2013 Technical Conference Program
All sessions, times and presenters are subject to change.
|WEDNESDAY, JUNE 12, 2013|
|1:00 pm - 2:00 pm | Knowledge Centers|
Engineer: Six Mold Design Best Practices, Cimatron (Knowledge Center South) (+)Ralph Picklo - Cimatron Technologies
Vice President of Sales
Knowledge Center: Engineer Six Mold Design Best Practices
A few key mold design strategies can go a long way in improving your mold building operations and customer support. The success of a mold manufacturer boils down to its ability to deliver high quality products at the shortest possible time and the lowest possible cost. The presentation will highlight some mold design best practices that will help you achieve these goals. While these best practices have proven to help other shops, the key to your success is applying the strategies and processes that are right for your business. Remember, these are best practices, not silver bullets!
Engineer:Streamlining CAD Data Workflow to Reduce Cycle Time, Kubotek (Knowledge Center North) (+)Matt Carr & Sean Demers - Kubotek & Synergetic Innovative Solutions
Knowledge Center: Engineer Streamlining CAD Data Workflow to Reduce Cycle Time
Sean Demers has 20 years of experience in the plastics industry, beginning as a Mould Designer in the world’s leading area for mould manufacturing: Windsor, Ontario, Canada. During his term as an apprentice he split his time up between mould design, tool making and machining. Since his time as an apprentice, Sean has developed expertise in the design of injection moulds (lighting, fascia tools, interior trim, wheel liners, and lawn chairs), blow moulds (automotive fuel tanks, washer bottles), compression moulds (G.O.R.s, household exterior doors, grilles, transport truck hoods) and compressed injection moulds (chain case covers, valve covers). Utilizing Cadkey (now known as KeyCreator) since 1993, Sean designed his first lawn chair part in solids using Cadkey 98.
Sean has put together engineering departments at two local mould shops and is currently the Engineering Manager at Synergetic Engineering and the Chief Training Specialist / Process Consultant at Synergetic Innovative Solutions. Sean specializes in training with XMD-S and Mould specific modelling in KeyCreator. Sean also uses is experience helping mould shops improve their overall efficiencies in all aspects of the design to manufacturing process, right from receiving the part data until the final screw is tightened.
With the sudden revival of the automotive industry and improving economy, mold makers are under more pressure than ever to decrease their times to market, improve productivity of their workforce and handle a larger volume of work with a shortage of labor. One successful strategy to alleviating these stressors, and thus reducing the time needed to make a mold, is to streamline the use CAD data (or more simply, the CAD geometry) throughout the plant and between the OEM and supplier.
|2:00 pm - 3:00 pm | Knowledge Centers|
Engineer: Save Thousands in Outsourcing by Bringing your EDM Process In-house, Delcam and Cavalier Tool (Knowledge Center North) (+)Mark Cadogan, Andy Bergstrom & Brian Bendig - Delcam
VP of Sales
Knowledge Center: Engineer Save Thousands in Outsourcing by Bringing your EDM Process In-House
Mark Cadogan , VP Sales Delcam – Mark Cadogan will be explaining the development of the Electrode software process.
Brian Bendig is President Cavalier Tool – Delcam customer located in Windsor successfully using the new software application from Delcam
Come hear about a completely integrated solution for the design, machining and inspection of electrodes, which has been made possible through a combination of developments in CAD, CAM and inspection software. At the heart of the solution is a new file format that contains all the information for each electrode project, including not only the electrode design but also the machining and inspection information, plus the set-up sheets for its manufacture and use. Having all the required information in a single file simplifies data management as well as increasing overall efficiency. Cavalier Tool will share it's experience and success story with this solution.
