Using a seamless modelling paste, combined with CAD/CAM and CNC, models to make the moulds for wind turbine blades are produced quickly and cost effectively.

RenPaste combined with CAD/CAM and CNC technology delivers 20% cut in production time and minimises required labour. RenPaste Seamless Modelling Paste from Huntsman Advanced Materials, has literally revolutionised manufacturing processes for one of The Netherlands' leading tooling and prototyping companies, Vostermans Tooling and Prototyping. Using RenPaste SV/HV 4503, combined with the latest CAD/CAM systems and CNC machines, Vostermans have been able to produce the models to make the moulds for wind turbine blades, measuring up to 46m in length, faster and more cost effectively than has been previously possible.

RenPaste SV/HV 4503 is used for the face layer of the model - the critical surface that will define the dimensions and surface quality of the mould tool, and then the final composite part.

Working from CAD/CAM data, the RenPaste is machine applied to a backing structure made from low cost substrate blocks that have been CNC milled to the required dimensions.

This gives a virtually void-free layer of paste, applied to the right thickness - 15 to 20mm provides the best balance of cost efficiency and performance.

After application of the RenPaste SMP, the model assembly is allowed to cure at room temperature for one day.

In applications where the model is to be used at elevated temperature a stepwise post cure up to the working temperature is recommended.

After curing, the SMP layer is milled to its final dimensions.

The milling is controlled by the original CAD model data to ensure accuracy, which in this case was critical as the maximum tolerances for the model were +5mm over the entire 46m length.

A minimal hand polishing of the pattern then gave the fine, smooth surface finish required.

The final step of the model building process was a spray coating of sealer as a base for application of the release agent prior to production of the composite mould tool.

'These wind blade models had to meet a range of demanding criteria and be produced to a tight timescale,' explained Rob Luijten, Location Manager at Vostermans Tooling and Prototyping BV.

'The best time to test wind blades is in the Spring'.

'This meant that the model had to be finished, the mould completed and the rotor blades produced in time for the test period 'window', Using RenPaste materials rather than traditional methods enabled us to cut overall production time of the model by up to 20%'.

'The model was also of a high and sustained quality throughout its 46m length, providing a smooth and seamless working surface'.

'This in turn reduced the labour time required to complete the project''.

'' The combination of RenPaste materials with CAD/CAM and CNC technology not only delivers benefits to our customers, ' continued Luitjen'.

''It has enabled us to differentiate the services Vostermans provides from those of our competitors and also opened up new markets we were unable to service before.'

European patent covers the mounting of hot runner controller to be mounted directly on an injection mould, saving expensive floor space and improving the reliability of the mold.

Moldflow Corporation, the leading global provider of design through manufacturing solutions for the plastics injection molding industry, announced that it will be granted a European patent for Altanium Mold-Mounted Hot Runner Process Control technology. The technology is also patented in the US, and a patent application is pending in Japan. The innovative technology covered by the European patent allows the Altanium controller to be mounted directly on an injection mold, saving expensive floor space and improving the reliability of the mold.

The technology also improves the temperature accuracy of molten plastics within a mold, which if not kept consistent often results in increased manufacturing scrap and unplanned downtime.

'Moldflow developed this technology in direct response to customer requests to eliminate numerous connecting cables that run from free-standing hot runner controllers to molds,' explained Matt Cummings, Moldflow's Altanium product line manager.

'Elimination of these cables significantly reduces clutter around an injection molding machine'.

'In today's highly competitive manufacturing environments, we are always looking for ways to help our customers streamline their processes, improve productivity and reduce costs.' Erie Plastics, a custom injection molder headquartered in Corry, Pennsylvania, USA, with multiple manufacturing facilities in the US and Europe, has been using Altanium mold-mounted technology for six years.

'Altanium mold-mounted technology has exceeded all of our expectations,' commented, John Runser, technical support manager, Erie Plastics.

'We have eliminated over 150 connecting cables on our manufacturing floor and plan on utilising this technology to further support our commitment to quality and efficient manufacturing in both our US and European facilities.' Altanium is a leading integrated process controller for hot runner injection molding.

The highly acclaimed Altanium technology is modular in design and easily adaptable to any hot runner technology.

* About Moldflow Corporation - Moldflow (NASDAQ: MFLO) is the leading global provider of design through manufacturing solutions for the plastics injection molding industry.

