WEDNESDAY, APRIL 23, 2008

LUNCHTIME LESSON
12:45pm-1:30pm
Session 8
Economic and Industry Outlook for Moldmakers: 10-Year Retrospective and Forecast
Bill Wood, Mountaintop Economics and Research, Inc.

Bill returns for a fourth year with his Mold Business Index presentation, which breaks down his monthly survey of North American moldmakers and examines current business activity levels. This year he will take a look back at the industry over the past 10 years, in addition to reviewing the details of the Index and teaching shops how paying attention to the direction of activity levels in moldmaking from month to month will serve as an indicator of what’s to come before it becomes an issue in your shop. This information serves as validation of what you are experiencing in your shop and can give you the business perspective you need to help you make informed business decisions.  *The MBI is a diffusion index calculated based on 50.0. A value above 50.0 for the MBI indicates that business activity expanded in the previous month, while a value below 50.0 means that business levels declined. The total MBI is a weighted average of the sub-indices for new orders, production, employees, backlog, exports and supplier deliveries.   

WORKSHOP: CONTINUOUS IMPROVEMENT
1:30pm-5:30pm
Session 9
AMBA-sponsored: How the Latest High-Speed Programming, Tooling and Machining Techniques Combine to Change Mold Manufacturing
Roger Goble, OSG Tap & Die, Inc.
Doug Noxell, Gosiger 3D
Todd Schuett, Creative Evolution

This association’s traveling seminar series is re-appearing for the third time at MoldMaking Expo 2008 and provides an intense, four-hour clinic for those moldmakers who want to learn to compete in today’s global marketplace. Experts on the three key aspects—toolpath, tooling and machine technology—will explain the cutting-edge techniques to use to maximize your equipment’s productivity. Real-world applications will be used. You are encouraged to bring your own specific problems and applications for discussion. Q&A time will follow the presentation.

CASE STUDY: MOLD MATERIAL
2:45pm-3:45pm
Session 10
Why Plastic Flows Better in Aluminum Injection Molds
David Bank, Aluminum Injection Molds
Ron Smierciak, Alcoa Forged Products

This case study presentation will pioneer a new set of standards for melt flow index numbers when using QC-10 molds. A direct comparison of melt flow values of non-filled, general-purpose resins when molding in QC-10 aluminum versus P-20 steel will be discussed. Testing includes the use of spiral melt flow molds constructed of QC-10 aluminum and P-20 steel with identical geometry, gating, and water lines in thicknesses of 1 mm, 2 mm and 3 mm. The difference in melt flow characteristics of a variety of general-purpose resins in both mold materials will be examined. Spiral test molds are used to directly compare flow characteristics and demonstrate how plastic flows better in QC-10.  The results—which fixes a pre-defined orifice, a predefined temperature with a predefined injection pressure—will reveal that plastic molded parts in QC-10 can: (1) minimize warp and enhance dimensional stability, (2) allow molds to fill faster and more efficiently; and, (3) allow any plastic material to flow greater distances compared to P-20. Melt flow index numbers from resin suppliers are based on data and processing techniques using only P-20 molds. 

CASE STUDY: EDM
2:45pm-3:45pm
Session 11
How Advancements in EDM Can Help Today’s Mold Manufacturers Compete
Brian Hahn, Holbrook Tool & Mold
John Bell, Holbrook Tool & Mold
Gisbert Ledvon, GF AgieCharmilles

The presentation will teach how new technologies can help moldmakers achieve better surface finishes in larger surface areas without compromising speed. Additionally, new technologies for micromold technology will be discussed (including information on what makes it micromolding) and what is needed to achieve micro, including thermo-stabilized and reduced wear technology—as well as inspection report technology from the machine. Information will be provided on the strategies, which have been proven successful, and how an investment in technology can prepare today’s moldmaker for success when competing in the world market. Particular attention will be paid to recent developments in technology, and the costs and benefits of the markets latest technologies will be evaluated. It will also focus on using complimentary technologies, EDM and high-speed milling.

PANEL DISCUSSION:  MACHINING/CUTTING TOOLS
2:45pm-3:45pm
Session 12
The Fatal Flaw that Keeps You from Ultimate Success
Chuck Graham, Overtime Tool
Brad Cook, Iowa Mold & Engineering
Walter Stuermer, Millstar

A cutting tool producer will moderate a discussion among three mold manufacturers—a plastic injection moldmaker, a rubber moldmaker and a forging die shop—as they field a number of questions regarding different aspects of their manufacturing process concluding with what they believe is the one "fatal flaw" that is keeping them from reaching ultimate success. This session will look at the proper application of new innovative cutting tool geometries, radical coatings and substrate enrichments that allow the end user to raise performance expectations while increasing profit margins and decreasing lead times. It also examine internal struggles—such as communication between individuals and departments, philosophy of implementing technological advancements and the importance of ongoing investment back into the company.

CASE STUDY: AUTOMATION/LEAN MANUFACTURING
4:00pm-5:00pm
Session 14
How to Reduce Labor Costs and Use Standard Procedures with Limited Automation
Mold Shop To Be Announced
Bob Byers, Erowa

This seminar will review how to reduce labor costs without going broke in mold manufacture by using standard procedures and limited automation that fit your budget as well as the current mindsets of mold shop owners. When the average shop starts to look at the true cost to implement automation they quickly shy away with multiple reasons why it can’t work in their particular case.  The reality of the past few years has forced many shops into a position of being cash strapped with an ever-decreasing margin and decreasing delivery times for the jobs they get. This creates a dilemma of what should be done with the resources they have and where to invest capital to get the maximum return.

This presentation will show how shops can grow into automation as their process becomes more standardized and the bottlenecks are more easily identified.

CASE STUDY: MACHINING
4:00pm-5:00pm
Session 15
Alternative Ways to the Benefits of Five-Axis Machining
Representative To Be Announced, Galaxy Tool
Jay Phillips, Tri-Tech Precision Products, Inc.

This session will uncover the benefits of five-axis machining, how the application determines your choice among the alternatives available for this kind of machining, and what is needed to effectively utilize this technology in today's moldmaking environment.

The technology and equipment for performing multi-axis machining has been around for a long time.  The methods used to achieve simultaneous five-axis in such industries as aerospace, energy production, oil and gas, medical, woodworking and moldmaking are similar, yet each industry has specific applications and needs that determine how a given manufacturer gets the job done. With careful consideration given to the specific application and the various alternate means of achieving five-axis capabilities, there are a large number of benefits that five-axis machining can bring to the moldmaker. Through the use of shorter tools, five-axis milling can complete an entire part without re-fixturing or using the long tools required in a similar three-axis application and still deliver the final product in less time and with a better surface finish.