Stelray Plastic Products said its expansion will allow it to better serve existing customers and further pursue opportunities in medical molding. Precision injection molder and mold builder Stelray Plastic Products Inc. is nearing completion on a 5,000-square-foot addition to its existing 14,000-square-foot molding department. The new space includes 20-foot clear-height ceilings to accommodate the installation of a Haitian 620-ton injection molding machine and integrated 3-axis robot. The project also includes the construction of a larger metrology lab and the addition of a new Micro-Vu vision system. The lab and equipment are designed to support precision measurement and product validation work for customers while seeking to further penetrate the healthcare space, said Stelray. Increased molding capacity enabled by the Haitian Jupiter JUIII 5500 will allow Stelray to fulfill customer needs across the 22- to 620-ton injection molding clamp force range. Stelray added that it plans to use the increased physical footprint to enhance operational efficiency through lean initiatives and a plant reconfiguration. Located in Ansonia, CT, and operating since 1961, Stelray is a second-generation family-owned business that has evolved from modest beginnings in injection molding to a one-stop source for precision injection molding, post-molding, and tooling for OEMs worldwide. Additional in-house resources include rapid prototyping, design consultation, a fully equipped tool room with complete mold-building capabilities, and cleanroom molding. The company also offers value-added services such as ultrasonic welding, painting/decorating, mechanical and electromechanical assembly, packaging, and soldering. “We are extremely excited about the completion of the new addition to our molding department — the additional space and high bay ceilings allow Stelray to enter market segments that we had not been able to participate in before,” said owner and President Lawrence Saffran. “We look forward to servicing our existing customers and welcoming new customers with the ability to mold larger parts and larger programs. We are thrilled about this new chapter and the opportunities it brings, and we look forward to continuing our journey of success while meeting the ever-growing demands of our customers.” Published by the Plastics Today Staff Link to Article: www.plasticstoday.com
Use of biodegradable plastics is soaring across industries, as consumers continue to demand more eco-conscious products in the wake of the green movement. In fact, according to recent research from Market Research Futures, the biodegradable plastics market will reach $16.8 billion by 2022—an impressive compound annual growth rate (CAGR) of 8.4 percent from 2016 levels—spurred largely by consumer demand. Whether your customers and clients are demanding a switch to biodegradable plastics or your consideration is being driven by a personal desire to be environmentally friendly, it pays to understand what options you have when it comes to biodegradable resins that can be used in plastic injection molding. Below, we explore the top five biodegradable plastics that you may be able to use for your plastic injection molding projects, as well as one emerging material that may be poised for strong growth. Types of Biodegradable Plastic Resin Biodegradable plastic is any of a number of plastic varieties that can decompose naturally in the environment, compared to traditional plastics which do not decompose as readily. Most biodegradable plastics are created by the fermentation of canola oil or sugar, and they decompose under the right temperature and humidity conditions. This quality makes biodegradable plastic especially well-suited for items and products which will be discarded after one use. The most common types of biodegradable plastic resins used in plastic injection molding include: Thermoplastic Starch-based Plastics (TPS) Polyhydroxyalkanoates (PHA) Polylactic Acid (PLA) Polybutylene Succinate (PBS) Polycaprolactone (PCL) 1. Thermoplastic Starch-Based Plastics (TPS) Starch-based thermoplastics (TPS) are cheap and abundantly available. They are often combined with other materials for use in plastic injection molding. They can be used for food packaging, carryout packages for fast food, and disposable utensils. Starch-based plastics are completely biodegradable and may end up being completely carbon neutral, an important consideration given the increased awareness that average consumer have regarding carbon emissions and global warming. 2. Polyhydroxyalkanoates (PHA) PHA (polyhydroxyalkanoates) is a plastic resin created by the action of bacteria on sugars or lipids. By combining various molecules, the resulting plastic resin takes on a variety of properties. PHAs are stable under exposure to UV, highly moisture resistant and do not easily absorb odors, making them ideal for food and cosmetics packaging, as well as certain medical devices, such as surgical mesh or sutures. 