Moldflow's products and services allow companies to address part and mold design issues at the earliest stage and maximize productivity and profitability on the manufacturing floor.

Rugged, high power laser welding system for repairing large mould tools is mounted on wheels and can easily be transported by road in the back of a van to the customer's moulding shop.

The new StarWeld Tool Open from Rofin-Baasel UK makes on-site tool repair practical and straightforward. Rugged and mounted on wheels the high power (150W) laser has an integrated air to water heat exchanger and can easily be transported by road in the back of a van. Repair of very large and heavy tools is now possible without moving them offsite.

In this case it is much easier to bring the laser to the tool than vice-versa.

Anticipated applications are the on-site repair of large automotive moulds (fascias and bumpers) and any other moulds which are heavy or large and require metal to be added by laser for repair or modification.

The high power output allows moulds in copper and aluminium to be welded at higher speeds as well as the more normal tool steels.

Features previously available on the StarWeld Tool Integral are available on the open system too.

Synchro-Weld allows regular spacing of weld spots even if the speed of the axes is varied.

This allows welding of arcs and circles to be improved.

Viewing of the weld location is by high resolution camera, or by stereo microscope or the system can be fitted with both viewing options using a trinocular head.

A weight-compensated cantilever arm with a reach of 1.7m and capable of a maximum working height of 1.8m is used to direct the laser beam to the tool.

During transport of the laser system the support arm can be folded and parked in a storage location to protect the optics during transit.

At the end of the arm is a swivelling mount which carries the XYZ axes and compact focus head.

Normally, a quick adjustment of this arm allows the weld seam to be aligned so that only one axis of motion need be used.

This technique avoids the need to tilt or manipulate large tools, the adjustment being carried out instead at the laser head.

A remote laser control panel allows the operator to vary the weld spot diameter from 0.4mm to 1.6mm, using motorised focus adjustment.

Miniature figure maker has transformed its tooling development by changing to a scanning system to scan prototypes, providing the data required to machine the moulds.

UK based Games Workshop Tooling sells a large range of incredibly detailed miniature figures worldwide. It has recently transformed its tooling development by changing from proven traditional pantographs to Renishaw's Cyclone scanning system. Cyclone rapidly scans prototypes, providing the data required to machine the moulds from which the highly detailed figures are moulded.

As its name implies, Games Workshop Tooling designs and manufactures injection mould sets for the mass production of the company's highly sought-after war-game figures, such as the hugely successful 'Warhammer' series.

With long-term planning up to five years ahead of the launch of products, it is vital for the group to keep designs confidential.

Keeping as much work as possible in-house and with a close vertical integration of the different arms of the group, it is easier to maintain the required level of confidentiality.

Initial concepts, sketches and drawings are sculpted by craftsmen into 3D figures, usually three times larger than the final product, from which it has been customary to produce resin patterns.

The traditional pantograph techniques previously used were slow, labour intensive and involved much work by highly skilled patternmakers.

The process was, however, well-proven and could be guaranteed to provide the superb detail expected by the discerning gamers, who are always eagerly awaiting release of the latest product.

* New technology - with the challenge of meeting and exceeding this quality of work, Renishaw engineers set about proving that Renishaw's Cyclone scanning system was indeed up to the job, by producing sample die sets.

This initial work was backed up by arranging visits for Games Workshop Tooling's managing director, Terry Ardener, to meet key Renishaw Cyclone users so he could satisfy himself on the suitability of such a system, when working in conjunction with modern CNC machine tools.

Suitably impressed, Ardener has invested heavily in a state-of-the-art, automated mould production shop.

This includes a full computer-editing suite, linked to the two Renishaw Cyclone systems, as well as DNC links to four new Bridgeport CNC vertical machining centres and four Lang Impala CNC machines.

* Automation - with the very small data intervals involved (due to the very high level of detail), the scanning of a typical four-piece mould can take up to 48h.

This is even at a scanning speed of 700mm/s and a data capture rate of up to 400 points/s.

Once set into operation, however, there is no need for any further human involvement, the Cyclones can be left running without supervision.

With the amount of different figures Games Workshop now develop, both are in use 24h/day, seven days a week.

