100635-JAN 2013.pdf
Transcript of 100635-JAN 2013.pdf
-
january 2013
Volume 16 / number 1
Design / bu ilD / repair
Simple
Considerations
For Automated
Mold Machining PG 28.
FEATURES
Help Your Customers
Reduce the Cost of Making
Plastic Parts PG 34.
Cooling Technology for
Cycle Efciency PG 37.
ViDeo
-
reset past practices.
Companies dedicated to continuous improvement are embracing
new capabilities of the CVe Monitor system. Maintain your eet of
molds by accessing these recently added features:
Store PM points and view deviation alerts to PM targets
Access disassembly/assembly PDFs on internal ash drive
Non-resettable lifetime count, plus resettable interval count
Begin a change for the better. Visit procomps.com/CVe to learn of
new ways to maximize your tooling investment for the years ahead.
a new years revolution
See Progressive at: PLASTEC West | AMBA Annual Convention | Amerimold | MD&M East | K 2013 | EuroMold
-
With Hurco 5-axis machine tools, its simple. Literally. When machinists
have the exibility to program in conversational or NC, 5-axis suddenly
moves from a costly undertaking to a pro table solution. Think 5-axis is too
complicated or expensive for your operation? Let us show you how Hurco
makes 5-axis make sense. >> HURCO.COM/5-AXIS
M A C H I N I N G C E N T E R S T U R N I N G C E N T E R S 5 - A X I S D O U B L E C O L U M N S U P E R I O R C O N T R O L S
achinists
suddenly
axis is too
ow Hurco
D O U B L E C O LC O U M NM N S U P E R I OR I O R CR C O N TT R OR O L S
Machines shown with options. Information may change without notice.
C O LC U MU M N SS U P EU P E R I O R C O NO N T R O LO L S
-
PublisherClaude J. Mas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 856-854-1715 / [email protected]
Metalworking Group PublisherTravis J Egan . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513-527-8808 / [email protected]
Editorial
Editorial DirectorChristina M. Fuges . . . . . . . . . . . . . . . . . . . . . . .800-579-8809 / [email protected]
Senior WriterSherry L. Baranek . . . . . . . . . . . . . . . . . . . . .908-537-6406 / [email protected]
Economics EditorBill Wood . . . . . . . . . . . . . . . . . . . . . . . . 413-772-6436 / [email protected]
Contributing Writer, Special Projects Jan Bottiglieri . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 847-923-5729 / [email protected]
art/Production
Art DirectorCarla M. Turner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Advertising Production ManagerBecky Helton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
MarkEting
Senior Marketing ManagerDave Necessary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Reprint SalesScott Clifton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
circulation
Circulation DirectorP. Ross Jacobs, CCP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
ExPositions
Senior Events ManagerAllison Miller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513-527-8800 / [email protected]
amerimold Event ManagerDave Necessary. . . . . . . . . . . . . . . . . . . . . . . . . . 513-527-8800 / [email protected]
corPoratE
President Richard G. Kline, CBC . . . . . . . . . . . . . . . . . . . . . . . . . . [email protected]
Executive Vice President Steven R. Kline, CBC . . . . . . . . . . . [email protected]
Chief Operating Officer Melissa K. Skavlem . . . . . . . . . . . [email protected]
Group Publisher Richard G. Kline, Jr. . . . . . . . . . . . . . . . . . . . . [email protected]
Executive Vice President, Content Tom Beard . . . . . . . . . . . [email protected]
Director of Information Technology Jason Fisher . . . . . . . . [email protected]
Director of Finance Ernest C. Brubaker . . . . . . . . . . . . . . . . . . [email protected]
Gardner Business Media, Inc.6915 Valley Avenue / Cincinnati, OH 45244-3029
Tel: (513) 527-8800 / Fax: (513) 527-8801
gardnerweb.com / moldmakingtechnology.com
MoldMaking Technology magazine (ISSN #1098-3198) is published monthly by Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244. 800-950-8020, 513-527-8800, Fax: 513-527-8801, gardnerweb.com. Canadian Agreement #40012278.Nonqualied subscription rates per year are $89.00 in the United States, $99.00 in Canada and
Mexico. All other countries are $200.00 per year, payable in U.S. funds. Single copies $10.00 per issue in the United States and Canada. CANAdA POST: Canada Returns to be sent to Bleuchip International, P.O. Box 25542, London, ON
N6C 6B2. Publications Mail Agreement #40612608. POSTMASTER: Send address changes to: MoldMaking Technology magazine, Gardner Business
Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Entire contents copyright 2013. No portion of this publication may be reproduced in any form
without written permission from the publisher.Views expressed by the bylined contributors should not be construed as a reflection of the opinion
of this publication. Publication of product/service information should not be deemed as a recommen-dation by the publisher. Editorial contributions are accepted from the moldmaking industry. Contact the editor for details. Product/service information should be submitted in accordance with guidelines available from the editor.Change of address: Send old label as well as new address to Circulation, MoldMaking Technology
magazine, Gardner Business Media, Inc., 6915 Valley Avenue, Cincinnati, Ohio 45244.Periodicals postage at Cincinnati, Ohio and at additional mailing offices.
PRINTED IN THE U.S.A.
2 MoldMaking Technology January 2013
hsk.com Your Complete HSK Source
EVERYTHING you need in HSK ThermoGrip Toolholders, Collet Chucks,
Runout Arbors, Blanks, and more! Most In-Stock for Immediate delivery!
HSK63A CAT40 HSK63F CAT50 HSK50E BT30 HSK40E BT40 HSK25E
Inch Sizes on The Shelf! Diebold Goldring Tooling U.S. A.
262.736.2204 [email protected] When Quality Counts!
Get Involved!Contact Bill Wood Today!
Call (413) 772-6436
E-mail [email protected]
Participate in the 2013
Mold Business Index!
Your participation in MoldMaking Technologys quick and
simple, monthly MBI survey allows us to provide you with
the industry data and analysis you need to make informed
decisions for today and for the future of your shop.
New Orders
Production
Employees
Backlog
Exports
Suppliers Deliveries
Materials Prices
Mold Prices
Future Expectations
The MBI survey tracks:
-
Helical Triangular insert
with 3 Cutting Edges
HM390 TPKT Insert
High Positive 90 Shoulder
Heli Cutting Edge for Soft
and Easy Cut
Less Vibration and Low
Power Consumption
Machines up to
.512" Depth of Cut
BrilliantMilling
.315
90
1
3
2
HELIMIL
L
3 HELICA
L
CUTTING
EDGES
www.iscarmetals.com
-
Great Tips from This Issue5TRICKS OF THE TRADE
Contents
4 MoldMaking Technology January 2013
Features
28 Machining/Automation Simple Considerations for Automated Mold MachiningStreamline your mold manufacturing process with machine automation.
32 Machining What Moldmakers Should Know about Cylindrical GrindingDiscover the advantages of cylindrical grinding in mold manufacturing.
34 Surface Treatment/MaintenanceHelp Your Customers Reduce the Cost of Making Plastic PartsHow to take advantage of the properties of DLC coatings to design better molds and improve cycle times.
37 Software: Cooling Technology for Cycle EfciencyA 3D simulation study helps quantify the effects of mold cooling design choices on cycle cooling time.
42 Software: Using Simulation to Locate and Size GatesConsiderations and trade-offs when determining proper gate locations with simulation.
45 Software: CAD/CADs Role in Customer CollaborationSeven skillsenhanced by the right CAD/CAM solutionthat will help you win more business.
Departments
6 From the Editor: New Year, New Opportunities 6 Whats New on MMT Online: Leadtime Leaders 8 New Business Opportunities: Increased Tooling Capabilities 10 Your Business: Healthcare Reform 12 Mold Business Index: Overall Business Levels Remain the Same 14 Profile: Rapid Mold Solutions 18 Case Study: Mold Design 21 Case Study: Business Management
24 Case Study: Software 50 Product Focus54 End Market Reports: Aerospace and Automotive55 Ad Index 56 TIP: CAD/CAM
On THE COvERImage courtesy of Makino (Mason, OH) and MGS Mfg. Group
(Germantown, WI). This photo captured at MGS Mfg. Group shows an
automated work cell designed for unattended hard milling of precision
molds that was built around a pallet transfer robot from System
3R that manages workflow between a Makino V33i high-speed VMC,
pallet stocker and coordinate measurement system (not pictured). This
has allowed MGS to streamline its processes for improved through-
put without adding manpower or labor shifts. Inset image is of a
precision hard metal mold. See article on page 28.
Images courtesy of (left to right) United Grinding, CAE Services and Hoosier Pattern.