3. Polylactic Acid (PLA) Polylactic acids (PLA) are derived from tapioca, cassava, sugarcane, or cornstarch. PLAs are used to manufacture a number of different kinds of goods, including medical implants—such as rods or screws—and also in consumer products—such as cups, food packaging, disposable tableware, and loose-fill packaging. As a note: It is important that this material is thoroughly dried prior to being processed via plastic injection molding. 4. Polybutylene Succinate (PBS) PBS (polybutylene succinate) is an aliphatic polyester with properties similar to polypropylene, but which naturally degrades into water and CO2. It is made from succinic acid, a naturally occurring chemical common to most living organisms. PBS is used in packaging for food and cosmetics, medical implants, and drug encapsulation. PBS is often mixed with PLA to change strength or impact resistance of a part or product, without unduly affecting thermal or tensile properties. 5. Polycaprolactone (PCL) Polycaprolactone, or PCL, is used in the production of polyurethanes to improve impact resistance or to add resistance to water, solvents, oils, and chemicals. It is made from vegetable oils and often mixed with starch-based plastics to reduce costs or to change the tensile characteristics of the material. Typical medical uses include drug delivery devices, sutures, or adhesion barriers and scaffolding to help in tissue repair. 6. Hemp: A New Entrant Though the five types of biodegradable plastic resins discussed above have a firm hold on the biodegradable plastics market, there is another emerging source of biodegradable plastic: Hemp. Hemp plastics may be made from 100 percent hemp and infused with hemp fibers for strength and durability, or they may be mixed with other plastics. Hemp plastics can be up to five times stiffer and 2.5 times stronger than polypropylene, and it can be used in standard plastic injection molding machines without requiring any machine modifications. Hemp plastic is used extensively in the automotive industry for panels, and in the building industry for a variety of products where fire-retardant properties are desirable. Hemp plastic water bottles eliminate the concerns associated with BPA plastics and are completely biodegradable. Hemp currently accounts for more than 500,000 tons per year in the European Union alone, with extremely high projected growth rates. Choosing the Right Biodegradable Plastic for Your Injection Molding Project If you are considering using a biodegradable plastic resin to create your plastic injection molded part or product, you’ve got a number of options at your disposal. Which resin or composite resin will make the most sense for you will depend on a number of factors, including the properties you desire in the end product. Though popular among consumers, it is important to bear in mind that biodegradable plastic resins may not be an appropriate choice for all projects.
There are many factors that contribute to the appeal of reshoring manufactured goods to the United States; cost impact of import tariffs, the diminishing delta of labor and energy costs compared to the U.S. in recent years, customer support (including expectations of quality), and most recently the impact of COVID-19 are all major points for OEM manufacturers to consider when sourcing their goods. The articles below help explain why many U.S.-based companies are reconsidering offshore production of their goods and now taking a hard look at contract manufacturers located within the U.S. as a primary source of supply. 64% of Manufacturers Say Reshoring is Likely Following Pandemic As disruption from the global pandemic continues, a survey of 878 of North American manufacturing and industrial sector professionals, concluded that 64% “are likely to bring manufacturing production and sourcing back to North America”. Why U.S. Manufacturers Are Turning Their Attention to ‘Reshoring’ Companies around the country are increasingly cashing in on ‘reshoring’ opportunities. In this article, the author explains “why” manufacturing moved overseas, and what we’ve learned since. Examples shown from professionals in the manufacturing industry. Reshoring, Tariffs Brighten US Manufacturing Outlook The Manufacturing ISM Report on Business, reported an increase of activity for U.S. manufacturing, earlier this year. Industry Week, believes that this is a trend that will continue for the “foreseeable future” At Stelray Plastic Products, Inc., we are seeing a significant rise in inquiries from companies expressing a sincere interest in the re-shoring of their products from Asia. These OEM companies have the clear objective of moving manufacturing back to the U.S. to ensure reliability of delivery, product quality, and cost control going forward. These critical factors are driving progressive manufacturers today, all seeking the ability to source production within close proximity to its U.S. destination, and maintaining ongoing effective communication and the necessary customer support with the OEM’s facility.
