The MIM Dura Atto cartridge heater nozzle turns the melt channel into an integral heater with an optimised axial profile.

At last year's K2001 international trade fair for rubber and plastics, Mold-Masters introduced a new line of small-pitch nozzles that are ideal for moulding in space-constrained applications and for small parts. The MIM Dura Atto cartridge heater nozzle turns the melt channel into an integral heater with an optimised axial profile. As the nozzle-body diameter is under 9mm and has minimal gate vestige, the nozzles suit small, aesthetically sensitive, or specialised products with core diameters greater than 16mm, such as lipstick caps, medical products and container caps.

HansHagelsteid, Technical Director for Mold-Masters Europe, said: 'Precision design and manufacturing, plus years of hot runner experience combine to make a small, highly accurate, and durable unit that is perfect for 'tight spots'.

It really goes where no nozzle has gone before.' The MIM Dura Atto nozzles come in two distinct flange designs.

The 10mm centre-to-centre pitch nozzle is suited for tight gating locations.

The 15mm nozzle is well suited for internal gating of small components and for applications that require high-rate cooling channels, complex inserts or mechanical components.

Because the heater, tip and melt channel are integral, the new nozzle provides better thermal control and needs less maintenance than conventional, multi-piece heater/channel assemblies with screwed-on lips.

The MIM Dura Atto family is the smallest in the Mold-Masters nozzle range and provides ideal heat control at the gate for shot sizes ranging from under 1g to 30g (0.04oz to 1.1oz).

Moldflow Plastics Xpert (MPX) 3.1 and Shotscope 2.4 software are now integrated to operate on one hardware platform.

Moldflow Plastics Xpert (MPX) 3.1 and Shotscope 2.4 software are now integrated to operate on one hardware platform. The streamlined package will help organisations reduce cost of ownership while providing additional capabilities. Traditionally, these software products required separate data acquisition devices and touch-screen computers.

Ultimately, this redundant hardware added to the costs and complexity associated with injection moulding manufacturing.

Now, both MPX 3.1 and Shotscope 2.4 support the A9800 data acquisition unit and can run simultaneously on the same touch screen computer.

A new Moldflow desktop application includes a comprehensive set of graphical user interface-based configuration utilities for easy setup and configuration of MPX.

Configuration utilities are now directly available within the Setup, Optimize, and Production Xpert modules.

This results in easy and dynamic application-specific customisation of any Xpert module.

Significant improvements to the Optimize Xpert user interface increase the ease of use of Design of Experiments (DOE).

Version 2.4 of the Moldflow Shotscope process monitoring and analysis system includes the following enhancements: * ERP/MRP interface: The interface to enterprise resource planning and Materials Resource Planning applications allows for resources and jobs to be imported into Shotscope and for production data to be exported from Shotscope.

* Blended materials tracking: This feature facilitates the creation of a blended material that can be tracked by lot number for the complete blend or by lot numbers of the individual components of the blend.

Enhanced capabilities in parametric strip design in the VISI Progress module and a range of new surface analysis tools are included in this latest release of mould and die orientated software.

CAD/CAM software specialist Vero International Software introduced release 10 of its VISI Series software solution at MACH 2002 exhibition, maintaining its strong focus on the mould and die sector but introducing a range of new and enhanced features. Among the new developments are enhanced capabilities in parametric strip design in the VISI Progress module, a range of new surface analysis tools, a new VISI-Manufacturing feature recognition module and VISI-Electrode software to assist with EDM manufacture, all of which will further VISI-Series' already considerable capabilities for mould and die design and manufacture. The VISI Progress has modules developed specifically for the design of the strip in progressive dies.

In this operation it is frequently necessary to change the configuration of the bending and shearing steps to arrive at the desired strip sequence for economical and practical manufacture.

As the design of a die strip progresses, VISI-Progress will give the designer information about shear stress and material utilisation.

As such, punches and positioning the forming stages to suit your component can be quickly designed and incorporated.

Simulation of the punching process ensures that the part is fully finished when it has passed through all the stages on the strip.