1. Trust MeLiving Trusts include, but are not limited to, Grantor Retained Annuity Trust, Qualied Personal Resi- dence Trust, Defective Grantor Trust, Private Foundation and Self- Canceling Installment Notes.PG. 21.
2. Get Grinding Moldmakers need to con- sider all of the possible congurations of a potential cylindrical machinehow the machine is equipped, type of wheel head conguration, etc. PG. 32.
3. Dry Running The low coefcient of friction and low surface energy of DLC coatings minimizes steels ten-dency to cold weld under cycling, so no lubrication is necessary for parts like nonmolding components to produce molded parts. PG. 34.
4. True Cost Although use of more conformal-like cooling design usually increases cost, the tool production cost may actually be less if the total cost calculated up to nal tool approval is used as the accounting benchmark. PG. 37.
5. As needed Basis Giving shops the ability to add on to a CAD/CAM product as needed for upgrade costs in function-ality is a better way to help them grow as they learn CAM technology. PG. 56.
January 2013 Volume 16 / Number 1
454232
vIDEO ACCESS
-
Engineered with an
expanded work envelope DElivered at an
affordable price
Reinforced with high-performance
features as standard
F400VM - 31" x 18" x 20"
f500VM - 43" x 22" x 20"
F650 VM - 51.2" x 26.4" x 25"
Extended Travels (X, Y, Z)
A new blueprint for Value.
Hyundai WIA redening engineering... redening possibilities.
Scan to get
a closer look
at value.
HORIZONTAL MACHINING CENTERS | VERTICAL MACHINING CENTERS | TURNING CENTERS | MULTI-TASKING MACHINES
Corporate Ofces and Eastern Regional Technical Center450 Commerce Blvd. , Carlstadt, NJ 07072 Tel: 201-636-5600 Fax: 201-636-5678
www.hyundai-wiamachine.com
30-tool ATC
Thru Spindle Coolant
Rigid Tapping
Big Plus Spindle System
Standard High-performance Features
Introducing Hyundai WIAs all new range of Value Master CNC Vertical Machining Centers F400VM, F500VM and the F650VM.
Each Value Master VMC has been designed and engineered utilizing a new blueprint for value. The foundation for value starts with an impressive list of premium, high-performance features that are included as standard on each model. In addition, the X-axis and Y-axis travels have been extended to provide a larger work envelope. Finally, each Value Master VMC is delivered at an affordable price.
To learn more about Hyundai WIAs new blueprint for value, scan the QR code below, or visit hyundai-wiamachine.com/value. Well show you rst hand how we measure up and set new standards in CNC machine value.
-
This MonTh on moldmakingtechnology.com
From the Editor
6 MoldMaking Technology January 2013
With moldmakers continuing to be busy as the
New Year unfolds, we informally surveyed read-
ers to find out in which technologies they are
interested and investing, so we can bring those
technologies to life on the pages of MMT. What
we found out is not surprising, but it does help us
to plan our content for you for the upcoming year.
Overall, moldmakers are searching for technol-
ogy to optimize their processes and to help them
get a part off the machine with a bench-free fin-
ishsaving time and money, but not sacrificing quality. That comes in
the form of automation solutions, CAM software, cutters, CNC graphite
machines, sinker EDMs, CNC lathes, mills, large 5-axis CNCs, program-
ming solutions, advances in toolholders and fixtures; machine monitoring
software and even additive manufacturing.
Moldmakers continue to be interested in high-speed, five-axis machin-
ing, but the key is also finding the right software and cutting tools, so
they can use this process effectively. Automation seems to be very popu-
laras in unattended machining, pallet changers, part loaders/movers,
robots, cell manager software, CAD/CAM to streamline programming,
in-process inspection; and even software for monitoring bottlenecks as
automation is added.
Other areas include CAD/CAM that is integrated to the machine for real-
istic simulations for testing the machine tool and cutting tools; and, machine
and spindle technology that delivers better accuracy for complex geometries
and long continuous motion with high RPMs and feedrates. In addition,
advanced CNC controls to process greater volumes of information, faster.
Also, tooling for hard milling, and refinements in tool geometry, insert
grades and coatings to extend tool life and remove more material faster.
To guide us with on-the-ground advice on how best to approach cov-
ering these topics, we have some new blood on our Editorial Advisory
Board. These new members help round out the variety of business types,
job functions, specialties and end markets represented, so the content we
provide can be all the more relevant for you.
Wayne M. Hertlein, Aerospace & Defense Applications Engineer, MMI
Engineered Solutions (Saline, MI)
David Hirt, AIS/FVSS/Lighting New Model Tooling/Feasibility Engineer,
Automotive Components Holdings, LLC (Sandusky, OH)
Dan Mishek, Managing Director and Co-Owner, VistaTek (Ramsey, MN)
Tim Peterson, Vice President, Industrial Molds Group (Rockford, IL)
Mike Walter, General Manager, MET Plastics, Inc. (Elk Grove Village, IL)
Heres to a Happy and Prosperous New Year!
Christina M. Fuges
Editorial Director
New Year, New OpportunitiesTaking advantage of opportunities that will present themselves
this year requires the right technology. MMT Zone: LeadTiMe Leader awards moldmakingtechnology.com/articles/ leadtime-leader-awardsThe Leadtime Leader Awards honor outstanding North American mold manufacturers who best demonstrate overall innovation, efficiency, quality and commitment within their moldmaking operations while raising the bar in terms of mold engineering, building, repair and management.
Browse PasT LeadTiMe Leader FeaTUres2012LeadtimeLeaderAwards,IndustrialMoldsGroup:
Thinking Outside of the Box2012LeadtimeLeaderAwards,M&MToolandMold: NicheManufacturingSustainsProfitability
2011LeadtimeLeaderAwards,UnitedTool&Mold,Inc.:ChargingForwardwithUniqueMoldRepairNiche
2011LeadtimeLeaderAwards,JMMS:ConstantReinventionResultsinGrowth,Success
2010LeadtimeLeaderAwards,TriangleTool: Product-to-ToolService
2010LeadtimeLeaderAwards,MoldCraft,Inc.: InnovationwithAutomation
BeneFiTs:IndustryrecognitionandcredibilityAttractnewcustomersandaddvaluetoyouroverall
service and productBoostmoraleintheshopDistinguishyourshopasanindustryleaderandpromote
your shops capabilities and services on sales callsBuildconfidencewithnewandexistingcustomersIncreaseawarenessandreinforceyourbrandRealizebusinessgrowthasyoucontinuetoenhanceand
develop your mold build process
eLiGiBiLiTYAnyshopperformingmoldmakingoperationsiseligible.Allapplicationsubmissionswillbeconsidered.
CaTeGorY winners and HonoraBLe MenTions earn THese BeneFiTs!
FreeexpandedshowroomonPTonline.comand moldmakingtechnology.com
AfullfeaturecoverstoryonyourshopinMoldMaking
TechnologymagazineAninvitationtositonMMTsEditorialAdvisoryBoardComplimentary10x10boothaswellas2complimentaryfullconferenceregistrationsforamerimold2013June12-13inRosemont,IL(amerimoldexpo.com).
eVen More BeneFiTs For CaTeGorY winners!Leadtime Leader Award Winners earn a targeted advertising
program in Plastics Technologymagazine(ptonline.com)to markettheirproductsandservicestomorethan25,500 moldingsubscribersatmorethan11,600moldingfacilities!
Follow MMT on
-
Whatever your situation, DME has a mold base to match. Tight timeline? Many of our
products ship same day. Too busy? Turn to us for a fully custom, ready-to-add-value
base. Need the work? Order from our standard lines and do the finishing yourself.
Choose any mold base you need with complete confidence, knowing the longtime
leader in mold base quality is with you every step of the way.
dme.net 800.215.3429
Find the right mold base at www.dme.net/moldbaseguide
PICK A MOLD BASE.
ANY MOLD BASE.NO ONE HAS MORE VARIETY.
-
8 MoldMaking Technology January 2013
New Business Opportunities
ing and tool design teams, we are able to provide technical
solutions and quick turnaround to support our customers
growthand further our core focus of quickly turning engi-
neering concepts into high-quality products.
Spectrum has plans to not only move all of the tool-
ing design, manufacturing and quality equipment into the
Spectrum facility, but has further plans to add on new capa-
bilities as business continues to grow. The first step in this
direction came in the form of Spectrum adding a 240-ton,
Arburg multi-shot injection molding press as well as additional
robotics to automate an insert over-molding application. Ahlm
concludes, Our customers want more than just another
injection molder; they want someone who can support them
throughout the entire product development lifecycle, and this
enhances our capabilities to do exactly that.
