TRANSFORMING THE FUTURE OF PLASTIC INJECTION MOLDING
Table OF CONTENTS
02 Who We Are & What We Do 04 Delivering Unique Value, Products, & Services 06 Join the Journey to Autonomous Molding 08 The iMFLUX Process Control System has Three Components 10 Break Free from the Constraints of High-Pressure Molding 11 Discover the Advantages of Low-Constant-Pressure Molding
12 Transform Your Results & Operations 22 Gain New Solutions for Sustainability 26 Your Purchase Options for the iMFLUX System 28 Experience Our Mold Building & Innovation Center 34 Discover Innovative DWL Molds 38 Our People. Your Partners. 42 Fearless Equality & Inclusion 44 Education is Always at the Forefront
Who We Are & What We Do
We’re iMFLUX ® —innovators transforming the future of plastic injection molding.
iMFLUX ® is the only company that integrates game-changing processing software and machine learning with a mold building and innovation center. Our revolutionary low-constant-pressure injection molding platform works on virtually any machine, material, and mold. With iMFLUX, your sites run more reliably with fewer operator adjustments. You’ll produce higher quality parts, reduce costs, and lower capital—all while advancing your sustainability efforts.
We believe the iMFLUX technology is one of the most innovative technologies to come into the PLASTICS Industry. It corrects many of the molding defects molders struggle with every day. It is a pleasure to work with the iMFLUX team, to bring this technology to our customers. Dale Bartholomew, National Technical Manager, Japan Steel Works America,
Delivering Unique Value, Products, & Service
Revolutionary Low-Constant-Pressure Molding Platform Automatically recognizes changing conditions and adapts in real-time, so your operation runs smoother, machines learn in real-time, and molding occurs uninterrupted. Distinctive Mold Building & Innovation Center Staffed by professionals, many leaders in their field, all with one goal, one win, your success. Education That Leads to Adoption We offer in-house, AIM certified, and on-demand educational experiences. Service and Support to Maintain Your Operations Our experts are ready both online and on-site to help with your mold-design, build, and process needs. 1 2 3 4
We truly believe the technology behind iMFLUX will drive a step change in the way injection molding is done. This is why we have been a partner and have systems running on large programs in Europe and North America, as well as development systems in our Innovation Center. Kevin Hedspeth, CTO, Technimark
Join the Journey to Autonomous Molding ™
iMFLUX instantaneously measures, calculates, and makes data-based adjustments for changes in the mold, material, machine, or environment. We continue to innovate in order to achieve a completely autonomous filling process.
A closed-loop between the material and mold enables machine learning and reduces the need for operator interventions.
Like adaptive driving features, iMFLUX’s processing platform automatically recognizes changing conditions and adapts in real-time for uninterrupted molding.
The traditional molding practice limits the flexible process parameters where the machine doesn’t consider the mold or the material. With the iMFLUX process the machine is now controlled by
the metrics of the mold and the material. Jason Hollbrook, Regional Sales Manager, Absolute Haitian
The iMFLUX Process Control System Contains Three Components
The iMFLUX System works on virtually any machine, new or old. The Low-Constant-Pressure Molding system enables your machine to mold with no flow hesitation, packing as it fills, adapting in real-time, and automatically adjusting to viscosity changes. iMLUX can be integrated in three different ways. 1. DIRECT INTEGRATION —iMFLUX can custom engineer a solution for your needs, which typically happens for older machines. 2. ONBOARD —iMFLUX can come already integrated into new injection molding machines. 3. iMPORT —iMFLUX can offer an easy installation kit to retrofit your existing machines.
This closed-loop processing technology combined with the accuracy and adjustment of our machines yielded amazing results with exceptional simplicity. Sonny Morneault, VP Sales and Marketing, Wittmann Battenfeld
Controller The box contains the software and communicates with the injection molding machine.
User Interface Comes as a separate unit or already integrated into the original machine display.
Melt Pressure Sensor Added to the machine nozzle to provide feedback during the injection phase, which closes the loop and controls the injection point forward.
Not to scale. For illustration purposes only.