In the development of a well designed and manufactured injection molded item, comes the decision-making process of determining what level of mold build you, or your company are willing to invest in. Some variables to consider are, your budget, part design complexity, number of parts required/life of project or life requirements for this phase, and plastic resin type that will be injected into the mold. To aid in this decision-making process, the toolmaking industry has developed standard classifications of molds to help sort through and designate mold classes available based on the molders and customer’s needs reflecting on the variables mentioned above that you will be assessing. Standard industry mold classifications go from class 101 through class 105, with class 102, 103, and 104 molds representing most molds being built today. Injection mold tooling and engineering involves an enormous amount of detail to the mold itself which can make the decision process as an outsider somewhat overwhelming. It is critical to at least be thinking about these standard mold classifications before going out for quotations and certainly have a mutual understanding with your molder/mold maker before getting your tool manufactured. As an example, certain molds have the durability to withstand 1 million cycles while others could last as few as 250 cycles. A class 101 mold would have higher production capacity, utilizing better grade tooling materials, and more robust construction overall. This higher class of mold build will translate typically in a better aesthetically looking part, dimensionally more accurate and overall, a higher quality product, and certainly longer lasting tool. Conversely, a class 105 mold has a very low production capacity and the intent for this mold would be for prototyping only, making this mold the least expensive out of all the classifications. As you work your way up the mold ‘classes’ to a class 101 mold you will find that the cycles, and production level will increase with each level offering a better-quality tool build and likewise a bit higher in cost. Choosing the right mold classification is essential for certain specifications. For example, when looking for a quality part with an anticipated life projection volume of 500,000 mold cycles, you will likely want to choose a class 102 mold. If you were to be looking to have a mold built for a plastic ‘cap’ that required 20,000 pieces per year, you could likely be fine specifying a class 104 mold. Several factors come into play when selecting the right mold; program volume, quality requirements, part size, and plastic resin being used. When going out for mold and product quotations, knowing what mold class to request for your company’s tooling application is a crucial step in the new mold sourcing/construction process. Do you have questions regarding mold classifications? Give us a call at (203)-735-2331.
Why draft angles are important in part design for plastic injection molding Injection molding is a fast and economical method of mass producing highly repeatable, accurate dimensions and aesthetically pleasing plastic parts – but all of these manufacturing attributes can become an injection molders nightmare if the product is not designed properly and the part hangs up in the mold. Shrinkage can pull the plastic tight around raised features, and when that happens the only way to get the part out is to peel it away. Cycle time increases, the machine operator gets frustrated and there’s more chance of damaging either the part or the tool. In the case of an automated injection molding process, ejection problems can bring it to a complete stop. Design engineers and toolmakers aren’t fans of draft angles because they complicate part design and tool manufacture. But without them a part becomes more expensive – maybe even impossible – to produce. Whenever a part is designed for injection molding it’s important to incorporate draft angles. Reasons to include draft angles for plastic injection molding: 1. Smooth, clean part release from tooling. 2. Prevent the part from hanging-up on internal tool projections. 3. Avoid surface damage caused by sliding contact. 4. Allow molding of textured surfaces. (Rougher textures need increased draft angles.) 5. Minimize warping of the molded part (by controlling how shrinkage takes place.) Draft Angle in Part Design and Differential Expansion: Plastic injection molding melt temperatures are typically around 400°F. That lowers viscosity to where the die fills quickly yet also allows rapid cooling and solidification. Thermoplastics have a higher coefficient of expansion than tool steel, so the parts contract more as they cool and tend to pull away from external walls. At the same time though, they shrink down onto raised internal features. Designing for Plastic Injection Molding Manufacturing: Molding variables, such as ejection, cycle times, and production yields, are determined by how the mold tool handles this shrinkage. It follows then that the tooling, and by extension the part, must be designed accordingly. That’s done by incorporating draft angles. Draft angles incorporated into the mold design alleviate ejection issues. A draft angle is a taper applied to a nominally vertical surface. How much taper depends on both the characteristics of the plastic and the functional requirements of the part. Many toolmakers will start out at 1° per inch of vertical height, but then adjust this as necessary. Draft Angles and Lower Plastic Injection Molding Costs: Failing to consider what the injection molding process needs in terms of part and tool design leads to higher manufacturing costs. Yields suffer as damaged and defective parts are scrapped and cycle times increase. It may be difficult or impossible to implement automated de-molding. By incorporating draft angles into part and tool design these problems are reduced, possibly even eliminated. It might complicate part design and add to tooling costs, but the result is less headaches for your molder, a better quality part, and ultimately a lower piece price to your business. Stelray is a full service plastic injection molding company ready to help with your next project.
