traverse past the moving platen to keep the robot workspace confined within the boundaries of the press itself. High-speed labeling of stadium cups will take place in Van Dorn Demag's cell, incorporating a 500-ton molding machine. 

Robotics are being applied to decorating and assembly functions, right on the show floor. See the system in action at Trans Tech. Another automation cell, from Tec Engineering, will move parts from an Arburg molding machine in a box-conveying system with a 60-ft travel path. Star Automation will also show a dual-arm carriage assembly design that is intended for use with bigger parts where height restrictions may exist. 

Remember all those stopwatches timing robot motion in 1994 and 1997? Well, robot manufacturer Ichikoh claims its new robot has the fastest vertical travel in the industry, at 3200 mm/second. The robot's speed will be demonstrated on Ube and Mitsubishi (MHI) molding machines. Also at Conair will be the PIP 3020HP, demonstrating .5-second takeout times with an overall cycle of 3.5 seconds. Another fast robot claim comes from Automated Assemblies, where its three-axis AZ Series servorobot will be doing a timed demonstration. Dedicated workcells will be everywhere; watch a robot spanning two presses at Ranger Automation, where it is transferring parts in an overmolding application. A CD case molding cell will feature a high-speed Sailor robot handling a multicavity mold. A cell for advanced part handling for medical equipment is operating at Automated Assemblies, a result of the company's joint venture with Innovative Products & Equipment. 

Also, with all the companies specializing in end-of-arm tooling for robots, you may have wondered if you could build your own. Well, Plastics Automation Engineering plans to demonstrate how to do just that. 

Web-wide manufacturing control
The Internet has become ingrained in our lives, both personally and professionally, and companies in the molding industry are devising new and different ways to make use of the technology. One such product is American MSI's new Internet-based Cell-Net product. This highly integrated system will monitor operations on a machine running in Sumitomo's booth, a machine running at MSI's home office in Moorpark, CA, and a machine at one other booth at the show. Visitors can view the system in the MSI booth on one of four interactive laptop systems the company plans to set up. Stop at Engel's booth for a look at its Internet-based Teleservice product.

Literally dozens of suppliers are making it possible for you to manage your processing with Web connectivity-and we're not talking about all those new e-commerce sites. Toshiba and others are offering Internet access from the machine control. Two such controls come from Ferromatik Milacron. The first will run on the new Robotshot i Series electric machine and uses artificial intelligence with real-time melt pressure control to adjust on the fly for viscosity changes, screw tip leakage, barrel wear, and inconsistent shot recovery. The second system is the company's Xtreem control, which offers Ethernet networking and Internet access through a standard PC configuration. 

Plant monitoring systems suppliers like Syscon are approaching the same challenge from the point of view of their own software programs. Branden is showing a Web-based production reporting system based on its Shotscope product as well. 

Many of the injection molding machinery suppliers will be showing off new control systems, but we thought you might find this next one of interest. Moog will provide a demonstration that compares the three types of molding machine controls-servo pump, variable-speed pump, and intelligent manifold with servo proportional valve. 

Web solutions
Three years ago the Internet was a playground. Now it's a place to make and spend money, and the plastics industry is no exception. NPE 2000 is the coming out party for a variety of companies that are using the Internet to sell resin and machinery, provide Web-hosting services, and connect molders with one another like never before. Below are the companies you'll find at NPE with an Internet-centered business model.

Micromolding
This technology will not be as prominently exhibited as one might think in this time of high interest, but the U.S. market is eagerly awaiting the stateside debut of the Micro System 50 from Battenfeld, the little machine that drew so much attention at K'98. Sodick, as well, will be touting a micromolding machine. Tooling solutions for micromolding are a focus at hot runner suppliers JPI/Heitec (with 7-mm nozzle spacing) and Günther, although we suspect these solutions are for larger parts than what we usually define as micromolding. This process typically doesn't use a hot runner tool because it requires too long of a residence time for the melt. Sumitomo machines will be running one of Makuta's small bobbins, with a width of 1.1 mm. Another molder on the floor talking about micromolding is STR. Finally, a 14-ton press in the Boy Machines' booth is molding micro medical parts, and Nissei's HM7 tabletop will also be running. 

Learning experiences
Aside from the NPE conference, where technology and business sessions are offered free of charge (see May 2000 IMM, p. 106), Lati is offering four mini workshops, short sessions on Speed to Market, Material Selection, High-performance Polymers, and Flame-retardant Materials, right in the booth. An