Moldmake Feb 2016

E N G I N E E R / B U I L D / M A I N TA I N
FEBRUARY 2016
Rough Milling:
Speed vs. Power PG 14.
Measurement Right on the
Shop Floor PG 20.
Benefts of Using MultipleGate Nozzles PG 24.
A property of Gardner Business Media
VOLUME 19 / NUMBER 2
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With your name on the outside of your molds, trust the
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Publisher
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Metalworking Group Publisher
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Products Finishing
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EDITORIAL ADVISORY BOARD (EAB)
MoldMaking Technology FEBRUARY 2016
Strategic Account Manager

Byrne Tool & Design
Rockford, Michigan
bakera@byrne-tool com
Vic Baez
Advanced Manufacturing
Engineering Executive
GE Energy Management
Industrial Solutions
Hartford, Connecticut
victor baez@ge com
Dan Mishek
Managing Director and
Co-Owner
VistaTek
Stillwater, Minnesota
danny@vistatek com
Tim Bartz
VP of Operations
Mold Craft Inc
Willernie, Minnesota
thbartz@mold-craft com
Ralph Neufarth
Design Leader
iMFLUX (subsidiary of
Procter & Gamble)
Hamilton, Ohio
neufarth re@pg com
John Berg
Group Marketing Director
MGS Manufacturing Group
Germantown, Wisconsin
john berg@mgstech com
Tim Peterson
Vice President
Industrial Molds Group
Rockford, Illinois
tim peterson@industrialmolds com
Wayne M. Hertlein
Program Manager
Wilbert Plastics Services
Troy, Michigan
whertlein@wilbertinc com
Steve Rotman
President
Ameritech Die & Mold
Mooresville, North Carolina
srotman@amdiemold com
David Hirt
AIS/FVSS/Lighting New Model
Tooling/Feasibility Engineer
Automotive Components
Holdings LLC
Sandusky, Ohio
dhirt@ventraplastics com
Mike Walter
President
MET Plastics
Elk Grove Village, Illinois
mwalter@metplastics com
Mike Zacharias
President
Extreme Tool & Engineering
Wakefield, Michigan
mike zacharias@extremetool com
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CONTENTS
February 2016 Volume 19 / Number 2
10
00
20
00
Features
24
00
Departments
14 Cutting Tools
Rough Milling: Speed vs. Power
A look at what works in rough milling applications with solid carbide
end mills.
20 Inspection/Measurement
Measurement Right on the Shop Floor
Portable, direct computer controlled coordinate measurement can
streamline processes and reduce inspection backlog for a better
bottom line.
24 Hot Runners
Multiple Impact
Incorporating multiple-gate nozzles means smaller molds, small presses,
a balanced fill rate, reduced residence time, temperature control and
design flexibility.
28 Process Cooling
Process Cooling Boosts Mold Effciency
Mold builders can optimize mold performance by taking advantage of
advanced process cooling technology.
6
6
8
10
34
36
38
42
44
46
55
55
56
From the Editor: Kick Things Up a Notch

Whats New on MMT Online
Profile: JMMS
Case Study: Software
Under The Scope: Understanding the Task
Keeping Up With ISO: High-Level Structure
The Bottom Line: Tax Extenders Package
Gardner Business Index: MoldMaking
End Market Report: Packaging and Medical
Product Focus: Hot Runners
MoldMaking Marketplace
Ad Index
TIP: Inspection/Measurement
ON THE COVER
Image courtesy of Iscar Metals Inc. This months cover shows a mold
base finishing application using the new evolution of Iscars Chatterfree
solid carbide end mill, a cutting tool designed for high-speed roughing
milling and finishing operations. High speed (trochoidal) rough milling is
a programming technique applying a small radial width of cut, and high
cutting speed and feed per tooth. This is a go-to technique for applications where a lack of rigidity exists and vibration becomes problematic.
This multi-flute end mill incorporates variable pitch/helix geometry to
increase productivity in material types commonly used for moldmaking,
such as alloyed steel, stainless steel and high-temperature alloys.
See related story on page 14.
Images above courtesy of (left to right) CGS North America, Fowler Precision and Osco Inc.
Great Tips from This Issue
1. Emphasize This!
To optimize metal removal

rates during high-speed
roughing on a low-power,
high-speed milling machine,
emphasis needs to be placed
on the cut parameters and
tool path to be used.
PG. 14.
VIDEO ACCESS
TRICKS OF THE TRADE
2. Power of
Portability
3. Not Too
Hot to Handle
4. H2O Flow
PG. 20.
PG. 24.
PG. 28.
A portable DCC CMM is manufactured as a compact, selfcontained unit, making it

different from conventional
CMM technology, as operators can take measurements
and run 3D programs with
substantially less training.
Having a heater and

thermocouple positioned
directly at each gate
provides the necessary
power and control needed
to handle a wide range
of resins, but especially
diffcult resins.
Free cooling with an

integrated closed-loop
water cooling system
allows the central fuid
cooler to provide water at
the necessary temperature
where needed without using
chilled water, resulting in
energy savings.
5. Check Your
Controls
High-end controls feature

measuring cycles for checking
workpiece geometry, enabling
users to recognize a workpiece, call a part program,
verify machining operations
and detect and compensate
for tool wear.
PG. 56.
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From the Editor
Kick Things Up a Notch

Meet Danny. Hes managing director and co-owner
of VistaTek in Stillwater, Minnesota, a secondgeneration, family-owned, custom manufacturer
that today provides moldmaking and injection
moldmaking services, as well as secondary operations such as decorating, packaging and assembly.
However, when I first heard of VistaTek, it was
focused on rapid prototyping and tooling. In fact,
when I met Danny, he and his father were doing
a presentation on dispelling the myths associated
with rapid tooling. A few years later, I invited Danny to lend his insight and
expertise to MMT by serving on our editorial advisory board. Since then,
the company has changed its focus completely by selling the additive manufacturing portion of its business to focus on its moldmaking and molding
divisions. Thats how Danny works. He follows the trends, thinks outside
the box and collaborates with a team to make things happen.
And now hes taken his passion for manufacturing, plastics, marketing,
education, community and the environment, and injected it into a new
project: the development of a new line of products and a new company
to go with it. SelfEco, owned and operated by Danny and his brother Al,
started after Danny attended a green conference to look for new business
opportunities. He came away with the idea for the new companys first
product: an industrial compostable pot with plant food built into its walls.
What followed was months of R&D on the unique material and 3D printing of prototype tools. The company had to learn proper gating, venting,
cycle times and mold temperatures. The concept turned out to be solid, but
also quite disruptive to the current marketplace. Thats when Danny discovered how difficult it is to bring disruptive technology to the market with
typical funding sources. He had to find other avenues of funding outside of
traditional banks or investors. Time to think outside the box again.
Enter Kickstarter, an online resource that helps inventors publicize
their ideas and find resources to make them a reality. SelfEcos Kickstarter
campaign launched last month and is still underway. Visit short.moldmakingtechnology.com/selfeco to see the companys cool product and how
Kickstarter works.
By nature, moldmakers are producers, problem-solvers and inventors.
Maybe its time for you to actually make that unique product solution you
have rolling around in your head. Kickstarter can help. And its not just an
avenue for new ideas, its a vehicle for new business as well. Danny says his
company has landed projects from people who have obtained funding on
Kickstarter themselves. Think about it. Someone has an idea. He or she gets
the funding but doesnt know how to actually make the product. But you
do! For future business or your next project, you might want to consider
kicking it around on Kickstarter.
Christina M. Fuges
Editorial Director
Follow MMT on:
Follow @ MMTMag
THIS MONTH ON
VIDEO: A Look at Self-Cleaning Mold Technology
According to one hot runner manufacturer, self-cleaning

can eliminate up to 400 hours of mold maintenance per
year, resulting in 5 percent more production time. Access
an informational video at short.moldmakingtechnology.com/
selfclean.
DIGITAL EDITION:
Additive Manufacturing
Check out the latest edition

of this quarterly magazine
dedicated to industrial
applications of 3D printing
and digital layering technology at
additivemanufacturing.media/
articles.
BLOG: What Are You Reading?
Review the Top 10 most viewed articles on our website

in 2015, capped off by Junes feature article on Leadtime
Leader Awards Winner Cavalier Tool & Manufacturing. This
blog post also reminds readers to check out the most popular pages within the site.
short.moldmakingtechnology.com/2015Top10.
SERIES: Finding,
Training & Retaining
Employees
Ryan Pohls series of

articles addresses the
skilled-labor shortage
and its potential to
dramatically hinder the
future sustainability
and growth of the moldmaking industry. He covers a range
of related topics, from structured training to educational
philosophies to evaluating training resources. Revisit these
topics at short.moldmakingtechnology.com/employ.
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Profle
JMMS Sees Growth with Focused Program Management
Investing in Partnership
In 2009, when most other companies were battening down
their hatches against a recession, JMMS surged ahead with
substantial capital investments and hiring of top-level personnel that would aid in the advancement of a newfound business
strategy. Specifically, JMMS spent close to a million dollars to
purchase a new OKK HM1250S horizontal machining center
to expand its capacity for building very large molds for a good
customer. Then the company set out to develop close, longterm business relationships by creating three project manager
rolesone to work closely with thermoset customers, one
to manage thermoplastic, and the third for cultivating and
maintaining die cast customers. The result was a 40 percent
increase in sales, signaling that the new strategy was a solid
one, Martin says. Seven years later, it still is.
Today our customer list is a much tailored version of its
former status, Martin explains. Our business model comprises targeting companies that are engineering-driven. They
view JMMS as a dedicated partner, not just a supplier. This is a
world-class caliber of customers were working with.
Each customer now has a go-to guy with the expertise
required to get their projects done right. We hear all the time
how much they like having dedicated project managers that
can respond quickly to their needs. We see no weeping or
gnashing of teeth over problematic customers either. It works.
Since 2011, JMMS has added 10 new die cast customers,
three new thermoset customers and nine thermoplastic customers to its select list, which includes OEMs in the power
generation, automotive and light packaging industries.
These companies are looking for the whole package, not
Images courtesy of JMMS Inc.
By Cynthia Kustush
Not quite five years ago, JMMS Inc., of Easley, South Carolina,
was featured in this magazine after having earned our 2011
Leadtime Leader Award: Small Shop Honorable Mention.
I remember completing the entry form for the Leadtime
Leader Awards, says Rich Martin, business development manager. We put hours into it, going through files and more files.
It wasnt the entry form as much as it was the fact that wed
been in business for 25 years by then, and nobody had taken
the time to keep score.
Martin credits the Leadtime Leader entry process with giving the company that extra nudge it needed to begin getting
a comprehensive business growth plan in place that included
systems for tracking operations throughout the plant; budgeting and forecasting; and measuring competitive profiles, delivery times and efficiencies.
It became much clearer to us who we wanted to be when
we grew up, so to speak, Martin says.
This hybrid mold for a recycling bin is designed for faster cycling time.
just to cut costs, Martin says. They want full-service benefits.