Analogue 3-axis probes with 0.5mm diameter styli balls are fitted to the Cyclone machines, which constantly maintain contact with the surface scanned, and are proving to be perfectly suited to the fine detail of the prototypes.

Games Workshop is also considering the use of Renishaw's non-contact laser scanning option for its next two systems.

The Cyclone systems are controlled during data capture with Renishaw's own Tracecut software, allowing subsequent 3D data manipulation and the generation of machining programs for the Heidenhain TNC 426 CNC control system fitted to Games Workshop's new Bridgeport machines.

Typically, the steel production moulds manufactured on these machines are made with up to eight 'inserts' per mould from the programs directly downloaded from the editing suite.

Again, this requires very little human intervention during machining.

Games Workshop Tooling can now look forward, secure in the knowledge that future fantasy figures can be made with significant productivity savings in time, material, labour costs and reliability, thanks to their major investment in new technology.

Moulding software products to be shown at the UK's PDM 2005 event include plastics melt quality simulation and run flow simulation for mould tool design.

At the PDM 2005 event, Moldex3D will be showing new products, in addition to the established range of simulation software, through their local distributor FlowHow UK . * ScrewPlus melt quality simulation - in the injection moulding process, one of the most important process conditions is the actual temperature and/or the temperature distribution of the polymer melt. However, the true polymer melt temperature is very difficult to determine and so an estimate is normally used for the mold filling and packing simulations.

To better predict the true melt condition, Moldex3D have added the ScrewPlus module to Moldex3D Ver 7.0 to simulate the behaviour of material within the machine barrel.

This is based on the FLOW 2000 Extruder simulation technology, developed by Compuplast International The ScrewPlus Simulator shows the effect of the melt inhomogeneity (unmelted fraction) and temperature variations both along the barrel and across the depths of the screw flights.

The screw and barrel parameters can then be optimised to ensure that the melt is fully homogenous that a true melt temperature is established for use in the full Feed and Cavity flow analysis.

Experiments have shown that improved melt quality can significantly improve Part quality and minimise Pressure to Fill and Clamp Force * Modex3D Express - Moldex3D-Express has been developed as a low-cost, easy to use and quick to run flow simulation tool for part and mold designers.

Geometry is imported into Moldex3D-Express in STL format and automatically converted to solid Voxel mesh (i e Cuboid elements).

The simulation is run in true 3D using the same HP-FVM solver technology as used in Moldex3D/Solid - Flow, so the accuracy of Solid flow simulation is maintained, with results being available anywhere within the thickness of the part.

Available filling results include: * Fill pattern.

* Pressure.

* Temperature.

* Shear stress.

* Shear rate.

* X-Y-Z velocity.

* Estimated cooling time.

Initial trials on a Pentium III PC with 1Gb of RAM show that, on a test part with 25,000 Voxel elements, a Filling simulation can be run in 6 minutes with the automatic mesh generation taking some 2.5 minutes .

By applying 2D and 3D off-line programming, a fast growing tooling and pattern maker was able to chop hectic two-day programming effort at the machine down to a simple, 2h programming job.

Even though it was very new to its SprutCAM 2D and 3D off-line programming system, fast growing tooling and pattern maker to the thermoforming industry Sterling Products of Bridgewater, UK, immediately chopped a hectic two-day programming job at the machine into a simple, program and run off cycle that took just two hours. In addition, the company no longer has to purchase or maintain expensive form cutters which also reduces costs and production lead times. It is very rare for a company to visit an open house or exhibition, see a demonstration of a product from cold and be so impressed that a director places an order on the spot for immediate delivery.

But that's what happened to Dave Pearson, managing director of Sprut Technology UK of Taunton, when Steve Riddle of Sterling Products turned up at XYZ Machine Tools Open House where the SprutCAM Expert Version 4 software was being demonstrated.

Confesses Riddle: 'We were struggling to keep up with demand, so I drove one junction down the M5 to the open house to look at the various technologies on show to see what was available that could help shorten our lead-times'.

'When I saw the demonstration of SprutCAM I was immediately impressed, and when I found out it could be in our works for just GBP 3,250 the deal was done.' Sterling Products employs 12 people to help it provide tooling and patterns for the thermoforming industry.

Typical end products range from plastic trays for cakes or chocolates in supermarkets through to food packaging.

Single patterns are machined from model board or resin for customer initial approval before the finished tool sets are produced in aluminium in batches that range between one and 12.

