Metal Joining Technology for 21st Century Hot Runner Systems

Polyshot eNews, 9/24/07

Polyshot Corporation has developed its own in-house technology to join manifold plates for state-of-the-art hot runner construction. This technology allows Polyshot Corporation’s engineers to design manifold flow passages based on the best conditions for the part being molded without the serious limitations of gun drilling flow passages.

Manifold plate fusion completely eliminates the use of end plugs and the mismatch they cause in the material flow paths. Instead of being restricted to flow paths drilled in straight paths in prehard manifold blocks, the plate fusing process allows Polyshot to machine curved free flowing configurations into hardened H-13 manifolds.

Below is a flow path extraction from one half of a two shot hot runner manifold system which Polyshot manufactured for a Japanese automotive manufacturer. Of particular note is the area of the flow path highlighted in green. This particular geometry was created to reduce injection pressure on the center row of nozzles and is typical with Polyshot manifold construction.

Polyshot Corporation’s engineering manager, Mr. Gilbert Chan, recently had an article featured in Moldmaking Technology Magazine that goes into detail relative to this hot runner construction process. You can read it by clicking here.

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Polyshot Receives “Essential Piece” Award from RAININ Instrument LLC

Polyshot eNews, 7/04/07

Rainin Instrument, of Oakland, California, the largest developer, manufacturer and distributor of the world’s most advanced pipetting products and services has chosen to award Polyshot Corporation its “Essential Piece” award. The award was presented in person by Mr. Don Dillon, Molding Manager for Rainin, to Doug Hepler, President of Polyshot Corporation, during a recent visit.

Polyshot has partnered with Rainin to provide hot runner solutions to compliment their needs in order to produce the highest quality Pipette and Pipette Tips in the industry for the past two years. Polyshot has provided numerous Hot Runner Systems to Rainin and currently has several ongoing projects with them. Rainin operates numerous molding machines in its state-of-the-art facility in Oakland on a 24/7 basis. It has separate molding cells to test and prove out new equipment and designs for the latest technology available, and Polyshot systems routinely pass through these cells on their way to high volume production.

To learn more about Rainin Instrument and their pipetting products and services, please visit their website.

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Accede Mold & Tool, Two-Shot Mold Building Wizards

Polyshot eNews, 7/04/07

Accede Mold & Tool of Rochester, New York, recently selected Polyshot Corporation to supply them a two-shot hot runner system for a very interesting mold they completed for an high volume agricultural component. The mold was an 8+8 cavity mold (8 out), with the first shot running black polycarbonate and the second shot running white polyurethane. The hot runner used was a Polyshot 050M Valve Gate System with two fully independent manifold systems housed in one hot half system.

Of particular interest in this mold is the use of Accede Mold & Tool’s internally developed, rotating two-shot core section system. This system eliminates the need to rotate the entire ejector side of the mold in two-shot molds. The elimination of the normal rotating platen is a huge cost savings to the molder and the rotation of the core section only reduces the overall cycle time.

As shown in the image above, upon mold opening, the ejector core section advances out of the mold. Through some truly amazing engineering, with the center core extended, a stripper plate mounted to the face of the rotation core is moved forward ejecting the finished parts. The center core then rotates 180 degrees, the mold closes and the cycle repeats itself.

A visit to Accede’s internal two-shot testing facility to witness this truly impressive chain of events is a trip worth making. Contact Mr. Roger Fox at Accede Mold & Tool for further information and to set up a tour.

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Polyshot Thinshot Hot Runner System

Polyshot eNews, 3/10/07

Polyshot has had great success with its new Thinshot Hot Runner System. This system has been used in molds where a close center to center nozzle distance is required and excellent throughput is required. The Thinshot nozzle is available in valve gate and pinpoint configurations, accommodating between 2-128 nozzles per system. As with all Polyshot hot runner systems, metal fusion technology is employed in the manifold construction to create internal material flow paths without the use of turn plugs.

The Thinshot nozzles can be arrayed with distances as small as .500" from nozzle to nozzle (in a row, between rows) which makes them very useful in molds where a common slide is required to pull many cavities in a mold making relatively small parts (.5 to 25 grams per nozzle). Additional versions of the Thinshot system are currently in development that will allow closer center to center distances for even smaller molded part applications.

