Today's KNOWLEDGE Share : "Clamping Force vs. Mold Weight"

Today's KNOWLEDGE Share

How to Correctly Use the "Clamping Force vs. Mold Weight" Correlation in Injection Molding

We often discuss the theory behind machine selection. Today, let's talk about the practical application. Understanding the non-linear relationship between mold weight and required clamping force is crucial, but it's only a guideline. Safety and precision come from a disciplined process.

Here’s a practical, two-way method to apply this knowledge and avoid costly mistakes.

1. Forward Estimation (The Right Way: From Product to Machine)

This is the standard, proactive approach for new projects.

Step 1: Calculate. Determine the required clamping force scientifically based on your part's projected area and material injection pressure. This is your non-negotiable starting point.

Step 2: Estimate Weight. Based on the part size and complexity, estimate your mold weight.

Step 3: Cross-Reference. Use the force and weight to check a correlation table . This gives you a target machine class (e.g., 600-1200T).

Step 4: Verify Specs. This is critical. For a specific machine in that class,

you MUST verify three physical parameters from its manual:

✅ Tie-Bar Clearance (will the mold fit?)

✅ Mold Thickness Range (is it too thick/thin?)

✅ Maximum Allowable Mold Weight (is it safe?).

2. Reverse Warning (The Safety Check: For Existing Tools)

This is your rapid risk-assessment tool, especially when repurposing a mold.

Scenario: You have a mold weighing, for example, 10 tons.

Check the Table: A 10-ton mold typically requires a 1500+ ton machine for safe structural support.

The Red Flag: If someone suggests running it on an 800-ton press, you now have a data-backed reason to say "Stop." Even if the clamping force might be borderline sufficient, the machine's platens and tie bars are not engineered for that static load and dynamic inertia. This prevents catastrophic damage.

The Key Takeaway?

The correlation table is your quick-screening ally, but the machine's official technical specification sheet is your binding contract for safety.

Industry Wisdom: Experience helps you ask the right questions, but only hard data from the manufacturer gives you the right answers.

What's your process for machine-mold validation?

source : Kim Su

#InjectionMolding #MoldMaking #Polymers

Today's KNOWLEDGE Share : Why the Melt Cushion Matters More Than You Think in Injection Moulding

 Today's KNOWLEDGE Share

💡 Why the Melt Cushion Matters More Than You Think in Injection Moulding

In injection moulding, everyone talks about cycle time, clamping force, or cooling efficiency — but very few talk about the melt cushion.

Yet this small, often overlooked parameter plays a critical role in ensuring process stability, consistent part quality, and machine repeatability.

The melt cushion (or cushion size) is the small volume of molten plastic left in front of the screw after the holding phase. It acts like a pressure buffer, ensuring that the material can still be packed properly as the part cools and the gate starts to freeze off.

If your cushion is too small — or worse, inconsistent — you’re basically losing control of your process.

👉 Pressure transfer becomes unstable.

👉 Part weights start to drift.

👉 Dimensional tolerances suffer.

👉 And your cycle-to-cycle repeatability disappears.

Maintaining a stable and adequate melt cushion is not just about machine setup — it’s about process discipline.

It reflects how well we understand our injection profile, screw recovery, material viscosity, and even back pressure.

The problem? Many technicians focus only on speed or pressure settings, not realizing that the melt cushion is the silent indicator of whether the process is truly under control.

So next time you’re optimising a moulding process —

check your melt cushion consistency.

It’s often the difference between “it runs” and “it runs well.”

source : Tivadar Hamzók

#InjectionMoulding #ProcessStability #meltcushion

Hyundai Motor Company postpones Hypercasting facility by 2 years due to EV demand slowdo

IDRA GROUP has already installed a 9,000-ton class die casting machine at Hyundai's Ulsan plant in South Korea, and test production has commenced.

However, reports from April and May 2025 indicate that Hyundai is postponing the full-scale launch of its Hypercasting facility by approximately two years, pushing the timeline from 2026 to potentially 2028.

The delay is primarily attributed to a temporary slowdown in demand for electric vehicles and the imposition of a 25% tariff by the United States.