Molders Increased Tooling Capabilities
Accelerate Time-to-Market
By Sherry L. Baranek
Spectrum Plastics Group, headquartered in Minneapolis, MN,
provides custom manufacturing solutions for its customers in
the medical, aerospace, defense and precision industrial indus-
tries. An alliance with an unnamed tool and design manufac-
turing company in the Twin Cities area is the next step for the
company to meet its customers needs for high quality, quick-
turn tooling.
The company offers an array of product development ser-
vicesincluding rapid prototyping, rapid tooling and production
molding. This recent alliance with a local mold manufacturer, the
name of which Spectrum Plastics Group CEO/President Randy
Ahlm wishes to keep confidential, has allowed them to relocate
operations into Spectrums injection molding facility. The
advantage of integrating tooling capabilities into our facility is
significant, notes Doug Johnson, General Manager for Spectrum
Plastics Groups Minnesota division. It enhances the Quick-Turn
molding capabilities of our business and allows us to help our
customers accelerate their time-to- market. We are now able to
quickly respond to tool modifications, revision changes and new
tool builds. This addition is a direct response to multiple requests
from its customers, and is another example of the companys
commitment to a customer-focused approach, Johnson adds.
Quick-Turn is a term coined by the company to describe its
process for rapidly turning CAD files into injection molded
parts, based on a customers specific project needs and require-
ments, Ahlm notes. The company also developed DynaClass
technology, which refers to
a hierarchy of rapid tooling
and molding capabilities at
Spectrum Plastics Group. It is
geared toward simplifying the
selection of tooling for a vari-
ety of applications, and align-
ing customers with the best
molding solution for their
application, Ahlm explains.
With four DynaClass options of tooling available, Quick-Turn
offers one of the most diverse tooling and molding options.
This new partnership further elevates Spectrum as a multi-
capable supplier of custom manufacturing solutions, Ahlm adds.
While each business will operate independently, Spectrum will
be the largest and most preferred customerenabling it to
shorten program lifecycles and reduce costs for its customers.
This move has been a long time coming, Ahlm continues.
We now have in-house tooling at all of our production facili-
ties, he states. Combined with our outstanding engineer-
For More inForMATion:
Spectrum Plastics Group / (952) 927-3212
[email protected] / spectrumplasticsgroup.com
This new partnership
further elevates Spectrum
as a multi-capable supplier
of custom manufacturing
solutions.
Spectrum Plastics Group has added tooling capabilities to its facility to
enhance its current molding operations and increase time-to-market.
Phot
o co
urte
sy o
f Sp
ectr
um P
last
ics
Gro
up.
-
POWERFUL, PRECISE, RELIABLE.
Powered by Tigertec Silver
The new generation of mills from Walter
BlaxxTM stands for a reliable system which captivates the user with its
absolute precision and stands out through its extremely high
productivity. The Blaxx F5041 and F5141 shoulder mills are therefore
based on a newly developed, incredibly robust tool body, which is
fitted with the most efficient of Walter Valenite indexable inserts,
powered by Tigertec Silver.
Find out more about the unbeatable combination of Blaxx and
Tigertec Silver now: www.walter-tools.com/us
Watch trailer:
Walter USA, LLC
N22W23855 RidgeView Pkwy W
Waukesha, WI 53188, USA
800-945-5554
www.walter-tools.com/us www.youtube.com/waltertools www.facebook.com/waltertools
WALTER NORTH AMERICA
Walter Canada
N22W23855 RidgeView Pkwy W
Waukesha, WI 53188, USA
800-945-5554
Walter Tools S.A. de C.V.
Boulevard Louis Donaldo Colosio 2255
2do Piso, Colonia San Patricio
25204 Saltillo, Coahuila, Mexico
+52 (844) 450-3500
-
Your Business
10 MoldMaking Technology January 2013
Healthcare Reform in 2013 and Beyond
The recent ruling on the Patient Protection and Affordable Care
Act (PPACA) by the U.S. Supreme Court has given employers
much to consider for the future of their sponsored healthcare
plans. The good news is that employers have another 12-plus
months to map out their strategies relative to the pay or play
mandate (and corresponding tax/penalties) and the forthcom-
ing healthcare exchanges. However, there are healthcare reform
issues that employers should be aware of for 2013. These include:
$2,500 salary reduction limitation on health flexible spending
accounts (FSAs) under a cafeteria plan; the requirement to dis-
tribute and make available Summaries of Benefits and Coverage
(SBCs); covering womens preventive health services at 100 per-
cent; and, reporting the value of the health plan on Form W-2.
Beginning with plan years after December 31, 2012, there is
a contribution limit of $2,500 on health FSAs. This new limita-
tion may require you, as an employer, to revise your Section
125 plan document and communicate this to employees. IRS
Notice 2012-40 clarified that this limitation would be effective
based on plan year rather than taxable year.
SBCs must be provided or made available to all applicants
and participants in the employer-sponsored health plan
beginning with the first open enrollment on or after Sept. 23,
2012. This is mostly an administrative task; however, there
are specific differences with
the responsible party depend-
ing upon whether the plan is
fully insured or self-insured.
Furthermore, there are a num-
ber of specific details regard-
ing how the SBC must be
distributed. Lastly, employers
will need to consider how the
SBC requirements are met relative to carve-out prescription
drug plans, health reimbursement arrangements (HRAs), etc.
It should be noted that the SBC requirement cannot be met
simply by distributing existing benefit summaries or summary
plan descriptions. In addition to the language used, the SBC
must be drafted using a specific number of pages, spacing and
font requirements. Examples and templates can be found on
the Department of Labors website (dol.gov).
For fully-insured plans the insurance company has the
responsibility for compliance. For self-insured plans, it is the
plan sponsor (the employer). For those employers that have
both plans, it falls to both carrier and plan sponsor/employer.
This is especially complex for those employers that have
adopted HRAs or wrap plans because there are actually two
plans: one fully insured and one self-insured. The self-insured
plan is the HRA or wrap, and the fully-insured plan is the
underlying medical plan. Each requires an SBC.
We recommend employers begin considering the impacts
of the 2014 changes now: the number of full-time equivalents
employed; penalties that might apply; net cost impact of the
penalties; compensation adjustments for the potential to
eliminate employer-sponsored benefits; the net cost impact of
any compensation adjustments; from an employees perspec-
tive, the net buying power of a compensation adjustment; the
recruiting/retention impact of any benefit and compensation
changes; and whether or not the healthcare exchanges are
accessible for the employer.
Its likely that healthcare reform is going to impact each
employer differently in 2014. Things such as average family
income and part-time vs. full-time employee counts will influ-
ence the strategies considered. While healthcare reform has
changed the landscape of employer-sponsored health plans
significantly, one thing has not changed: a single solution
applicable to all employers simply does not exist.
PMGBA II is an independent benefit consultant and agency that
works with employers of all industries to establish a cost-effective
benefit plan strategy that works best for each employer.
contriButor
Scott McLellan, Ed Murphy and Jonathon Trion are with Plante Moran.
FoR moRe inFoRmation:
Plante Moran
(248) 375-07281 / [email protected]
(248) 375-7412 / [email protected]
(248) 375-7475 / [email protected]
plantemoran.com
We recommend employers
begin considering the
impacts of the 2014
changes now.
-
N118 W18251 Bunsen DriveGermantown, WI 53022
(262) 250-4410Fax (262) 250-4409
KOR-LOK is a trademark of PFA, Inc. 2012 PFA, Inc. All Rights Reserved.
Designed & Made in USA
pfa-inc.com
Mold OPEN
Core Out
Mold CLOSED
Core OUT
Mold CLOSED
Core IN
Core PRE-LOADED
Against FULL
Injection Pressure
CANT DO IT!
CANT DO IT!
KOR-LOK TRADITIONAL
SIDE-ACTION VS. SIDE-ACTION SYSTEMS SYSTEMS
ZERO FLASHON THE FIRST SHOT
Be proactive Reduce mold size and complexity, while eliminating tryout issues, mold tweaks, and expensive maintenance.
Adding
A nEW
dimEns
ion to
AutomA
tion Pro
ductivi
ty!
uPgrAd
E robot
ic
PErfor
mAncE &
ProfitA
bility!
uPgrAd
E to PfA
!
Robotic Gri
ppers
Gripper Pad
s
Compliance
Devices
Robotic Cra
sh Protectio
n
ComPlet
e
SyStem
Solutio
nS
pfa-inc.co
mDesigned
& Made
in USA
Nut Clamps
Rocker Clamps
Die Lifters/Rails
Bolster Extensio
ns
Hydraulic Powe
r
& Control Module
s pfa-inc.com
CoMPLEt
E
SyStEM
SoLutioN
S
Adding A n
EW dimEns
ion to
mAchinE Pr
oductivity
!
uPgrAdE m
AchinE
PErformAn
cE & Profit
Ability!
uPgrAdE t
o PfA!
