DMS has announced the UK availability of a new mould cycle counter that provides moulders with a mould monitoring and maintenance planning aid.

DMS has announced the UK availability of a new mould cycle counter that provides moulders with a mould monitoring and maintenance planning aid. The unit, measuring 50mm x 30mm x 28mm, is claimed to be robust and that it contains no moving parts and uses an electronic circuit to count the number of mould cycles completed. The cycle number is shown on an LED display screen, which also records any attempt to tamper with the counter.

A second version of the unit includes an additional 'trip counter' option.

Using the cycle counter the moulder can check how many cycles the mould has performed in any given period, for example in the last hour, or in the last shift, since it was maintained, through its lifetime.

Each cycle counter is also marked with its own unique identification number, providing a guarantee for the mould-maker, said DMS.

DMS's managing director, David Odlin, commented: 'The new cycle counter provides moulders with significantly increased mould monitoring ability, providing improved security of operation and maintenance planning, so saving both time and money.'

The FASTOOL Project has resulted in the development of toolroom scheduling software which is being made available to project participants - giving them a competitive head-start.

The EU funded FASTOOL Project, led by GTMA, has resulted in the development of toolroom scheduling software which is being made available to project participants - giving them a competitive head-start. The latest version of the software has been tested and refined to accommodate users' requirements, obtained through the feed-back process, The scheduling software enables users to input detailed information about the items being produced and the resources required, including any NC code, and the software then automatically schedules the job to make the most efficient use of available high speed milling machines, electrode EDM machines and other resources. Different levels of user are defined in the software, from 'Administrator' through 'Designer' and 'Planner' to 'Operator' and each level is assigned its own range of permissions and access rights.

Thus, the Administrator has full control over user accounts, including creating and amending them, the Designer defines the jobs and enters them into the schedule, while the Operator can only view the Current Work Schedule and print out desired schedule records.

The FASTOOL Toolroom Scheduling software is usable as a stand-alone product and provides a user-friendly interface for allocating jobs and resources while schedules are represented in a GANTT chart representation.

Other special features provided by the new software include: * Full control over resource allocation (machines, personnel etc).

* Fully customisable working hours for each resource used.

* Full control over machine tool capacities and scheduling constraints.

* Automatic rescheduling of jobs for the optimum machine tool utilisation.

* Manual override and rescheduling facility through a drag and drop interface.

* Virtually unlimited job capacity The FASTOOL Toolroom Scheduler will form the heart of a demonstration facility being created at CRDM Research, within Buckinghamshire Chilterns University College in High Wycombe.

This facility will be used to promote the benefits of toolroom automation, as part of the European FASTOOL Collaborative Project, which, in addition to GTMA, also involves CRDM Research (UK), Metaalunie and TNO (The Netherlands), NCG and Faunhofer-IPT (Germany) and ASCAMM and Fatronik (Spain).

Build-up laser welding gets damaged mould tools back into shape quickly, with high quality and at low expense. The technique also enables existing tools to be altered.

Manufacturing tools and molds is an expensive procedure, and also very time-consuming. This is especially the case when a manufacturing tool has to be altered, or rebuilt because of damage. Build-up laser welding is the economical alternative.

The laser gets tools back into shape quickly, with high quality and at low expense.

Applications range from the repair of worn tools to design adaptations and build-up of complex contours.

'Laser welding has established itself as a reliable method, and is especially impressive for the durability of the applied material.

Refinishing work is minimal, and subsequent processing methods such as polishing or etching have no effect on the finished injection-molded component either', explains Michael Heinzmann, main application manager for tools and molds making at Trumpf Laser in Schramberg, Germany.

Trumpf provides systems specially designed for build-up laser welding, each adapted to the respective application.

Precise working with the Trumpf PowerWeld - 'All ergonomic factors were taken fully into account in the design of the laser workstation PowerWeld', according to Heinzmann.

This is important for precise, fatigue-free working.

Workpieces can be handled without a problem in the spacious working area of the PowerWeld.

The air-cushioned work surface ensures precise workpiece positioning and welding.

Various guidance systems and alignment aids can be retrofitted without a problem.

They include a joystick control, CNC programmable axes and also a motorized rotational axis, enabling precise application of contours according to coordinates.