The MoldMaking Business Index (Knowledge Center South) (+)Bill Wood - Mountaintop Economics and Research
Bill Wood is a writer/industrial markets economist/consultant at Mountaintop Economics & Research, Inc. Bill Wood is an economic analyst specializing in the plastics industry, and he is the founder of Mountaintop Economics & Research, Inc., (ME&R). He combines a detailed knowledge of the data on the plastics industry and U.S. economy with 20 years of experience in economics analysis and forecasting. Bill also possesses an objectivity that comes from working independently. He works closely with managers in the plastics industry, yet maintains a detached perspective on the market trends. Bill's expertise is determining how changes in the economy will affect the market for plastics products and machinery. This knowledge is converted into easy-to-understand forecasts that assist plastics professionals in making profitable decisions. ME&R's forecasts are based on proprietary indexes that measure changes in the supply and demand for injection molding, extrusion, and blow molding resins. There is a close correlation between the demand for resins and the demand for machinery and tooling. So, our indexes are superior leading indicators of the markets for plastics machinery and tooling, trends in resins prices, and also trends in the overall U.S. economy. Because of the insight and advance warning that these indexes provide, Bill is often commissioned to forecast the company sales data for manufacturers of plastics products and machinery. He frequently presents his industry outlook to meetings of senior managers or sales and marketing staffs. He also conducts seminars where attendees are taught to forecast their own company sales data. And he is a frequent speaker at plastics industry events and trade association conferences. Bill is a regular contributor to MoldMaking Technology and Plastics Technology magazines, and he has authored many articles explaining his research and forecasts. These have been widely published in the plastics industry trade press as well as Design News, Variety, Interior Design, The Wall Street Journal, and numerous business newsletters.
As always, the future will present a multitude of challenges to North American moldmakers and their suppliers. These include, but are not limited to: materials costs, energy prices, end-market trends, rapidly changing technologies, consumer trends, government policies, geo-political tensions, economic fundamentals, the skills gap etc. As always, the outcome is uncertain, and the choices we as citizens, consumers, and business leaders make today will go a long way towards determining our future.
The U.S. economy is a large and complex system. We all depend upon this “eco-system” for our livelihoods, but recent events have diminished our capacity to compete successfully in the global marketplace. The manufacturing sector is a “keystone” component in our economy’s competitive success. If we are to retain our position as a competitive leader in the global marketplace, and ensure the continued prosperity for our citizens, then we must regain our position as the world’s dominant manufacturing power.
We can only achieve this with strategies, policies, and programs that promote productivity. All other objectives will be rendered superfluous if we do not continue to enhance and nurture our national and regional productivity. This presentation will be another chapter in our ongoing dialogue about how to address this issue, and how our failures and successes will affect our industry.
|3:00 pm - 4:00 pm | Knowledge Centers|
Engineer: High Speed Machining versus High Efficiency Machining, CG Tech (Knowledge Center North) (+)David Sutkay - CGTech
Technical Sales Engineer
Knowledge Center: Engineer High Speed Machining versus High Efficiency Machining
Some think of “high speed machining” as simply running a CNC machine at maximum feed rates and taking multiple shallow passes. However, this strategy is often less efficient than taking fewer passes at slightly greater depths. Achieving the shortest cutting time is related to feed rates, but that is only one of many factors. High-efficiency machining -- cutting a part in the least amount of time -- is the real goal. Cutting at a greater depth is often more efficient, but the cutter may encounter an overloaded condition causing breakage or exceeding the horsepower on the machine. The key to achieving high-efficiency machining is to vary the feed rates to achieve the desired result for each cutting condition encountered. This presentation will provide an overview of the steps required to achieve the benefits of high-efficiency machining by utilizing software to automatically optimize NC program feed rates. Key points: Outline the difference between high speed machining vs. high-efficiency machining; demonstrate the benefits of optimizing NC program feed rates using real-world examples; and , explore ways to simplify the process of achieving high-efficiency machining.
Plastic Product Design Principles (Knowledge Center South) (+)Jim Kesteloot - TST Tooling Software Technology, LLC
Jim Kesteloot is president of TST Tooling Software Technology.