The use of hot runner systems in plastic injection molding has been possible for nearly 50 years, but it’s only since the late 1990s that the use of a hot runner system surpassed cold runner systems in plastic injection molding. In a hot runner system, a manifold system heats the mold tool and sends melted plastic to nozzles which deliver the plastic to various cavities within the mold. Hot runner systems may be either internally or externally heated. External hot runner systems are excellent for use with polymers that may be sensitive to temperature fluctuations, but internally heated systems offer better flow control. In a cold runner system, the plastic injection occurs through the sprue. The plastic fills the runners leading to the cavity. Both hot and cold runner systems have advantages and disadvantages that may make one system more applicable to a certain plastic injection molding use case. Here’s a look at the pros and cons of each. Hot Runner System in plastic injection molding Advantages Eliminates runners and material waste Can assist in even melt flow Faster cycle times Assists with post mold automation processes Disadvantages Higher maintenance costs More potential downtime Higher tooling costs Slower color changes Not suitable for thermal sensitivity materials Higher part production volume to pay for higher mold costs Cold Runner System in plastic injection molding Advantages Can accommodate a wide variety of polymers, including specialty polymers Quick color changes Disadvantages Slower cycle times than hot runner systems Creates more waste from runners Deciding Between Hot and Cold Runner System for Plastic Injection Molding Since the cold runner system wastes the plastic that fills the runner, it may not be the best choice if the job calls for an expensive specialty plastic. If the product won’t be used in food or a medical device, scrap from the runner can often be reground and reused. However, the regrinding process is expensive in itself, as well as noisy and dirty. In most applications, the proportions of new to reground materials are strictly controlled, which can lead to a build-up of unusable material. With the hot runner system, there is little or no scrap, eliminating this additional cost. Hot runner systems often have faster cycle times, which reduces processing costs. Hot runner systems also produce less wear and tear on the equipment, helping to increase uptime and reduce maintenance costs. The ability to design mold channels to ensure that the material flows the same distance from each nozzle helps improve quality by moderating pressure and thermal variations This may be extremely important with certain resins that have limited processing margins. In addition to the speed, product quality and resin characteristics of the job, it makes sense to consider other factors that can affect overall costs. Consider the availability of engineering and design assistance that the supplier may provide to help you get the most from the system you choose. Also consider service costs—cold runner systems may be more reliable because of their simplicity.
Reasons to Attend A Design-2-Part Manufacturing Trade Show Attending a tradeshow can be a valuable experience in finding vendors and learning about new technologies and changes in your industry. But in order to get the most out of any tradeshow, you need to be prepared and proactive. Attending a Design-2-Part show is no different. With so many different vendors to visit and so much to do, a Design-2-Part show can be overwhelming. You are bound to ask yourself a lot of questions: Where do I start? Who should I talk to? What are the hotspots? Ultimately, what you want to know is: How can I make the best use of my time a Design-2-Part manufacturing show? Below, we discuss some of the benefits of attending A Design-2-Part show, as well as offering tips so that you can get as much out of your experience as possible. What is Design-2-Part(D2P) Manufacturing Show? Design-2-Part manufacturing trade shows have been assisting contract manufacturers for more than 40 years, providing assistance to engineers and product manufacturers who are looking for the best suppliers of custom components, parts and contract manufacturing services. Exhibitor services can range from assemblies, plastic injection molding, 3D Printing, labeling, tooling for plastic injection molding and manufacturing consulting. Every Design-2-Part show includes hundreds of manufacturers from across American industry, who attend to demonstrate their design, prototyping and production skills. Where can I find a Design-2-Part Manufacturing Show? Design-2-Part has several shows throughout the year, each of which takes place in a different location around the country. As of 2019, there are shows scheduled in: Click here for the listing of upcoming shows. Reasons to attend a Design-2-Part Manufacturing Show Wondering if you and your team should attend a Design-2-Part show? Here are a few of the biggest reasons you might benefit from attending… There will be over 300 manufacturing categories including plastic injection molding, electronics assembly, mold tool making and packaging to name a few. Click here to view video from featured suppliers. Design-2-Part show allows you to learn from manufacturing experts about emerging technologies, discuss your specific issues and review suppliers that can address your needs for your prototype or product. The Design-2-Part show vendors make for a great networking opportunity to help your company reduce cost and increase quality. Getting the most out of the A Design-2-Part Show Below are some of our suggestions to get the most out of the Design-2-Part show. 1. Make travel accommodations in advance. As we all understand, tradeshows attract thousands of attendees to a single location. It is helpful to make your transportation and room reservations in advance to ensure you can get a good rate and to take some of the hassles and pressure out of the equation. By waiting until the last minute, you are only increasing the possibility of needing to pay a higher fee, and even potentially being unable to find transportation or lodging at all. 2. Review exhibitor listing and create the list of the top exhibitors you want to see. In order to avoid being overwhelmed, review the listing of over 300 Design-2-Part exhibitors and make a priority listing of the primary and secondary exhibitors related to your business or can help you solve a manufacturing challenge. Decide which of your team members can review and meet with each of your priorities during the show. Do you have a current manufacturing challenge for a new product? Maybe, looking at changing vendors to increase quality or reduce cost? Knowing your needs can assist in deciding how to best utilize your time and meet with the people to help you overcome your obstacle. 3. Take advantage of networking opportunities and plan to meet up at the Design-2-Part show. One big advantage of tradeshows is the ability to meet face to face and reconnect with business partners, customers and vendors to nurture relationships and create new opportunities for business growth. Take advantage of knowing who will be at the conference ahead of time and reach out to get on their calendar and meet at the conference. 4. Review the Design-2-Part magazine Review the Design-2-Part magazine for articles on the latest trends in manufacturing and review vendor services, product offerings and industry news. The magazine offers a design and engineering spotlight section as well. Some of the New England vendors mentioned in the magazine may be found at the show as well. 5. Have a Plan In order to get the most out of the Design-2-Part show, go with a plan in advance. The tips above will assist in walking away from the tradeshow with valuable information for your team to help increase quality and reduce costs. D2P Featured Supplier – Plastic Injection Molding Company – Stelray Plastic Products.
