Plastic Mold and Injection Molding Parts

HYX MOLD has a long history of service to the PLASTIC MOLD AND INJECTION MOLDING PARTS of experience.  Our materials scientists work closely with our customers to develop highly specialized materials unique to the field.

HYX MOLD designs develops, manufactures and assembles implants and instruments for the cardiac rhythm management (CRM), interventional, radiology/cardiology, cardiac surgery and peripheral vascular markets. These products are high precision, high reliability and are typically produced from plastic materials, electronic components and specialized metals, including nitinol, high strength cobalt chrome, and precious metals. We provide our customers with specialized services to help them develop a product from concept through to manufacturing and commercialization. Our services include prototyping, precision machining, material development, coiling and grinding, laser welding, plastic molded parts, tube drawing and extrusion, device assembly and packaging and sterilization management.

HYX MOLD cardiology products and services include:

Markets Served        Components and Services
Interventional Cardiology
Atherectomy devices
Guidewires, delivery systems Septal defect repair, and other occlusion devices Distal protection devices
Stent tubing, stents, mandrels Ground guidewires, tubular drive components Marker bands, catheter shafts, tooling mandrels, corewires, guidewire assemblies
Cardiac Rhythm Management
Implantable defibrillators
Implantable electrodes, connector blocks, lugs Electrodes & leads Material development, and cladding Stylets
Cardiac Surgery
Heart immobilization devices
Heart valves
Machined tubing Machined valve bodies and leaflets
Interventional Neurology/ Neuro Stimulation
Implantable coils
Catheters/delivery systems Distal protection devices
Wire coiling Guidewires Marker bands, catheter shafts, tooling mandrels, corewires, guidewire assemblies Conductor leads and subassemblies
Peripheral Vascular
Delivery systems Catheters/delivery systems Distal protection devices
Stents, stent tubing, guidewires, hypotubing Marker bands, catheter shafts, tooling mandrels, corewires, guidewire assemblies

Injection molders

Lubricant Pellets Cut Scrap & Cycle Times 
    Internal lubricants for a variety of thermoplastics are newly available in a 100%-active pellet form from Axel Plastics Research Laboratories, Woodside, N.Y. MoldWiz pellets come in several resin-specific formulations that contain no binders or fillers. Use levels are as low as 0.25%. 
   Precision Plastic Injection molders can tumble or dry blend these pellets with resin or feed them directly at the throat-an advantage over messy powders. For compounders, they are said to be useful in masterbatches because they improve dispersion of color, fillers, and other additives. MoldWiz internal lubricants reportedly improve resin flow at lower temperatures, helping to shorten cycles and reduce flow marks and knit lines on molded parts. The lubricants also do not leave any residue on molded parts, eliminating the need for cleaning before plating or other secondary processes, Axel says.

More Long-Fiber Pellets For EMI Shielding 
    The Incoshield family of long-fiber nickel concentrates for EMI/RFI shielding has been expanded to include three new masterbatches of ABS, nylon 6, and PBT. Previous grades are based on nylon 12, PC, PEI, PPS, and acrylic. Supplied by Inco SPP, Wyckoff, N.J., Incoshield concentrates contain 60% by weight nickel-coated long carbon fibers. These concentrates are dry blended with resin before being injection molded into housings for computers, electronics, and communications equipment.

FR Agent Doesn’t Get Steamed at a Little Heat 
    A new synthetic, halogen-free flame retardant gives up its water of hydration endothermically at higher temperatures than familiar alumina trihydrate. Basic Aluminum Oxalate (BAO) from Alcoa Industrial Chemicals, Bauxite, Ark., extends the processing range of aluminum-based flame retardants up to 625 F, versus around 392 F for ATH and 540 F for magnesium hydroxide. Price is about $1/lbÑmuch higher than for ATH and competitive with Mg(OH)2. 
    Like ATH, BAO has a white color, high brightness, and low toxicity. But the low soda content of BAO means less impact on electrical properties of wire and cable, Alcoa claims. BAO reportedly can provide UL 94V-0 ratings to a wide range of resins at loadings of 40-63%. Its specific gravity is 2.2. Available mean particle sizes are 0.3 to 2.7 microns.

Two shot Injection Molding

New Name in Two-Component Presses
    The first two-color injection molding machines from Toshiba Machine Co. America, Elk Grove Village, Ill., were introduced last month at the Western Plastics Exposition in Long Beach, Calif. The ISGN-2C machines range from 86 to 243 tons and support a variety of two-component processes. Currently, the machines are available only in an L-shape configuration with the secondary injector at a 90 degrees angle to the clamp. All models have wide platens except the ISGN90-2C. Closed-loop control is standard on all sizes.