Molded components have changed the shape of everyday items—lighter, recyclable and aesthetic design. 3D CAD/CAM systems have facilitated the evolution of product design, and as a result, ever -increasing geometry complexity . The objective of this presentation is to look at some key product design principles that will eliminate uncertainty and ensure manufacturability for your next project. While each of the points are generic and cannot be applied to every scenario, they provide a solid base from where to start your next design. consistent wall thickness, draft angle, boss design, rib design, part radii, part text, undercuts, side holes, living hinges, gate position and material choice.
|4:00 pm - 5:00 pm | Knowledge Centers|
Engineer: Improving Part Quality with Advanced Valve Gate Control, Synventive Molding Solutions (Knowledge Center North) (+)Leo Devellian - Synventive Molding Solutions
Technical Sales Manager
Leo Devellian is Technical Sales Manager for Synventive Hot Runner Systems, an industry leader in providing innovative melt delivery and flow control technologies to the automotive, electronics, telecommunications, packaging and medical industries. Leo began his career at Synventive 22 years ago as an Applications Engineer and has held positions in Product Management, Business Development and Technical Sales.
Valve gated hot runner technology has been available for many years. The ability to open and close the valve pins at a time of their choosing has given molders the ability to fine tune the filling of parts. Until recently, however, molders have only been able to control when the valve pins begin to open or close. Although this “on/off” style of valve gating has huge benefits over thermal gating, further benefits can be realized though additional control. Advanced Valve Gate Control refers to technologies that allow the molder to have additional control over the movement of the valve pins.
Engineer: Shrink and Warp from a Moldmaking Perspective, Beaumont Technologies (Knowledge Center South) (+)David M. Rose - Beaumont Technologies
Knowledge Center: Engineer Shrink and Warp from a Moldmaking Perspective
An important part of qualifying a mold is being able to produce stable parts within dimensional specifications, from all the cavities within the mold, within a specified cycle time. This often requires several machining iterations that are costly in terms of mold cost, time to market, and client credibility. There are some key considerations and engineering that needs to be done during the mold design and build phase if your goal is to produce the highest quality parts as efficiently as possible. This presentation will discuss key principles of how plastics shrink and why they warp, the influence of the mold design (which goes well beyond cooling), and the value of technical training on this subject. Let’s Talk Plastics!
|THURSDAY, JUNE 13, 2013|
|9:00 am - 10:00 am | Knowledge Centers|
Build: Direct Milling of Complex 3D Shapes in Cemented Carbide, U.S. Union Tool (Knowledge Center North) (+)Dr. Hidehito Watanabe Ph.D. Eng. - U.S Union Tool
Manager-Tool Engineering Dept
Knowledge Center: Build Direct Milling of Complex 3D Shapes in Cemented Carbide
This paper looks at the challenges in producing a cutting tool (End Mill) that can physically cut 3D forms into cemented carbide, using more traditional Hard Milling strategies, as opposed to EDM or Grinding. The paper will seek to show how a patented Diamond Coating, developed for this challenge, came into being and how it might change the way companies view using carbide in Molds and Dies for the future.
Build: High Speed Machining: Time is Money,Hurco (Knowledge Center South) (+)Michael Cope - Hurco
Applications Engineer Product Technical Spec.
Knowledge Center: Build High Speed Machining: Time is Money
The factors moldmakers should consider before purchasing a high-speed machining center. While spindle speed is the most often discussed specification, mold makers need to consider many other factors, such as the machine’s casting, base rigidity, thermal growth control systems, axis position feedback, and tool retention. This presentation will help moldmakers wade through the technical jargon so they can ask the right questions to figure out whether they should invest in HSM. It will also touch upon advancements in CAM systems and explain how the right control technology optimizes HSM for moldmakers.
|10:00 am - 11:00 am | Knowledge Centers|
Build: 3D Rough Milling -- A Tactical Approach, Things to Consider, Ingersoll Cutting Tools (Knowledge Center North) (+)William Fiorenza - Ingersoll Cutting Tools
Die & Mold Product Manager
Knowledge Center: Build 3D Rough Milling-A Tactical Approach, Things to Consider
A discussion on the basic considerations, techniques, tooling and forethought needed to develop a
3D roughing program. An effort will be made to emphasize the importance of the planning for success
through: the understanding of the 3D geometry, proper tooling selection and optimal toolpath creation.