With the new parametric strip design in Version 10 of VISI-Series, the Progressive Die designer will be able to design the strip, evaluate the results, and then simply change one or more elements of the strip configuration to improve their design.

The remainder of the strip design is rebuilt automatically, ready to evaluate the results again.

Because rebuilding the strip design only takes minutes, this process can be repeated as many times as desired until the optimum strip design is achieved.

The new surface analysis tools in Version 10 are being introduced to make it easier to examine and analyse complex imported CAD data.

For very complex CAD models it is often very difficult to see potential problem areas for mould design, such as undercuts and insufficient draft.

With the new tools, draft surfaces are automatically shaded so the user can instantly see where faces have little or no draft or where there is an undercut.

When working with supplier CAD data, frequent design changes can cause many problems in the tool design, primarily because it is difficult to quickly find where the design has been changed.

Included in the new surface analysis tools is model comparison, so that when a model has been altered, it is easy to see where the changes have been made, making it much simpler to evaluate the impact on the tool design.

With Vero's new VISI-Manufacturing Feature Recognition parts which have been imported into VISI-Series or modelled in VISI-Series can be automatically machined with the new VISI-Manufacturing Feature Recognition.

The software will interrogate the part, and automatically find holes, pockets, profiles and open sided pockets.

Where attributes are attached to holes - automatically the case for parts designed with VISI-Mould or VISI-Progress - the system will pick out a sequence of tools and apply the correct sequence of operations and tools to produce the required quality of hole.

For example one sequence of operations might be centre drill, drill, bore and counterbore.

For pockets, open pockets, profiles, and face milling, VISI-Manufacturing Feature Recognition will automatically find the majority of the features and where features are not so easily identified or for holes without attributes allocated, the programmer can manually identify them to the system.

The user can also set up preferred tools, feeds/speeds and cutting methods for each type of feature to suit their own machining methods.

VISI-Manufacturing Feature Recognition creates a tree structure showing the parent/child relationship between the operations directly from the feature recognition process so that it is easy to see the sequence of operations.

With the preferred methods set up, VISI-Manufacturing Feature Recognition will automatically apply the desired toolpath to the model to achieve the quality of finish and accuracy necessary for the finished component.

To allow full control, the user is still able to edit individual methods, the toolpath and tooling from the tree structure of operations to cope with special cases, where the preset methods need to be modified for optimum results.

'VISI-Manufacturing Feature Recognition takes the hard work out of CNC programming of models and ensures that the finished part is completed quickly, consistently and to the right quality', explains Gerard O'Driscoll, development director of Vero International Software.

VISI-Electrode: VISI-Electrode is another new module launched by Vero International Software at Mach 2002.

VISI-Electrode works in the same environment as all the other VISI-Series modules and permits, in tool design and manufacture, the creation of detailed shapes in the tool which may need to be manufactured by EDM.

In the new VISI-Electrode module, the user simply sketches the outside profile for the electrode above the desired area on the model, then using dialogue boxes picks the height of the electrode and the proposed EDM technology.

Alternatively, the user may select the individual faces of the model which need to be cut by an EDM electrode.

VISI-Electrode instantly creates the electrode shape based on the geometry of the underlying solid model with the offsets on the shape to suit the EDM technology chosen.

Different EDM technologies require different sizes of electrode to allow for the spark gap and the movement of the electrode during the machining process.

From a library of holders the user chooses the holder to suit the electrode.

The electrode can be machined directly in VISI-Machining, and it is automatically referenced to a datum to make sure the electrode is applied in the correct position.

VISI-Electrode produces an electrode report detailing information such as the datum, spark gap and holder to keep track of the electrodes their manufacture and their use to help control the tool building process.

These new features are introduced as part of Vero's on-going development of VISI-Series.

The Stroud, Gloucestershire based company is firmly established as one of Europe's top five software vendors in mould and die and has also achieved significant growth in the sector in recent times in Thailand, China, Japan and North America.

