New Innovations in Mold Design, Milling Cutters, 3D Scanning
MoldMaking Technology compiles a number of digital-only products from the past month, including mold design software, laser metrology 3D scanners, milling cutters and more.
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To catch you up on recent innovations for moldmakers, we’ve rounded up new products here. Below, learn about new mold design software, laser metrology 3D scanners, a three-axis milling and jig grinding machine, high-feed milling cutters and more.
For the full product post, click on each linked title, or find it under the “New Tech” section of the website. Additionally, check out more additive manufacturing and mold materials innovations in our latest technology roundup.
Controller Cart Transports Hot Runner Control Units Closer to the Mold
Hasco Hot Runner, a business unit of Hasco, introduces the Co-Cart transport trolley, which enable external hot runner control units to be positioned safely and optimally right next to the mold. The practical, robust cart offers many advantages, Hasco notes, including optimum ease of operation. The smooth rollers enable the safe transport of any hot runner control unit, and the slip-resistant tabletop and raised edges around the cart’s perimeter ensure that the device can neither slip nor tip over. A plastic box in the lower compartment of the Co-Cart offers storage space for all connecting cables and additional equipment; this prevents transport being blocked by cables hanging down when the cart is being moved.
High-Feed Performance for Small Parts
Ingersoll’s new NanoFeed technology provides mold builders with exceptional high-feed milling performance for machining of miniature components and smaller part features.
NanoFeed is a 20° high-feed indexable insert design that Ingersoll claims will replace smaller diameter solid carbide end mills in a variety of applications. Inserts have been designed with pressed-in coolant channels, directing coolant or air directly to the cutting edge for maximized tool life. Inserts also have backdraft side clearance for straight-wall milling capabilities.
CAD Software Improves User Functionality
Supply chain software provider, Kubotek3D, has announced the 4.0 release of the Kubotek K-Compare and K-Display software products. This release provides updates to CAD file readers, user interface improvements and several new functions for each product. The new releases are available for customers to download immediately.
A new ability to move and/or rotate objects relative to each other has been introduced. Moving objects apart from each other enables users to better visualize a complex assembly in which some part and sub-assembly locations in the original CAD assembly file obstruct the view of other parts. The ability to export files to a 3D PDF file has also been added to K-Display products in the 4.0 release.
Multifunctional Laser Handheld 3D Scanner
Shining 3D, a global provider of technologies for 3D digitization and 3D inspection, has expanded its FreeScan UE series of blue laser metrology 3D scanners with the FreeScan UE Pro.
FreeScan UE Pro inherits the high-precision, metrology-grade accuracy, and lightweight design of FreeScan UE, while improving the ability of fine scanning and global precision control of large-scale workpiece scanning, according to the company. It adopts 26+5+1 blue laser lines and has a built-in photogrammetric module. Taking into account speed, accuracy and details, the 3D metrology solution can be applied to different sized scanning scenarios and perform metrology-grade accuracy inspection, reverse design, additive manufacturing (AM) and other applications.
Cobot Integration Boosts Repeatable, Reliable Toolroom Production
Fast Heat by Spark Industries is highlighting the ReadyCobot, a collaborative robot solution enabling tool shops and molders to overcome labor shortages, improve quality and lead time, improve flexibility and ultimately reduce costs. Applications that can be performed by the ReadyCobot include assembly; bin picking; palletizing; inspection; machine tending; loading and unloading; drilling, milling, sanding or screw driving; and packaging.
Features include six-axis hand-guided or drag-and-drop programming via the wireless app, up to 39-lb payload, 52" working radius, max speed up to 3.5 m/s, repeatable to ±0.02 mm, configurable I/O integration and force control natural human-cobot cooperation.
Three-Axis Milling, Jig Grinding Machine Precisely Machines Large Molds
The RXU 2000 is a high-precision three-axis milling and jig grinding machine for large dimensions from machine tool company Röders. The machine is reported to achieve maximum precision when workpieces and molds with particularly large dimensions have to be machined. Designed for exceptional accuracy combined with high performance in machining hardened materials, the plant has a working area of 2,000 x 1,800 x 800 mm. The work table is designed for loads of up to 5°t. The Z-axis stroke has been intentionally limited in order to ensure maximum accuracy.