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Thinshot at MGS Mfg. Group

Polyshot eNews, 3/10/07

Among recent installations of the Thinshot systems one application stands out. Polyshot recently constructed a 32 Thinshot valve gate system (2 rows of 16 nozzles) for a consumer application that was ordered from MGS Mfg. Group in Germantown, WI.

This vertically molded application includes an overmold of a pre-stamped, .0015" thick stainless steel strip that is fed into the mold in a "reel to reel" fashion. The mold clamps over the strip and the material (K-resin) is injected through the Polyshot hot runner system, into .037" diameter valve gates and finally the 32 individual mold cavities. The strip is supported in the mold cavity by 14 strategically placed core pins. The fill pressure is critical to this particular application as the wall thickness of the overmolded material is as thin as .021".

The hot runner system also features a dual rack actuated valve gate mechanism, which is hydraulically driven with a single cylinder off to the side of the hot half system. This system was needed because of molding machine shut height limitations that required the valve pin actuation to be extremely thin.

MGS Mfg. Group is no stranger to challenging applications. With several divisions that include: Moldmakers Incorporated, TecStar Mfg. Company and Statistical Plastics Corporation, MGS Group is a big operation that has a reputation of being able to deliver on complex turn key projects with a specialty in multi material molding and equipment.

Of particular note is the Universal Multishot Systems (UMS) Portable Injection Unit/UMS Rotary Platen Unit MGS manufactures, that allows a conventional molding machine to be converted into a multimaterial machine. MGS also supplies complete automation services and equipment to complement its line of molding machinery.

Polyshot has had past experience running its hot runner systems on machines fitted with the UMS system and is particularly impressed with its ability to easily interface through the existing machine's RS232 port. The multimaterial injection unit bolts to the machine (typically the top) in about an hour, gets plugged in to the RS232 and is ready to go.

For information about the MGS Group, contact Mr. John Berg, Director of Marketing at john.berg@mgstech.com.

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The Polyshot P-050M Pinpoint Hot Runner System

Polyshot eNews, 9/17/06

Polyshot has manufactured a 32-nozzle Polyshot P-050M Pinpoint Hot Runner System. This system produces a very high precision polypropylene part to be used in the consumer industry.

The 050M has been the system of choice for many molders over the last eight years. It features Polyshot’s at-the-gate temperature nozzle sensing and Polyshot plate fusion technology to allow a fully balanced system with no hold up areas.

Featured Mold Design

Tech Tool & Mold, Inc. (website) recently partnered with Mr. Terry Fox (e-mail) of PD² for the mold design. The mold was built and is currently producing parts at Tech Tool & Mold, Inc. The mold features a multi-plate strip feature to release a set of undercuts in each cavity. It runs trouble free at a five-second cycle producing parts at the rate of over 500,000 parts per 24-hour period.

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Tech Tool & Mold: Staying Focused

Poyshot eNews, 9/17/06

While a number of mold shops start with humble beginnings, what makes each one different is how it evolves over the years. Tech Tool & Mold (Meadville, PA) is no exception. Founded in 1973 by William and Eva Hanaway as a precision tooling and heat treating shop, Tech Tool & Die started out as a small family business that slowly evolved into Tech Tool & Mold, Inc. in the late seventies as more complete plastic injection molds were being designed and built. In 1980, Tech Molded Plastics was formed to provide full-service, short- and long-run injection molded plastics production including integrated assembly and packaging.

In 1990, the role of President was assumed by Scott Hanaway. Scott shared his parents’ love of precision machining, product innovation and community involvement. Scott’s vision and motivation soon placed the company on the cutting edge of technology and training.

Through the years, Tech has grown from occupying rental space in a small garage to a $54,000-square-foot facility containing the latest in equipment and a highly skilled workforce of approximately 92 employees. Today the organization includes two award-winning, world-class manufacturing companies—Tech Tool & Mold, Inc. and Tech Molded Plastics LP—providing full-service contract manufacturing to industries that require highly complex, precision components.

Read the entire Moldmaking Technology article by Sherry L. Baranek.

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New Manifold Joining Technology from Polyshot Provides Hot Runners with Better Color Change and Multimaterial Technologies

Article, 9/6/06

Polyshot, Inc. has announced it is using a new plate fusion technology, developed in-house, to join the multiple plates of its hot runner manifolds. This technology provides numerous benefits for hot runner users, including smoother flow paths, excellent color change capabilities, and better performance in multi-material molds.