CAD/CAM developments will include a fully automated electrode creation application, automatic feature recognition, which will analyse and automatically identify machinable areas.

CAD/CAM software specialist Vero International Software will be launching release 10 of its VISI Series software solution at the forthcoming MACH 2002 exhibition. With release 10 of VISI-Series, Vero is maintaining its strong focus on the mould and die sector. Many of the new features have been specifically designed for mould and die design and manufacture, an area in which VISI-Series is highly acclaimed.

Vero is firmly established as one of Europe's top five software vendors in mould and die and has also achieved significant growth in the sector in recent times in Thailand, China, Japan and North America.

Detailed descriptions of the new features will not be released until the opening day of MACH 2002 but key new modules will include a fully automated electrode creation application, automatic feature recognition which will analyse and automatically identify machinable areas, parametric strip design within the VISI-Progress module and additional functionality within the surface tools module.

Details of other new features and modules will be released at the exhibition.

With more than 12,000 users world-wide, VISI-Series is recognised as one of the leading PC based design and manufacturing systems,' says Vero's marketing manager Richard Mortimer.

'As part of its policy to constantly update and enhance the product in line with market demands, Vero has continued to develop new features which will maintain VISI-Series in the forefront of CAD/CAM software products,' he adds.

Delcam has added new Wizards for the design of slides and cooling channels to its PS-Moldmaker software for the automated design of moulds for the injection moulding of plastics.

Delcam has added new Wizards for the design of slides and cooling channels to its PS-Moldmaker software for the automated design of moulds for the injection moulding of plastics. These additions will increase the time savings possible through using the software, while the automation of these operations will reduce the possibility of mistakes. The new Slide Wizard provides an automatic method for the design of any slides that are required when moulding parts incorporating undercuts.

The relevant areas of the part can be identified with the undercut shading option within PowerSHAPE.

Then the Wizard automates the slide creation process, using the user's selection from the range of formats available.

Once the slide design has been completed, the software automatically redesigns the split line and run-off surfaces within the core and cavity plates to accommodate the movement of the slide.

The Cooling Wizard uses the dynamic sectioning command within PowerSHAPE to create a plane, or multiple planes, within the mould core or cavity for the layout of the water channels.

The user then simply has to sketch the layout required.

As the channels are added, the software provides a warning if they impinge on the cavity, if they come too close to give sufficient wall thickness, or if they are too far from the moulding to be effective.

Once the complete layout has been defined, the model of the plate can be passed in to Delcam's PowerMILL machining software for the automatic creation of drilling instructions for the machining of the water channels.

Since its launch in 1997, Moldflow Plastics Advisers has influenced the way that designers check their plastic part designs to ensure that they are suitable for manufacture.

Plastics Advisers goes interactive in Version 6.0 Since its launch in 1997, Moldflow Plastics Advisers has influenced the way that designers check their plastic part designs to ensure that they are suitable for manufacture. Now, the release of Moldflow Plastics Advisers 6.0 (MPA 6.0) offers some new features and enhancements for collaborating with other users and with Moldflow experts. The Moldflow Community Center is a suite of tools based on a standard web browser interface, enabling users to access a discussion forum to exchange ideas and tips, ask questions and obtain answers, gathering collective knowledge to solve common problems.

This is also the place to look for hints and tips posted by Moldflow support engineers and fellow users.

The File Exchange Area is a common file storage and download area for useful files, such as common runner layouts and standard runner sizes.

Patch releases and a list of known bugs can also be accessed here, along with upcoming training sessions, both web-based and conventional seminars and workshops requiring physical attendance.

More specific problems can be addressed by utilising a product usage feedback facility, an automatic method of reporting issues directly to Moldflow from within the product.

A Moldflow customer support engineer will review the issue of concern, take appropriate action and update the user on the status of the enquiry.

Using the same communication route, MPA 6.0 users can have a say in future Moldflow software development.

The software is configured to log product performance and product usage information and automatically send that information to Moldflow through a secure FTP connection.

Information collected in these logs allows product usage patterns to be investigated and areas for future revisions to be identified.