The original plan aimed for mass production to begin in 2026, with the new EV plant in Ulsan scheduled for completion in 2025.

This is a significant development for the Western manufacturing capacity race.

Will Hyundai fall behind as Chinese OEMs continue to scale Gigacasting aggressively?

📰 Full article: industryarsenal.com

source : Luca Greco

Atomic-6’s composite tiles selected for protection against space debris

Atomic-6’s Space Armor tiles have been chosen by the spacecraft company Portal Space Systems as a Micrometeoroid and Orbital Debris (MMOD) protection system for its next spacecraft. MMOD protection helps shield critical spacecraft systems from the millions of debris particles that could strike them and end the mission by damaging the spacecraft.

The tiles will be installed prior to integration on SpaceX’s Transporter-18 Rideshare mission, scheduled to launch in October 2026 aboard a Falcon 9 rocket. This mission will be the first operational orbital deployment of the tiles and will therefore enable the system to be evaluated (installation procedures, in-orbit performance, best integration practices) in order to validate or reject other applications of this technology.

No emission of harmful secondary ejecta

The structure of Atomic-6’s Space Armor impact shielding tiles is entirely made of composites. This enables them to be lighter and more compact than legacy shielding ones, claims Atomic-6. They are available in two configurations depending on the debris size and can be radio frequency-permeable or -blocking, as desired. Besides, they stop debris without creating harmful secondary ejecta, which is not always the case with traditional MMOD systems, particularly those made of aluminium.

“Portal is pushing the boundaries of what’s possible in orbit, and they need protection that keeps up with their ambitions,” said Atomic-6 CEO, Trevor Smith. “These flights move Space Armor tiles from operational testing to real commercial use, and they demonstrate how quickly the industry can adopt better ways to survive in the harshest, most debris-filled operating environment while simultaneously helping to reduce the risk of Kessler syndrome [situation in which the density of objects in low Earth orbit becomes so high that collisions between these objects become exponential].

“Our customers rely on Portal spacecraft to remain maneuverable over extended mission timelines,” said Jeff Thornburg, CEO of Portal Space Systems. “That means protecting critical systems in a way that supports, rather than limits, on-orbit performance. By incorporating Atomic-6’s Space Armor tiles into our spacecraft, we’re expanding our ability to offer customers sustained maneuverability and longer operational time on orbit. We’re pleased to have Atomic-6 as part of the Starburst-1 mission.”

Cover photo: Side by side comparison of monolithic aluminum plate and Atomic-6’s Space Armor impact shielding tile during hypervelocity impact

source: Jec Composites

Today's KNOWLEDGE Share : PVC Compounding: Why PVC Absorbs Plasticizers Unevenly

 Today's KNOWLEDGE Share

🔬 PVC Compounding: Why PVC Absorbs Plasticizers Unevenly

One of the most misunderstood behaviours in flexible PVC is the uneven absorption of plasticizers. Although PVC particles may look uniform, their internal structure is far from identical. Differences in porosity, particle morphology and microvoid distribution affect how quickly and how completely plasticizers diffuse into the polymer. As a result, two particles from the same batch can behave very differently under the same conditions.

Temperature and mixing energy also play critical roles. If the dry blend heats unevenly, some particles begin absorbing plasticizer faster than others, creating regions with different gelation rates. This affects fusion, torque, melt strength and surface appearance. Even stabilizers, fillers and pigments can influence absorption by blocking diffusion pathways or altering the local polarity inside the mixture.

Converters notice this behaviour as variations in plastisol viscosity, calendering window, wire coating smoothness or the flexibility of the final product. The challenge is that uneven plasticizer uptake often originates long before extrusion begins, inside the dry blend itself.

In your view, which factor drives the biggest variation in plasticizer absorption: particle morphology, mixing temperature or the presence of fillers?

source : Orbimind AB

#PVCIndustry #PVCCompounding #Plasticizers #orbimindAB

Carbonova carbon nanofibers (CNF)

 What actually limits nano-reinforcements from performing at scale?

Dispersion.