Retrofit Your Press To Shoot Tiny Parts 
    The latest advance in molding parts weighing less than 1 gram is the retrofittable Nanomelt injection unit from Battenfeld of America, West Warwick, R.I. An enhancement of the company’s Micromelt injector, the Nanomelt is a two-stage unit with a 14-mm screw of a new design that drastically reduces the amount of material inventory in the barrel. The screw is mounted in line with the injection “piston,” to which the screw is directly attached. Once the material has been plasticated, it passes through the hollow centre of the tube-like piston into a small injection chamber. A ball valve at the end of the piston prevents any backflow during the injection. The shot capacity is 1.1 cc or 1 g of PS. 
    The Nano met, along with related software and enhanced-resolution linear position sensors, can be retrofitted on a standard molding machine. “It’s an economical way to get into micro-moulding,” says product manager David Tremblay.

Two-Stage Presses Arrive from Japan 
    At last month’s Western Plastics Exposition in Long Beach, Calif., Sodick Inc. of Torrance, Calif., introduced a new line of Japanese-built two-stage-injection molding machines with hydraulic clamps. These “V-Line” presses, whose angled screws feed melt into a plunger mechanism, span a range of 20 to 286 tons.

Molding Software Kit Now Has Flow Analysis 
    The Molder’s Technician software collection from Spirex Corp., Youngstown, Ohio, now includes flow simulation among its computation, reference, and decision-support tools for molders. “Spirex Mold Fill” simulates cavity flow–as opposed to spiral-flow–to predict injection times, pressures, temperatures, and shear rates. Introduced at K’98, the enhanced software has an introductory price tag of $1000.

Get Cavity-Pressure Sensors from New Source 
    Cavity-pressure transducers were recently added to the line of mold components from Hasco-Internorm Corp. West, Chatsworth, Calif. Available in a variety of sizes, these piezoelectric transducers come in standard or high-heat versions. Hasco has also developed its own cavity-pressure monitoring software for PCs.

Hot-Runner Controller Now Has Autotuning 
    The popular 9500 Series hot-runner temperature controllers from Gammaflux L.P. of Sterling, Va., have a new software enhancement that automatically checks and optimizes the PID tuning for each zone. It is intended to recognize and solve a variety of tuning problems, such as a nozzle or tip that reaches its setpoint too slowly. 
    Called TuneRite, the autotuning feature has been rolled into the company’s Mold Doctor fault-analysis program.

Hot-Runner Manifold Fits in Your Hand 
    A tiny new line of hot-runner systems has been developed by Polyshot Corp. of Henrietta, N.Y. Called the Bank System, these palm-sized manifolds (roughly 6 in. long) come in either two- or four-probe configurations with tip center spacings as small as 1 in. The Bank System’s in-line manifolds are naturally balanced, and the system has only a single zone of control. 
    The new system is about one-third as high and half as long as Polyshot’s previous in-line manifolds, which have multiple zones and are intended for applications needing tip control.

Program Sprue Pickers Faster Than Ever 
    HOP Series sprue pickers from Yushin America Inc., Cranston, R.I., feature a new hand-held controller with enhanced memory and plain-English error messages. To speed robot tooling changes, the controller has memory for 15 mold set-ups, and users can choose from dozens of pre-programmed robot motions and gripping methods. Also featured are simplified digital timers, cycle and reject counters, and a “step mode” to verify robot programs.

Upgraded Vision System Comes in Simple Version 
    New Windows NT software for mold protection and parts inspection is available from Avalon Imaging of Boulder, Colo. PlantVision Pro software works in conjunction with Avalon’s PC-based vision system, VisionScope Pro. Compared with earlier DOS versions of the software, the Windows NT version allows easier networking and enables users to engage in multiple tasks–for example, checking a troubleshooting log while running mold protection at the same time. 
    The operating system change also allows new software features. One of them, ProcessRx, archives and plays back images of the mold face before and after ejection, giving users a historical view of process upsets. 
    Avalon also introduced a new basic PC vision system for Windows NT. PlantVision Basic software and VisionScope Basic hardware are intended for less complex molds. They lack some of the functionality of the Pro products but can be scaled up to the “Pro” level later on.