Designed & M
ade
in USA
pfa-inc.com
Designed &
Made in USAAdding
A nEW dimEnsio
n to
mAchinE Produc
tivity!
uPgrAdE mAchi
nE
PErformAncE & P
rofitAbility!
uPgrAdE to PfA
!
ADDING A NEW DIMENSION TO
MACHINE PRODUCTIVITY!
UPGRADE MACHINE
PERFORMANCE & PROFITABILITY!
UPGRADE TO PFA!
HYDRA-JAWS
Variable Quick Mold Change
HYDRA-LATCH
Quick Knockout Systems
pfa-inc.com
10x the Preload Power of standard cylinders.
Low pressure preload activation only 1,500 psi.
Real Locking Hydraulics may be removed.
100% preload at ZERO psi after lockup.
Sensor veri es unit is locked as expected.
Easy mounting, preload adjustment and setup - No Shimming needed.
Multiple Sensor & Hydraulic Ports Standard.
Rear porting for set and pull Standard.
Fast Delivery on ANY STROKE size.
Easy Wiring Dry Contact SPDT Switches Standard.
NEW SIZE!100 SERIES
KOR-LOK
SIDE-ACTION SYSTEMS
VISIT OUR WEBSITE FOR PFA'S
ENTIRE FAMILY OF PRODUCTS
-
Mold Business Index
12 MoldMaking Technology January 2013
Overall Business Levels Remain the Same
By Bill Wood
For the fifth straight month, our survey indicates that overall
activity levels continue to decline slowly. The Mold Business
Index (MBI) for November 2012 is 45.8, which is a slight 0.2-
point increase from the October value of 45.6, but a 7.2-point
decrease from the 53.0 posted in November 2011.
A drop was reported in the New Orders category for the
seventh straight month. Yet despite the decline in new busi-
ness during the past summer and fall, moldmakers continue
Dat
a so
urce
: Mou
ntai
ntop
Eco
nom
ics
& R
esea
rch,
Inc
.
FOr mOre inFOrmatiOn:
Mountaintop Economics & Research, Inc. / (413) 772-6436
[email protected] / plasticseconomics.com
Total Mold Business Index for November 2012: 45.8
% % % Net % Sub-
Positive Equal Negative Difference Index
New Orders 30 28 42 -12 43.9
Production 15 52 33 -18 40.9
Employment 24 64 12 12 56.1
Backlog 30 31 39 -9 45.5
Export Orders 0 85 15 -15 42.4
Supplier Deliveries 6 82 12 -6 47.0
Materials Prices 12 85 3 9 54.5
Mold Prices 15 76 9 6 53.0
Future Expectations 55 36 9 46 72.7
The total Mold Business Index is a weighted average of the sub-indices for new orders,
production, employees, backlog, exports and supplier deliveries.
to hire new workers. Supply conditions and Materials Prices
were mostly unchanged. Mold Prices were steady-to-firmer,
though the gains in prices received for molds are still not
keeping pace with the increases in costs for most moldmakers.
Future Expectations remain optimistic.
Never in my memory has both the short-term and long-term
outlook for the U.S. economy been so dependent on a single act
of Congress. IF Congress does what needs to be done, then the
U.S. economy will quickly gain momentum. The distractions of
the recent election notwithstanding, the major macro-econom-
ic indicators are showing promise. The stock market has steadi-
ly increased during the past three years. Corporate profits are at
or very near all-time highs. The employment data is rising.
Most importantly, the recoveries in the housing and real
estate sectors are accelerating. This is not only because the
housing sector is a large end-market for many types of molded
products, but also because it is the best indicator of Americans
propensity to consume all types of products, including cars,
appliances, electronics, home furnishings, etc. The trends in
retail sales and consumer spending for durable goodsboth
of which are good indicators of the demand for molded prod-
uctsare connected to the trends in the housing data.
The real problem is confidence levels, both amongst busi-
ness leaders and consumers. But now that the election is over,
there is some real pent-up desire to get back to the business
of becoming more productive. This desire will be unleashed as
soon as a solution to the fiscal cliff is passed.
The New Orders component is 43.9. The trend of declining
new orders over the past few months continues to result in
diminishing Backlogs, which registered 45.5. Production slipped
back to 40.9, the lowest level in over three years. Once again,
the only significantly positive factor in the latest survey was
the Employment component that came in at 56.1.
The prices received for new molds continue to rise gradually.
Mold Prices is 53.0. Materials Prices this month is 54.2. Supplier
Delivery Times is 47.0. There was a significant decline in offshore
orders last month, as the Export Orders sub-index is 42.4.
Overall, business levels for mold shops have been stagnant for about the past
six months, but this has not yet prevented these businesses from adding new
workersif they can nd them. Each month, we ask our survey participants to
comment on the biggest problem they currently face, and for the past two years
the answer given most often has been the lack of qualied applicants for their
job openings. This is a complicated problem, because the best solution would be
to raise wages. Any time demand (job openings) exceeds supply (skilled labor) in
a capitalist system prices (wages) should go up. But North American moldmakers
can ill afford any increase in costsso the skills gap problem persists. The prices
received for molds have nally started to rise, but the increase in mold prices so
far is not enough to keep pace with the relentless increases in materials prices
and labor costs. These problems will gradually ease over the long term, but for
the foreseeable future, the problem of the skills gap will continue.
contRIButoR
Bill Wood is MMTs economics editor and founder
of Mountaintop Economics & Research.
-
While other suppliers turn their backs to supply
other hot markets, were stocking inventory,
investing, and servicing our customers 110%.
Its been that way for the past 100 years and
will continue for the next 100 years. At ESS, we
always focus on our number one priority you.
Its what we do.
United States
Ellwood Specialty Steel
800-932-2188
Canada
Ellwood Specialty Metals
877-978-2772
[email protected] Ellwood Specialty Steel - Ready and Reliable.
Were Focused on You.
-
Prole
14 MoldMaking Technology January 2013
These three prongs are fed by a focused sales effort
involving upper-level management, production and
engineering staff, and direct sales contacts to create
a dynamic workplace environment where variety
and innovation are enthusiastically accepted and
consequently promotes a culture of team interaction
and shared learning experience.
Rapid Mold Solutions, Inc.:
Three-Pronged Approach
To Prototype/Production
Mold Manufacture
In the fall of 1998, Damian Kuzmin and Scott Borstorffwho
worked together at Carlisle Engineered Products, Inc.were
sipping hot coffee and looking out the window on a typical
Northwestern Pennsylvania raw fall day at a vacant building
across the street from Carlisle. The two had worked together
through several different management groupsincluding
Johnson Controls, Inc. and Carlislehoning their knowledge
of under-the-hood automotive components and the rug-
ged, robust tools necessary to form the parts. The proverbial
writing on the wall from upper-level management, com-
bined with a yearning to strike out on their own and a vacant
opportunity across the street, was the catalyst they needed
to forge a new name in the Erie area industrial landscape
Rapid Mold Solutions, Inc.
of handling additional machines and capacity, and again in
2003 to a larger facility yet, the current location on Pacific
Avenue in Erie, RMS Vice President Scott Borstorff notes.
The business model itself underwent an array of changes
from 2003 to 2008 as new markets were tapped and the
array of capabilities on the shop floor changed as well. From
its automotive roots, RMS expanded into caps and closures,
consumer products, electrical components, sporting goods
and the medical device sectorsservicing both prototype
and production tooling needs for an increasingly diversified
customer base.
A Three-Pronged Approach
RMS is comprised of three business centers: the in-house
design and manufacture of prototype and production injec-
tion molds, the repair and alteration of injection molds built
by RMS or other moldmakers, and production machining.
These three prongs are fed by a focused sales effort involving
upper-level management, production and engineering staff,
and direct sales contacts to create a dynamic workplace envi-
ronment where variety and innovation are enthusiastically
accepted and consequently promotes a culture of team inter-
action and shared learning experience, says Matt Cannon,
Sales Manager of Rapid Mold Solutions. Our internal Big
3including Damian, Scott and CNC Department Manager
and Manufacturing Floor General Tim Petersonhave devel-
oped several procedures that would typically utilize EDM
technology by devising means by which the same or better
results can be obtained with milling technology. It is fasci-
nating to watch these guys implement their unique skill sets
in our day-to-day operations.
Phot
os c
ourt
esy
of R
MS.
RMS employee Craig Williams works on a MakinoV55 CNC mill.
According to Rapid Mold Solutions President Damian
Kuzmin, the companys business plan was a simple one at the
onset. We wanted to service the prototyping needs of the
Big 3 and the Tier 1s that supplied their specialty component
needs, he states. We learned how to design, build, and pro-
duce parts at the price point and timing necessary to earn
a lot of business quickly. The difficult part, as it turned out,
was determining what to name the new venture. Radiator
Mold Shop just wasnt conducive to future expansion
into new markets, so from the acronym RMS, Rapid Mold
Solutions was born.