Even the strongest carbon additives lose effectiveness if they cannot disperse well, leading to agglomeration and inconsistent performance.

Carbonova carbon nanofibers (CNF) exhibit excellent dispersibility in conventional compounding and molding processes, enabling highly uniform distribution, stable mechanical performance, and a smooth, consistent surface finish — all without requiring new equipment or complex processing steps.

Why this matters:

➡️ Well-distributed nanofibers with negligible aggregation, helping prevent surface imperfections and part failure

➡️ Enhanced mechanical properties

➡️ Predictable, repeatable performance at production scale

When carbon nanofibers disperse the way they should, engineers get to design for possibility instead of working around material limitations.

Interested in materials that enhance manufacturing rather than constrain it? Reach out today.

#Cleantech #CarbonNanofibers #NanoReinforcement

KRAIBURG TPE Enhanced PPE Performance for Occupational Safety

 High-altitude work in construction, utilities, and industrial maintenance increases occupational risks. Workers rely on personal protective equipment (PPE) that delivers grip, durability, and comfort under constant use. Material selection determines how PPE performs under these conditions.

KRAIBURG TPE, a global manufacturer in thermoplastic elastomer (TPE) compounds, offers innovative material solutions suitable for PPE used in high-risk, high-contact environments.

Material properties for secure handling

PPE components are subject to repeated stress, frequent handling, and abrasion from rough surfaces. KRAIBURG TPE compounds provide stable mechanical performance and consistent grip, its flexible over a wide temperature range to ensure reliable handling in various working environments. The materials bond well to polypropylene (PP), which allows efficient overmolding and strong bonding in multi-material designs. Selected TPE grades can also be overmolded onto other plastics or metals to support complex component integration.

Manufacturers can use soft-touch TPE for high-altitude work safety to improve handling and reduce hand strain during long tasks. The smooth surface and controlled elasticity enabling users to maintain a firm grip during repetitive motion.

Abrasion resistance for extended service life

High-altitude PPE often comes into contact with tools, edges, and abrasive surfaces. KRAIBURG TPE develops TPE with good abrasion resistance to reduce surface wear and extend product life. UV and weather-resistant grades are available, making these materials suitable for outdoor applications exposed to harsh environmental conditions. These properties of KRAIBURG TPE solutions make them suitable for grips, handles, flexible joints, and protective elements where material failure could compromise safety.

Design flexibility for PPE manufacturers

KRAIBURG TPE materials allow full colorability for visual identification and functional differentiation. The compounds process efficiently and accommodate ergonomic shapes and compact designs. These features make them practical TPE for PPE applications such as gloves, harness components, grip zones, seals, and soft-touch interfaces.

Versatile range of applications across industries

KRAIBURG TPE materials are used in a range of applications requiring ergonomics, durability, and design flexibility. Common uses include car mats, functional and design elements, tool handles, toolboxes, ski poles, and soft-touch surfaces such as thumb wheels, push buttons, and switches.

KRAIBURG TPE at CHINAPLAS 2026

KRAIBURG TPE will exhibit at CHINAPLAS 2026, from 21–24 April 2026 at the National Exhibition and Convention Center (NECC) Shanghai, China, Hall 7.2, Booth D13. Visitors can explore the company’s portfolio of TPE materials and access the free one-on-one consultations with technical experts for material recommendations and application support.

Sustainability from the get-go

At KRAIBURG TPE, sustainability drives our innovation. Our portfolio includes bio-based TPEs and compounds with post-consumer (PCR) and post-industrial (PIR) recycled content. Selected TPEs are certified under GRS and ISCC PLUS. We also provide Product Carbon Footprint (PCF) data upon request to support sustainability decisions.

We proudly earned the EcoVadis Gold Medal in 2025 and are committed to the Science Based Targets initiative (SBTi), aligning our goals with global climate action.

From reducing emissions to increasing circularity, our sustainable TPEs deliver reliable performance and are available worldwide to support your applications while advancing your sustainability goals.

Get in touch today to learn how KRAIBURG TPE can support your sustainability and product development journey.

source : KRAIBURG TPE