Today, we can offer that. For example, JMMS builds all of the
tooling, and provides mold maintenance and repair services for
a major thermoset molders North Carolina facility. The company also manages all tooling, including engineering changes,
maintenance and repair, for a light packaging OEM customer
According to JMMS, product launch meetings are critical to understanding

customer requirements.
in South Carolina. Anything that is too large for the company

to handle is subcontracted, and that subcontract is managed
by a JMMS project manager.
JMMS also maintains a ISO 9001:2008-certified quality
management system as a way to reinforce its project management qualifications for overseeing each phase of a molds lifecycle, from design through to production and maintenance.
The company employs 27 workers, including one apprentice,
at its Easley plant, and has grown the staff at its Dongguan
City, China, location from three to five with the recent addition of two more mold designers. A business director and program manager round out the team there. Customers also can
benefit from JMMSs follow the sun design and development
strategy, which is intended to help speed productivity by providing 24-hour continuous design and development services.
Equipment-wise since 2011, the company has added a 2013
Mitsubishi MV2400S wire EDM to replace an older machine
and bring this work back in-house. A 2000 Roeders RFM600
high-speed vertical machining center has also been added,
and an upgrade was made to JMMSs Cimatron CAD/CAM
software, which Martin says is phenomenal on roughing and
very fast. As a final step in its new business strategy, JMMS
created a maintenance and repair department that is separate
from general shop operations to begin promoting that side of
its value-added services.
100-Percent on Time
JMMSs focused project management strategy has enabled the
company to deliver tooling when the customer requires it
another key cog in the wheel of the companys success.
In 2015, we delivered 100-percent on time, Martin says. We
The Particulars
JMMS Inc. was founded as JM Mold South in 1986 by David M.
Bowers. Today, it remains a family-owned company, run by Bowers
as president, with his children, David M. Bowers II as chief executive
offcer and Michelle Powell as chief operating offcer. Located within
a 20,000-square-foot facility in Easley, South Carolina, JMMS prides
itself on serving a blue chip list of customers with next-generation
tooling by investing in continuous improvement initiatives such as
training and quality assurance, as well as new capabilities like hybrid
tooling and working with alternative materials.
JMMS designs, engineers and builds plastics tooling as heavy as
30,000 pounds, including thermoplastic injection molds, thermoset
injection and compression/transfer molds, extrusion blow molds, and
low-pressure injection structural foam molds. Markets served include
appliances, automotive, consumer, electronics, lawn and garden, medical
technologies, power generation, power tools and returnable packaging.
The company also has expertise in die cast design and engineering,
as well as metals tooling, producing high- and low-pressure casting
dies for automotive OEMs and their Tier One suppliers. Maintenance
and repair services for die cast tooling are also offered.
These parts made from thermoset tooling represent some of the injection
and compression/transfer processes offered at JMMS.
have an excellent quality manager, and the results of a recent

ISO audit revealed zero defects. If we detect any chance of a
mold being late, it is identified in our project meeting, and we
alert the customer. Then steps are taken to alleviate the issue.
Every project begins with a routing meeting centered
around how JMMS plans to build a tool. Everyone who will
have a hand in a project is at the table, Martin explains. Every
step and every inch of the tool is examined, piece by piece,
and we determine one of two things: make it or buy it. This
pertains to everything from bolts to bases, programming, engineering, toolmaking, assembly, EDM wire, CNC, and more.
Hours are assigned to each step. Maybe the quoting team
estimates 500 hours for a job, but the routing team, during its
meeting, quotes 650. Now the creative juices get flowing as we
work together to cut that extra time out of the job.
Martin asserts that its not some secret machining center
that provides the companys competitive advantage. Rather,
its being completely transparent and honest with customers,
in addition to providing focused program management. We
build tooling here and in China, he says. Where its built
depends on whats driving the market. But well never send a
mold or any project to China without a customer knowing it.
Our customers are always part of the process.
Going forward, Martin says the company is once again poised
to make further capital investments and is busy investigating its
options. Among the items on the table are changes to plant layout and floor layout, as well as adding more automation in the
form of palletizing, robotics and five-axis machining.
Getting a P.O. from a customer is easy, Martin says. The
trick is to keep the relationship with the customer in honeymoon mode. We cherish our customers. We listen to them.
We thank them, sincerely and often.
FOR MORE INFORMATION
JMMS Inc. / 864-855-0450 / jmmsinc.com
Case Study / Software
By Cynthia Kustush
Accuracy is paramount when machining molds,
and as automated as machining has become, it
often still makes necessary an array of less-efficient
secondary operations and handwork to achieve
the geometry and surface finish required to meet
product design specifications. This is especially
true when a design calls for ribs and other tightdetail areas that a tool path must navigate.
Jason Alsleben, a mold designer and toolmaker
for Unique Tool Inc. in Hutchinson, Minnesota,
CGS CAM-Tool simplifes
was well-versed in the multi-step process for
the process of controlling
achieving accurate tool paths and proper surface
multiple tools at once by
using the faces not to
finishes when that became unnecessary with the
companys switch to CG CAM-Tool, part of the CG machine option. For example,
here, the user has assigned
Series of 3D CAD/
a unique color to each tool path
The tool paths are so
CAM systems for
needed to fnish a cavity insert
molds and dies
for a medical device part versus
precise and the surface
from CGS North
using just a tool boundary.
fnish is so good that
America Inc.
we can almost eliminate
Unique specializes in building
small, intricate molds for
the slow and costly EDM
medical applications such as
process, and as a result
over-molding electrical congood that we can almost eliminate the slow and costly EDM
process, and as a result reduce the hours it takes to build our
reduce the hours it takes nectors and fluid connectors.
The mold designs range from
molds by as much as a third.
to build our molds by
one to eight cavities, includas much as a third.
ing master unit die (MUD)
Accurate and Safe
units and small, self-contained
According to Gerry Byykkonen, Uniques technical sales reptools. For Alsleben, making
resentative at CGS, the CAM software creates toolpath points
the switch to CG CAM-Tool was a big step toward simplifydirectly on the surfaces to be machined versus using a not-soing machining operations.
exact triangulation mesh. When toolpath data is created using
We used another CAM system for several years, he says.
the true surfaces of the model, the software can generate
Surface finish was always an issue, and with small end mills,
many more points of contact between the cutting tool and the
tool breakage was common. Since we switched to CG CAMmodel, he says. This increased point data results in a smoother
Tool, having the ability to machine smaller details into our
tool path that follows the surfaces to be machined with greater
molds has reduced or often even eliminated the need to
accuracy.
machine electrodes and burn these details into our molds.
Other CAM products place the mesh over the entire part
The tool paths are so precise and the surface finish is so
and use this to create the tool paths, Byykkonen explains.
10
Images courtesy of Unique Tool Inc.
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Case Study / Software

Topic
A model (top) was created for this cavity insert (bottom) and used to wire
EDM in two directions. That same model was then used as a stock model in
CG CAM-Tool (middle) to save time. From the stock model, CG CAM-Tool can
tell that the top profle has been machined, so it does not waste time cutting
air. The fnal product is an effciently machined cavity insert for a lever.
The problem is, those toolpath points are not generated as

accurately, and they inevitably lead to inaccuracies in the
machined surfaces, including a subpar surface finish and premature tool failure.
Alsleben concurs. CG CAM-Tool has been extremely
accurate in its tool paths, he says. Where using another
softwares triangulation mesh only gives us an approximate
surface and tool path, CG CAM-Tool shows us exactly where
the tool path is and verifies it. Theres virtually no need to
use the sinker EDM because we get what we need using CG
CAM-Tool. Its pretty much one and done.
Data used to generate tool paths in the software are processed directly within the program. After calculation and
verification, a color system indicates the status of the tool
path: Green indicates that a correct and safe tool path has
been generated, yellow indicates a potential problem that
should be addressed, and red indicates a serious problem that
prevents the software from outputting the toolpath program.
Alsleben says he also appreciates that the system generates a new stock model with each tool path that accurately
represents the stock remaining from the previous tool, a feature not found in most other CAM software. By doing this,
it enables users to accurately verify if there are any interferences between the cutting tool and holder, and the part being
machined. This accurate verification also greatly reduces the
possibility of costly machining errors.
CG CAM-Tools delete air-cut function helps Alslebens
programs work more efficiently, too, he says. After I do the
initial roughing, I can replace the first end mill with a smaller
one and avoid cutting air all the way down. CG CAM-Tool
knows the material is out of there and doesnt waste time
getting to work. This software works really well for Z-level
roughing, especially when following a larger end mill.
As for lights-out machining without worry, Alsleben says
he sleeps peacefully. I feel much safer about the tool path
Im putting out because of the accurate verification, he says.
When I write the tool path, I know the cutters are going
to work correctly. When I walk out the door at night and
machines are running, Im not scared about walking back in
on any disaster the next morning.
Ease of Programming
Alsleben has extensive experience using SolidWorks software
programs, and since CG CAM-Tool is designed to run within
12
the SolidWorks platform, he says the learning curve was greatly

reduced, as were the steps required to program tool paths.
I dont have to make an IGES or STEP file to translate into the
CAM software, because its already standard within the system,
he says. It simplifies so many things.
Programming is much easier with the user interface in CG
CAM-Tool, he continues. To machine a part, I simply start
a new project, add tools from the machining template, define where I want
each tool to cut, and then calculate. It
makes cutting even the most complex
parts just that easy.
In addition, if any revisions to an
existing tool path are necessary down
the road, Alsleben doesnt have to recreate the entire project. For example, if
a diameter or radius change is needed,
or a detail is added to the design, the
project parameters are already integrated in the software, and the updates
can be made automatically by regenerating the tool path. It is so simple that
it reads like a book, he says. You can
see exactly what you did at any point
within the program.
used to program a similar future job in just a few minutes.

When I have multiple projects in the queue, CG CAMTool lets me continue programming while other parts of a
program are calculating, Alsleben adds. Im not wasting
time waiting for toolpath verifications that could take several
minutes to calculate. Its efficient. Its fast. Its very accurate.
It has really advanced the way we build molds.
Sharpening your
cutting edge.
LEARN MORE
Visit our Software Zone for more
information about this and other
CAD/CAM products.
moldmakingtechnology.com/zones/
cad-cam-and-other-software
While no two mold jobs are exactly

alike, Alsleben does find added convenience in CG CAM-Tools ability to use
previously programmed toolpath templates to save time on future jobs. For
example, it may take half an hour to
program the process for squaring up a
new block for a set of mold bases from
scratch, but the saved templates can be
Why not take your technology to the next level? Its easy with solutions
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13
Cutting Tools
Access video
at end of article.
Rough Milling:
Speed vs. Power

A look at what works in rough milling applications with
solid carbide end mills.
ftentimes, we get so caught up in the hype about

something new that we lose sight of the value of
what already exists and truly works. This is especially
true in the recent fad of using solid carbide end mills for
high-speed milling in rough milling applications. Instead of
presenting whats new in cutting tool technology for mold
manufacturers, lets take a look at what already works.
The moldmaking community is no stranger to high-speed
milling using solid carbide end mills. Its been nearly two
decades since the most adventurous and technology-driven
moldmakers started using high-speed, hard-milling techniques for core and cavity finishing applications (mostly using
ball mills). Many moldmakers started investing in high-speed
milling machines that had spindles capable of 20,000 rpm
(or higher) with the intention of using these machines only
14
for finishing operations. Roughing operations would be performed on another, better-suited milling machine (one with
more power, for example) and before the material was hardened/stress-relieved.
This approach of roughing on one machine and finishing
on another is a solid process, but it still begs the question:
Can we rough and finish on the same high-speed machine?
The simple answer is yes. However, to be productive in
terms of metal removal during the roughing phase requires a
different approach.
Multi-fute cutting tools can optimize material removal rates for milling operations that require extremely light radial engagement (usually less than 10 percent).
Image courtesy of Iscar.
VIDEO
By Thomas Raun
Rough Milling: Speed vs. Power
Optimizing Metal Removal