When it comes to choosing the right resin for your plastic injection molding project, there are a number of considerations that should be kept in mind. After all, different plastic resins and materials have different properties that can (and often do) influence the performance of a part. The first and most important question to ask in a fundamental part assessment is: What is the application of the part to be injection molded? What will it do and how should it ultimately function? The below considerations are addressing this fundamental question. For example, you have made a shiny plastic part. When we ask what is the purpose of this part, your simple answer is a plastic case for a dental appliance. The below considerations explore of all the scenarios, expectations and possible future needs and options you anticipate for your plastic part. There are several considerations to review before making the final selection on which plastic resin works best for your part. Plastic resins come in many varieties and there may be additives available to help you meet specific needs. There are commodity resins and engineering resins. The choices can be endless from a very common ABS plastic to TPE a plastic material that looks and acts more like silicone than plastic. This article will review the most important considerations that you should keep in mind when deciding which plastic resin would work best for your project. Some key considerations in deciding the right plastic resin to use for your injection molding project include: Will your plastic product be exposed to temperature variation? Will your plastic product be disposable or be used over a long life? Is your plastic part more functional or aesthetic requirements such as a high gloss finish? Does the product need to be made from a flexible plastic or a more rigid plastic? What plastic product regulatory requirements have to be met? Is the part functional or strictly aesthetic? Will the plastic part be required to withstand a specific mechanical or physical load? Let’s review each of these factors. 1. Will your plastic product be exposed to temperature variation? There are a few reasons that temperature variation will come into play in impact your resin selection, largely tied to the environment your part will be used in and the purpose that it will fulfill. For example, if the product is for use outdoors, it may need to be able to withstand both heat and cold temperatures without compromising its integrity. There are products that are for use with applied heat or cooling. Nylon, for instance, provides excellent thermal resistance, making it an ideal engineering grade to choose from for a product that will withstand demanding performance needs. If you’re creating something that only needs to weather common environmental or household conditions, you might choose a commodity grade like ABS, which is weather resistant but can be damaged with extreme conditions. If you’re making something that’s unlikely to see extreme conditions in use, that wouldn’t be a concern. 2. Will your plastic product be disposable or be used over a long life? Another consideration in your material choice is the lifespan of the product. If you’re creating a part that works inside of a mechanical setting—for instance, medical grade equipment—there’s a definite need to make sure that the durability of the material matches the purpose of the product. However, you wouldn’t need to create such durability for a piece that will be used in packaging, such as disposable water bottles or casings for consumer goods which will be thrown away when the product is finished. The balance point here is in using the right material for the right purpose. You want disposable goods to be easy to recycle. You also don’t want them to cost more in production than they’re worth in price point. On the flip side, you need your long life goods to withstand the environment they’re created to perform in. If you were making a food container that’s disposable, you might choose something like Polypropylene because it’s a lower-cost material that will work for your purpose. But if you were making medical grade products, you may look at lower grade engineering resins such as PC(Polycarbonate), POM(Acetal ) or PET(Polyester) or a higher grade engineering resin PEEK(Polyether ether ketone) might be a more appropriate material because the strength of this resin is very high and you can sterilize it, which is obviously important in the medical field. It’s also quite a bit more costly than materials like ABS, but that cost is necessary for the product. 