The previously mentioned and more will be discussed relative to the many variables that exist in a
machining process, specifically related to a 3D cavity or core. Some of these variables include: machine selection / relative to what’s available; machine characteristics; workholding; toolholders; and, required tool extensions / stick outs. A special emphasis will be place on the tool path fluidity and the importance of always maintaining the maximum possible tool rigidity for all machining operations. Also, discussed will be the importanceof developing a plan-b programming scenario ready to go should the primary plan fail. This portion of the discussion will point out the importance having alternate programs available upfront to keep the machining process moving forward.
Build: Selecting the Right Machining Technology and Differentiating Your Mold Design, GF AgieCharmilles (Knowledge Center South) (+)Eric Ostini & Chuck Klinger - GF AgieCharmilles
Knowledge Center: Build Selecting the Right Machining Technology and Differentiating Your Mold Design
Now, 20 years working for AgieCharmilles in many different departments.
Selecting the right technology, machining your mold components, ensuring the most cost-effective way and differentiate your mold design from your competitors by applying the latest in laser texturing
technology. When to select milling, 3- or 5-axis, and when EDM is the better solution showing some practical examples and then getting into the surface texturing options.
|11:00 am - 11:30 am | Knowledge Centers|
Engineer: Injection Molding Applications with 3D Printing, Stratasys (Knowledge Center South) (+)Susan York - Stratasys
National Field Manager
Knowledge Center: Engineer Injection Molding Applications with 3D Printing
Injection Molding Applications with 3D Printing, Stratasys
Injection molded products are made of thermoplastics that feature properties difficult to simulate with 3D printed prototypes. Printing the tool, rather than the part, offers an alternative approach to product development. Rapid tooling via 3D printing allows the part's actual material to be molded in a tool that is fabricated within several hours at low cost. Attendees of this presentation will learn about the development of an ABS-like tooling material offering high-temperature resistance and a good combination of stiffness and toughness. The presentation provides examples of tools and molded parts of different geometries and molded materials, demonstrating the range of industries impacted by this solution. Participants will also learn how the same approach applies to plastic blow molding process, i.e. using printed tools for the fabrication of final-material blow-molded prototypes
Made In The USA – Supporting The Plastics Industry – The Timing is Right! (Knowledge Center North) (+)Robert Schiavone - R&D/Leverage
Global Marketing Director
Knowledge Center: Maintain Made In The USA – Supporting The Plastics Industry – The Timing is right!
How one mold maker -R&D/Leverage- uses American pride to support our industry while getting young adults to look at manufacturing as a career.
|12:00 pm - 1:00 pm | Knowledge Centers|
Build: Modernization in Tooling Technologies for Moldmaking Milling Applications, Haimer (Knowledge Center South) (+)Brendt Holden - Haimer USA
Knowledge Center: Build Modernization in Tooling Technologies for Moldmaking Milling Applications
Advances in tooling for milling machines has allowed Moldmakers to machine their parts faster, more accurately, and with less hand work after the milling process. This presentation will explain some of the new tool holder technologies that assist in allowing moldmaking companies to push the limits.
Build: Modular Inspection Technologies Support Unattended Moldmaking, Marposs (Knowledge Center North) (+)Sharad Mundra & Jorge Pena-Mena - Marposs Corp., Artis Systems
Product Manager MIDA Probing & Software Systems
Knowledge Center: Build Modular Inspection Technologies Support Unattended Moldmaking
Jorge Peña-Mena is the General Manager and Director of Application Engineering at ARTIS Systems, Inc. He joined ARTIS Systems in October, 2000, as application engineer with responsibility of supporting and servicing manufacturing customers in the USA, Canada and Mexico. ARTIS Systems, Inc. became part of Marposs in October, 2008. He holds a Bachelor of Science, Mechanical Engineering with Emphasis in Construction Machine from the Technology High Polytechnical Institute “Jose Antonio Echeverria” in Havana, Cuba, where he also instructed courses in metal forming, tool die design, material science and programming of CNC machines. He served as a member of a national team to develop and manufacture slide bearings for the heavy industry in Cuba. He is the winner of two National Awards in Cuba for the design, manufacturing and production of a glass capillary tubes cutting machine.