W. HENRIETTA, NY -- Polyshot, Inc. has announced it is using a new plate fusion technology, developed in-house, to join the multiple plates of its hot runner manifolds. This technology provides numerous benefits for hot runner users, including smoother flow paths, excellent color change capabilities, and better performance in multi-material molds.

"We have worked for the past three years perfecting this process, and now use it on all of our hot runner manifold systems," said Doug Hepler, President of Polyshot. "All of the technology was developed in-house. We feel it provides our customers with some significant advantages."

Smooth flow channels in any hot runner system are important to ensure the molten plastic is delivered to the mold with no "hang-up" areas, where small amounts of material can get caught. When this happens, the material will degrade and cause black specks to appear in the finished parts. Flushing out the manifold will only provide temporary relief of the problem.

Polyshot's new approach involves machining the flow channels into the manifold plates, then joining the plates using their new proprietary fusion technology. With this new technology, Polyshot can join up to four plates at a time. The technology allows Polyshot to design and produce systems with gradual turns in the flow channel, and even provide different flow path diameters (starting off with a small channel, enlarging it, then going back to a smaller diameter, for instance).

"This technology has proven very beneficial in the construction of multi-material (2-shot) hot runner manifolds, where flow paths often need to be different diameters," said Hepler.

Other benefits of this new technology include:

• no "turn plugs" are required, which are difficult to install without some mismatch between the plug and the manifold flow path;
• no secondary "honing" of the flow path is required;
• all Polyshot manifolds are constructed out of hardened and ground tool steel

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Polyshot Introduces New Retrofittable Single Nozzle Valve Gate

New Product Release, 7/5/05

Polyshot, Inc. has introduced a new single-nozzle valve gate for single-cavity mold applications where zero vestige and cosmetic part surfaces are essential.  This new product is suitable for processing both filled and unfilled engineering resins. 

The new MS75SNVG Polyshot single-nozzle valve gate is designed to be retrofittable to existing molds. Because the piston assembly is internal to the nozzle, no thickness changes are required to the top clamp plate of the mold. In addition, like Polyshot’s manifold-mounted valve gate hot runner systems, the nozzle features a cylindrical valve pin shut off design, which leaves a minimal gate vestige on the part surface that resembles an ejector pin mark. This unique design is also beneficial to the moldmaker and processor as it eliminates the need to fit a tapered shut off pin. 

The MS75SNVG nozzles are pneumatically operated. Air is fed into the nozzle piston through lines that run through the top clamp plate into the nozzle. Two heat zones on the nozzle ensure excellent temperature uniformity, which is critical to finished part quality.  Polyshot’s patented low-profile tapered heater is used on the nozzle body, and the top of the assembly is heated by an easily-accessible external heater band. 

A four-component stacked assembly features an independent valve cylinder and piston for each hot runner nozzle. The cylinders can be operated with either pneumatics or hydraulics.  Access lines are fed through holes in the top clamp plate, reducing the need for hoses. 

Further designed for ease of operation, the nozzle features stacked construction for easy access to the piston assembly. The piston is designed with a custom profile that allows material feed and assembly screws to pass in the area that is normally required for piston movement. This allows the outside of the nozzle to fit easily within a 4" locating ring diameter. In addition, no "O" rings are required on the valve gate pin piston. Polyshot’s unique construction has eliminated the need for them, resulting in a very low maintenance product.

For complete information on the new single nozzle valve gate product, or the entire line of Polyshot hot runner systems, contact:

Polyshot, Inc.
75 Lucius Gordon Drive
W. Henrietta, NY 14586-9682
USA

Tel. (585) 292-5010, or toll-free (800) POLYSHOT (765-9746)
FAX (585) 292-5015
E-mail:  info@polyshot.com

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Valve Gate Hot Runner Systems

PM&A Infolink 145

June 2005

A new line of valve-gate hot runner systems was designed for applications where zero vestige and cosmetic part surfaces are essential. These systems are suitable for processing both filled and unfilled engineering resins. The MS75VG Polyshot valve-gate system has a cylindrical valve-pin shutoff design, which leaves a minimal gate vestige on the part surface that resembles an ejector pin mark. This unique design is also beneficial to the moldmaker and processor as it eliminates the need to fit a tapered shutoff pin.