The optional focus-finder allows the focal point to be pre-adjusted independently of the stereo microscope.

For simple loading of the working area, even with heavy workpieces, the air-cushioned work surface needs simply to be moved out of the working area onto an additional table.

More options and possibilities with the PowerWeld open and the Mobile Manual Laser Welding Device - the laser workstation PowerWeld open gives even more options where large and especially long, asymmetrical workpieces are concerned.

The working area is not closed off, enabling free access to the working surface as well as easy loading.

A processing optic that can be swiveled as well as moved in the y direction provides even more processing flexibility.

Mobile manual laser welding devices make it possible to process very large and heavy workpieces that should not be moved.

Here, the welding equipment is brought to the workpiece, rather than the other way around.

As the processing optic is guided by hand it can thus be adapted to the welding point location.

A camera integrated into the processing head visualizes the working area.

The operator can then follow an enlarged version of the process on a monitor.

Trumpf solid-state lasers for welding build-up - 'In connection with the processing systems TRUMPF pulsed solid-state lasers from 20 - 200 Watt are used' says Heinzmann.

The modular optic design on the laser devices, together with flexible laser light cables, make it possible to power several processing stations, such as the PowerWeld and a manual laser welding device, thus enabling one to enhance the other.

Since acquiring latest CNC milling software, a mould maker reports ten times the flow of work and that higher cutting speeds and more accurate toolpaths are reducing benching time by 50%.

Michigan, US-based Eifel Mold and Engineering combines 30 years of experience with advanced CADCAM and machining capabilities, including Delcam's PowerMILL cam software and new high-speed machine tools, to provide tier-one automotive suppliers with comprehensive product design and mouldmaking services. President Rick Hecker claimed, 'We're not simply a mouldmaker or a design house. We deliver the whole package for tier-one suppliers who need a project taken quickly from start to finish.' Eifel founder Josef Hecker emigrated from Germany to North America in 1957.

He worked as a pattern- and modelmaker in the automotive and aircraft industries for more than fifteen years before beginning his own company in 1973.

Customers still benefit from that long tradition of craftsmanship, precision and detail.

Meeting short lead times is Eifel's specialty.

'Usually we are involved with things that have to be turned around quickly.

We used to be happy when we got 16 to 18 weeks to make a typical production tool.

Now the time isn't there anymore,' Mr Hecker said.

Eifel's quest for speed and efficiency includes using the machine operators to create toolpaths for the company's milling machines with PowerMILL directly on the shop floor.

CNC machinist Gary Schulz explained, 'A lot of people create programs up in a CAM room but toolpaths are so much faster when they are programmed by the operator who knows the tools, knows how to cut steel, and can manipulate the set-up to make the machine do what he wants.' 'We've used PowerMILL on five different machines for many years,' Hecker added.

'We're very happy with the software.

You don't have any issues like gouging, and it's pretty easy to use.' Confidence in the toolpaths generated by PowerMILL enables Eifel to maximise machine utilisation through unattended, overnight finish machining operations.

High speed machining is becoming a key factor in Eifel's work, because it offers benefits in both productivity and product quality.

'The new technology in controllers and machines is remarkable,' noted Hecker.

'With our new machines, I'm putting out ten times the flow of work,' he said.

'I'm also getting high accuracy and better surface finish as well.' The high cutting speeds and accurate toolpaths are reducing benching time by 50%.

'Previously, we'd spend 30 man hours on a full wheel mould to get it to match up perfectly,' Hecker remembered.

'Now, we can do it in 10 hours or less.' High speed machining also enables Eifel to cut many features it used to burn with EDM.

Latest release of software for the 3D design of injection mould tools offers an extra wizard for design of mould locks and creation of stepped split surfaces in the Die Wizard.

Delcam will demonstrate the latest release of its PS-Moldmaker software for the 3D design of injection moulds at the euromold exhibition to be held in Frankfurt, Germany, from 30th November to 3rd December, 2005. In this release, Delcam has introduced a new type of parametric component incorporating Power Features. The new release also offers an extra wizard for the design of mould locks, the ability to create stepped split surfaces in the Die Wizard, and faster creation of 2D drawings from the 3D model.