Moldmaking presents a unique combination of machining challenges including aggressive metal removal rates, extremely high precision requirements and very long machining cycles, which make it an attractive, albeit difficult, candidate for process automation. Historically, both integrated one-size-fits-all systems and piecemeal ad hoc approaches have proven to be less than satisfactory. There is, however, a third alternative based on a suite of independent, but fully interoperable technologies that can be implemented individually, sequentially or as an integrated system. The elements include both contact and noncontact tool setting; sophisticated process monitoring including tool breakage and wear detection; crash detection; and, precision post process probing, gauging and analysis capabilities. The modular nature of this approach distinguishes it from the one-size-fits-all systems currently available, and the fact that all of the elements are available from a single source ensures the interoperability that is frequently lacking in ad hoc systems. This seminar will provide detailed application guidelines for each of the individual elements, an overview of the strategies available to integrate them into a comprehensive automation solution and an analysis of the potential cost reductions and productivity improvements such system can produce.
|1:00 pm - 2:00 pm | Knowledge Centers|
Maintain: Eliminating Grease in Molding Operations with DLC Coatings, Poco Graphite (Knowledge Center North) (+)James Swager - Poco Graphite-Entegris Specialty Coatings
Mold Coating Specialist
Knowledge Center: Maintain Eliminating Grease in Moldiong Operations with DLC Coatings
Diamond-Like Carbon coatings via a PECVD (Plasma Enhanced Chemical Vapor Deposition) process can act as a solid and nearly permanent lubricant on injection molding knock-out pins, leader pins, lifters, wear plates, and other molding components.
Maintain: Sustainable In-Machine Mold Cleaning Using Dry Ice (Knowledge Center South) (+)Steve Wilson - Cold Jet LLC.
Business Development Director
Steve Wilson is currently the Business Development Director for the Plastics’ Industry for Cold Jet, LLC. Cold Jet produces and distributes dry ice cleaning and dry ice production equipment. With over 30 years of sales, marketing and product management experience in the plastics industry, Steve serves as the subject matter expert and commercial team liaison between sales, marketing, operations and engineering for Cold Jet’s plastics industry initiatives. He began his career at Cincinnati Milacron, serving in a variety of product line management roles for the plastics’ machining market. Steve has also managed his own business, Wilson Engineering Sales, as a manufacturers’ representative for injection molding and packaging equipment. Steve is a recognized expert in the injection molding marketplace and a frequent speaker at Society of Plastics Engineers’ events. He holds a Bachelor of Science in Business Administration from Cedarville University and an MBA with a focus in Management from Xavier University.
This presentation will discuss the advantages of dry ice blasting as a replacement for solvent and/or mechanical cleaning for the removal of contaminants from tooling as well as its use to deburr and deflash plastic parts. While the principles discussed herein are applicable to multiple plastics processes (BM, Ext., etc.), the focus will be on injection molding and the various steel and aluminum mold substrates commonly used. Attendees will achieve a benchmark understanding of the role and relevance of dry ice in mold cleaning, part deburring and deflashing and its impact on product quality, production cost, production efficiencies, worker safety and health and environmental responsibility. Research from several industry case studies will be discussed. The results confirm that dry ice cleaning can remove contaminant layers from various common mold metals and is a good alternative to other commonly used manual, abrasive methods as well as successfully deburr and deflash plastic parts.
|2:00 pm - 2:30 pm | Knowledge Centers|
Maintain: The Benefits and Drawbacks to the MoldMaking Industry, Alliance Laser (Knowledge Center North) (+)Paul Dynak & Jeremy Willingham - Alliance Laser
Laser Welding Technician
Knowledge Center: Maintain Laser Technology: The Benefits and Drawbacks to the Mold Making Industry
The process of laser welding and engraving has opened the door to a wide range of possibilities in tool making that have previously been cost prohbitive. As experienced laser welding technicians we will explore a few of the common processes that benefit from the laser method, as well as discuss the positives and drawbacks of this growing technology.
Maintain: Maximize Mold Production and Protection, Bales Mold Service (Knowledge Center South) (+)Harry Raimondi - Bales Mold Service
Technical Services Manager
Knowledge Center: Maintain Maximize Mold Production and Protection
Get the best out of molds with the right coatings to protect from corrosion and wear. How to use coatings and finishes to increase mold longevity and production.