3. Is your plastic part more functional or are there color requirements/aesthetic requirements such as a high gloss? Some parts are simply functional and not seen by the consumer such as the inside of car versus other parts are mainly for aesthetic such as a faceplate for a wall switch. This is a determining factor for the deciding which type of resin would work best. Color matching might seem like a small portion of the process, but many products are made for consumption by consumers, and this means that consumer appeal is important. Ultimately, this can make color and aesthetics a big concern, especially in areas where consumers will use these products for a long time. An important consideration when thinking about color and plastic choice is: what is the use of the product? In some cases, parts that go into larger mechanisms may not need a wide color variety. In these cases, you can likely let other factors—such as strength, durability, and cost—influence your decision more than the color capabilities of a plastic. In other cases, though, color and other aesthetic elements may be of greater concern. Resins used for car interiors, toys, and other products that people purchase for the visual appeal will need careful consideration aesthetically such as in regards to texture or high polish. Texture and high polish would also reference back to mold cavity specifications – not just the raw material. The plastic you choose in these cases will need to be a balance between performance factors as well as aesthetic elements such as a particular plastic’s color-lasting or matching capabilities. 4. Does the product need to be more of flexible plastic part or more of a rigid plastic part? Flexibility and rigidity requirements are also important factors to take into consideration when choosing a plastic for your project. This requirement will often be considered along with the strength of the product—does it need to replace a machined or die-cast metal part in a machine? Will it be load bearing? Does rigidity compromise its lifespan or add to the lifespan? Some resins, such as Polycarbonate (Lexan), are naturally more rigid than others. Some, such as Polyethylene, are more flexible and may work better for your flexible injection molded part. Some, like PVC, might be made rigid for certain uses and flexible for other uses. 5. What plastic product regulatory requirements must be met? Almost any industry you might create a part or product to accommodate has its own regulatory requirements that you will need to meet. These requirements are integral to the creation of your products. Regulatory needs may vary, but it’s important to research individual compliance issues before choosing your resin. Of special importance will be requirements around durability and strength, depending on the end use of the product or part. Some regulatory bodies you may need to work with include: The FAA, FDA, REACH, NSA, and the EPA. 6. Will the plastic part be required to withstand a specific mechanical or physical load? It is important to look at properties of a resin such as impact and strength for those plastic parts whose primary purpose is for function versus aesthetic. These parts include parts inside your printer, under-the-hood automotive applications, or motor brackets for example. Some plastics inherently handle mechanical or physical load better than others and, in some cases, there are additives to assist in meeting load or strength requirements. See our reference tables for density values and abbreviations for common resins. Weighing All of Your Options Ultimately, choosing the right plastic resin for your plastic injection molding project will come down to balancing multiple considerations against others. How does your need for strength and durability balance against your budget? How does your desire for certain aesthetic qualities balance against performance needs? Etc. Answering these questions can help you settle on the best plastic for your particular needs.
Attending an expo or conference can be an excellent way for your team to build relationships within the industry and stay in touch with the latest trends and innovations. With the right preparation, you team can come away with tons of new knowledge and valuable contacts. What is BIOMEDevice and why should your team attend? The BIOMEDevice Boston expo and conference is New England’s premier medtech, design engineering, and embedded systems event that is bringing together the top companies in the industry from May 15-16, 2019. The event encompasses three expos and two conferences over a two-day span, all in one comprehensive meeting place. If you’re thinking about attending BIOMEDevice Boston this year, the benefits are clear. You’ll be able to connect with more than 3,300 industry professionals to find potential business partners and build relationships with experts and suppliers who can help you overcome your biggest challenges on current and future projects. Free expo education sessions will allow you to gain a broader understanding of new technologies and processes in addition to hands-on training from experts in the medtech, manufacturing, and embedded design industries. In order to take value away from the event, you’ll have to do more than just show up. It is important to plan ahead to make sure that your team accomplishes all of the goals you hope to complete by attending, rather than becoming overwhelmed upon arrival. How to get the most out of BIOMEDevice Here are a few tips to keep in mind to help you get the most out of the info-filled two-day event. 