A four-component stacked assembly features an independent valve cylinder and piston for each hot runner nozzle. The cylinders can be operated with either pneumatics or hydraulics. Access lines are fed through holes in the top clamp plate, reducing the need for hoses.

The hot runner systems are available in configurations from 1 to 96 nozzles, with a variety of manifold shapes. All systems are preassembled and heat tested before shipment and are available with or without a complete hot-half assembly.

In addition, Polyshot has a pneumatic valve-gate sequencer for use with pneumatic valve-gate systems. These feature an easy-to-use touch-panel operator interface. Graphical representations and instructions are printed directly on the sequencer cabinet to assist the operator with all connections and timer settings.

Polyshot, Inc., W. Henrietta, NY

585 292-5010

www.polyshot.com

PM&A Infolink 145

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A Polyshot Solution for Advanced Cable Ties!

Advanced Cable Ties, of Gardner, Massachusetts, was having a problem with heated Sprue bushings on an extremely high volume cable tie application.

Dick McGrath of Plastixs LLC, Polyshot's representative in the New England area, was contacted by Mr. David Hewes, the A.C.T. Tooling Engineer, regarding the problem.

A.C.T. was using a heat pipe style bushing. There were two basic problems with their heated Sprue bushing: (1) there was a string being formed during mold opening (due to down stream automation that is required to degate and pack the tie wraps, stringing is of particular concern as it literally can tear bearings apart), and (2) a delay in the cycle for any significant period of time caused the bushing to freeze off and a heated rod would need to be used to unfreeze the heated Sprue bushing.

Polyshot made an on-site visit to see the mold run and offer an alternative. An evaluation was submitted for a P-100-C Heated Sprue Bushing with a #3600F Firebox Temperature Controller. Along with the bushing, Polyshot also furnished several replacement bushing gate inserts that allowed A.C.T. to sample the mold with different gate diameters.

After receiving the new bushing, A.C.T. quickly settled on a gate diameter that allowed them to run production with an acceptable quality of part. Another real benefit was the ability to stop the molding cycle for as long as required by simply closing the gate and starting to mold again. Because of the effective design of all Polyshot nozzles, they are highly resistant to gate freeze-offs.

A.C.T. rewarded Polyshot with four additional orders to replace more bushings.

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Polyshot Introduces New Line of Valve Gate Hot Runner Systems

New Product Release, 3/23/05

Polyshot, Inc. has introduced a new line of valve gate hot runner systems for applications where zero vestige and cosmetic part surfaces are essential. These systems are suitable for processing both filled and unfilled engineering resins. 

The new MS75VG Polyshot valve gate system features a cylindrical valve pin shut off design, which leaves a minimal gate vestige on the part surface that resembles an ejector pin mark. This unique design is also beneficial to the moldmaker and processor as it eliminates the need to fit a tapered shut off pin. 

A four-component stacked assembly features an independent valve cylinder and piston for each hot runner nozzle. The cylinders can be operated with either pneumatics or hydraulics. Access lines are fed through holes in the top clamp plate, reducing the need for hoses. 

Polyshot valve gate hot runner systems are available in configurations from 1 to 96 nozzles, with a variety of manifold shapes. All systems are pre-assembled and heat tested before shipment to the customer, and are available with or without a complete hot-half assembly. 

In addition, Polyshot also offers a pneumatic valve gate sequencer for use with pneumatic valve gate systems. These feature an easy to use touch panel operator interface.  Graphical representations and instructions are printed directly on the sequencer cabinet to assist the operator with all connections and timer settings.

For complete information on Polyshot hot runner systems, contact:

Polyshot, Inc.
75 Lucius Gordon Drive
W. Henrietta, NY 14586-9682
USA

Tel. (585) 292-5010, or toll-free (800) POLYSHOT (765-9746)
FAX (585) 292-5015
E-mail:  info@polyshot.com

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New Injection Molded Wire Retainers

New Product Release, 12/04

Polyshot has eliminated the use of metallic wire retainers on its Hot Half Assemblies. A new retaining clip was designed and tested using finale element analysis. The new wire clip is molded out of glass filled Ryton R4 and is hot runner gated using a Polyshot P-100 Series Heated Sprue Bushing.