Of course, no proprietary or confidential information is gathered in this process.

Other technical enhancements embedded in MPA 6.0 include: Gate modelling and design - to aid troubleshooting and optimising the gate design, two powerful tools are being introduced with MPA6.0.

The first is the ability to run an automatic gate sizing analysis, which estimates the best gate dimensions and automatically updates the mould with the calculated dimensions.

The second tool is automated gate design advice, which removes the guesswork involved in troubleshooting gate-related problems.

The information provided is specific to the type of gate being worked on at the time.

Two new gate cross-sections -- half-round and trapezoidal - have been added to the database of supported gate types.

The half-round gate can be used to model gates that are part of an ejector pin or an insert.

The trapezoidal gate allows for easier modelling of typical edge, fan and tab gates.

Within MPA 6.0, it is possible to perform an analysis with only the gate(s) attached to a part cavity model.

This is extremely useful when several gate design analysis iterations are planned, and when analysing a complete multi-cavity layout with the feed system attached would be time-consuming.

Once an optimised gate design is determined, the sprue and runners can be added easily to complete the feed system.

Users can now automatically create runners in three-plate moulds, which eliminates the tedious task of manually creating runners for standard three-plate mould layouts.

Another useful modelling enhancement is the facility to create a mirror copy of a part cavity model.

Users no longer need to depend on their CAD system for importing mirrored components, and therefore on separate CAD models for analysis purposes.

The ability to edit runner system lengths easily decreases modelling time and makes it possible to re-use previously created runner system layouts.

A library of standard geometric sizes can be created for use when modelling sprues, runners and gates.

MPA users who want to perform more in-depth analysis can export their data using the Moldflow Plastics Insight 3.0 (MPI 3.0) study file format.

All pertinent model, material and analysis information is exportable from MPA, eliminating the need for redundant actions in the MPI 3.0 environment.

Results comparison - MPA 6.0 includes a powerful results comparison utility for simultaneously comparing analysis results from two or more models.

Users simply open two (or more) models with results, then synchronise the Windows displays and the results plot scales.

This is an aid to interpreting results and to being able to identify quickly optimised combinations of part geometry, materials selection, gate locations and processing conditions.

CAD interfaces and integrations - Moldflow Design Link 3.0 (MDL 3.0) is integrated with MPA 6.0.

MDL 3.0 provides a geometry data translation interface between MPA 6.0 and leading CAD systems using standard file formats such as IGES, STEP and Parasolid, as well as allowing the direct import of native Pro/Engineer part files.

The MPA CAD integrated versions have been updated to support the latest product releases from leading CAD vendors, including SolidWorks 2001Plus, Solid Edge 11.0, SolidDesigner 2001 and Mechanical Desktop 6.0.

In addition, autodesk inventor 5.0 is now integrated with MPA 6.0.

The materials database has been redesigned to save commonly used materials as a separate list.

Search criteria can be customised to search by virtually every materials property in the database.

A powerful tool views, measures, refines, and corrects solid surface models imported from popular CAD/CAM/CAE systems.

Moldflow STL Expert is a powerful tool for viewing, measuring, refining, and correcting solid surface models imported from popular CAD/CAM/CAE systems. It outputs high quality stereolithography (STL) models, which can then be used for Moldflow Plastics Advisers (MPA) and Moldflow Plastics Insight (MPI) analyses, or any other application that uses STL as input. Now, Version 3.0 has been released which contains a number of important new features: Enhanced mesh repair tools - A complete suite of mesh repair tools, including global node merging, swap/remesh edges, remesh areas, insert, move, and align nodes, orient individual or groups of elements, and fill holes.

These tools allow users to optimise meshes more efficiently.

Dynamic model diagnostics and statistics - A diagnostics window provides a quick overview of the model and serves to highlight potential problems as well as dynamically update the status of these problems as they get fixed.

STL Wizard enhancements - The STL Wizard walks users through a series of steps to automatically repair five common STL mesh problems.