1. Get to know the area ahead of time. If you are not very familiar with the area surrounding the convention center, it’s a good idea to take a few minutes to explore your options for transportation before you arrive. The Boston Convention and Exhibition Center (BCEC for short) is located at 415 Summer Street, Boston, Massachusetts. For those planning to drive to the event, the convention center offers valet parking at most events for $30. Visitors can also choose to self-park for $18 or $36 for oversized vehicles. Public transportation is easily accessible throughout Boston. If you are planning to take the subway, or “the T” as it’s known to locals, you should know that the convention center is located on MBTA’s silver line at the World Trade Center stop. BCEC is also a fifteen minute walk from South Station, which provides local services via bus, subway, and commuter rail. In addition, side sharing services like Uber and Lyft are also popular throughout the city. 2. Browse the list of exhibitors and prioritize your trip Even though the event is two days long, with over 375 exhibitors, it will be near impossible to visit every booth. A few days before the event, visit the exhibitor directory and take note of the companies you are interested in visiting, as well as their booth numbers. Look for exhibitors that are most relevant to your company, project, or business challenge and prioritize visiting these booths first. If you are attending with a group of people, it might even make sense to split up to ensure that someone from your team has met with every one of the key exhibitors that you have identified. On the same note, be sure to follow these steps for the conference portion of the event to decide which speakers you want to be sure to see. Take a look at the full list of speakers and write down the times each person is scheduled to speak so you don’t have to worry about missing anything. There is nothing worse than getting to the end of the day and realizing you missed out on something important, so take the time before the event to plan ahead to ensure nothing is missed. 3. Identify networking opportunities and make plans to meet. One of the main reasons teams choose to attend an event like this one is for the endless networking opportunities that are presented. With so many industry professionals in one place, there are so many chances to build relationships with peers, suppliers, and even potential clients. One downfall of these events though, is that there is so much going on that people’s schedules tend to fill up quickly. To avoid missing a valuable networking opportunity, consider reaching out to specific people or companies that you want to meet with and book some time in their calendar to get together. If you just try to catch them at the show you might be disappointed to find that they are too busy to have a meaningful conversation with you. 4. Make time for fun. As exciting and valuable as it is, two full days of conferences and networking can end up being somewhat taxing on your team. It’s worth it to plan some time into the schedule for people to take a breather and have some fun. Plus, if you’re already devoting the time and resources to travel to Boston, it makes sense to take advantage of some of the other things the city has to offer. There is something for everyone in Boston: Foodies are in luck: The Boston Convention and Exhibition Center is located in the Seaport District, which is home to some of the best restaurants in the city, especially for seafood. Take a break and have a bite to eat at some of the coolest spots in the city. Museum lovers will have plenty to see throughout the entire city including the Museum of FIne Arts, Museum of Science, the Harvard Museum of Natural History, and more. Sports fans can take a trip the famous Fenway Park to catch a ball game during their stay. The Boston Red Sox will face the Colorado Rockies on May 14th and 15th at 7:10 pm. History Buffs will love the Paul Revere House, The Old State House, and the Freedom Trail, as well as many other historic sites that call Boston home. If you are more interested in shopping you can take a stroll down Newbury Street or visit the Prudential Center for the best fashion finds. No matter what you are interested in, you are bound to find something fun to do during your visit. Have a Plan One of the most important things you will need to do to get the most out of BIOMEDevice Boston 2019 is plan ahead. Following the tips above will help you ensure that your team has a valuable experience at the leading industry event of the year. While you’re at BIOMEDevice Boston 2019, be sure to come see us! Stelray Plastic Products is a full service plastic injection molding company for medical parts based in Ansonia, Connecticut. Get to know us and learn more about what we do by booking time during the show. See you at booth 956!