Automate Toggle Tonnage & Shut-Height Control 
  Automatic shut-height and tonnage control is a new option for the HT Series of toggle presses from Van Dorn Demag Corp., Strongsville, Ohio. Available on the company’s Pathfinder 3000 and 5000 controllers, the option employs two types of transducers on the link housing: A strain gauge on the back of the housing measures deflection during clamp lock-up. From these measurements, the controller can monitor or control clamp tonnage in a closed loop. A linear transducer on the link housing indicates mold thickness and shows the clamp position needed to achieve a given tonnage at lock-up. Want to know more information about two shot mold & double injection molding, please go to

Plastics Technology

Structural Foam Goes All-Electric

What may be the first all-electric structural- foam molding machine was recently built by Milacron’s Elektron Technologies unit in Batavia, Ohio, in cooperation with structural-foam specialist Uniloy Milacron in Manchester, Mich. This development occurred because a major foam molder wanted a large all-electric machine for the sake of energy savings, oil-free operation, and noise reduction. Uniloy’s Springfield Div. always uses two-stage injection for its structural-foam machines, so Milacron adapted its Sidewinder two-stage electric injection unit to this process. This being the first foam application of a two-stage electric machine, Milacron says, Uniloy developed a new screw design, a barrel-cooling system, and gas- injection metering hardware for the Sidewinder. 

The result was a 550-ton Powerline machine that reportedly provides highly consistent foam melt with both gas injection and chemical blowing agents, as well as a wide range of shot sizes. The separate shooting pot allows use of any shot size from 100% down to 3% of machine capacity. The machine molded an electrical housing (see photo) of GE’s Noryl PPO/PS alloy with nitrogen gas. The part weighs 83 oz and has a 15% weight reduction with a typical foam/skin structure. The Sidewinder unit can be converted to standard high- pressure injection molding with a simple screw change. 

Cooling Screw Cranks Up Foam Output

A new screw design for foam extrusion is believed to be the first to use cross-flight melt channels to increase cooling and foam output. The channels perforating the curved flights scoop hot polymer off the screw root and brings it into contact with the cooled barrel. In the single-screw cooling extruder of a tandem foam line, it reportedly increases output by 25-40%. Developed and patented by Plastic Engineering Associates Inc., Boca Raton, Fla., The Turbo-Cool screw was publicly discussed for the first time at the SPE ANTEC meeting in Dallas in May, though it is already used commercially by several large producers of PS-foam sheet for clamshells and board for construction. 

Integrated Stretch-Blow Machine Is All-Electric

The upcoming K 2001 show in Dusseldorf, Germany, will see the debut of the first all-electric integrated PET injection stretch-blow molder from Automa of Italy (represented here by Automa Machine & Tool Inc., Maple Grove, Minn.). The servo-driven NSB100 system is designed to run at three times the production rate of conventional ISBM machines. For example, it reportedly can mold 16-oz bottles at 5000/hr. NSB100 will have a 5:1 ratio of injection to blowing cavities (up to 20 and four, respectively). 

Automotive TPO Goes Antistatic

Two versions of Sequel 1514, a new mar-resistant TPO from Solvay Engineered Polymers, Auburn Hills, Mich., are being used in the tailgate liner and protective moldings atop the tailgate and side rails surrounding the cargo box on the Ford Explorer Sport Trac vehicle. The liner compound is the first static-dissipative TPO to be used in an automotive role. The parts are molded by Ventra Plastics in Russellville, Ky. 

Although Ford initially specified ionomer for the moldings, Ventra foresaw processing advantages in TPOs that could cut costs. Tests by Ford and Ventra confirmed that durability of Sequel 1514 matched that of ionomer, but the TPO’s improved flow permitted downgauging from 3.5 to 3 mm, and the ionomer required longer cycles to prevent sticking in the plastic mold.

Colorants for Packaging Offer Light Protection

A new line of color concentrates for packaging of light-sensitive retort products has been developed by Ferro Corp.’s Plastics Colorants Div., Stryker, Ohio. The new Light Blocker Concentrates are said to be heat stable and to meet FDA standards for direct food contact at retort temperatures. Five light pastel shades are said to provide both uv and visible-light protection for nutrients in milk-based products. 

These concentrates are intended for use in LDPE, LLDPE, HDPE, PP injection molding, and PS bottles, injection molded containers, and thermoformed sheet. Letdown ratios are 10:1 to 50:1, depending on layer thickness and shelf life. These customizeable concentrates reportedly offer cost- saving opportunities. For example, they can permit downgauging an outer white layer over the light barrier, using a monolayer structure, or eliminating foil.