To optimize metal removal rates on a low-power, high-speed
milling machine, emphasis needs to be placed on the cut
parameters and tool path to be used. Sometimes the cutting
tool will be entirely different and designed to take advantage
of the cutting strategy and/or material being machined.
Cut parameters. Radical adjustments of speed, feed, and
depth and width of cut are all necessary considerations for
optimizing high-speed roughing. With this approach, the
radial engagement of the cutting tool is limited, so speed can
be increased (often to the maximum spindle speed). Its not
uncommon to use spindle speeds ranging from two to five
times the normal operating speed for a given material. In
many cases, spindle speed is limited by the overall feed rate
that the machine can keep up with. Milling machines, for
example, accelerate and decelerate the feed rate to ensure
accuracy and/or to optimize rough milling operations. Its
possible to reach a point where the machine tool will not
feed any faster and will not achieve the programmed feed
rate. If this occurs, the chips being generated will not be
thick enough to carry heat away from the cutting zone. Then
temperatures in the cut will be higher, and tool life will be
negatively affected.
To accommodate for the light radial engagements being
applied, feed rates must be adjusted. This adjustment is due
to radial chip thinning (RCT), and it occurs anytime less than
50 percent of the tools diameter is engaged. The feed rate
Image courtesy of Iscar.
should be increased to achieve the recommended chip thickness, or tool life will decrease. (If you operate CNC machinery and are not familiar with RCT, an Internet search on the
subject can get you moving in the right direction.)
For high-speed roughing, width of cut is usually set at somewhere between 5 and 10 percent of the cutting tool diameter.
This means a 0.50-inch end mill will be engaged 0.025 to 0.050
inch. This setting will impact RCT calculations as well. For
example, the average recommended feed rate for a 0.50-inch
tool is approximately 0.002 inch per tooth. For a 0.50-inch tool
operating at 0.025-inch width of cut, the feed would need to
be programmed at 0.0046 inch per tooth to accommodate for
RCT. RCT has a great impact on productivity when such small
radial engagements are used. In this example, the tool would
be operating 56 percent slower than it should be, and tool life
would most likely be negatively affected.
If workpiece geometry allows, depth of cut should be set to
the maximum possible depth (flute length) of the cutting tool
(up to 3D end mills). Light depths of cut using this approach
would result in very low metal removal rates and poor utilization of the solid carbide end mill.
CAM tool paths. Many CAM systems have developed tool
paths that enable precise control of tool motion. Simply
put, the tool path maintains constant control on the radial
engagement of the cutting tool, and this allows the cutting
parameters to be increased to the highest possible level (usually limited by what the machine tool and/or workpiece will
allow) without incurring a catastrophic cutting tool failure.
It is very challenging to consistently apply the high-speed
approach to roughing without access to modern CAM tool
paths that control engagement.
An additional consideration for optimizing high-speed
roughing are CAM systems with functionality to ease necessary calculations, such as CAM software that includes a
slider bar that dynamically populates speed and feed adjustments for a given width of cut. All the math is performed by
the software, so programmers can quickly and easily get a
machine up and running in an aggressive manner.
Variable pitch/helix end mills enable more aggressive cutting parameters

to be used for rough milling processes.
Analyzing the Approach: Speed vs. Power

High-speed milling is fun to watch. When seeing a machine
travel this fast (500 inches per minute or faster), its easy to
become enamored with, and overuse, the approach. However,
the vast majority of rough milling applications with solid
carbide end mills are more productive when modern programming is combined with conventional cutting parameters
(large widths and depths of cut). Think of this conventional
approach as a power approach.
The same end mill that one would use for a conventional
power approach can be used productively for most highspeed roughing applications. There is a tendency to use end
mills with five or more flutes for high-speed roughing, but
15
Cutting parameters can be

set as if the tool is machining in
a straight line, without worry
about variations in chip thickness that result from old-style
tool paths. In the past, cutting
parameters had to be reduced
to accommodate for unexpected
tool motion that might bury the
tool, spike the chip load and,
most likely, break the cutting
tool. This reduction caused a lot
of vibration. As a result, more
manufacturers chose to use the
high-speed machining approach.
Here, it was easier to find a
stable machining zone (reduce
vibration) and limit catastrophic
tool failures. However, easy is
not necessarily productive.
Since newer CAM tool paths
eliminate unexpected tool
motion, cutting tool utilization
and metal removal can be maximized by fully engaging the
A slider bar feature provides programmers with a quick and easy way to calculate the correct cutting parameters
solid carbide end mill. Its typifor a high-speed, rough milling process.
cal for depth of cut to be set at
2D (full flute length for most
operators should beware: If the machine is not reaching the
standard designs) and, in order for maximum performance
programmed feed rate, the additional flutes will have a negato be achieved, for width of cut to be set between 60 and
tive impact on tool life. Workpiece geometry plays a big role
80 percent of the cutting tool diameter. Operating at these
as well. As geometry gets smaller/tighter, the aforementioned
parameters quickly reveals the quality of the solid carbide
acceleration and deceleration functionality may prevent the
end mills being used.
machine from reaching programmed feed rates.
The conventional, high-depth-and-width-of-cut approach
to applying solid carbide end mills is nothing new. What
is new is the composition and design of solid carbide end
mills, and the CAM tool paths that are driving them. As mentioned previously, solid carbide end mills used for the power
approach will, for the most part, be of the same designs that
would be used for the high-speed approach. The one big difference is that they will always be four-flute end mills.
The same CAM tool paths that are applied for the highspeed approach to roughing should be employed in the
power approach. These tool paths are vastly underutilized
for more conventional rough milling strategies. The same
control of radial engagement that allows us to execute a
high-speed approach gives us the opportunity to be more
aggressive in the more conventional power approach. Its not
uncommon for cutting parameters to be nearly double what
Many CAM systems create tool paths for precise control of tool motion like
they were just a few years ago, even when milling the most
the one shown here, which maintains constant control on the radial engagement
of the cutting tool.
complex geometry.
16
Image courtesy of Mastercam.
Image courtesy of Mastercam.
Cutting Tools
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Cutting Tools
Making a Decision
Material removal rate (MRR) is the main factor for determining whether to use the high-speed or power approach to
roughing. A quick and simple method for close estimation is
to multiply the width of cut by the depth of cut by the feed
rate (inches per minute). This formula for MRR will involve a
small amount of error, as it is a linear calculation that does not
account for all the motion/acceleration and deceleration of the
machine tool during an operation. The larger the tool path,

the more deviation there will be from the calculation, particularly with the high-speed approach, since it involves more
toolpath motion.
The tool paths discussed here involve a lot of motion,
moving in and out of the cut multiple times to maintain
controlled engagement. This means there is some air time
between each pass. The larger the tool path, the more this
air factor can skew the material
removal estimations. Again, the air
factor will be greater in the highspeed approach, because it involves
more toolpath motion. Most CAM
systems have controls to help minimize the air factor, but this also will
skew metal removal calculations. All
these factors should be kept in mind
when using MRR to help choose
between the high-speed vs. the power
approach to roughing.
A final important factor in the decision is rigidity. It is advisable to consider if any of the variety of manufacturing technologies used in the roughing process (machine tool, cutting
tool assembly, fixtures, machine tool
attachments like angular heads) pose
a rigidity issue. The recommendation
would be to use the power approach
for rigid scenarios and the speed
approach for non-rigid scenarios.
Regardless of the roughing approach
best-suited to your environment, you
will most likely need to change how
youre programming and the cutting
tools you are using in order to achieve
optimal results.
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CONTRIBUTOR
Thomas Raun is a machine tool OEM specialist at

Iscar Metals Inc.
VIDEO:
Right Machine, Cutter and
Toolpath Formula
short.moldmakingtechnology.com/formula
Iscar Metals Inc.
877-294-7227
traun@iscarusa.com
iscarusa.com
18
www.thermal-tech.com
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Inspection/Measurement
VIDEO
By Jeff Petersen
Access video
at end of article.
Measurement Right on
the Shop Floor
Portable, direct computer controlled coordinate
measurement can streamline processes and reduce
inspection backlog for a better bottom line.
Images courtesy of Fowler High Precision.
s technology progresses and more mold shops are

using 3D CAD models for their designs, highly accurate 3D measurement tools have become increasingly
necessary for inspection, both during mold design and manufacturing. And, just as the technology related to the design and
manufacture of molds has progressed, so, too, has technology
related to quality, measurement and inspection tools.
One such technology advancement is in the size of such tools.
The availability of compact, portable direct computer control
coordinate measuring machines (DCC CMMs) means designers
and manufacturers can now bring automated, accurate, repeatable 3D measurement directly to the engineering room or shop
floor. Previously, this measurement could only be completed
in a dedicated area or with a less-accurate piece of equipment.
So, what do mold builders need to look for in a portable
DCC CMM in order to maximize their investment and reap
the most benefits? Following are four attributes of a portable
DCC CMM that, when applied correctly, can streamline processes and produce less waste, ensuring a better bottom line:
1. Speed and accuracy. Time savings equal cost savings,
regardless of the industry. The ability to quickly and accurately inspect a mold at any time during the design or production processes can help an operator identify defects or signs
of wear before too much waste is produced or production is
impacted significantly.
DCC technology in a portable CMM allows the device to
take over and conduct automatic measurements instead of
the operator having to perform repeated manual inspections.
This technology can reduce typical error that can accompany
handheld measurement tools or other manual measurement
processes, including varying measurements from one measurement to the next, or from one operator to the next.
While accuracies on the shop floor or in the manufacturing
environment are highly dependent on climate (temperature)
20
Because of their all-in-one design, icon-driven touchscreen and teach and

repeat mode that allows direct computer control technology to take over and
conduct measurements, operators can be trained to run complex 3D measurements programs on a portable direct computer control CMM within a day or two
of on-site training.
and conditions (vibration or moisture), portable DCC CMMs

have been tested in laboratory environments to perform at
diametral (round-part) accuracies of 3.0+ (D/100 mm) and
linear accuracies of 5.0+ (L/100 mm)an average of three to
five times higher accuracies than manual, portable articulatedarm CMMs. Conventional CMMs have higher accuracies than
portable ones, but they also come at a higher price tag, and
require a dedicated space and often a dedicated employee to
perform inspections.
DCC technology also allows for repeatable measurements at
speeds ranging to 150 millimeters per second (mmps), which
Measurement Right on the Shop Floor
means inspections happen more quickly compared with manual methods. In addition, with 360-degree rotation, parts can be
nested around the entire perimeter of the device for efficient
and repeatable group inspections.
2. Ease of use. Aside from speed and accuracy, another important feature of measuring equipment that ultimately helps with
the moldmakers bottom line is ease of use. A portable DCC
CMM is manufactured as a compact, self-contained unit, making it fundamentally different from conventional CMM technology, design and operation, as operators can take measurements
and run 3D programs with substantially less training.
For example, the programming process with a portable DCC
CMM is done by first teaching the device the program to be
written through manual inspection. The device then learns
the measurement program from that inspection and can take
over in its automated, or DCC, mode at repeatable speeds and
accuracies. In fact, with touchscreen, icon-driven operation
similar to a smartphone, operators with a very basic understanding of geometry can write complex 3D programs within a
couple of hours. Not only is program development simplified
so that more employees can be trained on the device, but once
a program is written, anyone can conduct inspections at the
same accuracy, speed and repeatability, eliminating measurement differences attributable to differing users.
The reduced time on training alone can translate into significant cost savings. Full training for a portable DCC CMM
requires no more than a day or two on-site, compared with
off-site training costs,
Rotary motion as the primary travel fees and other
axis on these devices, allows expenses associated
with other sophisticated
for a smaller footprint than
metrology devices.
CMMs often have their
a conventional CMM. The
own proprietary software
type of motion allows the
that requires updates and
measuring device to turn
licensing fees, particularly
for producing 3D meaaround in a circle while the
surements. Therefore,
part under inspection sits
another consideration
outside it.
that can lower training
time and further save
money is an open architecture software interface that gives moldmakers the ability to
continue using their existing, already-familiar metrology software instead of learning a completely new platform.
For companies that do not need to leverage more complex
or third-party 3D metrology software, and that also want to
conduct common geometric measurements (plane, sphere,
angle or cone), built-in geometric measurement software
enables them to take advantage of the DCC technology right
out of the box, without the need for a secondary computer.
Portable DCC CMMs also have icon-driven screens that
With the availability of portable DCC CMMs, designers and manufacturers

can bring automated, portable, accurate, repeatable 3D measurement directly
to the engineering room or shop foor.
enable the user to view measurements. Without this interface,

a secondary computer would be required for users to view
results and run programs. Portable DCC CMM devices typically also come equipped with an Ethernet cable for data transfers
or a WiFi option that supports data transfer in many formats,
including Excel spreadsheets.
3. Portability and versatility. Undoubtedly one of the most
unique benefits of a portable DCC CMM is the portability and
versatility it offers. A typical hand tool can only take a single
dimensional measurement at a time, while a portable CMM
gives operators the flexibility to take 3D measurements directly
at the mold. Direct computer controlled 3D measurements can
be taken on the shop floor at the point of production, inside
a part, outside a part, or even on a conference table or desk.
Manufacturers can also measure and inspect for wear anytime
for earlier maintenance and less downtime due to failures.
The benefit of the ability to deploy automatic 3D measurement directly on the shop floor cannot be overstated. Rotary
motion as the primary axis allows for a smaller footprint than
a conventional CMM. This type of motion allows the measuring device to turn around in a circle while the part under
21
Inspection/Measurement
inspection sits outside it. Many conventional CMMs move

rectilinearly (in a straight line) and use air bearings to provide
precision movement while the part being measured sits inside
the machine. A compact, self-contained unit, particularly if it
is lightweight and battery-operated, has few restrictions on
where it can move. Taking automated measurements directly
to the part saves time and money.
In addition, the weight and height of a portable DCC CMM
(typically less than 30 pounds and 24.4 inches (620 mm) tall)
means these devices can be shipped directly back to the manufacturer for service instead of requiring an in-house service call.
4. Total cost of ownership. Other considerations that contribute to a better bottom line for the moldmaker and the
devices total cost of ownership are initial equipment price,
upgrade costs and licensing fees. Because of its size and allin-one design, a portable device tends to be on the low end of
the cost range for DCC CMMs, making
it attractive to users who have tighter
tolerance requirements than manual
inspection can provide and a need to
conduct portable measurements. The
value of free hardware or software
upgrades, and no licensing fees also
should not be underestimated.
Additionally, because, as stated earlier, a portable DCC CMM is designed
to be ready to use directly out of the
box, all of the equipment, including
the probe and built-in software, are
installed ready for use without requiring lengthy calibrations. Together,
calibration setup and training time on
a conventional, non-portable CMM can
take eight weeks or longer before it is
up and running.
Time is money in todays world, and
portable DCC CMMs may help moldmakers meet their inspection needs
while saving both. For high-throughput
shops, or any application that requires
repeatability and flexibility, the faster
and more accurately parts can be measured, the better.
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22
CONTRIBUTOR
Jeff Petersen is vice president of sales for Fowler