Break Free From the Constraints of High-Pressure Molding
Discover the Advantages of Low-Constant-Pressure Molding
iMFLUX is an adaptive process, that controls for pressure by varying the injection velocity. This platform uses 20–50% less pressure, on average, and packs as it fills, with no flow hesitation. Overall cycle times are faster because
Conventional molding is a static process that controls for velocity. It injects the material with high shear heat, and pressure at the beginning of the process. This process leads to challenges in part quality and shot-to-shot consistency. Given the shear heat and pressure, conventional molding requires a separate pack and hold phase once the part has been filled. After 60+ years, conventional molding does not provide enough levers to solve today’s molding challenges.
the process doesn’t require a separate pack and hold phase.
Today iMFLUX has emerged as a method and a highly advanced control system that is providing a much-needed alternative to the way the industry currently thinks
of injection molding. John Beaumont, President , Beaumont Technologies Inc., AIM Institute.
THE BLUE CURVE illustrates conventional high-pressure molding with its fill, pack and hold, and cooling stages.
THE GREEN CURVE ™ illustrates the iMFLUX adaptive molding process with fill and cooling stages.
Rethink Part Design with No Flow Hesitation
This test part with its tiny runner is virtually impossible for conventional molding; if the flow hesitates, the plastic would immediately freeze.
Transform Your Results & Operations
Results For You • Make higher quality parts with less stress, warp, and sink. • Mold new designs, with even greater complexities. • Create thinner parts with smaller cold runners.
Because The iMFLUX platform never hesitates when filling the mold and achieves a near-perfect laminar flow for any mold, no matter the complexity.
• Process with greater efficiency and less stress, wear, and tear on your molds and machines. • Deliver better parts with higher quality and aesthetics. • Reduce part wall thicknesses and weight. • Adapt automatically to changes in materials, including massive viscosity shifts. • Operate more reliably with less operator adjustment and downtime.
COLD RUNNER 3.0 inch (7.62 cm) long; 0.030 inch (0.75 mm) diameter
MAKING THE IMPOSSIBLE PART POSSIBLE.
MOLDED IN STRESS
Your Parts Pack as They Fill
Lower Pressure Reduces Stress
Results for You • Your parts will have better dimensional stability with less shrinkage. • Lower pressure results in less wear and tear on your machine and mold, which means less downtime and maintenance. Because • Our low-constant pressure molding process eliminates the high shear of conventional high-pressure molding.
Results For You • Mold with faster cycle time. •Enjoy better aesthetics such as surface finish and less sink. Because • We’re filling so slowly that most of the cooling and densifying occurs as the mold is filled. • The part is completely formed and almost ready when the mold is filled.
Joint iMFLUX-Milacron customers have seen many benefits, including, cycle savings, energy savings, scrap reduction, reduced tonnage, and tighter and more consistent part dimensions. Andy Stirn, Director NPD and Product Management, Milacron
Mold Lighter-Weight Parts with Low-Constant-Pressure
The precise melt flow front basically gives us the ability to pack thin walls at lower speeds and pressures, certainly compared to conventional processing techniques. Mike Ortolano, CTO & Co-Owner, Haitian Absolute
Low Pressure Differential
High Pressure Differential
Results for You • Reduce your overall part weight. • Achieve lighter weight with equal or superior quality and performance. Because • Plastic flows farther and through thinner wall sections without freezing.
Cavity Pressure in PSI
Cavity Pressure in PSI
ON AVERAGE, 1–3% WEIGHT REDUCTION
Auto Viscosity Adjust ™ Means Greater Material Flexibility for You
ADAPTS AUTOMATICALLY Consistent Part Weight | Consistent Part Quality
Results For You • Process 100% PCR, composite, variable MFI (Melt Flow Index), and bio-derived materials with consistent part weight and quality.
Because • iMFLUX is an adaptive process able to adjust to shifts in viscosity.
• As material viscosity decreases , the iMFLUX process decreases the driving pressure to compensate for that reduction. • As material viscosity increases, the iMFLUX process increases the driving pressure to compensate for that increase.