Not long after that, the first request for production tooling
came across their desks and the current form of RMS began
to take shape. The expansion of the business into produc-
tion tooling necessitated a move to a bigger facility capable
-
At Plastic Engineering & Technical Services, we will.
We defne performance. Our engineering team is Expert
Gold certifed and the recognized industry leader in the use of
leading-edge analytical tools. We bring more than 25 years of hot
runner design, manufacturing and plastic processing experience
into every analysis we do. No one else in the industry has the
tools in their arsenal that we have. We ofer mold flling, mold
cooling, shrink & warp analysis, gas assist analysis, injection
compression, co-injection and more.
Once the frst analysis is completed, we re-analyze it, utilizing a
diferent sofware to cross check the results, to ensure accuracy.
We help you increase your efciency, reduce costs and improve
product integrity.
We deliver value. We were the frst hot runner manufacturer to
use Mold flling sofware as part of our daily business and more
than ever, were committed to your success. Contact us for your
mold flling analysis and your manifold build, and we will do
whatever it takes to make sure our hot runner/manifold
system works to your complete satisfaction, and stand behind
its performance.
Call us today at 248.373.0800 or visit us at www.petsinc.net.
WHO STANDS BEHIND THE PERFORMANCE OF YOUR HOT RUNNER/MANIFOLD SYSTEM?
-
Prole
16 MoldMaking Technology January 2013
This inductive tool shrink tting technology RMS uses improved tool mounting
by approximately 33 percent, notes RMS President Damian Kuzmin (pictured).
According to Peterson, one of the companys biggest and
ongoing challenges lies in keeping a constant, consistent
flow of information between sales, engineering, and the
floor. To address this challenge, weekly meetings between
all departments are held to keep the entire team informed as
to the status of jobs working their way through the system,
new ones entering the system, as well as individual kick-off
meetings involving sales, engineering, CNC, EDM and tool-
makers when new builds, engineering changes, and repair
work to coordinate each departments role in fulfilling the
work requirements, Peterson elaborates.
The company has also added some new technology in
the mill department which is already paying dividends,
Peterson continues. Our inductive tool shrink fitter is cut-
ting tool mounting times by upwards of 30 percent; and our
tool pre-setter with vision system is cutting set-up times
dramatically by enabling the quality department to take on
the task instead of the operator as well as giving us the abil-
ity to calibrate specific tools to specific sleeves, he states.
Additional benefits from the new system include increased
tool life, improved machining conditions and tool perfor-
mance repeatability with the specific calibration techniques,
Peterson adds.
Team Building
To keep up with attrition and expanding capacity, RMS has
taken a multi-faceted approach to addressing its personnel
needs, Kuzmin notes. New talent is acquired through online
advertising, direct solicitation of local vocational techni-
cal schools, and word-of-mouth throughout what Cannon
calls the capitol of the tool & die industrynorthwestern
Pennsylvania. For the younger, less experienced recruits, a
mentor in their chosen specialty department is assigned
to them to help address concerns and questions, Kuzmin
says. This less restrictive, more casual approach has reaped
benefits for RMS and led to productive employees in a
shorter period of time. The additional benefits to this men-
tor approach include more rapid integration of the new
hire into the team concept, the ability to have less seasoned
employees address the variety of work that permeates the
shop floor, and a hands-on approach that is truly learn while
you earn. To further enhance the learning experience of the
new recruits, they often participate in the part production
process from the prototype tools. Actually molding the parts
and pulling hand-loads press side enables them to develop
a much more thorough understanding of the components,
actions, and overall function of the tools used to make vari-
ous features of the parts.
To further build on the team concept, RMS has several
other unique activities and opportunities that enable employ-
ees to regularly interact outside the confines of the regular
workplace atmosphere. One of the common threads that tie
many in the region to one another is a shared love for the
outdoors, and RMS is no exception, Cannon notes. From
Damians love of the pursuit of waterfowl to Scotts love of
snowmobiling and golf to my love of fishing, guys through-
out the shop regularly get together on the weekends to
enjoy the natural bounty of the region, he comments. This
enthusiasm for the outdoors is taken a step further with
regularly planned, theme meals served during lunch. Some
of these meals have included fried walleye and grilled King
Salmon. It is often commonplace to see a Ziploc bag of fresh
John Massing of RMS ts a slide into a radiator end tank mold.
-
moldmakingtechnology.com 17
For more inFormation:
Rapid Mold Solutions, Inc. / (814) 833-2721
[email protected] / rapidmoldsolutions.com
deer jerky or goose sausage stick passed around the shop dur-
ing December and January. The most noticeable team build-
ing exercise that takes place at RMS can be heard throughout
the shop during 9:30 a.m., lunch and 2:30 p.m. breaks when
the tell-tale explosions from Call of Duty 4 ring throughout
the facility, Cannon adds.
a new mindset
As RMS continues to evolve, there
is a movement underway to change
the way in which the mindset of the
organization functions. The industry
has changed, and RMS will lead the
industry in adapting to those changes,
Cannon notes. No longer is a mold-
maker a manufacturer; the once time-
consuming and cumbersome design
and manufacturing processes have
been streamlined with the advent of
new technologies and more efficient,
faster machines. The modern mold-
maker has become a service provider
in essence a contract manufacturer
and needs to develop a customer-ori-
ented mindset, high level of customer
service, and regular contact with the
critical components of the customers
business from part designers and tool
engineers, to molding operators, to the
sales and management teams in order
to truly provide the value a customer
requires.
To adapt to those customer require-
ments, RMS has implemented the
regular use of online meeting software
to coordinate part design discussions
and tool design reviews with custom-
ers. According to Cannon, this tool has
expanded contact with customers and
provides a unique platform by which
both sides of the equation can develop
a better understanding of form, func-
tion and design. Sales calls are no
longer just salespeople, but upper-level
management, mold repair technicians,
and engineering staff from time to
time, Cannon concludes. This new
approach to sales calls creates a more
significant bond of trust between cus-
tomer and moldmaker. We are always
looking for ways to improve customer
interaction.
-
18 MoldMaking Technology January 2013
Case Study / Mold Design
Moldmaker Does Not Wine
About Precise Undercut And Cross Cavitation Challenges
By Sherry L. Baranek
Stacked Wines LLC (Newport Beach, CA) was conceived by
creator and company co-founder Matt Zimmer when he
sought a stylish, portable and recyclable packaging solution
for informal consumptionwhether it be tailgating, a picnic
or in a backyard. He teamed up with two fellow MBA students
at UC-Irvine to develop a product that offered quality taste, a
simple style andmost importantultra-convenience.
Zimmer, who has a background in plastics and beverages, says
he had one too many drinks from a stale bottle of wine and had
an a-ha moment on how to solve the problem. So he and his
partners put Zimmers vision to paper and sketched a practical,
easily stored, four-pack of stem-less wine glasses that vertically
stacked to form the equivalent of one full 750 ml bottle of wine.
According to Zimmer, each individual serving was to com-
municate the look and feel of a real wine glass and deliver the
durability of plastic. A foil seal would preserve the wines fresh-
ness within each single serving and an overwrap would deliver
brand messaging and consumer product information. The
compact, stacked format, Zimmer correctly reasoned, would
also appeal to shelf-space starved retailersand would allow 30
percent more cases per truckload than other format options.
His industry connections led him to R&D/Leverage (Lees
Summit, MO)a company that provides structural brand devel-
opment and mold manufacturing for the food, beverage, home,
personal care and healthcare industries. The company specializ-
es in full-service plastic product solutions. We needed expertise
into how to commercialize our vision, which led us to R&D,
Zimmer says. And with so many launches in our industry, time
was of the essence, since we compete against standard bottled
wines and boxed wines, which are increasingly popular.
Compressed Time-to-Market
According to R&D/Leverage Project Engineer Jeff Beason, his
team developed a product design from the customers initial
product sketches and delivered a manufacturable product design
with the snap-together feature that was a key to enhanced con-
sumer and trade functionality. The design was completed and
approved in just three weeks using Pro/E by PTC (Needham, MA).
Stacked Wines had a concept and basic design, which they
provided to us, Beason says. We were hired to develop the
design of what they wanted the bottle shape to be with the fin-
ish they needed to accommodate the filling process they chose.
It was stated that the stacking feature was a requirement and
this snap feature would be a very high value addition if we
could make it work. Obviously, the stacking function in and of
itself can have issuessuch as under-blown areas of the bottle
geometry. The stacking was to facilitate using the shrink-wrap
sleeve that they wanted to use to market the product.