The new wire retainer allows more room for manifold wiring without increasing the thickness of the manifold support plate. Because of its design using radii on all areas that make contact with system wiring, wire chafing is eliminated.

The new Polyshot wire retainers prominently sport the Polyshot logo. Look for your new retainers the next time you remove the top clamp plate on your next Polyshot Hot Runner System!

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New Ceramic Heater Termination Assemblies

New Product Release, 12/04

Polyshot has developed its own ceramic heater termination assemblies that significantly improves the reliability of its manifold heaters. The new assembly uses a high temperature ring terminal crimped to the heater wire. This ring terminal(s) is sandwiched between two jam nuts threaded onto the heater lug. This assembly is then covered by a ceramic cover and retained by a ceramic nut.

This benefits of this new assembly are an improved electrical connection between the wire and the heater and the exit of the wires 90 degrees from the heater axis. Having the wires exit at 90 degrees to the heater avoids bending the wires at a sharp angle and reducing the distance from the end of the heater and the manifold pocket.

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New Miniature Manifold System

New Product Release, 11/04

Polyshot has developed a new line of very small manifolds called Micro Manifolds. They are available in 4 to 32 probe configurations and operate on one zone of control.

The Micro Manifold features vacuum brazed, hardened tool steel construction. The use of Polyshot layered vacuum brazing technology, allows the construction a naturally balanced manifold with smooth curves that flow from layer to layer and to each probe.

One of the first applications was the use of a 32 probe Micro manifold for the production of a polypropylene insulator used in used in the cable TV industry. This mold fits in a 84/90 MUD frame and is currently producing over 276,000 parts per 24 hour period.

The Micro Manifold features field replaceable probes, heaters and thermocouple and are made to customer specifications in as little as 4 weeks. A 16 probe system measures 2.875" wide x 3.500" long.

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A Great Job On the GS34!

Satisfied Customer, 10/04

ITW Tomco

We have successfully shipped our first 6,000 sets of GS34 window lift housings on time.  It took less than 32 weeks from the date that we were kicked off until we made our first production shipment.  This is quite an accomplishment when you consider:

- This part has over 500 dimensions called out on the drawing.

- This is a new resin and new Supplier.

- We had to establish non uniform shrink targets based on a new part configuration, new resin and different hot runner system.

- We had to utilize some new measurement methods.

- The inserts are new.

- We had to obtain a new press.

- We had to have designed and built new automation.

- We are loading 16 inserts in to a horizontal tool.

- We had to move 2 presses to make room for the new press.

- We had to be able to switch back and forth between a 2 cavity and 4 cavity set-up.

- Etc.

As a bench mark, the 1st window lift housing tool that we developed took over 2 years before we made our first production shipment and that required nearly 50% of the dimensions to be deviated.

It clearly takes a great Team with everyone working towards the same goal, and willingly making personal sacrifices, in order to accomplish what we have accomplished.  I want to give special recognition to the following:

Steve Balbaugh, Tommy Wagner, Brian Schuman, Jennifer Wyman, Jeannie Trisel, Bill Shoemaker, Todd Noble, David Helbert, Tony Kunkle, Renea Brown, Mike Walter, Joe Shepard, Gary Handshoe, Karena Woods, Paula Murley, Tom Buck, Cindy Abbott, Scott Davis, Tracy Dalton, Deb Stark, Tom Mack, Marsha Clark, Bob Wisler, Accutech (David Geiger), Conair, Polyshot, and Toray

Thank you very much for an exceptional job,
Joe

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The Mold Junction Box

New Product Release, 08/04

The Polyshot 12 Mold Junction Box (PT# PCT12SBS) features:

• 12 prewired zones.
• Manifold heater and thermocouple wires are attached directly to the
  numbered terminal strips. The top strip is for power and the bottom for
  thermocouple.
• Massive construction...5.5 lbs in weight. Steel construction with
  .093" wall thickness. Much more resistant to damage than competing
  designs.

The Access panel is clearly marked and easily removed with 4 screws. All wiring
is done from one side of the box (which is mounted opposite from the
molding machine platen). There are no more problems with having to remove the box
from the mold to get at a terminal strip.

The Power and Thermocouple connections are clearly marked on both sides of
the box so there is no chance of plugging the wrong cable into the box.

Powder coated paint with epoxy baked graphics are used and will keep
the boxes looking good for a long time.