The 'remove overlap' feature has been enhanced to detect and repair partially overlapping elements or intersecting elements.

Enhanced CAD interfaces - Moldflow STL Expert 3.0 supports Moldflow Design Link 3.0, a geometry data translation interface that allows the direct import of native Pro/ENGINEER part files, as well as Parasolid, STEP, and IGES file formats.

Moldflow STL Expert 3.0 supports Microsoft Windows 2000/XP/NT 4.0, as well as a range of UNIX platforms, including Silicon Graphics IRIX 6.5, SUN Solaris 2.7 and 2.8, Hewlett Packard HP-UX 10.2 and 11.0, and IBM AIX 4.3.

Vero International Software has announced the opening of a new direct sales and support operation in France for its VISI-Series products.

Vero International Software, the specialist in CAD/CAM solutions for the Tool and Die industry, has announced the opening of a new direct sales and support operation in France for its VISI-Series products. Operating from offices strategically located in Lyon and Lille, the newly established Vero International Software France will provide direct sales and support in this key market. The opening of a direct sales company in France is part of a planned expansion programme for Vero International Software.

Six new personnel with extensive experience in CAD/CAM and the Tool and Die industry will provide local and expert support for the VISI-Series suite of software, enabling them to build on an already established customer base.

Richard Youhill, Sales Director commented: 'France has one of the largest mould and die sectors in Europe and was previously addressed by a distributor offering multiple products.

This move follows increasing demand for our products in France and gives us a much stronger presence in this market.

With the forthcoming launch of Release 10 of VISI-Series, this new organisation provides an outstanding opportunity to increase our market share, whilst better supporting the established base of existing users of our products.

Vero International Software based in the UK already has offices in the USA, Italy, the Czech Republic and distributors in 70 countries around the globe.

Mould design software, that updates injection mould designers to methods based on 3D computer modelling, will be demonstrated at Diemould India exhibition to be held in Mumbai during February.

Delcam will demonstrate the latest release of its PS-Moldmaker mould design software at the Diemould India exhibition to be held in Mumbai from 28th February to 2nd March. PS-Moldmaker provides a powerful, highly-automated system that will allow designers of injection mould tools to move from processes based on two-dimensional drawings to new methods based on three-dimensional computer models. PS-Moldmaker offers a broader solution than other similar systems, both through the inclusion of catalogues from a wider range of standard component suppliers and through the inclusion of a range of Wizards to automate many parts of the design process.

Most importantly, PS-Moldmaker is fully integrated with Delcam's PowerSHAPE hybrid modelling program.

PowerSHAPE provides a wide range of tools to repair any problems with the component design, including missing, duplicate, overlapping or poorly-trimmed surfaces, before work begins on the mould design.

Combining the two programs also gives PS-Moldmaker the unique ability to produce non-standard components or mechanisms by allowing the user to exit from the automated process at any stage, carry out some manual adjustment to the design within PowerSHAPE, and then return to the automatic methods to complete the mould.

This means that users can benefit from the speed and simplicity of the high level of automation, and can also produce exactly the results they want, without any restriction on the size or complexity of the work that they can undertake.

Using PS-Moldmaker and PowerSHAPE allows companies to move from a two-stream system, where the core and cavity are designed and manufactured by one team using three-dimensional methods and the components making up the rest of the mould are produced by a second group using two-dimensional drawing and machining techniques.

Instead, the whole mould can be developed entirely in three dimensions by a single team using a single software system.

While moving to three-dimensional design may offer some time savings in the creation of the mould design, much more significant improvements can be made through eliminating mistakes during both design and manufacture.

Realistic representations of the individual components and computer simulations of the mould's operation will help ensure that the mould will operate as expected.

At the same time, the automation of routine and repetitive operations will minimise calculation errors, while the use of computer models is less prone to errors in dimensions and positions than using drawings.

Direct links from PS-Moldmaker to Delcam's PowerMILL cam software ensure highly reliable machining of both holes and pockets.

Local CNC programming facilities and Ethernet communications with machine tools helps a mould maker to complete in 6 hours machining which previously would have taken 15 hours.