High Precision.
VIDEO:
Measuring Odd-Shaped Parts with a DCC
CMM
short.moldmakingtechnology.com/
portable
EOE M/F/D/V
Fowler High Precision

800-788-2353
fowlerprecision.com
Hot Runners
By Peter Rebholz
Multiple Impact
Incorporating multiple-gate
nozzles means smaller molds,
small presses, a balanced fill
rate, reduced residence time,
temperature control and
design flexibility.
24
The main body of this system acts as a distribution

manifold by taking the single point of injection from the
machine and distributing the feed equally in a spoke-like
manner to any gates within the body.
its 1-inch minimum to 4-6 inches (depending on the application), which allows the use of more gates.
Here are three key benefits associated with independentgate-probe-style, multiple-gate nozzles:
1. Design flexibility. The fact that the diameter of the gate
probe can increase to any dimension ranging to 4 inches and
the number of gate locations also can increase presents new
mold opportunities that might not previously have been considered. Take, for example, a mold for a glass-filled nylon fan
Images courtesy of Osco Inc.
multiple-gate-nozzle hot runner system offers design

flexibility, increased application opportunities, and
cost and processing advantages. Such a system consists of a main body with multiple gate probes. The body acts
as a distribution manifold by taking the single point of injection from the machine and distributing the feed equally in a
spoke-like manner to any number of gates within it. The body
is heated with a single heater and controlled by a thermocouple.
Two primary multiple-gate-nozzle types are differentiated
by the design of their gate probe elements. In one design, the
gate probes are heated
The intrinsically balanced feed individually, with a
from this nozzle provides the heater and thermocouple
for each gate probe. In
required concentricity, and
the other, the probes
are manufactured from
the independently heated
a conductive alloy that
hardenedcarbide-tipped
relies on the heat proprobes provide the required
vided by a single heater
around the body. Noncontrol at each gate to
produce quality parts without heated probes offer a
smaller gating diameter
stringing or drooling.
( inch), and because
of the separate heat
source are generally
limited to a maximum diameter of approximately 2 inches.
The independent power source at each gate of an independently heated gate probe allows for a wider application window than the conductive alloy gate probe, enabling, for example, the use of more high-heat resins. Also, the gating diameter
of the independently heated gate probe can be increased from
This glass-flled nylon fan was produced from a single-cavity mold using a
multiple-gate-nozzle hot runner system with multiple gate probes.
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Hot Runners
that is molded using a multiple-gate nozzle with one gate

probe per fan blade. A multiple-gate-nozzle hot runner system
can be equipped with seven, nine or 11 probes, depending on
the number of fan blades on the piece part. The gate on each
blade can be located where it is best-suited for the application.
The intrinsically balanced feed from this nozzle provides the
required concentricity, and the independently heated and hardened carbide-tipped probes provide the required control at each
gate to produce quality parts without stringing or drooling.
LEARN MORE
For more information on hot runner technology, visit our Hot
Runner Zone at moldmakingtechnology.com/zones/hot-runners.
2. Processing advantages. Having a heater and thermocouple positioned directly at each gate provides the necessary
power and control needed to handle a wide range of resins, but
especially difficult resins such as nylon, Amodel, Ryton, polyesters and other high-heat resins. Without the heat source right
at the gate, these types of resins would likely freeze off or drool
due to the inconsistent heat from the one body heater to each
A heater and thermocouple positioned directly at each gate provide the

necessary power and control needed to handle a wide range of resins.
individual gate probe. The spoke-shaped

feed-channel design is geometrically balanced from the machine nozzle input to
each of the gates, enabling a balanced fill
rate. This design also means there will be
minimal residence time within the multiple-gate-nozzle hot runner as compared
to a traditional hot runner.
3. Cost savings. Generally, a multiplegate-nozzle hot runner system will be
less expensive than a system with a separate manifold with nozzle drops, which
requires more steel and additional components. A multiple-gate-nozzle hot runner
system also has a smaller footprint and
enables use of a smaller mold, which not
only requires less material and machining
time, but may also allow for a smaller press
with a less expensive hourly rate.
HAIMER
Power Clamp:
Reliable shrinking
Fastest in the galaxy.
CONTRIBUTOR
Peter Rebholz is vice president of sales at Osco Inc.

Shrinking Technology
Tooling Technology
Balancing Technology
Haimer USA, LLC | 134 E. Hill Street | Villa Park, IL 60181 | Phone: +1-630-833-1500
Email: haimer@haimer-usa.com | www.haimer-usa.com
26
Measuring Instruments
Osco Inc.
248-321-5230
prebholz@oscosystems.com
oscosystems.com
Process Cooling
By Al Fosco
Process Cooling
Boosts Mold Efficiency
Mold builders can optimize mold performance by taking
advantage of advanced process cooling technology.
hether its for a precision mold with a relatively

low production volume or a straightforward mold
designed specifically for a high production run, the
importance of incorporating process cooling continues to
increase for mold builders.
The reason is clear: Process cooling and its associated data
points, including flow, pressure and temperature, play an
Images courtesy of Frigel North America.
essential role in optimizing mold efficiency, which translates

to reduced cycle times. To be competitive, mold builders
must optimize a mold for efficiency, record the data used to
achieve this efficiency and share the data with molders so
they can achieve the same results.
Fortunately, advanced process cooling technology is available in the form of a closed-loop fluid cooler and a combination chiller/temperature control unit (TCU) at each machine.
Such an integrated system can help moldmakers more readily
optimize a mold for efficiency. More specifically, the system
provides greater flexibility in temperature control compared
with a conventional central process cooling system. It also
provides constant water pressure and flow to the cooling
process. The end result is the ability to optimize a tool for
maximum results. Additionally, by recording all pertinent data
on a process sheet, moldmakers can relay critical information
to molders.
This closed-loop fuid cooler, which is housed outside a facility, serves as

the primary component of an integrated, closed-loop cooling system. It provides
clean water at the right temperature to molding machines year round.
28
Cooling Basics
Process cooling typically consumes 60 to 70 percent of a
molding cycle. Simply put, nothing else is happening in the
molding process while the mold cools. The ability to reduce
the amount of required cooling time therefore translates to
an exponential decrease in cycle time, which means improved
production for the molder and better profit margins.
What it boils down to for the molder is the need to maintain product quality from cycle to cycle and even cavity to
cavity while still meeting production goals. Validation is
mandatory in industries that require critical parts, such as
those used in medical, aerospace and other applications.
However, validation perhaps is equally important even in
less-critical applicationsbottle caps, for example,since the
ability to save just pennies on millions of parts still results in
substantial gains in profitability.
In a nutshell, the function of a process cooling system is
Pre-Cooling
Chamber
(operates only
when required)
This closed-loop fuid cooler design uses heat exchangers and an internationally patented pre-cooling chamber to cool water circulated to it from process
machines. The chamber pre-cools ambient air on hotter days before it enters
the units heat exchanger compartment. Cooled water is then re-circulated to a
facilitys process machines.
Closed-loop fuid coolers can be used with individual combination chiller/

temperature control (TCU) machines to achieve accurate temperature control with
minimal temperature variation at each molding machine.
to remove the heat from the mold. Key process cooling

parameters include cooling system capacity, coolant pressure
and coolant temperature. These factors help determine the
optimal operating point for each mold because they dictate
the efficiency of the heat transfer and, therefore, optimal
cycle time.
Moldmakers should tell their customers what parameters
were used to achieve tool quality in a specified cycle time.
Specific data should include capacity used for mold validation,
coolant type (water or water/glycol mixture), coolant supply
pressure to the mold, flow rate from the cooling system and
individual flows for each mold circuit, temperature of the
coolant supply to the tool, and temperature differential across
the tool and each individual cooling circuit. The lower the
temperature differential across the tool, the more efficient the
tool, as this number signifies high flow and turbulence.
Of course, if the customer does not follow the mold builders recommendations, this molder may not achieve the same
results.
Cooling Approaches
As mentioned earlier, there are multiple approaches the
moldmaker can use to supply process cooling to molds.
Traditional methods typically involve a central proA closed-loop system
cess cooling configuration
eliminates the problems
that takes the form of either
associated with dirty water, an open cooling tower, or
air- or water-cooled central
and it uses less water and
chillers. These methods
energy than a traditional
often fall short in identifying and validating the
confguration, because it
characteristics needed to
takes the cooling tower
optimize the mold for peak
and the air-cooled chiller
efficiency, however. They
also can stand in the way of
out of the equation.
profitability.
An open cooling tower
provides cooling water
directly to both the machine and the mold. The cooling
tower extracts heat by allowing a small portion of the water
to evaporate into a moving air stream to provide significant
cooling to the rest of that water stream. If the cooling tower
is used as the central system, however, it cant effectively control the temperature of the process cooling water, because
it cannot provide water below the ambient wet bulb temperature it is capable of producing. In other words, the more
humid the atmosphere, the lower the capacity of the cooling
tower.
Another challenge related to evaporative cooling towers
is poor water quality, which results in contamination and
scaling inside the mold cooling channels. Scaling reduces
29
Process Cooling
Positioned next to molding machines, combination chiller/TCU machines ensure consistent

supply pressure and high turbulent fow throughout a mold in addition to providing more precise
temperature control.
the efficiency of heat transfer, since

scale buildup acts as an insulator and
prevents the water from scrubbing
the heat from the tool. Therefore, frequent mechanical removal of the scale
is required.
An open-air system also creates the
risk of waterborne illnesses such as
Legionella, since the stagnant water
typically present in the basin of a cooling tower provides ideal conditions for
the growth of bio-organisms, and the
potential for contaminated water
vapor or droplets to be introduced to
surroundings.
To avoid problems associated with
dirty water, some moldmakers install
air-cooled chillers to cool molds and
machines. Air-cooled chillers use ambient air to remove heat through a refrigerant circuit, similar to a household air
conditioner that removes heat from the
air and dissipates it outside the house.
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However, because such air-cooled chillers rely on ambient air

to remove the process heat, this setup is costly. The higher
the ambient air temperature, the higher the compressor condensing temperature and therefore the lower this compressors efficiency and the more electrical energy required to
provide the chilled water.
The air-cooled chiller setup also adds complexity, as
some operations might call for higher temperatures
than an air-cooled chiller can provide.
This increased cooling temperature
would be determined by the mold
design and desired cycle times. In such
cases, a TCU is needed to increase the
cooling temperature and therefore
optimize the tool. The need to heat
water that was previously cooled also
adds operational costs in the form of
energy consumption.
culated from the molding machines. This systems process is

as follows:
1. In the pre-cooling chamber, a fine mist of water is pulsed
into the incoming air stream in high ambient temperature
conditions.
2. The mist evaporates instantly, cooling the air before
it impinges on the cooling coils that carry the process
water.
A combined chiller/TCU machine can provide