The new Mold Junction Boxes are currently in stock and will be installed on
all Polyshot manifolds that use a side-by-side configurations at no
additional cost. A front-to-back configuration version of the box will
be available fourth quarter of 2004.

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The Polyshot Pneumatic Valve Gate Sequencer

New Product Release, 05/04

General Overview: The Polyshot Pneumatic Valve Gate Sequencer features an easy to use touch panel operator interface. Graphical representations and instructions are printed directly on the Sequencer cabinet, assisting the operator with all connections and timer settings.

A rugged, sealed aluminum enclosure houses the internal valves and circuitry protecting it from the molding environment.

Large 3/8 NPT connections allow excellent air volume to and from the valve gate.

Key Features:

• Easy to understand touch pad entry panel with operating instructions printed directly on the side of the unit.
• Large 3/8” NPT ports for air supply, exhaust, piston forward and piston back. All ports are clearly labeled.
• Illuminated on/off front mounted power switch.
• Rear mounted fuse with fuse type/size printed on the controller.
• Air supply pressure gauge.
• Housing is constructed of an extruded aluminum with aluminum end panels.
• Cycle Start connection receptacle with printed circuit schematic on rear of unit.

Voltage Required: 120VAC Single Phase

Line Pressure: 120PSI

Line Size: 3/8”NPT

Dimensions: 6”High x 6.6” Wide x 10” Long

Shipping Weight: 12 Lbs.

The Polyshot Pneumatic Sequencer is manufactured by Polyshot Corporation in the USA and has a sale price of $1,995.

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Keeping Up with Tooling

QMC Hot-Runner System for Tiny Electric Press, 04/02

A turnkey, quick-change hot-runner mold system has been designed by Polyshot Corp., West Henrietta, N.Y., specifically for the tabletop HM7 injection press from Nissei America Inc., Anaheim, Calif. The HM7 is a 7-ton all-electric machine. The Polyshot mold system bolts directly onto the machine platens with no modifications required.

The section mounting on the fixed platen contains a Polyshot Multitip hot-runner system for direct part injection. It operates one zone of control, and has a tip-to-tip center distance of 0.75 in. The assembly has mounting holes and guide pins that allow interchangeable cavity inserts to be bolted on. The movable half contains an ejector housing and allows interchange of cavity inserts. A special feature automatically connects the waterline circuits in the mold cavities upon installation.
Polyshot Corp.: (585) 292-5010, www.polyshot.com. Nissei: (585) 693-3000.

Polyshot
75 Lucius Gordon Dr.
W. Henrietta, NY 14586-9682
Phone (800) 765-9746, Fax (585) 359-8849

Serving the Plastics industry since 1955.
Plastics Technology and all contents are property of Gardner Publications, Inc.
All Rights Reserved.

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A Big Closure Molder's Thinking Small

By: Carl Kirkland

IMM recently ran an article about a rather unusual new tooling product from Polyshot Corp. (West Henrietta, NY)—a little hot runner mold designed for a 7-ton tabletop molding press (see "Hot Runner Micromolding," May 2002 IMM, p. 58). You might have wondered who would have commissioned such an unusual little product, and why. We did, too.

As it turns out, it was originally designed for Caplugs, one of the largest U.S. suppliers of molded closures. Privately held with $34 million in sales and ISO 9001/QS 9000/AS 9000 certified, Caplugs has been a major player in the protection products market since 1948.

Says Mark Sporysz, design engineer, "We mold more than a billion parts a year for 20,000 customers. We have more than 165 million parts ready to ship every day. For us, run sizes range from 5,000 to more than 5 million."

The demand for the 5 million parts Caplugs runs on its new 7-tonner, a model HM7 from Nissei America Inc. (Anaheim, CA), certainly fits the bill. They are tiny LDPE bearing retainer plugs for rocker arms with no room on them for a gate vestige. They have a ±.002-inch OD tolerance specification, but the company is molding to within ±.0005-inch. Caplugs runs them in the eight-cavity Polyshot runnerless mold for one of its customers.

The molder had never run such a small machine before, never mind one running such an unusual mold. But when Caplugs makes a commitment to a customer, it keeps it.