Beason explains that the bottles were not just sitting on top
of each other, they were nesting. That is why the snap feature
was so important. It involved precise undercuts, he elabo-
rates. You can always design special features into a container,
but you have to make sure they are functional when the con-
tainer is molded. It all starts with design goals, and realizing
what is actual. In both cases, we were able to create the stack-
ing and the snapping feature on the design.
Forming the snap feature was a challenge, but the largest
challenge was to maintain the form that was created by the
mold, Beason adds. Oftentimes when a design includes an
undercut area, it will not demold or the area will distort to
allow it to clear the mold surface. He adds that the process
development R&D used to create the features he wanted is
proprietary and part of a unique process.
It all starts with a very accurate design, Beason notes. We
created shrinkages, etc. based on what the PET is going to do
as it moldsand after moldingso those adjustments become
part of the complete tool design.
Phot
o co
urte
sy o
f R&
D/Le
vera
ge.
The compact, stacked format of Stacked Wines wine bottles appeals to
shelf-space starved retailers.
-
Simple. Innovation.
H a a s A u t o m a t i o n , I n c . | 8 0 0 . 3 3 1 . 6 7 4 6 | w w w . H a a s C N C . c o m
Single setup
Machine 5 sides
Repeat (max prot)
The UMC-750 | 3+2 machining | Affordable Haas price.
Universal Edition
-
20 MoldMaking Technology January 2013
Case Study / Mold Design
For More inForMation:
R&D/Leverage, LLC / (816) 525-0353
Stacked Wines, LLC / (714) 870-1227
[email protected] / stackedwines.com
PTC / (781) 398-6614
[email protected] / ptc.com
Stacked Wines was on board very quick with approvals, and
those are the kinds of things that can bog a project down if
approvals dont happen fast enough, Beason continues. Email
and phone calls were major communication tools. Even though
they are on the west coast there was very little delay in commu-
nications. Since they were so very hands-on it just came down
to building the tooling. Their original idea was well conceived so
once we created the design with the requested finish and func-
tions, the feedback/approval phase was on a fast track.
Each container was made in its own cavity with its own push
up, according to Beason. That means all of the cavities had to
perform the same, he says. With each container being formed by
a combination of several components, it is crucial that a bottle off
any cavity would snap on containers formed by any other cavity.
The unit tool was built in early June, with a final sample deliv-
ered three months later; and the production tool was shipped
November 10th. Thanks to the technical support of R&D/
Leverage, we commercialized a breakthrough concept loaded
with consumer and trade appeal, Zimmer notes. Regional sales
volumes have validated our vision. As a result, we will continue
to expand distribution and, in time, become a national brand.
I am still excited about this project, Beason emphasizes.
What stood out for me was that this was a fresh idea from a
small group of people that were so enthused about it, and to
be able to work so closely with them and see their excitement
and anticipation build as the project moved forward really set
it apart from others for me. It felt very grassroots.
Zimmer adds, As a start-up, with limited capital and a
new concept, we needed to get into production fast and have
the design and tooling rightthe first time. R&D/Leverage
proved to be a great partner to work with, and they delivered
on all counts.
-
Case Study / Business Management
moldmakingtechnology.com 21
Business Succession Planning
Protects Shop in the Long-Term
By implanting an annuity trust, a mold
manufacturer can ensure a successful
business succession from one generation
to the next.
By Sherry L. Baranek
Since 1969, Bomatic Inc. (Ontario, CA) has been producing
plastic containers of all shapes and sizesfrom blow mold
designs and building to final productin the following indus-
tries: personal care, automotive, pharmaceutical, medical, lawn
and garden, food, household cleaners and industrial chemicals.
Current owner Kjeld Hestehave is extremely proud of the
fact it is a family-owned business passed down to him from
his father, and wanted to make sure he secured its success for
future generations, but did not know where to begin.
Hestehave was a young man himself when his father
brought him into the business. I worked part time until the
age of 22, at which time I became a full-time employee and the
heir apparent recipient of the business, he recalls. After his
dad retired at the age of 75, Hestehave found himself as the
new President and CEO. I know plastics, he states. I have
worked in the business for more than 48 years and I know
what it takes to make quality molds and plastic parts. What I
dont know is financial planning and/or business succession
planningwhich includes the transfer of a business from gen-
eration I (my parents) to generation II and III (me and my chil-
dren and nephews, who are now working in the business).
Enter Kevin La Mont, Vice PresidentAdvance Planning and
Investments at RB Capital Management LLC (Fresno, CA), an
investment advisor firm specializing in estate tax planning,
hedged strategies and managed fixed-income portfolios. La
Mont approached Hestehave two years ago, and asked if he
could stop by Bomatic and chat with him about the business
and what factors the company was facing in the current eco-
nomic climate.
As Kevin and I were talking, he looked around and asked
who owned the business and the building, which housed the
business, Hestehave states. I told Kevin that my parents were
the primary owners of both, which prompted his next ques-
tion, What planning has been implemented by my parents in
order to avoid the estate taxes upon their demise?
At the time, Hestehave believed that there would not be any
taxes since the business and building were held by his parents
in their living trust. Kevin informed me that a Living Trust
is great for avoiding probate and its inherent cost, delays and
publicitybut does very little to avoid estate taxes. After pick-
ing myself up off the floor and regaining my composure, I
ask Kevin if there was anything that could be done to reduce
and eliminate the familys estate taxes and the possibility of a
forced liquidation of assets.
Kevin assured Hestehave that there were a number of trusts
available that could be used to meet the needs and desires of
the family. These trusts include,
but are not limited, to Grantor
Retained Annuity Trust, Quali-
fied Personal Residence Trust,
Defective Grantor Trust, Private
Foundation and Self-Canceling
Installment Notes, La Mont
explains.
By using these trusts alone or
in combinations with each other,
the parents would be able to
achieve the following:
Keep Bomatic Inc. as a thriving
company.
-
22 MoldMaking Technology January 2013
Case Study / Business Management
Transfer the bulk of value of the business and building to
trust for estate tax planning.
Maintain a degree of control over the business and its operation.
Continue to receive income from the business and/or real
estate in order to maintain their (parents) standard of living.
Provide protection against claims judgments and possible
lawsuits.
Keep the business and building in trust for multiple
generations.
The Hestehave family chose to use a combination of a
Private Annuity for the building and a Grantor Retained
Annuity Trust for the business. The Private Annuity allows
Kjelds parents to receive the rent from the building (just as
they do now) in order to maintain their standard of living, La
Mont explains. However, upon their demise the building will
not be considered part of their estate. As for the business, the
Grantor Retained Annuity Trust will allow Kjelds parents to
receive income, but only for a number of years at which time
the business will transfer to a trust for the benefit of Kjeld, the
grandson and nephew.
As many know, being a business owner is hard work, says
Hestehave. The hours are long and the stress can be relent-
lessnot to mention the daily interruptions and distraction
one is constantly bombarded withand those are the good
days. With all that we endure as business owners, I feel a great
burden has been lifted off my shoulders. There is a sense of
comfort knowing that at some time in the future, the family
business (which we have poured our hearts and souls into) and
the real estate will be protected from estate taxes.
Hestehave advises: Dont assume that what you think will
happen, will happen. Meet with an advisor who understands
complex estate and business succession planning tax laws and
available tools. Our plan now ensures that Bomatic will be
herenot only during my years of running the businessbut
for my children and nephews as well.
For More inForMation:
RB Capital Management LLC / (949) 861-4362
[email protected] / rbcapitalmanagement.com
Bomatic Inc. / (909) 947-3900
[email protected] / bomatic.com
-
SAVE DATETHE
amerimoldexpo.comDonald E. Stephens Center, Rosemont, IL
PRESENTED BY
The Event for Mold Manufacturing
Plan to attend amerimold 2013
and get connected to the people,
the products and the processes
that make molds!
Exhibit hall featuring all aspects
of the mold manufacturing
industry from design to
production to maintenance
Technical conference
presentations by industry
leaders and innovators
Keynotes addressing current
issues in the world of mold
manufacturing
AND MORE!
Visit amerimoldexpo.com/contact to
register for the amerimold e-newsletter.
-
24 MoldMaking Technology January 2013
Case Study / Software
CNC Software
Delivers 50-Percent
Leadtime Reduction
For Complex Molds
Industrial Molds Group (Rockford, IL), is a leading manu-
facturer of precision injection molds and the 2012 winner of
MoldMaking Technologys 2012 Leadtime Leader award. The
companys extensive investment in equipment, technology and
employees has enabled it to reduce average leadtimes by 50
percent over the last five years.
Industrial Molds considers Delcams (Windsor, ON)
PowerMILL CNC programming software to be critical to
achieving its 8-week average leadtimes. PowerMILL reduces
our leadtimes in a number of ways, explains Greg Osborn,
Industrial Molds account manager.