process cooling water temperatures from 48F (for
non-glycol systems) to 195F, with accuracy of 0.5F.
In addition to compensating for

proper temperatures, moldmakers
and molders alike also must address
the reality that water pressure (and
therefore flow) will rise and fall as the
numbers of machines being cooled go
on and offline, no matter what type
of traditional central process cooling
configuration is used. Fluctuations in
pressure and flow in process cooling
are similar to the same fluctuations
that occur when water is used in a residential home.
An increasing number of mold
builders are now turning to integrated,
closed-loop process cooling systems
that incorporate central fluid coolers
and a combined chiller/TCU at each
machine. One such integrated system
uses a closed-loop fluid cooler with a
pre-cooling chamber to cool water cir-
31
Process Cooling
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3. The process drops the temperature

at or below the setpoint. Cooled water
is then re-circulated to the facilitys
molding machines.
4. A microprocessor-based controller
automatically maintains targeted cooling temperatures.
This closed-loop system, eliminates
the problems associated with dirty
water, and it uses less water and energy
than a traditional configuration, because
it takes the cooling tower and the aircooled chiller out of the equation.
The closed-loop fluid cooler and
combined chiller/TCU also offers
simplicity and cost savings versus a
cooling tower/central chiller/TCU
configuration, given that fewer pieces
of equipment are required. Less water
and energy consumption also translates to savings over the life of the system. Additionally, maintenance costs
associated with cooling towers are
eliminated, on top of the reduced
costs associated with chemically
treating the system.
Key to the integrated system are
machine-side combination chiller/
TCUs, which include packaged watercooled refrigeration systems and,
depending on the machine, either one
or two TCU circuits housed inside a
compact cabinet. A solution like this
provides flexibility, because each chiller/TCU is dedicated to its own molding press and operates independently
from the other units. It isolates the
mold from the rest of the facility, and a
high-flow process pump feeding water
to each machine ensures consistent
supply pressure, temperature and delivery of high turbulent flow throughout
the mold.
The combined chiller/TCU also independently controls

each mold half and accommodates precise heating and cooling requirements. Users can adjust each zone to readily
achieve temperatures ranging from 48F (for non-glycol systems) to 195F. Additionally, combined chiller/TCUs with servo-proportioning, three-way temperature-control valves offer
consistent and precise temperature control, which can yield
an accurate temperature setting for a
given mold and specific material. The
valves tightly control the amount of
cold water bleeding into the mold from
the refrigeration circuit. In combination with tight control of the internal
heaters, temperature can be smoothly
fluctuated up and down within 0.5F of
the setpoint.
chillers is significantly reduced, providing cost savings.

To remain competitive, mold builders must focus on ways
they can speed cycle times, from mold design to declamping/
open/eject rates and everything in between. Those who pay
extra attention to process cooling options will find they can
add value for their customers and improve profitability at the
same time.
LEARN MORE
Check out our online Supplier Directory
to learn about companies manufacturing
related processing equipment.
moldmakingtechnology.com/suppliers
Another benefit of an integrated

closed-loop system is free cooling,
meaning the central fluid cooler
provides water at the necessary temperature where needed without using
chilled water, resulting in significant
energy savings. Additionally, the unit
automatically cycles off its compressor
to satisfy the cooling load at the exact
temperature requirement and delivers
only the level of refrigeration needed.
The clean water central cooler provides
the rest of the load without the need
for refrigeration. The need to power
energy-intensive compressors used on
CONTRIBUTOR
Al Fosco is global marketing manager for Frigel

North America.
Frigel North America
847-540-0160
sales.fna@frigel.com
frigel.com
33
UNDER THE
By Eric Hild
A single day in a tool welding shop is filled with a variety of
projects that demand immediate attention, from retrofitted
molds and inserts to damaged pins and slides. Some molds
arrive after being damaged in service, while others require an
engineering revision. Every job is hot, and that means each
one needs to be turned around as quickly and efficiently as
possible to keep customer downtime at a minimum. A tool
welder never knows the type of repair he or she will encounter on any given day, so preparation is essential. Asking the
following three questions for each job will help:
1. What is the damage? A direct line of communication
between the tool welder and mold builder is essential when
Fixing damaged edges is the most common mold repair.
repairing a mold. Both parties have to listen and be heard.
Each needs to be clear about what he is explaining and what
require a specific set of skills in torch position, amperage
he is understanding. Simply marking up an area to be welded
control and welding puddle control.
does not give the whole story. Ideally, the mold builder or
Every job is different to a tool welder, even if he or she
toolroom supervisor is present at the welding shop to explain
has previously worked on the same mold. There is always
the repair and answer any questions. However, due to time
something new that can be encountered, including cracks,
and distance, this is not always possible. Plus, molds are often
coatings, oils or even a detail on the mold thats blocking the
at the mercy of delivery by a shipping department, driver or
microscope. Also, the customer may have special requests,
mail service. In these situations, it is essential that the mold
such as asking that little to no heat be applied on the mold.
builder mark up the area to be welded and provide paperFulfilling this request is only possible through laser welding,
work with drawings and a contact name.
so the welder must be prepared to discuss all advantages and
I also recommend following up any written explanation
disadvantages. With all of these variables in play, the welder
with a phone call, unless the damage is clearly evident and
constantly relies on his or her experience to provide the best
potential for problems does not exist. Under a microscope,
possible outcome for the customer.
the welder may notice something that was missed previously,
3. Will welding fix the damage? Welding is not always the
such as damage thats not marked for welding and areas that
answer for achieving a successful mold repair, and sometimes
could potentially be damaged by welding. Other times the
tool welder might need clarification on the steel type or
size of the buildup, since the
customer is requesting a hard
or soft weld depending on
the area being welded. Also,
unforeseen problems, such as
cracks, can be encountered
during welding that will
require the repair to cease and
the customer to be contacted.
2. What is to be welded?
Obviously whats to be welded
determines task difficulty.
The most common repair is
fixing a damaged edge. Other
repairs include filling in subgates and gates, and restoring
A runner that is flled in during a tool repair will need to be
Here, laser welding is used to repair a pad and
re-machined after welding.
edges on an aluminum bronze mold.
broken details. These repairs
34
Images courtesy of Toolweld Inc.
Understanding the Task
Laser welding can also be used to repair a shut-off edge.
welding can damage the mold further, such as when welding

a deep area in a cavity where there is no easy access for a TIG
torch or laser optics. Attempting to weld in these areas could
create damage to other areas that are extremely difficult to
fix. The customer must be made aware of these problems as
they occur so that he or she can consider a repair method
other than welding.
In these cases, it is essential to take a step back and provide
feedback to the customer, including alternative repair methods. Occasionally, due to time constraints and pressure from
the customer, the welder may be required to perform a repair
in a manner that he or she knows will spell disaster. In those
instances, a general rule of thumb should be to ensure that the
customer is fully aware of the risk before proceeding with the
weld repair.
CONTRIBUTOR
it is only a temporary solution to a recurring problem in mold

operation that is causing the damage. When inspecting and
diagnosing a job, the tool welder should always consider multiple ways to fix the problem, because there is risk involved in
welding. Adding a weld means making chemical and molecular changes to the mold. There are also situations where
Eric Hild is a laser and micro-TIG welding specialist at Toolweld Inc.

Toolweld Inc. / 847-854-8013 / 847-809-3959
eric@toolweldmicro.com / toolweldmicro.com
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35
KEEPING UP WITH
A New High-Level Structure

By Lewis Yasenchak
The CEO/owner of a company is responsible for its strategic leadership, ensuring the organizations future relevance,
credibility and viability. Now, as outlined last month, the ISO
9001:2015 standard for quality management requires that
leadership steer the compliance process as well. This forces
them to also be leaders in their tool and die and injection
molding related industries, using their capable workforce
and modern technologies to produce quality products. It also
requires an understanding that all products and services are
the result of a process, and that all processes must be continually improved by the process owners.
Your organization can be on its way to reducing costs,
increasing efficiency, gaining access to new markets and establishing a competitive advantage by examining and complying
with the 10 new or revised clauses of ISO 9001:2015, which
can be found in this chart. (ISO 9001:2008 has eight clauses.)
NEW OR REVISED CLAUSES OF ISO 9001:2015
ISO 9001:2008 Structure
Scope
Normative References
Terms and Defnitions
Quality Management System
Management Responsibility
Resource Management
Product Realization
Measurement, Improvements
Clause
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
ISO 9001:2015 Structure

Scope
Normative References
Terms and Defnitions
Context of the Organization
Leadership
Planning
Support
Operation
Performance Evaluation
Improvement
To provide a clear understanding of each clause, the

respective changes and the business impact, we will examine
a few each month in this column. This month, we review the
first three.
1.0 Scope: ISO 9001:2015 now requires records of transparency and accountability for all employees, including those
involved in CNC machining processes, finite element analysis,
mold flow analysis and CAD/CAE/CAM analysis. Prior to this
revision, keeping of such records was only recommended, not
required. Basically, this clause of the quality standard for moldmakers and molders serves to support their business plans.
2.0 Normative References: ISO 9001:1987 was revised in
1994, 2000, 2008 and 2015. The standard was first introduced
in 1987 as a manufacturing processes standard. In 1994,
emphasis shifted to producing assurance using preventive
actions. Those changes were followed by a large update in
2000 that focused on quality management and further refinement in 2008. The latest evolution of the standard uses the
new Annex SL structure, which harmonizes the text, terms
36
and definitions for all management system standards, including ISO 9001; TS 16949, 13485 and 14001; and OHSAS 18001.
The revision also adds new contextual requirements such as
records of confidentiality and intellectual property protection
on businesses. It also emphasizes the importance of understanding the internal and external context of the organizations with which a company has relationships, verifying and
validating process/product manufacturing flow, for example.
3.0 Terms and Definitions: The following terms have
been added to properly define the supply chain: supplier,
organization and customer. Prior to this revision, only the
company and customer relationships were recorded and
under control. The organization maintained records for customers in sales, accounting and auditing to ensure achievement of the organizations objectives in operational effectiveness and efficiency. Few suppliers (vendors) were providing
help with financial reporting and complying with laws, regulations and policies. Now, supplier performance metrics are
required as well.
A supply chain includes all activities, functions and facilities (directly or indirectly) in the flow and transformation
of goods and services from raw material to finished product
to end user delivery. These activities include procurement,
customer service, distribution, transportation, inventory
control with information systems, sales, planning, order
entry, receiving, shipping, inspection, purchasing, production
scheduling, master scheduling, warehouse management and
supplier management. The supply chain also encompasses all
interconnected relationships,
Examining and complying including the moldmaker,
molder, designer, materials,
with these frst three
sales channel, distribution,
warehousing, manufacturing,
revised clauses should
transportation and suppliers.
enable your company
ISO 9001:2015 now requires
to produce metrics on
an increased emphasis on
achieving value across the
problem areas, track
entire supply chain by offering
customer feedback
guidance on reducing total
and establish a changecost of ownership, producing
customer surveys, improvmanagement process.
ing suppliers performance
report cards, emphasizing
risk-based management across
all departments, and how to use corrective and preventive actions (CAPA) to identify risk levels (high, moderate
or low). CAPAs are improvements to a companys processes
that eliminate causes of non-conformities or other undesirable situations. Examples are putting in place a system that
provides notification and escalation of CAPA due dates and
building risk into the process to identify the biggest areas of
improvement.
Clause 3.0 requires certain documentation to be included
in a companys capability statement. For moldmaking, this
might include something along the lines of the following:
Milling Division: The company uses the most precise CNC
milling machinery available, and the milling department is
fully equipped to accept a wide range of applications from
small to large components with complex surfaces and contouring.
Lathe Division: The company uses multiple CNC lathes
with four-, five- and six-axis and bar-feeding capabilities.
Personnel participate in weekly planning meetings to decide
how work will be most efficiently distributed to ensure high
morale and a high level of competence.