PS-Moldmaker is a knowledge-based system that provides a unique combination of automation to speed the design process and flexibility to manage design changes efficiently.

Together with the other programs in Delcam's Power Solution range of CAD/CAM software, it allows designers of injection mould tools to move successfully from processes based on two-dimensional drawings to more productive methods based entirely on three-dimensional computer models.

The latest release includes an extra level of intelligence through the introduction of Power Features.

A parametric component that contains Power Features will react automatically as it is placed into an assembly, adding all the necessary fit-features to the connecting components.

For example, if a mould designer adds an ejector pin to the mould assembly, the software will automatically create the corresponding hole features in the plates through which it passes.

Furthermore, the tolerances between the various components are also defined automatically.

Thus, a sealing-fit hole is placed in the die block and the necessary clearance allowance added to the holes in all the other plates through which the pin passes.

Of course, Power Features maintain relationships in a similar way to parametric objects in other CAD systems so that, if the pin moves, all the associated holes move with it.

However, the automatic creation of relationships makes the development of the design much quicker than other systems and also makes errors in the design process less likely.

PS-Moldmaker still retains its high level of intelligence when suggesting appropriate sizes for components defined with Power Features and will recommend standard sizes whenever these are available from the many catalogues within the system.

Similarly, the software will still recommend the nearest alternative component when changes are made to the design, rather than using simple mathematical changes to the component dimensions.

This minimises the need for non-standard components, which take longer and are more expensive to make.

Mould locks are the components used to lock the mould in position during the injection cycle.

The new Mould Lock Wizard in PS-Moldmaker provides a similar automatic method for defining these parts to the previous Wizards for the design of slides and cooling channels.

The locks can be created and edited individually, or the complete set can be generated together using common pre-defined layouts, with automatic mirroring of the initial assembly to create the others in the set.

Stepped split surfaces are used in moulds to give a smaller contact area and, therefore, higher pressure at a given load over the contact area.

This minimises flashing in the final component.

To create a stepped split surface, the Die Wizard within PS-Moldmaker first generates the split curve automatically in the usual way.

However, the user then has the option to specify the land distance required from the component and the angle at which the split surface then needs to fall away.

The two halves of the mould can, and generally do, have different split surface profiles, but both are created as a matching pair by the same wizard operation.

Experience has shown that many mould design projects need as much time to create the 2D drawings as is needed to generate the 3D model.

To meet these requirements, an outline general arrangement drawing and a full set of component drawings are created automatically by PS-Moldmaker from company-specific templates as the computer model is developed.

The latest release enables much quicker initial production of drawings and also faster associative updating of the drawings if the design is changed.

To minimise the need for manual dimensioning, each component drawing now includes a bitmap image of the part, together with a table showing its key dimensions.

To provide injection molders with an improved control solution in multi-cavity moulding, Synventive has introduced a new small nozzle series, the 04C and 06C.

To provide injection molders with an improved control solution in multi-cavity moulding, Synventive has introduced a new small nozzle series, the 04C and 06C. The nozzles will replace the older generation CA nozzle, which has featured in the company's product line up for over 10 years. The biggest benefit offered by the 04C and 06C compared to the CA nozzle is the incorporation of replaceable heaters for easy and quick maintenance.

This makes the 04C and 06C highly suitable for multi-cavity applications.

The properties of the 04C and 06C nozzle are equal to the old CA model, which means that it can be used for the processing of all commonly used thermoplastics, including those with highly abrasive reinforcements.

Also, new tip inserts are available for the direct gating of polypropylene (PP) in combination with fast cycle times.

However, multi-cavity applications require more than just user-friendly nozzles.

Reliability and a high level of control are of equal importance.

For those reasons, Synventive has introduced a new Multizone temperature controller.

The controller completes the range that starts with the Hi-Q controller, for up to 24 zones.

The new Multizone controller is designed for up to 192 zones and provides moulders with simple to operate control, even with high zone numbers.

Because floor space is always at a premium in an injection moulding workshop, the Multizone temperature controller is designed to be compact without compromising its performance.

The controller features a variety of configurations, using a wide selection of control card options, including three-zone 15 Amp, two-Zone 20 Amp or three-zone 30 Amp cards.

Depending on the type of cabinet selected, the controllers are supplied with an eight-inch or 12-inch fully-featured colour touch screen for maximum efficiency.