No fasteners, no adhesives, fewer components and simplified assembly – that’s the beauty of ultrasonic welding. A proven technique for joining plastic parts, it’s fast, cost-effective and reliable. However, as with any manufacturing process, getting the best from it means designing appropriately. In the paragraphs below we’ll share some advice on ultrasonic welding of plastic parts. Consider these your ultrasonic welding plastic part design guidelines. Ultrasonic Welding Basics Ultrasonic welding, also referred to as 'sonic welding', uses friction to heat plastics to a temperature high enough that they’ll bond together. This frictional heat is applied through high speed vibration generated in a sonotrode and delivered by a welding “horn.” Ultrasonic welding machines look similar to spot or resistance welders. A horn pushes against the parts being joined, applying pressure and energy until they fuse together. With modern industrial controls it’s a fast and repeatable process. When and Why to Use Ultrasonic Welding Consider ultrasonic welding whenever the design calls for joining separate plastic pieces. One common reason is because it’s not feasible to mold the pieces as one unitary part. Another is that the pieces must be assembled around another part or parts. (Think motor housings or enclosures.) Sonic welding can simplify part design. There’s no need for large flat areas or holes and it’s possible to create hermetically tight enclosures. By eliminating fasteners it reduces piece count and weight, saving time, money and factory space. It’s also cleaner than adhesives with none of the mixing, storing and dispensing challenges. Ultrasonic Welding Part Design To use ultrasonic welding in assembly plastic parts must be designed appropriately. This means considering both the materials and the joint design. Review common materials and their effectiveness in different ultrasonic welding applications with this free guide. Material Considerations Ultrasonic welding works best on plastics that soften gradually over a temperature range. Typically these are thermoplastic materials with an amorphous structure. Their melting behavior is characterized by a “glass transition temperature” or Tg. Among the easiest plastics to weld ultrasonically are polyphenylene oxide (PPO) and acrylonitrile butadiene styrene (ABS). In contrast, a semi-crystalline structure makes polyvinyl chloride (PVC), cellulose acetate (CA/B/P) and polyolefin materials difficult. Dissimilar Plastics The easiest situation is where parts being joined are molded from the same material. At the other end of the spectrum are assemblies where the component parts are molded from plastics with different properties. (Note that semi-crystalline plastics can in general only be welded to themselves.) Gauging the weldability of dissimilar thermoplastic materials entails considering Tg, chemical compatibility and melt flow index (MFI). As a rule, the Tg of two dissimilar plastics should be within 40°F for them to fuse successfully. Chemical compatibility is a complex topic that comes down to the proportions of radicals within the polymers. Compatibility exists when these values are similar within the two materials. Melt Flow Index is a measure of how easily a plastic flows as it transitions to a liquid state. For any given material the MFI can be found in the manufacturers literature and is given as a single number. For best results plastics being joined should have similar MFI’s. Joint Design In ultrasonic welding it’s important to focus the energy in as small a region as possible. This means incorporating an “energy director” into your sonic welding plastic design. An energy director is a raised region with a triangular cross-section. The triangle tip is pressed against the mating plastic part and ultrasonic energy applied. With friction occurring over a very small area the local temperature rises quickly. As it goes through the Tg melting begins and the plastic components join together. An energy director design is used with almost all ultrasonic welding plastic part designs, except when the materials are semi-crystalline. As these have a narrow glass transition temperature range they tend to move quickly into a liquid state rather than the “gummy-ness” typical of amorphous plastics. To address this, such parts are designed with shear joints. Shear joints are formed when the side walls of opposing parts are pushed together. Common Types of Energy Director Designs The main types of energy director designs are: 1. Butt Joint Image Source: Emerson Here one surface is flat while the other has the triangle shape. Keeping the triangle point as sharp as possible maximizes energy transfer. 2. Step Joint Image Source: Emerson The mating surfaces have a stepped design that minimizes lateral movement while the triangle point presses against a flat surface. (This simplifies part location for assembly.) 3. Tongue and Groove Image Source: Emerson The energy director is on a raised tongue that fits into a groove in the mating part. This provides good alignment of the two parts and minimizes flash. 4. Criss-Cross Image Source: Emerson Both surfaces have energy directors but are aligned perpendicular to one another. This yields stronger welds but can also produce a lot of flash. To achieve an air-tight seal configure the crossing energy directors as a sawtooth. 5. Textured Surface Texturing the non-energy director surface is an effective way of increasing weld strength. 6. Perpendicular Image Source: Emerson In this design the energy directors run perpendicular to rather than parallel with the joint faces. This reduces flash. 7. Interrupted Image Source: Emerson Here energy directors are kept short. This reduces the energy needed to make the weld. 8. Chisel Image Source: Emerson A variation of the step joint, by putting the energy director along the mating wall this enables welding of thinner sections. Considerations for using energy directors Smaller initial contact area reduces the energy needed, so only put energy directors where needed. The exception is when a hermetic seal is needed, in which case an energy director is needed on all of the mating surface. Parts must be aligned before welding. Step or tongue and groove joints can be useful for this. Shear Joint Considerations Image Source: Emerson Shear joints require side walls with an interference and their strength is proportional to vertical direction of overlap. They work better for regular/symmetrical parts than those with irregular shapes. Design for the Process For many plastic assemblies ultrasonic welding is a better joining method than fasteners or adhesives. It produces a strong joint while avoiding any mess or additional components. The key to successful sonic welding is appropriate material selection and part design. Use these plastic part design guidelines as a starting point, but don’t hesitate to ask a specialist for more detailed advice.