It delivers the accuracy we need to get to net shape, which
reduces the amount of hand finishing we do. It also has a
number of features that
reduce programming time
and powerful functionality,
such as arc fitting allows
us to run our machines at
top speeds, which reduces
machining time.
Established in 1968,
Industrial Molds specializes
in all facets of injection mold
manufacturing including
design, engineering, tool-
ing and special machining services. The company has earned
an excellent reputation as a premier precision mold manu-
facturer, designing and building molds for thermoplastics,
thermoset, die cast and insert precision applications. Its port-
folio includes molds for a wide range of industries including
automotive (engine covers, surge tank bottles, seating, throttle
PowerMILL features, which
save programming time,
are another factor that
contribute to Industrial
Molds rapid mold
development process.
Imag
es c
ourt
esy
of D
elca
m a
nd I
ndus
tria
l M
olds
.
Video
Access video
at end of article.
Typical mold detail requires accurate CNC programming
and precision machining.
-
moldmakingtechnology.com 25
bottles); electronics (modules, coils, electronic panels, and cir-
cuit boards); packaging (caps and closures); medical (disposable
syringes, medical equipment cabinets, and housings); recre-
ational (engine covers, seats) and many more.
Strategy
As customers pushed for faster mold development, Industrial
Molds began implementing a strategy to shorten leadtimes.
The strategy consisted of buying the best equipment, deploy-
ing the best technology, and hiring the best people while
keeping their skills up-to-datea practice the company fol-
lows to this day. Deploying the best technology included a
switch from previous CNC programming systems to Delcam
PowerMILL on the recommendation of its distributor, CAD/
CAM Systems (Rockford, IL).
PowerMILL has been a key factor in the companys 50-per-
cent leadtime reduction by delivering a level of accuracy
that makes it possible to machine molds to net shape. This
shrinks leadtimes by reducing the bench work previously
needed for final fitting.
PowerMILLs roughing routines work very well, but thats
only 20 percent of the CNC work in a typical project, says
Mark Hastings, High-Speed Machining Manager. Then we
utilize its rest roughing machining strategy for semifinishing.
Finally, PowerMILL offers a lot of features that help us get to
the actual net shape, such as picking radii and corners, pencil-
ing out details, and flow line machining.
Control
PowerMILL also provides close control over machining toler-
ances to make sure that the machined parts meet the spec.
The tighter the tolerance, the longer it takes to generate the
toolpath, says Hastings. We can loosen it up while we are
roughing, which generates the toolpath quicker, then tighten it
up for finishing. Because we can control the accuracy, we can
achieve close tolerances without sacrificing speed.
Its really the synergy of PowerMILLs tight tolerance tool-
paths, along with the high-end Makino machines, good tool-
ing, good holders and skilled operators that allows us to get to
net shape, Osborn says. Its everything being at the same high
level. An important benefit of net shape machining is that you
know exactly where the steel is. As soon as you put a stone to
something for hand working, you no longer match CAD. You
dont know where the steel is. With PowerMILL, we can get
tighter shutoffs, and if the mold is damaged, such as destroy-
ing a parting line, we can recreate the exact shape because we
cut to net shape and there is no handwork.
In addition to shortening the mold development process,
getting to net shape makes an impressive sales demonstration.
When I bring customers in, they are surprised that our shut-
offs still have cutter marks, adds Osborn. They dont see a lot
of polishing on the parting lines because we can cut so close to
net shape that we dont need to handwork parting lines. They
are very impressed with that.
Automation
PowerMILL features, which save programming time, are
another factor that contributed to Industrial Molds rapid
mold development process. One such feature is the softwares
openness, which allows for the creation of macros that auto-
mate repetitive tasks. For example, one macro performs multi-
ple collision checks and multiple gouge checks. I select all my
toolpaths, and gouge check
and collision check on mul-
tiple toolpaths at one time,
explains Hastings. Theres a
lot of automation built into
PowerMILL and we run a lot
of macros for carbon cutting
of electrodes.
Another programming
time saver is the ability to
save projects and re-use the
majority of their program-
ming when developing
toolpaths for similar parts. I
save out generic projects that
already have a roughing tool,
a semi tool and a finishing
tool. Then I bring in a new
CAD model with similar fea-
tures and batch process the Delcam PowerMILL software is used to generate CNC programs at Industrial Molds.
-
26 MoldMaking Technology January 2013
Case Study / Software
PowerMILLs support for arc
tting enables Industrial Molds
to take advantage of high-speed,
high-feed cutters.
toolpaths over the new geometry, Hastings notes. Theres
hardly any editing. PowerMILL gives me what I need for the
new size part.
Faster Cutting
The third way PowerMILL speeds mold development at
Industrial Molds is by reducing machining time. PowerMILLs
support for arc fitting allows us to take advantage of high-
speed, high-feed cutters, Osborn explains. When you
use software that doesnt allow you to arc fit the toolpath,
you have to slow the machine way down to make corners.
High-speed cutters can go 300 inches/minute, but if tools
have to slow down for corners, they wont reach that speed.
PowerMILL offers smoothing and arc fit, which lets it travel
smoothly around corners at much faster speeds. By smooth-
ing out the transitions, PowerMILL allows for faster cutting
while maintaining accuracy.
Covering All Bases
Because Industrial Molds serves customers in such a wide
range of industries, the breadth of functionality in PowerMILL
is another key advantage. Every part we cut, from hardened
steel to soft aluminum or graphite, we program differently,
states Osborn. PowerMILL covers all those bases. It isnt lim-
ited to one type of machining. Some components we cut from
outside in and others from the inside out. With PowerMILL,
the programmer has so much control.
For more inFormAtion:
Industrial Molds / (815) 397-2971 / industrialmolds.com/
Delcam / (877) DELCAM1 / delcam.com
Customer-Driven
Advancements
Finally, Industrial Molds
appreciates the fact that
Delcam keeps PowerMILL
state-of-the art and listens
to its users. They stay up
with technologyusing
64-bit software is a good
example, Osborn says.
And they are continually
developing features to
speed up our job and make
things more efficient, such
as performing the process-
ing in the background so
you can use the computer
to do other things. We
request functionality and
Delcam adds it.
Accuracy, programming automation and support for high-
speed machining are important ways in which PowerMILL
supports Industrial Molds leadtime reduction. And while the
company is always being approached by vendors wanting them
to look at other CNC software options, PowerMILL remains
their software of choice. The toolpaths are accurate and the
finishes are good, notes Hastings. In short, we can count on
this software being right and accurate the first time. Osborn
concludes, When you have high-end equipment and people,
you need to match that with high-end software. This is the
role PowerMILL fills for us.
ViDeo: CnC Software and Complex molds http://short.gardnerweb.com/mmtpower
-
amerimoldexpo.comJune 12-13, 2013 / Donald E. Stephens Center, Rosemont, IL
MoldMaking Technologys editorial staf is now accepting
papers for consideration to be presented at the amerimold
2013 Technical Conference. If you are selected as a
speaker, you will receive a free full conference pass,
including admission to conference sessions, access to the
exhibit hall and tickets to meals and networking events.
WHO SHOULD PRESENT:
Moldmakers / Molders / OEMs: share your experiences, lessons learned, tips and best practices for better moldmaking and molding.
Technology suppliers: share your technology reviews and
application stories.
SUGGESTED TOPICS INCLUDE:
Machining (5-axis, EDM, hard milling, etc.)
CAD/CAM
Cutting Tools
Mold Maintenance / Repair
Mold Materials
Molding / Processing Troubleshooting
Mold Components
Hot Runners
Additive Manufacturing
Business Management / Operational Eciencies
Education / Training / Workforce Development
PRESENTATION SUBMISSION GUIDELINES:
Summarize your paper in 200 words
Due by February 15, 2013
Include the title of your paper, author
and/or speakers name, a brief bio and
contact information
Include your preferred presentation
format: Workshop, Seminar or Panel
Discussion
Speakers are responsible for providing
content for inclusion in the conference
proceedings by May 1, 2013
SUBMIT YOUR PROPOSAL TODAY!
Contact: Christina Fuges
Editorial Director
ph: (800) 579-8809
Call for Papers Is Open!
PRESENTED BY
Share your expertise Submit your amerimold
presentation, today!
The Event for Mold Manufacturing
Donald E. Stephens Center, Rosemont, IL
-
Machining/Automation
28 MoldMaking Technology January 2013
Simple Considerations for
Automated Mold Machining
By William G. Howard
Gaining a competitive edge in todays mold and die
manufacturing market requires a streamlined approach
to the manufacturing process that focuses on increas-
ing throughput while reducing or eliminating operator inter-
vention. The most effective means for accomplishing this task
is through machine automation.