Röders says the RXU 2000 is suited for 3D milling as well as for jig grinding, vertical grinding or profile grinding. This combination of operations in one setup on the same machine is particularly ideal for many jobs in machine and moldmaking including large mold plates (such as for progressive dies); large, flat injection molds with fine contours (for seals), which have to be machined with relatively small tools; machine components (like guide rails); and large, high-precision workpieces.
Ceramic Deburring, Deflashing Tools take Into Consideration Difficult Materials, Operator Safety
Boride Engineered Abrasives introduces a new series of safe and easy-to-use ceramic deburring and deflashing tools. The Work Finisher Tool, for example, is ideal for deburring and chamfering non-ferrous metals such as copper, aluminum and brass products and excels on ultra-hard resins like glass fiber, carbon fiber and talc-filled plastics while reportedly eliminating the fear of cutting hands and fingers, or damaging the molded part in the process.
Available in three sizes — large, small and micro — the Work Finisher is lightweight, long lasting, won’t rust and, according to Lesley Murphy, Boride’s marketing and sales manager, is an ideal alternative to other deburring knives.
Inserts Improve High-Feed Milling Performance in Exotic Materials
Tungaloy America has expanded its DoFeed high-feed milling cutter series by adding six LNMU0303UER inserts. DoFeed, a high-feed milling cutter series, features economical double-sided inserts with four cutting edges, offering a wide variety of cutter body diameters and styles.
The LNMU0303UER inserts are designed to provide a smaller approach angle than existing LNMU0303ZER inserts when set on the cutter body so that the insert generates thin chips. This chip thinning effect reduces cutting loads, minimizing damage on the cutting edges during machining of exotic materials for longer insert tool life. Also, a small approach angle directs the cutting forces in the axial direction towards the spindle. This amounts to less tool deflection, as there is much less radial force pushing the cutter off its center axis, enabling stable long overhang machining without compromising cutting parameters.
Indexable Milling Grades Achieve 30% Longer Tool Life
Kennametal has introduced the PVD-coated KCK20B and KCKP10 indexable milling grades for higher wear resistance, up to 30% longer tool life when machining cast iron and compacted graphite iron components and no rework needed. Both grades are said to offer higher productivity and consistent, repeatable performance during roughing, semi-finishing and finishing operations; the inserts also work well when profiling and copy milling cast iron and steels up to 45 HRC.
In addition, KCK20B and KCKP10 are suitable for wet or dry cuts. These include rotor hubs used in windmills, pump housings, steering knuckles and gear housings for heavy equipment, and automotive components like crankshafts and cylinder heads.
Power Sliding Clamps Enable Faster Mold Changes
Globeius Inc., the North American distributor for Mouldpro ApS products, has introduced a Power Sliding Clamp, designed to allow for faster mold changes.
The clamps can accommodate a range of different mold backplate sizes and thicknesses. The clamps can be used in threaded platens or t-slot platens, Globeius says. They are designed to slide by virtue of an integral t-slot, which enables it to be fixed in the optimal position for clamping. An adjustable bolt prepares for different clamp heights. Suitable for Quick Mold Changes (QMC), these clamps feature a nickel-plated finish for optimized corrosion and wear resistance.
Wire EDM Function Eliminates Wire Breakage, Reduces Consumption
The new iWire function from GF Machining Solutions automatically identifies and adapts wire speed to changing erosion height conditions during the wire EDM process. This capability reportedly eliminates wire breakage while reducing overall wire consumption per job, in some instances by as much as 29%.
Featured on new GF Machining Solutions’ Cut P Pro Series wire EDMs, the iWire function works in tandem with the company’s Intelligent Spark Protection System (ISPS), both of which are part of the company’s Uniqua control.
