The Event For
Mold Manufacturing

June 17-18, 2015 • Rosemont, IL
Donald E. Stephens Center

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Technical Conference Program

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

ENGINEER | BUILD | MAINTAIN | WORKSHOPS | MOLDING 2015

ENGINEER CONFERENCE > WEDNESDAY, JUNE 17, 2015
SESSION: Mold Steel - Does It Make a Difference?
8:00 am - 8:45 pm
Moldmakers strive to design and build the most efficient, durable molds to enable their customers to produce quality parts in a cost-effective manner. As part of that effort does the choice of mold steel play an important role or will any steel do the job? What determines the quality of steel as it applies to moldmaking? What differences are there in the grades of steel used for plastic injection molds? These and other questions will be addressed in this presentation.
Richard Polenick - Technical Manager, Ellwood Specialty Steel

SESSION: Trying to Solve Molding Problems? Think in Plastic, Not Steel
9:00 am - 9:45 am
Do you want your moldmaking to add more value? Do you want to solve or improve plastic injection molding problems? If you answered yes to either of these questions, then try thinking in plastic first, not steel. This “townhall” presentation, based on MoldMaking Technology’s monthly Pellet-2-Part (P2P) article series, will challenge you to consider modernizing your current approach to mold manufacturing by gaining a greater understanding of the plastic injection molding process. Come learn from the daily processing challenges presented and return to work prepared to provide permanent solutions for your customers. The path a plastic pellet takes as it is transformed from a pellet to a part will be reviewed. Discussion points include raw material, melt delivery systems, hot runner controllers, mold cooling, automated part handling as well as the basics of energy management, including its generation, application, control and removal within the process. However, you can help shape the content of this discussion by bringing your specific questions and concerns. A shop case study reviewing successful applications of a variety of the strategies and solutions discussed will also be presented.
Rich Oles - Tooling Manager, Stone Plastics

Adam Domoraunt - Strategic Account Manager, Mold Masters

SESSION: Scientific Runner Design
10:00 am - 10:45 am
Why is it that every time you start up a brand new injection mold you expect it to fail? Why is it that your more than $100,000 multi-cavity mold cannot make the same parts in each of the cavities? Why are you using naturally balanced runners if they are not providing a balance? Why do you use runners with graduated diameters? How do you size your runners?  This presentation will show how these questions are related and how many runner design practices, engineering methods and tools are the source of the biggest problems and roadblocks to increased productivity.
John Beaumont - CEO, Beaumont Technologies

SESSION: An Easy Mold Cooling Design Approach
11:00 am - 11:45 am
Every shop strives to do their design work better and faster. Extra time spent on each facet of mold design adds up to additional time and cost to the bottom line. Cooling is one specific area in mold design that can now be done quicker and more efficiently than ever before.  Attend this session to learn how your mold cooling design can be made easy.  You will witness quick creation of complex water circuits, speedy placement of cooling components using a rich set of catalogs, fast installation of baffles at various depths, methods for analyzing the circuit (for correct water path), cooling analysis results and real-life examples of shops benefiting from this mold cooling design approach.
John Barnes - Applications Engineer, Cimatron Technologies Inc.

ENGINEER CONFERENCE > THURSDAY, JUNE 18, 2015
SESSION: Aluminum Mold Alloys: What’s the Right Choice?
8:00 am - 8:45 am
As the use of aluminum for molds continues to grow, so do the available mold plate offerings. Unlike the steel industry, the aluminum mill industry uses brand names to differentiate products.  Most shops wouldn’t think twice about ordering P20 from any reputable source of tool steel, but are very risk averse when it comes to selecting an aluminum alloy.  New mill production in Canada and Europe has added to the mix of offerings.  This presentation will review currently available alloys produced for the mold market, and discuss the differences and similarities between and within each alloy family. Production methods and the effects on availability and general production cost will also be covered. With all of the available aluminum mold alloys, it can be difficult to sort out which alloy is the right choice for a specific application.  If we took four different alloys, and exposed them to identical machining conditions, what differences, if any, could we find?  A partnership project with Sable Engineering in Port Huron provided some revealing data on this subject. For this project a 5000 cast mold alloy, a 2000 cast mold alloy, a 6061 rolled plate and a 7000 series rolled plate block of identical size were machined.   This presentation will share the project details and results, including beginning block size, rough machining for squaring up, CNC machine tool type and the resulting movement that was observed in the blocks.  Dimensional stability is a key part of moldmaking, and this project demonstrated that aluminum alloys can and do behave differently during the machining process.  
Matt Kaye - VP Sales and Marketing, Clinton Aluminum

SESSION: Multiplying Your Options with Additive Manufacturing
9:00 am - 9:45 am
Additive manufacturing is a rapidly expanding segment of manufacturing today. Typically, industry views additive manufacturing as a process used to create prototypes; however, additive manufacturing has advanced well beyond prototypes. Today’s additive machines are capable of printing various materials to accuracies that seemed unfathomable just a few years ago. Moldmaking has evolved over the years from manual machines to sophisticated CNC machines adept at quickly removing material and maintaining tight tolerances. In an effort to continually evolve moldmaking, mold builders are beginning to explore the benefits of additive moldmaking. While not a solution for every mold, additive manufacturing, when implemented correctly can provide substantial benefits over conventionally manufactured molds.     
Keith Schneider - General Manager, Harbec

SESSION: Redefining the Manufacturing Process
10:00 am - 10:45 am
Find out how one company changed the way it thought about manufacturing and increased its efficiency by empowering the complete workforce. The net gain is significant.   The “power of change” philosophy at Paragon D&E is about the whole team working together to develop methods to do things more efficiently.  Paragons is best known for its capabilities in producing very large and accurate tooling and components for a variety of industries. This diversity has been an important part of the company’s success as it allows ideas developed for one area to be applied across other applications. In contrast, standardizing on a single CAM software for all of its machining has proven to be a key component of the “power of change” philosophy.  Jobs are coming in weeks ahead of schedule. Projects that would traditionally have taken 10 weeks are being completed in four or five weeks.  In this case study presentation you will hear how the “power of change” can motivate a new generation workforce that works together to become more efficient, without compromising labor, quality and customer service.
Andrew Samrick - Managing Director, Paragon D & E

Mark Cadogan - VP Sales, Delcam

SESSION: What You Don’t Know about High Efficiency Roughing Is Costing You Money
11:00 am - 11:45 am
High Efficiency Roughing or HER is arguably one of the most talked about and exciting technologies (and machining techniques) to hit the machining world in the last decade. However, as vendors rush to define terms like high speed machining (HSM) and high efficiency machining (HEM), business owners and CNC programmers are left struggling to make sense of it all. This presentation is designed to educate attendees about high efficiency roughing and how this powerful machining strategy can reduce cycle time and help moldmakers increase profits.
Al Whatmough - CAM Product Manager, Autodesk