Commonly perceived as a complex task, adoption of
machine automation can be simplified by understanding the
technologies available and how they can be effectively applied.
These technologies can range from control software to remote
monitoring and robotic systems. When effectively introduced
to a mold/die manufacturing system, manufacturers can expect
to see game-changing improvements in cycle time, workpiece
quality, unattended capabilities and overall cost per part.
For mold and die manufacturers interested in automating
their manufacturing systems, there are three simple tech-
nologies to consider: advanced machine control software,
unattended monitoring, and automated workpiece and tool-
transfer capabilities.
Advanced Control Technologies
A manufacturers primary consideration for automating a
mold/die manufacturing system should be the machine tool
and its control software. Advanced machine control soft-
ware offers manufacturers the ability to dramatically reduce
machine downtime, labor costs and human error through
in-process monitoring capabilities, such as laser tool measure-
ment, broken-tool detection, spindle-load monitoring, spare-
tool selection, tool-life monitoring and touch-probe routines.
Laser Tool Measurement
Laser tool measurement capabilities are essential for precision
applications. Whether the application demands a drill, ball mill,
flat mill or bull nose end mill, laser tool measurement capabilities
enable the control system to gather both the length and radius
dimensions of any tool design. Laser measurements can be con-
ducted as each new tool is introduced to the spindle, ensuring that
accurate tool offsets are entered into the program for the highest
level of accuracy and worry-free unattended machining operations.
A secondary function to laser tool measurement control features
is the ability to recheck a tool post-process in order to determine
excessive wear or breakage. Under these conditions, several options
can be programmed, such as stopping the machine with an alarm
or selecting a spare identical tool and rerunning that portion of
the program. This option is extremely valuable when automating
a manufacturing system, providing manufacturers with the level
of comfort to walk away or leave the shop without concern of part
damage or additional tool destruction.
A streamlined approach to
your mold manufacturing process
is accomplished most effectively
through machine automation.
Video
Access video
at end of article.
Laser tool measurement is an essential component to unattended precision
machining that enables accurate tool offset programming and tool wear monitoring.
Phot
os c
ourt
esy
of M
akin
o an
d M
GS
Mfg
. Gro
up.
-
moldmakingtechnology.com 29
Spindle-Load Monitoring
Spindle-load-monitoring capabilities are one of the best safety
protections that can be easily applied to any program. In the
event of tool failure, programming error or a power spike, the
spindle-load monitor stops the machine and signals an alarm
before any damage can occur to the tooling, workpiece or
spindle. These capabilities are ideal for unattended roughing
operations, particularly in hard milling applications. Advanced
spindle-load-monitoring systems allow each tool to be pro-
grammed separately with its own load restriction to ensure
accurate monitoring. This
protection can be set man-
ually or read automatically
while the tool is cutting.
Spare-Tool Selection
To minimize machine
disruption due to tool
degradation, a spare-tool-
selection feature is essen-
tial. This feature enables
tooling to be matched
up with other identical
tools within the machine
control for backup use.
When a tool is disabled
and recalled to the tool
changer, tools of matching
identity can be called up
and loaded into the spindle
on the fly.
Spare-tool selection can work in conjunction with other con-
trol features to automate machine processes for extended
hours of unattended operation. Whether there are multiple-
part setups or single-part runs, spare tooling allows manufac-
turers to cut downtime and save money.
Tool-Life Monitoring
Tool-life monitoring is another advantageous control feature
for unattended mold/die operations that studies the approxi-
mate life span of each tool. With tool life values determined,
manufacturers can control the duration for which a tool is
allowed to run. Once that programmed limit is reached, the
tool is automatically recalled and cannot be loaded back into
the spindle. Tool life can be measured in three different forms:
cutting time, distance traveled and workpiece count.
When measuring based on cut time, the machine tracks the
time a tool spends in feed mode and issues an alarm when that
time has expired. Tool-life presets based on distance are mea-
sured based on the length of tool travel and can be controlled
by estimating tool wear through the amount of surface area
machined. A warning can also be set to give advance notice to
an operator that can also be signaled by a stack light. Tool-life
monitoring measured through workpiece count can be set
based on individual workpieces or the number of workpieces
produced per pallet load.
Touch-Probe Compatibility
Advanced machine controls can enable further automation
through touch-probe compatibility. Touch probes offer endless,
customizable routines to reduce workpiece setup time, incor-
porate safety checks and set accurate work offsets.
By using a touch probe to measure a few points, manufac-
turers can accurately determine part location and set work
offsets directly to the machine, enabling longer unattended run
times. Additionally, touch probes can be applied to verify block
sizes and the data to start roughing without being near the
machine. Checking for machined features is an excellent way
to protect the machine and tooling.
For example, before starting a finishing operation, a pocket
can be probed to verify that it has been fully roughed, pre-
Touch probes provide additional
unattended reliability by accurately
determining part location for automatic
adjustment of work offsets following
workpiece change over.
Machine disruption can be minimized through spare-tool selection control
features that replace worn or broken tools with preset identical tooling.
Automated work cells enable manufacturers from any industry to achieve
the highest level of around-the-clock unattended machining.
-
Machining/Automation
30 MoldMaking Technology January 2013
venting damage due to higher-than-expected spindle loads.
Probing can also establish rotational offsets to square up the
workpiece in all axes.
From laser-tool measurement to part-probing capabilities,
advanced tool features can be combined and used to create cus-
tomized cycles for a wide variety of applications. With demands
differing from one shop to another, the versatility of a machines
control is critical for establishing an effective automated system.
Remote Machining and Monitoring
In recent years, there has been tremendous growth in the
area of remote machining and monitoring. These technolo-
gies have provided manufacturers with the ability to view and
even control machines without being present in the shop. In
many cases, these capabilities have let manufacturers focus
greater attention on growing their customer base and reduc-
ing their number of operating shifts.
Remote machining technologies are designed to provide
operators with full control of the machine from any location
with Internet access. By applying this technology, operators can
tap directly into a machines control to view current param-
eters, check machine history (e.g., broken or worn tools and
alarms) or add toolpath programs. Several remote machining
technologies also provide text-message alerts to cell phones,
notifying operators of specific machine alarms that have
occurred. Operators can then decide if it is necessary to go into
the shop or not. Whether operators are away from the shop or
working remotely from an office down the hall, these capabili-
ties are an ideal way for manufacturers to save time and money
through improved efficiency, reliability and productivity.
An additional benefit to remote machining is the ability to
provide remote access to third-party engineering service provid-
ers and machine tool manufacturers for more rapid service or
application support. This capability can eliminate costly trips for
service support and save several hours of machine downtime.
Remote monitoring extends the capabilities of remote
machine access with work-zone and shop-floor visibility via
webcam. With live viewing capabilities of machining operations,
operators can perform visual inspections of physical problems,
such as a crashed machine or damaged tool, from any location
with Internet access. Operators can see if a machine has stopped
before a job was completed and determine whether a trip to the
shop is necessary or not. Several mold/die manufacturers are
already employing these capabilities to their automated opera-
tions for decreased idle times and faster turnarounds that meet
or exceed customers needs.
These cameras can be password-protected for confidential-
ity purposes. Cameras can be viewed individually or simulta-
neously. The cameras are easy to install and can hold up to
extreme cutting conditions. By using both remote machining
and monitoring technologies, manufacturers can guarantee full
control of their machining operations anytime and anywhere
with Internet access.
Automated Work Cells
For around-the-clock unattended machining capabilities, mold/
die manufacturers can invest in a fully automated work cell.
Historically positioned as a solution for production machining
LeArn MoReVisit our Automation and Machining Zones for more information
on a variety of machining technologies including milling, grinding,
boring, drilling, as well as automation solutions.
Go to moldmakingtechnology.com/zones for a complete list.
Pallet-transfer systems enable manufacturers to setup and load parts into
a work cell without interrupting the machine process.
-
moldmakingtechnology.com 31
contributor
William G. Howard is vertical product line manager for Makino, Inc.
For more inFormation:
Makino, inc. / (800) 552-3288 / makino.com
Video: automated Work Cell for Unattended Hard milling of Precision mold applicationshttp://short.moldmakingtechnology.com/mgsmakino
environments, work cells have diversified to include a number
of unique configurations geared specifically to the mold/die
industry.
Automated work cells can be created by linking multiple
machines and robotic part-loading systems together to
provide a start-to-finish operation without operator
intervention and unnecessary downtime. Manufacturers
of automated work cells provide many options for using
tool magazines and pallet-change racks to run multiple jobs
of similar workpieces.
Applying advanced tool-control options, such as tool-life
monitoring and broken-tool detection, to an automated
work cell can ena