Grinding Division: Cylindrical grinding (OD, ID and centerless) is an integral part of the mold machining process for
this company. From large to small products, grinding is the
most cost-effective approach to ensure consistent sizing and
a precise finish.
Metal Prep Division: Properly preparing metal for tooling is an important step for the moldmaker. Management
understands that precision sawing combined with facing
and centering are essential steps toward ensuring a quality
finished product.
Projects Division: The company brings engineers and toolmakers together to manage a customers job in the most
efficient and quality-conscious manner possible. Advanced
planning and coordination ensure customer satisfaction.
From problem-solving and prototyping to manufacturing
and delivery, the company can easily accommodate one,
1,000 or 100,000 pieces.
Engineering: The companys goal is to meet customers tooling, engineering and production needs. If the CNC program
for a job requires geometrical support, engineering may assist
the moldmaker with developing the project. The company has
developed a unique and diverse approach toward helping customers solve technical problems and industrial challenges.
Examining and complying with these first three revised
clauses in ISO 9001:2015 should enable your company to produce metrics on problem areas, track customer feedback and
establish a change-management process. (Change management encompasses the people side of the processes, tools and
techniques that are necessary to achieve a required business
outcome.)
One of the keys to compliance is benchmarking against
metrics. Consider a centralized reporting system to help
build reports and analytics related to company processes.
Another key is post-market feedback, which is a central area
for collecting adverse event data. If you are not collecting and
captioning these items, you may miss key compliance issues.
Lastly, take event data and automate the process of operational change. All of this will reduce costs, increase efficiency
and yield a competitive advantage.
Next month, we will examine Clauses 4.0 to 6.0.
CONTRIBUTOR
Lewis Yasenchak, MBA, BS, is the founder/owner of P&Y Management

Resources, which specializes in building and improving the plastics industry
supply chain.
P&Y Management Resources
706-694-2977 / lewis.yasenchak@windstream.net
37
THE BOTTOM
Tax Extenders Package

By Michael J. Devereux II, CPA, CMP
On December 18, the U.S. Congress passed and President
Obama subsequently signed the Protecting Americans from
Tax Hikes Act of 2015 (the Act), commonly known as the
Tax Extenders Package. Without passage of this legislation,
which retroactively extended many important tax provisions,
hundreds of thousands of individuals and companies would
have seen a higher tax bill for 2015. Some provisions also have
important modifications that will affect businesses. Most
importantly, several of these provisions have been made permanent, which is great news. Here is a summary of the most
prominent tax provisions affecting mold builders:
Increased expensing limitations for Section 179 property.
The legislation permanently extends the small business expensing limitation and phase-out amounts, which had been in effect
from 2010 to 2014, to $500,000 and $2 million, respectively. Prior
to this legislation, the amounts had been reduced to $25,000
and $200,000, respectively. The expensing limitation is modified by indexing both of those limits for inflation beginning in
2016. Air conditioning and heating units placed in service in tax
years beginning after 2015 are also eligible for expensing.
Research tax credit. There are several key points to be aware
of related to the credit for increasing research activities. First,
the credit has been permanently extended. In addition,
Without passage of this
for tax years beginning after
legislation, hundreds of
December 31, 2015, the Act
thousands of individuals allows eligible small businesses
with average sales of less than
and companies would
$50 million over the prior
have seen a higher tax
three tax years to claim the
credit against the Alternative
bill for 2015.
Minimum Tax (AMT) and
small start-up companies with
less than $5 million of gross
receipts to claim the credit up to $250,000 a year against their
FICA payroll tax liability.
Mold builders that are developing new tool designs, developing part-specific fixturing or manufacturing processes, or
improving production processes through automation may
qualify for the research tax credit.
Bonus depreciation. The Act extends bonus depreciation
for assets acquired and placed in service during 2015 through
2019. For property placed in service during 2015, 2016 and
2017, the bonus depreciation percentage is 50 percent. This
percentage phases down to 40 percent in 2018 and 30 percent
in 2019. In addition, businesses may elect to accelerate the
use of AMT credits in lieu of bonus depreciation under special rules for property placed in service during 2015.
38
Work opportunity tax credit. The legislation extends the

work opportunity tax credit (WOTC) through 2019. This
credit rewards companies for hiring specific targeted groups,
such as qualified veterans, food stamp recipients and exfelons. In addition, beginning in 2016, the credit has been
modified to apply to employers who hire qualified long-termunemployed individuals, those who have been unemployed
for 27 weeks or more. The credit is also increased with
respect to such long-term-unemployed individuals to 40 percent of the first $6,000 of wages paid. This tax credit is one
of the few that may offset the AMT, making it particularly
advantageous to those companies subject to the AMT.
179D energy-efficient commercial buildings deduction.
Available to taxpayers implementing energy-efficiency improvements to lighting, heating, cooling, ventilation and hot water
systems of commercial buildings, this provision allows for accelerated deductions worth as much as $1.80 per square foot. The
legislation extended these deductions through 2016.
Additional Provisions
Here is a complete list of provisions addressed by the Act:
June 8-9, 2016 | Donald E. Stephens Convention Center | Rosemont, IL
Maintenance. Repair. Operations.
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THE BOTTOM
Permanent Extensions
Tax Relief for Families and Individuals
Child tax credit
American opportunity tax credit
Earned income tax credit
Deduction for certain expenses of elementary and secondary
school teachers
Parity for exclusion from income for employer-provided mass
transit and parking benefits
Deduction of state and local general sales taxes
Incentives for Charitable Giving
Special rule for contributions of capital gain real property
made for conservation purposes
Tax-free distributions from individual retirement plans for
charitable purposes
Charitable deduction for contributions of food inventory
Tax treatment of certain payments to controlling exempt
organizations
Basis adjustment to stock of S corporations making charitable
contributions to property
Incentives for Growth, Jobs, Investment and Innovation
Research credit
Employer wage credit for employees who are active duty
members of the uniformed services
15-year straight-line cost recovery for qualified leasehold
improvements, qualified restaurant property and qualified
retail improvement property
Increased expensing limitations and treatment of certain real
property as section 179 property
Treatment of certain dividends of regulated investment
companies
Exclusion of 100 percent of gain on certain small business stock
Reduction in S-corporation recognition period for built-in
gains tax
Subpart F exception for active financing income
Real Estate Investment
Temporary minimum low-income housing tax credit rates
for non-Federally subsidized buildings
Military housing allowance exclusion for determining whether
a tenant in certain counties is low-income
RIC-qualified investment entity treatment under FIRPTA
Extensions through 2019
New markets tax credit
Work opportunity tax credit
Bonus depreciation
Look-through treatment of payments between related controlled foreign corporations under foreign personal holding
company rules
40
Extensions through 2016

Tax Relief for Families and Individuals
Exclusion from gross income of discharge of qualified principal
residence indebtedness
Mortgage insurance premiums treated as qualified residence
interest
Above-the-line deduction for qualified tuition and related
expenses
Incentives for Growth, Jobs, Investment, and Innovation
Indian employment tax credit
Railroad track maintenance credit
Mine rescue team training credit
Qualified zone academy bonds
Classification of certain race horses as three-year property
Seven-year recovery period for motorsports entertainment
Accelerated depreciation for business property on an Indian
reservation
Election to expense mine safety equipment
Special expensing rules for certain film and television
Deduction allowable with respect to income attributable to
domestic production activities in Puerto Rico
Empowerment zone tax incentives
Temporary increase in limit on cover over of rum excise taxes
to Puerto Rico and the Virgin Islands
American Samoa economic development credit
Moratorium on medical device excise tax
Incentives Energy Production and Conservation
Credit for non-business energy property
Credit for two-wheeled plug-in electric vehicles
Second-generation biofuel producer credit
Biodiesel and renewable diesel incentives
Production credit for Indian coal facilities
Credits with respect to facilities producing energy from certain
renewable resources
Credit for energy-efficient new homes
Special allowance for second-generation biofuel plant property
Energy efficient commercial buildings deduction
Special rule for sales or dispositions to implement FERC or
State electric restructuring policy for qualified electric utilities
Excise tax credits relating to alternative fuels
Credit for new qualified fuel cell motor vehicles.
CONTRIBUTOR
Michael J. Devereux II, CPA, CMP, is a partner and director of manufacturing,

distribution and plastics industry services for Mueller Prost LC.
Mueller Prost LC / 314-862-2070
mdevereux@muellerprost.com / muellerprost.com
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A P R O P E R T Y O F:
GARDNER BUSINESS
MOLDMAKING
December 2015 45.7

Improved capital spending plans may mean that indicator has bottomed out.
By Steve Kline Jr.
With a reading of 45.7, the Gardner Business Index showed
that the moldmaking industry contracted in December for
the seventh month in a row. While the index had improved
notably from October to November, it took a bit of a dip
again in December, returning to about its September level.
New orders contracted for the sixth month in a row, but
this index still reached its highest level since June 2015.
Production also contracted after increasing in November.
The backlog index remained mired in contraction, remaining
below 40 in five of the previous six months. This indicates
that capacity utilization in the industry likely will continue
to fall through at least the first half of 2016. Employment
contracted in December for the first time since June 2015.
Because of the strong dollar, exports continued to contract as
well, although the rate of contraction has improved slightly
since June. Supplier deliveries shortened in the month for
the second time since August.
The material prices index contracted for the fifth month in
a row, reflecting the fall in almost all commodity prices due
to the weak global economy. Prices received contracted for
the third month in a row, however, the rate of the decrease
in November and December was
relatively modest. Future business expectations have improved
significantly in the last two
months of 2015, reaching their
highest level since May.
The index for companies with
Steve Kline Jr.
more than 250 employees had
Director of Market Intelligence
grown significantly since July but
Gardner Business Media Inc.
contracted in December. Plants
with 100-249 employees grew for
the second month in a row and the third time in the previous five months. Facilities with 50-99 employees grew at
their second fastest rate since March 2014, while companies
with 20-49 employees contracted at their fastest rate since
the survey began in December 2011. Finally, companies with
fewer than 20 employees posted an index below 40 for the
second time in the last three months of the year.
Custom processors contracted for the sixth month in a row
to their lowest level since December 2013. Meanwhile, metalcutting job shops contracted for the seventh time in eight
months, although their index improved in both November
and December.
The Southeast grew at the fastest rate by far in December
for the second month in a row. In fact, it was the only region
42
to expand in the month.

The North Central-West,
North Central-East, South
Central and Northeast
regions all posted indexes
in the mid-40s. The West
contracted at the fastest
rate, with its index fallTo see the historical breakdown of
ing below 40 for the secour business index and each of its
ond time in the last five
subindices, visit gardnerweb.com/
months of the year.
forecast/moldmaking.htm.
For the first time since
October 2014, future capital spending plans increased compared with one year earlier,
and the annual rate of change contracted at a slower rate for
the first time. It could be that future capital spending plans
have reached a bottom and have started to improve.
Subindices
Dec.
Nov.
Change
Direction
Rate
Trend
New Orders
47.8
47.1
0.7
Contracting
Slower
Production
48.3
51.2
-2.9
Contracting
Growing
Backlog
37.1
39.4
-2.3
Contracting
Faster
13
Employment
47.2
51.1
-3.9
Contracting
Growing
Exports
45.9
45.1
0.8
Contracting
Slower
10
Supplier
Deliveries
47.8
51.2
-3.4
Shortening
Lengthening
Material
Prices
48.9
47.6
1.3
Decreasing
Less
Prices
Received
48.8
48.2
0.6
Decreasing
Less
Future
Expectations
69.3
66.9
2.4
Improving
More
49
MoldMaking
Business
Index
45.7
47.5
-1.8
Contracting
Faster