Five-Flute End Mill Delivers Dynamic Performance
The M.A. Ford TuffCut XV Series XV5CB is said to be a stable, reliable solution for deep, dynamic milling applications, especially developed for mold builders. The five-flute chipbreaker end mill was designed to deliver exceptional metal removal on steels and stainless steels. Offered in both 3xD and 4xD length of cut options, M.A. Ford says the XV5CB increases productivity through its aggressive stepover capabilities.
The tool’s combined variable pitch geometry flutes and thick core design minimizes harmonic vibration and increases strength. Along with the company’s staggered chipbreaker technology — to reduce cutting force and extend the life of the tool — a good balance can be reached, the company contends, increasing machining performance.
Virtual Injection Molding Tools Enable Holistic, Simulation-Driven Product Design and Manufacturing
Simcon’s software suite bolsters Altair’s existing polymer engineering offerings – which already includes materials data, CAE workflow and manufacturing solutions – and will help Altair customers drive the digital transformation of the plastics engineering value chain. By adding Simcon, Altair says it now boasts the most complete set of plastics engineering solutions and expertise. Simcon’s solutions enable customers to digitally revolutionize their entire plastics engineering value chain. With industry-leading precision and speed, customers can anticipate and fix issues like air entrapments, weld lines, hot spots, sink marks, shrinkage and warpage virtually — before molds are built.
Through the APA, Simcon will offer three packages for injection molding simulation and design optimization, and a separate package for optimized mold tryouts.
Software Remotely Monitors, Measures Critical Process Conditions
ATC Diversified Electronics has introduced scalable technology that enables remote monitoring of critical processes for a wide range of conditions. ATC’s Sensert remote monitoring and alert system is said to set up easily, is affordable and uses a shop’s existing sensors.
A variety of sensors can be hardwired directly to the Sensert base unit or wirelessly connected via the software’s remote I/O for true wireless, remote, online capability. ATC says sensor data is monitored in real time and alerts are triggered based on customizable thresholds, configurable through the Sensert mobile app or web portal. Each channel can be configured for a high and low threshold value as well as custom alerts. Moreover, Sensert can reportedly work with any commercially available 0-20 milliamp, 4-20 milliamp, 0-5 volt or 0-10 volt sensors.
All-in-One CNC System Advances Speed, Accuracy, Operability for Moldmakers
Mitutoyo America Corp. announces the release of the RTX Roundtracer Extreme, an all-in-one measuring system that integrates roundness, contour and surface roughness measurement functions on a single platform to save moldmakers time and improve productivity. The advanced CNC machine is said to utilize speed, accuracy and operability at the highest level to measure a wide variety of workpieces with various geometries, such as camshafts and bearings.
According to Mitutoyo, a new motorized sliding axis, detector and detector holder gives the system the ability to change the stylus angle, making it easier to perform an inside diameter measurement of thick workpieces while avoiding interference.
Larger Capacity Auxiliary Injection Unit Introduced
Mold-Masters is introducing its largest capacity E-Multi auxiliary injection unit for multishot molding, the EM5. The E-Multi is an all-electric auxiliary injection unit that offers multimaterial and coinjection molding capabilities for single-shot machines. This new unit expands the shot range of the E-Multi from 550-1,237 g (18-42 oz).
The E-Multi platform converts any existing injection molding machine for multishot, multimaterial or coinjection molding, with significantly lower capital investment requirements and faster lead times than a traditional multishot injection machine. E-Multi units are available from EM1 through the EM5, giving molders a broad shot range from 7.7-1,237 g (0.26-42 oz). The system is compatible with a range of plastics including post-consumer recycled resins and bio-based plastics. An E-Multi for LSR is also available.
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As the year comes to an end, I would like to take this opportunity to reflect on some of the interesting and inspiring stories that we covered in MoldMaking Technology in 2023. It has been a busy and exciting year for the moldmaking industry, with developments in technology, innovation and business strategy. Here are some of the highlights that caught my attention.