It displays graphics that provide full details of system performance.

Furthermore, diagnostics check the mould for heater, thermocouple and wiring faults and can predict any imminent heater failure.

A standard network connection cable enables web-browser, remote monitoring from anywhere in the world.

One of first applications utilising the new 04C nozzle and the Multizone temperature controller was a 64 port hot half for the production of coffee pads.

The 1gm parts, moulded in PP, have a total cycle time of only eight seconds.

The nozzles gate directly on to the part leaving a clean mark and a 75 zone Multizone temperature controller gave optimal control over the mould and nozzles.

Switching to apowerful CAM system doubled productivity at a Chilean mouldmaker and helped it to win new business from the largest important electrical appliance manufacturers.

Switching to Delcam's PowerMILL cam system has doubled productivity at Chilean mouldmaker Comberplast. The software also played a major part in convincing CTI, one of the most important electrical appliance manufacturers in the country, to buy its first moulds from the company. Located in Santiago de Chile and with more than 30 years in the market, Comberplast has become recognised throughout the Latin American plastics industry for the quality of its work.

The company has been involved with many applications, including packaging and telecommunications, as well as electrical appliances.

One of the keys to its success has been considerable investment in new technology and automation.

In the case of the Mould Department, Comberplast has installed new machine tools that let it provide its customers with moulds matching European or American standards, at competitive prices.

Delcam's PowerSHAPE hybrid modelling software and the PowerMILL CAM system were added after an intensive testing period with a number of CADCAM systems.

These trials demonstrated that the Delcam software best satisfied Comberplast's needs.

'With PowerMILL, we have been able to reduce machining times by 50%, which in other words means we have doubled our working capacity,' said Shop-floor Manager Marcos Guevara.

'It's like having new and more precise machine tools.' The improvements made possible by the Delcam software were crucial in convincing CTI to place work with Comberplast.

The first project was a rotor for a washing machine, a very complex part that is at the heart of the machine.

'Until we completed this job, CTI had never thought of buying this kind of mould from a local supplier,' claimed Guevara.

'They would only use European tool shops.

Now, CTI recognises that we are able to compete not only in quality, but also in customer service, delivery times and price.' 'Starting with a prototype of the product and an incomplete CAD model, we could help our customer finish the design in PowerSHAPE,' explained Guevara.

'Even though we were in the early stage of implementing 3D mould design, with PS-Moldmaker and the experience of Delcam's reseller MultiCAM Chile, we could efficiently complete this stage in about one third of the time it would have taken to do it in the traditional way.' The manufacturing process was equally successful.

'With the strategies available in PowerMILL, we could machine the inserts very easily,' he added.

'We produced very efficient toolpaths, even for several very difficult areas of the mould.

The overall result of using the Delcam software was a high quality mould, completed in half the time that the customer was expecting,' he concluded.

Internet 'pay-per-use' solution enables the automatic design of plastics injection molds by combining the expertise of a CAD/CAM editor and European Technical Mold centres.

Missler Software will shortly launch TopSolid'MoldXpress, the internet, 'pay-per-use' solution for the design of plastic injection molds, based on its TopSolid'Mold integrated module. TopSolid'MoldXpress enables the automatic design of basic and medium plastic injection molds by combining the expertise of a CAD/CAM editor and various European Technical Mold centres. TopSolid'MoldXpress gives the operator access to a leading CAD module for mold makers without the need to heavily invest in a software.

A design assistant looks after the entire design process with automatic design rules being used throughout the process.

The TopSolid'MoldXpress operator logs on to the pay-per-use server via the internet.

At the end of the process the operator will be advised of the cost of the study.

He needs to validate the command in order to obtain the plans and the mold model in the format of his choice (TopSolid, Parasolid, Step or Iges) TopSolid'MoldXpress is the result of close collaboration between Missler Software, AIJU ASCAMM and ISMO, technical centres in France and Spain, in addition to TecnoCim (Missler Software official partner in Spain) The project has been co-funded by the Spanish Ministry of Science and Technology.

Missler Software is the number 2 CAD/CAM software supplier in France and number 7 worldwide.

It offers a fully integrated CAD/CAM solution with TopSolid'Mold, specifically adapted for the needs of mold, tool and die makers.