skline2@gardnerweb.com / gardnerweb.com/economics/blog
Search Machines Smarter.
Spindle: Milling
Direction: V or H
# of Main Spindles:
Max. HP:
Top RPM:
Envelope:
Max. Table Length:
Max. Table Width:
Max. Part Weight:
Machine Type:
Machining Center
Drill/Tap
Boring Mill
The Machine Tool Search Engine
SOURCE: Hwacheon
Milling Machine
A Gardner Business Media Metalworking Group Product
techspex.com
END MARKET
By Steve Kline Jr.
Packaging & Medical
All Signs Positive for Packaging in 2016
12
10
10
-2
-2
-4
-4
-6
-6
n10
n11
Ja
n12
Ja
n13
Ja
n14
Ja
n15
Ja
n16
Ja
Ja
08
09
Ja
n-
07
n-
Ja
n-
n-
Ja
Ja
n-
Ja
n-
Ja
n-
n-
Ja
Ja
06
-12
04
-12
05
-10
03
-8
-10
02
-8
Food Production
12
TSI-Freight
Packaging Leading Indicators
12-Month Rate Of Change)
Packaging is not an end product in and of itself. So, like a number of other
industries, you cannot just grab industrial production data for packaging to
see how the industry is performing. However, there are two major industries
that drive packaging demand: food and industrial (primarily shipping materials). So by tracking what is happening with the food and beverage, clothing and
footwear, and trucking industries, we can get a feel for what is happening in
the packaging industry.
Food and beverage spending was virtually flat for most of 2015, but with the
strong growth in income, food and beverage spending should see accelerating
growth in 2016. In turn, food and beverage spending leads food and beverage
production, which is already growing at nearly its fastest rate in eight years.
Food packaging seems poised for significant growth in 2016.
Primarily, institutional packaging consists of stretch film, and sheet and
tubing, but consumer and industrial product liners and shrink film also are
a significant part of institutional packaging. The Bureau of Transportation
Services freight index is virtually at its all-time high, nearly 20 percent higher
than in 2000 and roughly 10 percent higher than in 2007. However, despite this
all-time high, the rate of growth was relatively flat in 2014 and even decelerated
somewhat in 2015. The growth rate is still strong enough that this is a posi-
tive for packaging demand, but the fact that the growth rate is decelerating
indicates that institutional packaging is probably a weaker market than food
packaging going forward.
Is Medical Equipment Production Poised for Growth?
10
10
Steve Kline Jr., Director of Market Intelligence, Gardner Business Media Inc.
skline2@gardnerweb.com / gardnerweb.com/economics/blog
n15
n16
Ja
as it seems to have bottomed back in July 2015. And a number of the other
subindices also seem to indicate that the industry has reached a bottom and
is beginning to improve.
FOR MORE INFORMATION:
44
Ja
Ja
Ja
Ja
Ja
Ja
nJa
nJa
nJa
nJa
n14
-10
n13
-10
n12
-8
n11
-8
n10
-6
09
-4
-6
08
-4
07
0
-2
06
0
-2
Medical Equipment Production (12-mo ROC)
Real Medical Care Spending Leads Medical Equipment Production
Real Medical Care Spending (12-mo ROC)
Since the passage of the Affordable Care Act in 2010, the normal cyclical
patterns have broken down, making it much more difficult to see the future
direction of the medical equipment industry. In the chart at right, note how
the regular ups and downs of medical equipment production (the blue line)
have become not so regular since 2010. What was once a lag time of six to 12
months between medical care spending and medical equipment production
seems to have become a two- to three-year lag time. And the complete market
cycle between peak growth rates in production every two years is nonexistent.
If my assumed correlation above is true, then medical equipment production should begin to grow at an accelerating rate sometime in 2016. It has been
about two years since the slowest rate of growth in medical care spending.
Therefore, we should expect the slowest rate of growth in medical equipment
production at any time, since the new lag time between spending and production seems to be two to three years. That is, the blue line on the chart should
stop going down and start going up at any time.
Our medical business index is providing some indication that this is
happening. The overall index seems to indicate that the medical equipment
industry has been contracting at a slower rate since the middle of 2015. The
new orders index grew in November and December for the first time since
May 2015. The production index grew in November and was flat in December,
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Product Focus
HOT RUNNERS
Hot Runner Manifold Design
Features Compression-Seated Nozzles
Thermoplay has developed a hot runner manifold that features balanced flow
channels and has nozzles seated to it by mechanical compression, enabling
them to be always centered within the mold cavity and reducing wear in the
coupling zone. The nozzle plate is conditioned to have the same temperature
as the mold (30C). This is unlike common injection system made up of an
unbalanced manifold with nozzles threaded on it. These nozzles are often free
flow and are heated by the heat transferred by conduction from the manifold.
In the Thermoplay design, an outer body is screwed externally on each
nozzle (so that it can be easily removed), which couples with the forming cavity. All nozzles are provided with plastic sealing zones to avoid plastics leakage
and to guarantee a high-quality injection point on the preform.
Other benefits include material uniformly distributed on the product and
even wall thickness; no strands at the injection point, color streaks or discoloring; tighter tolerances on the bottle neck; temperature detection close
to the injection point; uniform heat distribution on the whole nozzle length;
nozzle bushing replacement with nozzle drive and tightness; a complete selfstanding hot half, ready for installation and suitable to virtually any press
machine; and direct injection systems with a shutoff option.
Thermoplay S.p.A. / 39 125 800311 / thermoplay.com
Distributed in North America by
Alba Enterprises / 909-941-0600 / albaent.com
Single-Zone Temperature Controllers

Include User-Friendly Features
SISE offers several lines of hot runner temperature controllers, including the
World Series modular range, which controls five to 12 zones. Specially designed
for the North American and Asian markets, this temperature controller is a
microprocessor-based, single-zone unit compatible with virtually all standard
mainframes. It features a user-friendly click and rotate control button; two
red and green three-digit LED displays; and discrete indicators for a manual
mode, heating power and a soft-start mode.
All of the companys temperature controllers use self-tuning software
designed and developed by SISE that continuously recalculates the best settings for each zone, instantly responding to any changes in process parameters.
SISE Plastics Control Systems Inc. / 404-495-5968 /
sise-plastics.com
Systems Designed for Fast Cycle Times and

High Production Volumes
The Multitech line from INglass HRSFlow brand offers hot runners designed
for fast cycle times and high production volumes, making them well-suited for
injection molding of packaging, caps and closures, and products for the medical, electronics and automotive industries. These types of parts typically have
large numbers of cavities and require short cycle times, uniform balancing
and/or rapid color changes.
A variety of nozzles is available, including the Multitech Fast (MTF) line,
suitable for fast-cycle applications; the Multitech Valve Gate (MTV) line, suitablefor precision applications; and the Multitech Spring (MTS) line, suitable for
applications that require simple maintenance operations.
HRS Flow North America / 519-973-0212 / hrsflow.com
46
Hot Runners Systems

Boast Affordability, Reliability and Delivery
The Emerald hot runner system from PCS Co. is designed to be affordable
and reliable, and to meet demanding delivery requirements. Available in
configurations for eight drops or fewer, each system is designed, constructed
and heat tested to ensure proper performance, the company says. All systems
also are fully balanced with nozzle heaters and thermocouples designed for
easy maintenance.
PCS Co. / 586-294-7780 / pcs-company.com
Modular Hot Runner Controllers Available

in Variety of Confgurations
Vulcan Hot Runner Controllers YK Series modular hot runner controllers

target customers who prefer high-quality, no-frills, low-price controllers.
Prices include the mainframe, modules, connectors and cables. A variety of
configurations are available, from a standard single-zone module, which can
be used with applications of one to two zones or hot sprue bushings, to a
48-zone mainframe package. Vulcan will display its products at the Plastec
West show, February 9-11, in Anaheim, California.
Vulcan Hot Runner Controllers / 601-372-4452 / vulcanhrc.com
Trigger Your Brilliance

2016 AMBA Annual Conference
MAY 11-13, 2016 | THE HENRY HOTEL | DEARBORN, MI
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Visit www.amba.org for additional details coming soon.
47
Products
Enhancements Made to Auxiliary Injection Units

Milacrons Mold-Masters hot runner brand has added several enhancements
to its E-Multi line of all-electric, servomotor-driven, mold- or platen-mounted,
mobile auxiliary injection units for multi-material or multi-colored applications. The units are not brand-dependent, and therefore can be used with
a Milacron injection molding machine or with a machine made by another
manufacturer. The line includes four core models: the EM1, EM2, EM3 and EM4.
The mold-mounted E-Multi EM1 features
a new carriage that provides enhanced
utility and a compact fit of the unit
into the molding area. It also has a
relocated spring pack to provide
increased tie-bar clearance and
increased mechanical nozzle protrusion adjustment from 5 to 15 mm.
EM1 and EM2 mold-mounted models with
servo carriages are designed for applications requiring sprue break (the ability to
retract the nozzle each cycle away from
the melt inlet). This allows these models
to be utilized for applications where injection
at the parting line is required or in applications where the melt inlet moves relative to
where the secondary injection unit is located.
The larger E-Multi EM3 and EM4 models are
now capable of being outfitted with a radial
option that allows the units to mount to the top
of the stationary platen and rotate to a parked
position, providing unobstructed access to the
mold mounting face for quick mold change.
Servo sprue break motion is standard. The EM3 and
EM4 units are capable of shots of 57 to 499 cc.
Milacron / 888-246-2665 /
milacron.com
Mold-Masters / 905-877-0185 /
moldmasters.com
Low-Profle Clamping Useful for

Both General and Dedicated Fixturing
Jergens has added OK-Vise clamping systems to its range of workholding
solutions. The systems are built around a patented wedge-operated, lowprofile clamp that provides uniform pressure via a single hex screw. System
components can be used to build both general-purpose and dedicated fixturing, and work in conjunction with other Jergens workholding platforms.
Among the components are Multi-Rail and Combo-Rail units, to which
multiple clamps can be attached to accommodate numerous parts in a single
setup. The rail system can be modified depending on the need of the parts to
be machined. Additionally, the line offers grid fixturing and blank fixturing for
custom workholding needs.
The clamps are available with several jaw styles, including serrated, smooth,
machinable and adjustable. Single-wedge and double-wedge, pull down styles,
and a simplified economy version of the clamp round out the offering.
Jergens Inc. / 216-486-5540 / jergensinc.com
Software Eases NC Code Generation

OSGs ThreadPro software is designed to generate NC code for thread milling
applications without the hassle of having to enter data as text, copy and
replace. The configuration of multiple paths, which was not adjustable before,
has been simplified to enable the easy creation of zero cut programs. In addition to multiple-feed (machining at each cutting edge length), single-feed (one
pitch per cut) is also available, which is well-suited for machining high-hardness
materials. Additionally, with the capability to review machining trajectory,
trouble-free tool movement can be confirmed to minimize tool damage.
The software is available in 12 different languages and supports eight NC
programming languages. It also incorporates the reference value of the tool
radius offset (the RPRG value) to reduce setup and machining time.
OSG USA Inc. / 630-790-1400 / osgtool.com
48
EDMs Boost Flexibility, Time to Market

The AgieCharmilles CUT E (for efficiency) Series of wire EDMs, available from
GF Machining Solutions, incorporates a range of technologies designed to
help manufacturers increase their flexibility and accelerate time to market.
These include large-touchscreen human-machine interfaces (HMI) that are
intuitive in operation and feature onboard Intelligent Collision Protection, builtin machining strategies and flexible job management. Information about geometries, machining processes and command programs is processed in a single
file, allowing jobs to be transferred among different machines within the CUT E
Series. The machines then automatically manage all necessary modifications.
More than 10 automated measurement cycles are available to assist with
workpiece preparation. The machines onboard AC CAM Easy systems also allow
operators to prepare ISO files and post-process them into a job during machining.
The Intelligent Power Generator (IPG) is said to further improve cutting
speed, precision and surface quality. The machines can use dedicated wire
for decreased part cost and increased throughput, and their Power-Expert
modules automatically determine the optimal power to send through the wire.
The Corner Strategy module automatically adjusts parameters during changes
in direction to produce sharp angels and small radii. These features combine
to reduce cutting times compared to standard machines, the company says.
The CUT E 350 will be among several machines the company showcases at
MD&M 2016, February 9-11, in Anaheim, California.
GF Machining Solutions / 847-913-5300 / gfms.com/us
Mold and Die Repair

THE
PUK U4
Keep mold
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An alternative to expensive
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Magnetic Base
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YOUR SOURCE FOR QUALITY MOLD COMPONENTS FOR OVER 40 YEARS
49
Products
Modular Rotary Tables Handle Virtually Any Workpiece Size

Available from Exsys Tool, pL Lehmanns 500 series of modular multi-axis rotary tables is designed
to allow users to upgrade a vertical machining center to increase productivity without having to add
a new machine. Adaptable to virtually any workpiece or production situation, the tables are available
in four basic models that can be assembled into as many as 240 different configurations. More than
20 different clamping methods and behind-the-spindle accessories such as rotary unions, special
clamping cylinders and angular position measuring systems further extend the systems adaptability.
The compact tables consume a minimum of space in the machine work envelope, facilitating
optimal tool access to the workpiece. Despite their space-efficient dimensions, however, the tables
and spindles offer strong resistance to pullout torque and axial force while providing high levels of
clamping torque, the company says.
Both single-spindle and multi-spindle tables are available in four-axis and four/five-axis versions.
Exsys Tool Inc. / 352-588-4345 / exsys-tool.com
CNC Process Control Software Designed to Help Maximize Productivity

Makinos MPmax is a real-time CNC machine process-monitoring and data-management software designed to help manufacturers optimize production efficiency.
Connecting multiple machines to a centralized computer, the software is able to collect, store, analyze and display high volumes of actionable machine data in real
time. This enables operators and managers to detect and react to bottlenecks, using instant mobile alerts and remote machine monitoring to minimize downtime.
Compatible with Makino milling machines, EDM machines and other manufacturers machines that support MTConnect, MPmax acts as a central hub for monitoring
critical processes across a variety of machine platforms. It tracks a variety of key machine performance indicators, including status monitoring, utilization monitoring, alarm analysis, spindle and axis monitoring, tool data management, probe data analysis, camera monitoring, and power-consumption monitoring (optional).
Makino / 513-573-7200 / makino.com
Precise Rolling Mold Alignment
Permits pre-centering of mold halves

50% longer centered travel
on mold separation
Brass cage for better wear
resistance
Rolling elements for high
precision mold alignment
100% Quality
Assurance.
New, Longer Round Fine

Centering System
Quality you can trust!