Utilizing IMFLUX’s Auto-Viscosity Adjust™ software, we were not only able to improve cycle time by 15%, but also reduce part weight and reduce scrap rate to less than 1%. It was a significant win for both us and our customer. Glen Fish, CEO, Revere Plastics Systems LLC
Greater Production Reliability, More Uptime, & Less Scrap
Adding iMFLUX to our production cells has enabled our presses to run with less downtime and higher output. Quality has also improved, which frees up our operators to focus on higher value work. George Staniulis, Vice President AGS Technology
Results For You Your operations remain running without
Because iMFLUX intelligent control is an adaptive process that: • Adjusts based on melt pressure feedback. • Delivers consistent processing conditions despite material changes, shot-after-shot, for improved aesthetic and dimensional quality. PP (Polypropylene) to HDPE (High Density Polyethylene). • Down cavities do not affect the process, nor do leaking check rings. • Shifting environmental conditions operator adjustments even when you experience: • Massive changes in viscosity like going from
HIGHER (HDPE/PP) BLEND
ONE CAVITY DOWN
TWO CAVITY DOWN
Gain New Solutions for Sustainability
The Green Curve has proved invaluable in our effort to establish more processes using sustainable resins. Not only have we been able to increase our percent of regrind used, but we are seeing more consistency than ever before. Brandon Meadors, Engineering Manager , Clarios.
Running recycled and reprocessed materials is hard to do, often requiring frequent operator adjustments and dealing with higher scrap rates. iMFLUX adjusts the process keeping parts consistent
Our low-constant-pressure molding platform delivers three separate types of sustainability advantages: 1. Run more sustainable materials, including 100% PCR and bio-derived materials. 2. Produce with much l ower energy, wear, and waste. 3. Make lighter parts using less plastic.
ACHIEVE YOUR TRIPLE BOTTOM LINE OBJECTIVES
and in quality spec without operator time sitting at the monitor —all while avoiding scrap. Joe Carter, Operations & Maintenance Manager, Greystone Logistics
People, Planet, Profit.
Produce with Less Energy
Consider Light Weighting by Reducing Wall Thickness
COMPARING IMFLUX PROCESSING VS. CONVENTIONAL Molding on a Sixteen (16) cavity deodorant cap.
TOTAL Kw used per kg of material processed
The iMFLUX process provides energy savings, but you can also take advantage of a lower pressure process by lowering melt temperature, clamp tonnage, or cooling time for additional energy savings. These savings can add up quickly, so you can move closer
WEIGHT REDUCTION WEIGHT REDUCTION WEIGHT REDUCTION 25% 35% 5%
iMFLUX Process Alone
+ Melt Temperature Reduction
+ Clamp Tonnage Reduction
to your long-term ROI and SUSTAINABILITY GOALS.
+ Cooling Time Reduction
These savings opportunities occur on all types of machines regardless of the press size or material processed.
Total Combined Factors
AVERAGE ENERGY SAVINGS RANGE FROM 10–30%
AVERAGE WEIGHT REDUCTION RANGE FROM 1–3%
Your Purchase Options
We offer two purchase options so you can make the right choice for your business. 2 UPFRONT PURCHASE SUBSCRIPTION
Monthly subscription/IMM, prorated cancellation fee, with three options at the end of subscription term.*
Flat purchase price includes hardware, software license, training, installation, and warranty.
Elevate your operation and improve your results with our Mold Building & Innovation Center, staffed by professionals, many who are leaders in their field, all with one goal, one win, your success. We utilize one of the largest automated fabrication lines for lean manufacturing, which drives down your cost and lead time. All of iMFLUX is under one roof, so you will have seamless access to experts in process, controls, and software. We’re Transforming the Future of Plastic Injection Mold Design, Build, and Qualification. Experience Our Mold Building & Innovation Center
Innovation, Repeatability, and Speed to Meet Your Critical Timeline Our center is built in an immaculate setting equipped with a system that delivers quality, uniformity, scalability, and interchangeability within your molds. Thanks to our palletized automatic line, expertise teamwork, and full-suite of precision machining equipment, we produce ultra-tight tolerances, net-shaped mold components, and surfaces.