ASCAMM is an organisation representing mold makers in Catalonia, AIJU regroups companies in the mold and plastic toy sectors in Valencia and ISMO is the French organisation representing French mold makers.

TopSolid'MoldXpress enables calculation of the shrinkage factor, analysis of the undercuts, calculation of the parting line and the surface of the joint, automatic creation and definition of the core block and cavity, implementation of the standard carcass, systems of injection and ejection and analysis of the cooling system.

TopSolid'MoldXpress is ideal in situations where the design of the mold is quasi-automatic.

Where the operator needs a more comprehensive solution he will be informed as soon as possible that his project cannot be completed and he will be redirected towards the complete mold making module TopSolid'Mold.

TopSolid'MoldXpress is an innovative solution serving the needs of mold makers designing simple molds.

Traditionally, editors have served the needs of mold makers who design complex tools whereas TopSolid'MoldXpress is designed to quickly and effectively design basic tool assemblies.

Single wire technology that simplifies sensor installation can now be specified on all Kistler sensors for monitoring cavity pressure in both multi-cavity moulds and large, single component moulds.

Single wire technology can now be specified on all Kistler sensors for monitoring cavity pressure in both multi-cavity moulds and large, single component moulds. The main benefit of the unique Kistler single wire technology is the simplification of installation as the single wire sensor, being installed without a connector, requires only a bored hole to accommodate the cable. As several cables can be threaded down a single bore, the single wire sensor is ideal for multi-cavity applications.

The pre-fixed connector, on a conventional screened sensor cable, can make installation both difficult and costly as a milled channel is often needed for each sensor.

Unlike conventional screened cables, which must be replaced or repaired by the manufacturer, the single wire connecting cable can be cut to the required length after installation and easily extended and repaired by the user without special tools.

The cable can be terminated with a quick fitting connector or multi-channel charge amplifier mounted on the mould and is compatible with all existing Kistler charge amplifiers integrated into injection moulding machines.

From the connector or charge amplifier, the sensor signal is carried by screened cable to the monitoring equipment, such as the Kistler DataFlow system.

Kistler single wire technology simplifies the installation and maintenance of cavity pressure sensors in all types of injection moulding machines and will deliver significant cost savings, especially in multi-cavity applications.

* About Kistler Instruments - established in Wintherthur (Switzerland) in 1957, Kistler is represented in over 50 countries and has subsidiaries in Germany, France, Italy, UK, Japan, USA, China, Korea and Singapore.

Heavy investment in research and development, 15% of staff worldwide are engaged in research and development, has generated a number of innovations using piezoelectric, piezoresistive and capacitive techniques to provide solutions to numerous force, pressure and acceleration measuring problems.

These innovations include the world's first commercial quartz sensor, two-wire constant current technology to integrate sensors with microelectronic circuitry, high-temperature pressure sensors for use up to 400 Deg C and three-component force measuring sensors.

For the second time in 2004 Toolcraft has expanded its production facility with a Hurco VM1 integrated into the all embracing plastics mould tool manufacturing system.

For the second time in 2004 Toolcraft has expanded its production facility with a Hurco VM1 integrated into the all embracing plastics mould tool manufacturing system. For the second time in 2004 Toolcraft has expanded its production facility at Swindon as a Hurco VM1 is integrated into the all embracing plastics mould tool manufacturing system. This, the latest in CNC, touch control machining centres has a 16 station ATC (2.5 seconds tool to tool) and high capacity spindle.

Programming of 'follow-on' operations can be completed whilst the machine is running saving valuable production time.

It will be linked to the Toolcraft design office to enable direct transfer of data, ensuring speed and accuracy of mould tool manufacture.

Fending off aggressive overseas competition is not easy according to Toolcraft managing director John Hemsworth, but continuous investment to hold reasonable price levels and giving companies the close dialogue they cannot get from distant suppliers, puts us in right at the front for reliable supplies of precision plastic parts and mould tools.

Particularly when it comes to tool changes, introducing second and third generation product, and rapid response to changes in demand, many now respect the value of a UK manufacturer.

A very powerful software module for mould and die makers has a more simplified user interface being highly visual and easier to use for operators, with dialogue boxes replacing manual operations.