AGATHON Machine Tools, Inc
9 Parklawn Drive
Bethel, CT 06801
Tel: 203-730-8741
mailamt@agathonusa.com
www.agathon.com
50
Each MBI mold base is built to your exacting standards and

completed in the shortest possible lead time. MBI mold bases
are finish-machined so you simply install cavities, cores, and
auxiliary items, making your mold ready for testing.
Mold Base Industries, Inc.

7450 Derry Street, Harrisburg, PA 17111
Phone 800-241-6656 FAX 717-564-2250
Internet: www.moldbase.com
E-mail: sales@moldbase.com
Custom Mold Bases Self-Lubricating Components Mold Plates
Low-Profle Collet Chuck Offers More Tool Clearance

Featuring a lower profile for increased tool clearance, Hardinges latest FlexC
quick-change collet chuck is available in four popular spindle sizesA2-5,
A2-6, A2-8 and 140 mmand can be customized to fit any other spindle.
The low-profile, 65-mm, dead-length chuck features a reduced nose diameter that gives users higher tool clearances than similar alternatives, the company says. Additional enhancements include reduced hang weight, installation
simplifications, and a new work stop and accessories.
Hardinge Inc. / 607-734-2281 / hardinge.com
I
guide
your
driving force.
Z 1880 /. . .
Slide modules
Fast calculation and planning with slide
assemblies that are tuned perfectly and
are manufactured with the highest level
of precision.The contour slide inserts
Z 1802 /. . . are available for the molding
area in two different materials.
Now in the online shop at
www.hasco.com
AMERIMOLD
Novi, Mi, Booth 111
June 15 16, 2016
HASCO Open House
& Motor Cycle Run
Fletcher, NC
September 16 18, 2016
HASCO America Inc.

270 Rutledge Road, Unit B
Fletcher, NC 28732 USA
info.america@hasco.com
51
Products
Universal Cylindrical Grinding Machines

Offer Larger Workspace
Varia universal cylindrical grinding machines from Hardinge Grinding Groups
Kellenberger division have been updated with a larger workspace, a longer
machine table and a distance between centers of 63 (1,600 mm).
Well-suited for high-precision production of prototypes and small and
medium-size production batches, typical areas of use include machine
construction, production of tools and molds, and production of precision
components.
Hydrostatic guideways offer high form accuracy for all grinding tasks involving interpolating axes, providing excellent damping, stick/slip-free operation,
high rigidity and a constant machine temperature. According to the company,
this results in outstanding surface quality and productivity, and more process
and operation reliability, without any friction loss and wear. Direct drives on the
rotary axes guarantee high positioning speeds and accuracy.
The solid machine table with reinforced bed improves rigidity, enabling
the grinding machines to handle workpieces as heavy as 661 lbs (300 kg). The
machines are available with distances between centers of either 39.4 or 63
(1,000 or 1,600 mm), and heights of centers of 7.8, 9.9 or 11.8 (200, 250 or
300 mm). Larger heights of and distances between centers make the machines
faster and more precise, offering improved performance and productivity, the
company says.
Kellenberger / 607-734-2281 / hardingeus.com
52
Fiber Laser Series Spans Power, Pulse Ranges

Designed for direct part and product marking, the Y-Series from Alltec GmbHs
FOBA Laser Marking + Engraving brand is a modular platform of nine compact and flexible fiber marking lasers spanning power and pulse width ranges.
A proprietary scan head technology offers tunings for optimal marking quality
and high marking speeds.
The fiber lasers are said to be easy to integrate in production lines and laser marking stations, and ensure tailored solutions for a variety of marking applications. The
systems are well-suited for marking plastics, metals and a variety of other materials.
The Y-Series includes nine different ytterbium fiber laser sources (1,064-nanometer wavelength) that are identical in construction, spanning power from 2 to 50
W and pulse width from 1.5 to 200 nanoseconds, and two continuous-wave lasers.
FOBA / 519-746-7190 / fobalaser.com
Tooling Data can be Imported into Simulation

Users of CGTechs Vericut 7.4 software now can import an entire tooling package
from the MachiningCloud data platform into the software in one simple step. The
verification and simulation software is used to detect CNC programming errors,
as well as potential collisions and areas of inefficiency. MachiningCloud is an
independent provider of CNC cutting tool and workholding product data.
According to the company, after defining a tooling package on MachiningCloud,
users can directly download all the tool assemblies within the package and use it
within Vericut with fewer steps compared to manually configuring a tool for use
in a simulation session. This prevents users from having to create duplicate tool
assembly models for simulation when the tool geometry already exists.
The process is simple: Users build a MachiningCloud job containing specified tool assemblies, export the job to their local computers, import all the
tools from the job into Vericut, and simulate using the tool assemblies.
CGTech / 949-753-1050 / cgtech.com
53
Products
Optical System Offers Easy 2D Measurement
Exclusive Home
of NLMKs
SERIES
Holder Steels
Verona
VR Stainless
VR P-20
VR Holder
Save on Time and

Resources
Let us grind, saw, mill and
machine your raw stock to
machine-ready blanks &
finished plates.
National Tool &
Manufacturing Co.
581 Wheeling Road
Wheeling, IL 60090
P: 847.806.9800
F: 847.806.9827
E: cs@ntm.com
www.ntm.com
54
Zeiss automated O-Select optical measuring system is designed to minimize operating errors,
enabling 2D measurements to be completed quickly and reproducibly. Measurements are initiated at the push of a button: the operator places the workpiece in the measuring field and
launches the program. Within seconds, the camera captures the contours, analyzes all characteristics and documents them in Zeiss PiWeb quality data management software.
The system is well-suited for a range of industries from automotive to electronics to
plastics, and is particularly suitable for checking the dimensional accuracy of distances, radii
or angles. Examples include punched and formed parts, and injection-molded and laser-cut
workpieces.
Zeiss Industrial Metrology / 800-327-9735 / zeiss.com
DLC-Coating Adds Durability to Two-Stage Ejectors

Meusburgers two-stage ejectors are now available with DLC-coated functional surfaces. The
coating minimizes wear to the surfaces and increases the durability of the ejectors, resulting
in longer tool life and longer maintenance intervals.
Thanks to the optimal dry-running properties of the-DLC coated functional surfaces, the
two-stage ejectors can be used without any lubricant, making them particularly suitable for
medical and food processing applications. Required strokes are infinitely adjustable and forcecontrolled.
Meusburger US Inc. / 704-526 0330 / meusburger.com
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ADVERTISERS INDEX
41
Milacron
AGATHON Machine Tools, Inc
50
Missler Software, Inc
30
American Mold Builders Association
47
Mold Base Industries, Inc
50
amerimold
Back Cover
Inside Back Cover, Insert
Molding 2016
25, Insert
Beaumont Technologies, Inc
18
National Tool
54
Better Molding Solutions
55
NSK America Corp
33
CUMSA USA LLC
32
OSG USA, Inc
23
DMS
49
PCS Company
Edro Engineering
27
PFA Inc
Fabricating com
45
Precision Laser Technology
Gesswein & Co , Inc , Paul
49
Progressive Components
Haimer USA
26
Renishaw Inc
Hasco America, Inc
51
SCHUNK Inc
Hurco North America
Insert
7
55
Inside Front Cover
35
11
Society of the Plastics Industry
39
INCOE Corporation
17
Sumitomo Electric Carbide Inc
Iscar Metals, Inc
Techspex, Inc
43
iWarriors
Machinemonster com
MC Machinery Systems, Inc
Thermal Tech Systems
19
51, 53
52
Tool-Flo Mfg , Inc
31
22
WALTER USA, Inc
13
55
TIP
INSPECTION/MEASUREMENT
By Dan Miller
Its hard to imagine quick, accurate mold measurement today
without the use of workpiece touch probes directly on the
machine tool to help moldmakers perform setup, measurement and inspection during a mold build. This is one way to
ensure a mold is in tolerance before it is removed from the
machine, but it is critical that users select the correct probe
type with the control features and options they need.
When it comes to inspection, most high-end controls have
standard probing cycles for workpiece measurement that will
allow users to update the tool offsets for length and radius, as
well as record the results to a file for printing. The inspection
program can be created on the machine, although most CAM
systems already support machine probing cycles and allow
users to verify the program for collisions. If an inspection
result is out of tolerance, the user can force the tool path to be
run again with updated tool data.
Before an inspection program using a probe can be run on a
machine, the user must first calibrate the probe. The calibration routine should be run first on a tooling ball located on
the mold. This can be part of the inspection program. He or
she should make sure the probe is in good working order, and
check for wear and minimal runout of the stylus. Also part
cleanliness should be ensured by incorporating a cleaning
program using high-pressure coolant, such as when a probe
blows compressed air through the spindle to finish cleaning
the probing point.
Many high-end controls also feature a number of measuring cycles for checking the geometry of the machined workpieces. This enables the user to recognize a workpiece, call
an appropriate part program, verify that all machining operations were conducted correctly, and detect and compensate
for tool wear. For example, some controls provide cycles for
a wide variety of applications in automatic mode, including
surface, hole, length, width, bolt pattern and vector. These
automatic measurement cycles are all valuable during mold
manufacture and inspection.
Crash protection is another important probe feature for
workpiece inspection. Touch probes should offer a large
deflection path and additional safety with rated breaking
points in the stylus or a connecting pin to the probe contact.
For expanded collision protection, users should consider a
mechanical adapter between the touch probe and the taper
56
Image courtesy of Heidenhain Corp.
Avoid Mold
Reload and Rework with
Machine Probes
Many high-end controls provide surface, hole, length, width, bolt pattern
and vector cycles in automatic mode. These automatic measurement cycles are
all valuable when making and inspecting molds.
shank. This will allow the touch probe to absorb the shock in
the event of a light collision against a fixture or workpiece. At
the same time, the integrated switch will deactivate the ready
signal and the control will stop the machine. The collision protection adapter also functions as a thermal decoupler that can
protect the touch probe from being heated by the spindle.
Probing on a machine with ready-to-use probing cycles can
be an important part of manufacturing a quality mold. It can
help reduce setup times, increase machine usage time and
improve the dimensional accuracy of the finished workpiece.
All of these factors impact a molds productivity and profitability by eliminating the need to reload and rework molds.
CONTRIBUTOR
Dan Miller is a CNC engineer for Heidenhain Corp.

Heidenhain Corp. / 847-490-1191 / heidenhain.com
Novi, MI | June 15-16, 2016
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