The Event For
Mold Manufacturing

June 15-16, 2016 • Novi, MI
Suburban Collection Showplace


Technical Conference Program

NOTE: All sessions, times and presenters are subject to change.


SESSION: Maximizing Efficiencies When EDMing Copper Alloys
8:00 am - 8:45 am
When it comes to EDM, applications with copper alloys can be a little tricky and must be handled differently than other common mold materials. Due to its high thermal conductivity, copper alloy materials offer quick heat dissipation, and therefore are very popular as injection mold inserts. However, this same property tends to work against efficiency in the EDM. The ability to quickly dissipate heat from the EDM cut leaves the moldmaker having to “think outside the box” when dealing with these material types. Otherwise, they often find themselves fighting through the application or turning the job away. Either way, there is a financial impact. 
David Pedersen - Applications Engineer / Sales Specialist, Poco Graphite

Jack Fiorito - Tooling Manager, Flextronics, Inc.

SESSION: Fundamentals of Optimized Mold Cooling Circuits
9:00 am - 9:45 am
Historically, mold cooling was designed to circulate water or a cooling medium through the mold base plates and not within the cavity or core inserts. This would require different levels of cooling lines and thicker mold plate assemblies. With today’s technology you can create optimized circulation within the mold plates and cavities/cores to reduce mold heights. For optimal results, designers must understand the design recommendations and cooling requirements for each application, including the mold and part materials and part geometries. This presentation will review optimized mold cooling circuit design for injection mold assemblies with current techniques. It will examine how mold cooling is evolving as new software and mold cooling components, such as specialized materials and conformal cooled inserts, increase cooling efficiency, and reduce machining time by decreasing mold component lengths and shortening plate thickness. 
Brenda Clark - Engineering Manager, HASCO America, Inc.

Jay Fidorra - President, Fidorra Design

SESSION: Reducing Costs with Safer, More Reliable Machining
10:00 am - 10:45 am
Safety and reliability help to ensure efficiency without compromising productivity or cost reduction goals, and using proven strategies and keeping up with the latest technologies is key. This presentation will discuss the benefits of truly understanding the effects of heat, methods and resources for heat reduction and its impact on the bottom line. It will examine technologies that allow for safer and more reliable operation in environments where machinists are required to operate multiple pieces of equipment at one time and where lights out manufacturing is occurring. For example, high efficiency machining (light radial engagement at high speeds or high feed with axial chip thinning); insert pocket designs with secure clamping that allow harder, more wear-resistant grades to be used for longer tool life or higher productivity; and insert pressing technologies that permit shapes for greater productivity at reduced costs. Attendees will walk away knowing where the costs are and how to reduce them.
Tom Raun - Machine Tool OEM Specialist, Iscar Metals

SESSION: The Lights Out Imperative
11:00 am - 11:45 am
What is the lights out imperative? This presentation will answer that question by revealing how one shop is competing globally by producing more without adding employees. Work smarter not harder! You will learn a systematic approach to establishing a more productive process for your company. You will also get a glimpse of how remote machining permits control of your machines from your Smart Phone including notifications of machine stoppages or alarms. This gets jobs running again rather than paying someone to come onsite every shift to keep jobs going. Workforce on one shift, production on three shifts equals less down spindle time, better productivity and more profit.
Corey Greenwald - Owner, Hard Milling Solutions

Dr. Chad Duty - Senior Research Scientist, Oak Ridge National Laboratory

SESSION: You Can’t Afford Not to Automate
1:00 pm - 1:45 pm
Large manufacturers have been the pioneers in automation, but today it is quite easy for small to medium size companies to introduce this technology into their shop. In fact, what was an expensive, customized implementation in the past is now a relatively inexpensive turnkey solution. By automating existing and new equipment, companies can get 30 to 50 percent more utilization with the same staff. This presentation will explore the variety of automation solutions available as well as introduce some case studies showing how automation has improved throughput within some companies. 
Chris Norman - President / COO, EROWA Technology, Inc.

JR Hommer - President, Hommer Tool & Mfg, Inc.

SESSION: Mold Considerations when Assessing Robotics Requirements
2:00 pm - 2:45 pm
The interaction of the mold to the molding machine impacts mold and part quality, as does post molding care and handling. This presentation will discuss what the moldmaker should consider when assessing options and requirements for robotics used in post-molded product handling. This assessment of technology should occur during the applications engineering phase of the mold build process to ensure proper use of technology for efficient plastic part handling. Attendees will learn about robot technology and conveyor systems including two-shot, pick-and-place versus rotator system, soft drop conveyor systems and more. 
Jason Holbrook - Injection Molding Division, Kraus Maffei

Rich Oles - Owner, ROI, Inc

Dr. Chad Duty - Senior Research Scientist, Oak Ridge National Laboratory

SESSION: Key Elements of Shop’s Milling Program
3:00 pm - 3:45 pm
This presentation will break down the reasons why programming is key when it comes to machining. It will explain why you shouldn’t think carbide first, but instead the machine, fixturing and toolpath. Proven strategies for cutting tool optimization will be shared to help to answer the question, “What drives this process? A process review for selecting the right milling tool and secrets to keeping your cutting tool alive will also be presented. All of this will help to increase milling success.
WIlliam Fiorenza - Product Manager - Die & Mold, Ingersoll Cutting Tools

Bill Kloskowski - CNC Foreman, Chicago Mold and Engineering

SESSION: Machining Strategies to Transform from Moldmaking to Mold Manufacturing
4:00 pm - 4:45 pm
This presentation will share real world examples on how the application of the latest high-speed machining technology transformed a moldmaker from a shop using conventional production techniques of machining, fitting and polishing to a world-class mold manufacturer applying highly precise, predictable machining as well as faster, streamlined production and fewer operations.  You will get a look at how ultra-high precision machine technology using sub-micron accuracies and thermal compensation enclosures directly contribute to net (zero) and/or negative stock machining, cycle time reduction and reliable/predictable machining results. Additionally, you will learn how substantial mold process improvements and cycle time reductions have been achieved on cavity and core blocks, including polishing time reduction or elimination, and cost-effective cavity milling in materials up to 60 Rc and harder with polish-level surface finishes. 
Jeff Johnson - Die and Mold Industry Project Manager, YASDA/Methods Machine Tools

Mike Zacharias - President, Extreme Tool and Engineering

SESSION: Big Area Additive Manufacturing
11:00 am - 12:00 pm
Oak Ridge National Laboratory (ORNL) has developed a Big Area Additive Manufacturing (BAAM) technology that has the capability to deposit  components that are 10x larger, 100x cheaper, and 100x faster than current polymer-based commercial systems.  ORNL's Manufacturing Demonstration Facility has recently partnered with Cincinnati Inc. to commercialize a large scale 3D printer (BAAM-CI) and has demonstrated the "real-time" production of an automobile body at the International Manufacturing Technology Show in coordination with Local Motors. This presentation will highlight the latest applications of the BAAM technology, including the production of large components and tooling for automotive and aerospace industries. This research is  sponsored by the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC.
Dr. Chad Duty - Senior Research Scientist, Oak Ridge National Laboratory