A Helping Hand

It may have never run such a small press before, but Caplugs knows how to mold. It has 64 molding machines up to 400 tons. Caplugs builds its own molds, too. It has about 3,000 injection tools. But the bearing project was different from anything Caplugs had ever encountered, according to Sporysz.

"Most machines are over capacity for this kind of part," he explains. "Their barrels are not set up for parts this size. That's why we went with the HM7. Our sister company is Mokon (Buffalo, NY). We put a 1-ton Mokon thermolator on the HM7. Think Mokon gave us a special deal? No way."

Sporysz says the hot runner system and the HM7 have been running flawlessly so far. Time for the next job on it has already been booked.

Contact Information
Caplugs Div.
Protective Closures LLC
Buffalo, NY
Mark Sporysz
(716) 876-9855, ext. 274

IMM-September 2002

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Parting Shots: The Way to a Toolmaker's Heart

By: Carl Kirkland

Only a precious few employees have ever left Polyshot since it opened for business 13 years ago. The last person left to work in a Christian ministry.

In addition to being blessed with a near-zero employee turnover rate, Polyshot has enjoyed a good rate of growth. In fact, this hot runner systems manufacturer recently grew itself into a brand new 13,000-square-foot facility in West Henrietta, a suburb of Rochester, NY.

Doug Hepler, president, says he spent about 10 percent more on interior decoration than what he could have. But he says the extra initial outlay is insignificant when compared to the morale dividend.

Polyshot is a place where people enjoy coming to work. Everyone feels comfortable sharing their creativity. And they have all the tools they need to get the job done right. A good working environment helps Hepler keep good people on board, people who help Polyshot sustain its good growth.

The offices are elegantly appointed. Skylights are everywhere. The spacious, temperature-controlled shop floor has windows instead of walls and is equipped with leading-edge manufacturing systems. But if any one thing in Polyshot's new HG best expresses Hepler's master plan, it's the company cafeteria.

A retro design harkening back to a 1950s-vintage malt shop, or an all-American diner, it's the kind of place where everyone at Polyshot, including customers, can have fun while taking a break. In a word, Daddy-o, it's cool.

Polyshot
West Henrietta, NY
(585) 292-5010

Submissions to Parting Shots are welcome. If you have a favorite sign, saying, quote, or part that is used in this section, we'll send you a check for $25. For our What Is It? series, be sure to identify the part, material, manufacturer, and function. We're also looking for stories about molding ingenuity. Send your submission ideas to Arnie Chitwood, managing editor, fax (303) 321-3552, or email architwood@immnet.com.

IMM-June 2002

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Polyshot Building New Plant

By Bill Bregar, Plastics News Staff

Construction will begin in May on Polyshot Corporation's headquarters plant in Henrietta, N.Y., at a business park next to the Rochester Institute of Technology.

When the new building is completed this fall, the manufacturer of hot runners will move from its 5,500-square-foot plant a few miles away. President Douglas Hepler said the building in RIT's business and technology park will total 13,000 square feet—10,000 square feet for manufacturing and 3,000 square feet of office and engineering space.

In the next two years, Hepler plans to begin another expansion at the 5-acre site that will expand the building to 43,000 square feet.

Founded by Hepler in 1989, Polyshot now employs 17. Rapid growth means Polyshot is adding employees—and hepler said access to skilled engineers from RIT is the main draw for locating the headquarters at the 40-acre industrial park.

"They’re looking for companies to place co-op students, and we have a need for co-op students," Hepler said.

Polyshot began with two employees in a tiny office. The company has expanded twice since then into leased facilities, moving into its current headquarters in 1994.

Hepler said Polyshot runs three computer numerically controlled milling centers to cut metal parts, such as hot-runner manifolds and probes. With the expansion, the company will buy more equipment, including a mill with a shuttle table that will allow the continuous machining of manifolds.

Hepler said Polyshot’s investment will be more than $1 million, but he declined to be more specific.

In other news, Polyshot has started making a new carbide hot-runner probe for molding abrasive materials such as glass- and mineral-filled resins. Hepler said the probe’s construction is unique because the entire flow path and tip are machined from a blank of solid carbide.

Competitors, he said, insert a carbide tip at the end of a probe, but the tip can become dislodged.

Polyshot covers the carbide probe with a sleeve of beryllium copper. The beryllium conducts heat to the tip of the hot runner, but it never comes into direct contact with the abrasive resin, according to the company.

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