While tolerances do not tend to be severe at +0.1 mm they are very demanding for the level of surface finish that has to be maintained.

'Within days SprutCAM had a huge impact on our business,' says Riddle.

'With hindsight it makes our previous methods seem extremely onerous'.

'We used to receive DXF files, decipher them and program the milling machines manually'.

'SprutCAM has already saved us hours and hours of programming time and reduced the likelihood of costly errors, improved lead time and considerably improved our machine utilisation because we work directly from the customer's original surface model.' With over 1,000 users worldwide, SprutCAM offline programming software is ideally suited to pattern making, toolmaking and subcontract machining.

Starting at just GBP 1,295 for the 2, 2.1/2-D Machinist milling package, this includes 12 months telephone and Internet support.

The higher functionality 2D and 3D Expert package, as bought by Sterling Products, has full on-site training, 12 months telephone and Internet support, and can be installed for just GBP 3,250.

Both levels of system are available with a 30-day free-of-charge trial licence that allows potential users to experience the full system and see the benefits in their own working environment.

SprutCAM 3-D Expert Version 4 combines powerful 2D and 3D strategies, model feature recognition and surface analysis capability with high quality toolpath simulation.

In addition, it is now an accepted SolidWorks Solution Partner product.

This means that users can continue to design the CAD model and then update and apply existing toolpaths without having to switch between one application and another.

At the end of January, when the seat of SprutCAM Expert was commissioned at Sterling Products, the company wasted no time putting its new acquisition to work.

Confirms Riddle: 'It was so straightforward to use that we machined our first job the same afternoon.' Following further training from Sprut Technology UK, the company has become even more adept at manipulating its new cam system and has been able to generate additional savings for which Riddle outlines: 'We no longer have to purchase nor wait for delivery of form cutters'.

'With the new CAM system we simply make use of standard ballnose milling cutters and leave all the calculations to SprutCAM.

Innovative hot runner nozzles are specifically designed for use in difficult-to-access off-centre gate locations, and offer a maximum offset of 30mm and a minimum pitch of 13mm.

Visitors to the DMS-Diemould stand at PDM'06 in Telford, UK, showed particular interest in the offset version of the popular Flat-Line hot runner nozzle from Heitec. These innovative hot runner nozzles are specifically designed for use in difficult-to-access off-centre gate locations, and offer a maximum offset of 30mm and a minimum pitch of 13mm. DMS managing director, David Odlin, commented, 'Once again, PDM attracted serious buyers looking for solutions to increasingly difficult moulding challenges - the offset Heitec nozzles proved to be just the type of thing they were looking for.' The new nozzles can be used in situation where previously an offset would require an additional separate manifold and nozzle, with all the associated expense in time and money that involves, with the off-set Flat-Line nozzle it is possible to achieve the desired position simply by using the special nozzle and an adaptor.

The nozzles are not only appropriate for off-centre and diagonal, and off-centre, diagonal and narrow locations, but also for use with nearly all commercial resins, including those with glass reinforcement.

The units also offer side-supports to stabilize them against injection unit pressure.

With the option of modification to suit customers' specific requirements, the nozzles provide extensive design flexibility.

They are available in single and multiple units and, when used in conjunction with a manifold, open up extensive new layout possibilities, particularly with regard to exactly balancing flow channel distances.

Kistler has developed a completely new technique based on the mould cavity pressure and the surface temperature of the moulded product which can automatically determine the residual cooling time.

Experience shows that in 70 % of injection moulding processes,the cycle time is 20 % longer than necessary reducingproductivity of the entire process. In co-operation with theUniversity of Applied Sciences in South Westphalia, Germany,Kistler has developed a completely new technique based on themould cavity pressure and the surface temperature of the mouldedproduct. The new system can automatically determine the residualcooling time making the empirical setting of theinjection-moulding machine or the use of a cooling time formulaunnecessary.

The new system is an option for self-optimisingdemoulding systems using the smart Type 5155A charge amplifiersand can be fully integrated into the injection-moulding machine.In addition to the automatic cycle time calculation during mouldsampling and optimisation processes, the system will control theresidual cooling time during the active production process.

Thisensures optimum part geometry irrespective of processfluctuations and keeps the cycle time to the minimum necessary.