Show goers will see an electric injection machine in nearly every press maker’s booth this year, and electric/hydraulic hybrids in several.

The first gas-assist injection molding process for thermosets, and the use of gas assist for molding smaller parts were two new areas explored in papers presented at the 13th International Molding Conference and Exhibit held in February in New Orleans.

Programming software for the top-of-the line gas controller from Cinpres Gas Injection Inc., Whitmore, Mich., has been improved for greater ease of use and operating efficiency.

One of the industry’s first uses of nanocomposite foams for strong, lightweight composites was introduced at April’s 2007 Plastics Parts Innovation Conference of the SPI Alliance of Plastics Processors (APP) in Memphis, Tenn. (The APP was formerly SPI’s Structural Plastics Div.) Other news highlights of the meeting included one of the first uses of external gas-assist molding in the U.S., a new use of direct in-line compounding of long-fiber thermoplastics (D-LFT) to make glass-mat thermoplastic (GMT) sheet, and a unique one-piece automotive grille guard with a molded-in chrome tube. Lighter, stronger foamsNanoclays and carbon nanotubes from 5 to 10 nanometers thick have been incorporated into foams of PVC, polystyrene, and polypropylene in a collaborative project called the Center for Multifunctional Polymer Nanomaterials and Devices (CMPND) at Ohio State University.

Research into a new melt-oscillation approach for injection molding has yielded a means of enhancing mechanical properties without use of fillers or additives.

A novel combination of internal and external gas assist is the secret to injection molding a large panel that is both structural and requires a highly cosmetic surface.

Commercial applications in hollow-part molding with water—or water and gas—are starting to accelerate. They are driven by recent enhancements of process technology, equipment, and materials.

Car makers' all-out effort to cut costs is giving rise to new paint-free technologies, including an innovative 'simultaneous-shot" injection molding process that was presented at the SPE Automotive Division's latest annual Innovation Awards ceremony.

New approaches to injection molding reduce costs by saving material, eliminating secondary operations, and allowing use of smaller presses.

A simpler approach to in-mold film decorating was one new injection molding capability presented at the SPI Structural Plastics show and conference.

A new method of coinjection molding dissimilar materials was presented at this year's SPE Annual Technical Conference in San Francisco.

Water-assisted injection molding is the newest way to mold hollow or partly hollow parts.

The abundance of injection molding news at this year’s show is staggering.

Keep an eye on the increasing prominence of so-called “3D” mold analysis. Two vendors of simulation software from Europe and Asia think it’s the best solution for a big proportion of injection molded parts. Established U.S. suppliers aren’t so sure. In any case, the capabilities of both 3D and standard 2.5D simulation are expanding rapidly.

The October show in Dusseldorf saw an onslaught of new all-electric and hybrid-electric presses, with modular designs, new clamping styles, and new sizes available from an ever-growing range of suppliers.

External gas injection is finally getting molders’ attention as a means to improve part surface quality. Two different approaches are available for licensing. Here’s a look at the processes, the potential benefits, and the commercial players.

The abundance of injection molding news at this year’s show is staggering. There are more and bigger all-electric machines than ever, including first-time introductions by several suppliers. Electric technology is also taking new forms, such as beltless drives and “direct-pressure” clamping without a toggle. Energy-saving electro-hydraulic hybrids are also evolving.