Local CNC programming facilities and Ethernet communications with machine tools helps a mould maker to complete in 6 hours machining which previously would have taken 15 hours. Modern Moulds and Tools, based in Lancing, West Sussex, UK, has been making tools for over twenty years. It has a ten-year relationship with NC Graphics, with four seats of DEPOCAM and four of toolmaker connected through wireless networking.

This allows mobile workstations on the shop floor, which provide local CNC programming facilities and Ethernet communications with its machine tools.

The initial choice of ToolMaker and DEPOCAM was due to its compatibility with other systems, enabling solid models to be reliably imported, while ToolMaker additionally enables the repair and manipulation of surface data, which can be difficult to achieve in solid modelling systems.

John Horspool, Works Director for Modern Moulds, has been working with CAD/CAM systems since 1987 so he is well aware of the technical implications of re-engineering customer's design data to generate the necessary electrodes and toolpaths to produce a completed mould tool.

He realised that conventional machine tools and tooling were not capable of economically producing the complex shapes required in the latest plastics components.

'We chose to implement a complete package of DEPOCAM, DEPO-FHT tooling and a Bridgeport machining centre to meet our requirements for high speed machining.

Now we rough out core and cavity details to within 0.2mm, before vacuum hardening.

Next we grind to fit into the mould base, and then in the hardened state, semi-finish and finish using high speed machining techniques.' Modern Moulds is now able to complete in 6 hours machining which previously would have taken 15 hours.

'DEPOCAM allows us to rough out true to the form being generated, and introduce surfaces to trim toolpaths.

These features keep the tool in the material for the maximum possible time.

In addition the DEPO-FHT indexable button cutters and Tornado cutters enable us to cut up to 62 Rockwell,' continued Horspool.

Its confidence in DEPOCAM and ToolMaker has enabled Modern Moulds to introduce the concept of synchronised manufacture.

For it to succeed it requires absolute confidence in the reliability of the toolpaths, a multi-skilled workforce, and individual responsibility for quality, combined with modular fixturing.

Horspool explains, 'We design the tool around the customers component, applying shrinkage and developing moving parts.

The cavity machining is prepared, and where electrodes are required, they are created on System 3R holders.

Inside DEPOCAM the electrodes are positioned at a common datum and the cutter path is programmed around that.' With sixteen skilled toolmakers, and the ease of use of DEPOCAM, each machinist is able to program his own electrodes, and because the fixturing is common to machining centres, lathes and die sinkers, individual tool setting is eliminated.

The set-up sheet provides all the information required for each electrode, the X and Y position relative to the common datum, together with lift or drop for height, which is kept to a round number for simplicity.

With this method of manufacture every job is the same, in that the sparking operation ends at Z zero, removing the need to specify a depth to spark to, the associated possibility of error, and multiple setting operations.

'Centring the spark eroder off an edge for each electrode used to take a considerable time, especially when fifty electrodes were required in one tool.

The new methods we have introduced with DEPOCAM make it only necessary to do this once,' said Horspool.

The accuracy now possible through the use of DEPOCAM and high speed machining techniques has encouraged Modern Moulds to split complex electrodes into smaller and simpler elements.

'We know that the individual electrodes will produce a perfect result when used together on the cavity, the quantity per job can vary between five and seventy five depending on its complexity,' said Horspool.

The benefit for the company is that individual electrodes are easier to manufacture, and should an error occur, the cost in time and materials of remaking a simple one is much reduced.

For maximum efficiency Modern Moulds needed to introduce flexibility in its highly skilled workforce.

Systems which were simple to use and reliable were essential for mobility between tasks.

Introducing structured working methods, the use of a common datum, the short learning curve for DEPOCAM and the power of ToolMaker were major factors in the successful implementation of synchronised manufacture.

Additionally, each toolmaker checks his own work, inspecting and signing off his completed operations, making the whole team communally responsible for the finished tool, ensuring high quality is built into the manufacturing process and that it is a core principle for the company.