We Apply a Science-Based Approach to Mold Design, Building, and Qualification
Design We use the most powerful industry-recognized tools to optimize your technical mold designs, manufacturing simulation/optimization, and bottom-up part cost modeling. Build We’ll rapidly build your prototype molds, quantify pilot and unit molds, and deliver best-in-class precision production molds. Qualification Our quality management system and metrology lab ensure you have the finest fidelity. Enjoy access to nearly 20 process engineers across 13 molding machines to conduct trials, inspect parts, and certify molds.
Can we get MORE CAVITIES in this mold?
>> D ES I G N WITH O UT LI M ITS
• DWL Molds empower the use of new technologies, ideas, and possibilities, creating new opportunities for success. • Achieve more up-cavitation, put big molds in small presses, thin wall parts, change gate positioning, and realize faster cycles. •You’ll increase your throughput, reduce capital costs, and energy usage. Optimize productivity and capability by designing and building molds uniquely enabled by iMFLUX Process Control. AN EXCLUSIVE OFFERING TO OUR iMFLUX PROCESSING CUSTOMERS.
Can we fit this in a SMALLER PRESS?
Can we use MINI RUNNERS in this mold?
HAYCO Unlocked a Wide-Range of Significant Advantages
The benefits we have seen with iMFLUX have been a reduction in cycle time of existing molds and also the ability with new tools to increase cavitation by up to 50%, which allows us to free up injection molding capacity and production space for other activities. Christopher Hay, CEO, Hayco
Hayco DWL Mold Results
50% UP-CAVITATION 8 Cavity to 12 Cavity 37% CYCLE TIME REDUCTION DOUBLED THROUGHPUT
400 TON PRESS VS. 500 TON PRESS
ENTIRE SYSTEM QUALIFIED AT iMFLUX
$1.6M CAPITAL AVOIDANCE $1.7M COST SAVINGS
SWIFFER BALL JOINT MOLD
Our People. Your Partners.
We’re an AGILE AND COLLABORATIVE organization of unwavering partners and innovative change agents. Our teams are ALWAYS READY TO LEND A HAND and do whatever it takes to make your goals a reality. OUR PURPOSE —is to transform the future for the many companies, teams, and people who make up the plastic injection molding industry. TOGETHER , we will elevate your operations, grow your business, and bring new capabilities to your customers.
iMFLUX is a game changer for AGS. Lower costs and a better product. What more could one ask for? George Staniulis, Vice President AGS Technology
From machine and resin manufacturers to mold makers and production lines in every industry— iMFLUX is partnering with companies who want to achieve the impossible.
We feel like it [iMFLUX] gives processing opportunities that go outside the box of conventional processing with utilizing the low and constant pressure platform, which automatically monitors changing conditions and adapts in real time. MIchael Ortolano, CTO and Co-Owner, Absolute Haitian
Fearless Equality & Inclusion
At iMFLUX, we will continue to strive for a culture that is trusting, accountable, and fearless. We celebrate different cultures, backgrounds, genders, ages, thinking styles, and all diversity, that allows us to innovate as a cohesive team. • The Educate Team helps foster safe learning environments, new conversations, and information and resources that build awareness and understanding. • The Change Team addresses representation, retention, and personal growth. • The Influence Team spotlights our people, culture, and experiences through stories to help change both the plastics industry and the communities in which we live.
Education is Always at the Forefront
Access iMFLUX Process Education
Courses In-Person at the AIM Institute, as well as On-Site at Our iMFLUX Headquarters.
Access In-person iMFLUX Process Education Courses At The AIM Institute
Visit Our Innovation & Education Center for Demos, Trials, and Certifications
View Our Learning Management System (LMS) for Continuing Education and Learning Materials
We Partner with Universities and Vocational Schools to Develop Future Fearless Innovators.
LET’S CHANGE THE WAY THE WORLD MOLDS
CONNECT WITH US | INFO@IMFLUX.COM | 513.973.2042
ACCESS THE DIGITAL VERSION OF THIS BOOK
VISIT OUR WEBSITE AT iMFLUX.COM
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