Missler Software will be launching the new version of its mold module, TopSolid'Mold 2005, in the last quarter of this year. TopSolid'Mold is a very powerful module designed to meet the highly specialized needs of mold makers and tool and die specialists. The new version, TopSolid'Mold 2005, boasts many new functionalities with a lot of emphasis being placed on a more simplified user interface being highly visual and easier to use for operators.

Dialogue boxes replace many operations which previously were manually executed TopSolid'Mold 2005 offers key improvements in the following areas: * Part Update Management - TopSolid'Mold 2005 incorporates the addition of new tools to help the user manage model changes (surface analysis, sewing tools, parting elements repair and update) * Lifter Sub-System - The addition of a lifter sub-system which lifts and pushes simultaneously to eject the part is now a feature of TopSolid'Mold 2005.

* Hot Runners - The use of hot runners is an important innovation in TopSolid'Mold 2005.

This allows the melted plastic to flow directly into the mould from the hot runner.

Thus, there is no wasted left over plastic material resulting from the melted plastic being poured through the stalk.

* Core/Cavity blocks - TopSolid'Mold 2005 enables easier management of multi-cavities and allows the automatic creation of the multi-cavity through the addition of the easy-to-use dialogue box which guides the operator through the process.

* Management of the core/cavity block corner - this function is now fully automated allowing the automatic insertion of rectangular molds into structures with right angles.

* Flat and trimmed parting surfaces - This new function allows the selection of several parting lines to create flat and trimmed surfaces.

* Inserts and TopSolid'Electrode - Through the addition of the new dialogue box operators can now manage complex shapes more easily by creating the insert using TopSolid'Electrode functionalities.

* Ejector Pins - TopSolid'Mold is the only CAD supplier which has incorporated the automatic trimming of superimposed heads.

This is especially useful for small parts and makes the life of the mould maker easier.

In addition, a pocket is automatically created in the ejection plates and this pocket is recognised by TopSolid'Cam.

* Cooling system - TopSolid'Mold 2005 allows the opportunity to modify the diameter of all drillings at the same time and the graphical management of the direction of the cooling pipes.

* 2D Drafting - The operator can now customize a table of coordinates with different information on standard components.

* New components - TopSolid'Mold 2005 incorporates the addition of new sub-assembly components and the new libraries: Fodesco, PCS Inch, Progressive Inch and DMS TopSolid'Mold 2005 once again confirms Missler Software's position as one of the leading providers of CAD/CAM software for moldmakers.

About Missler Software - Missler Software is one of the leading global suppliers of CAD, CAM and ERP solutions.

The company's product lines include TopSolid, TopManufacturing and Goelan.

Missler Software offers a uniquely integrated solution for the mechanical engineering industry (general mechanical design, special machinery, tooling, boilerwork.) and for sheet metal and wood industries.

Thanks to its advanced technology and its fully integrated solution, Missler Software is experiencing rapid growth in the global CAD/CAM market.

Brass moulded-in inserts feature hexagonal heads and a large centre undercut to provide a high level of bi-directional torque resistance and contribute to high pull-out/pull-through strength.

Spirol Industries, the leading supplier of engineered fastener solutions, have introduced a new range of brass Moulded-In inserts. They are designed to be placed in the plastic mould prior to plastic injection. Two types of Moulded-In insert are available: Series 40 is a through hole type and Series 44 a blind end type.

Both types feature hexagonal heads and a large centre undercut to provide a high level of bi-directional torque resistance and contributing to exceptional pull-out/pull-through resistance.

The Series 40 also has generous internal counterbores to allow quick and easy installation on to guide-pins.

An internal minor thread is designed to eliminate insert wobble on the guide-pin.

Moulded-In inserts, like Spirol's renowned brass expansion range, do not require any specialised insertion tools.

The operator simply places the insert directly into the mould prior to plastic injection.

The inserts design simplifies orientation and placement on to the mould core, thereby increasing productivity and reducing potential scrap.

Literature is a variable on the new range directly from Spirol Industries.

This new range is the latest addition to the company's range of engineered insert solutions.

Rather than providing off the-self products, the company provides a full technical advisory service to all OEMs to ensure specification of the most appropriate Spirol product and installation methods.