This year, the world’s leading trade show K has succeeded in presenting practical solutions for greater resource efficiency on a broad front. A first foray through the trade show grounds.

K 2022 gave numerous practical examples showing visitors how recyclates can be reliably processed with digital aids.

16:9

State-of-the-Art Injection Molding Solutions for Greater Resource Efficiency.

State-of-the-Art Injection Molding Solutions at K 2022

Spritzgießen

Kunststoffverarbeitung: Verfahren

Doriat, Clemens, Dr.

Solar / PV

Energieerzeugung

Erneuerbare Energie

Schaumspritzgießen

Temperiertechnik

Messe K-Kunststoffmesse

kunststoffe-international.com

Mehrkomponenten-Spritzgießen

Condition Monitoring / Prozessüberwachung

Instandhaltung

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Biokunststoffe

Kunststoff Werkstoffe

Handling, Handhabungstechnik

Automatisierungstechnik

Elastomer-Spritzgießen

Oberflächentechnik

Energieeffizienz

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Digitalisierung

Spritzgießmaschinen

Kunststoff-Rezyklat

Silikonkautschuk

Kautschuk / Elastomere

Kreislaufwirtschaft

Compoundieren

Kunststoff-Aufbereitung

It Can Be Done!

Direct recycling of cured thermosets as fillers in the injection molding process increases resource efficiency due to material recycling.

Recycling of sprue loss through shredding, blending with virgin material and direct recycling.

Direct Recycling of Cured Thermosets as Fillers in the Injection Molding Process

Nachhaltigkeit

Umweltmanagement

Duroplast-Spritzgießen

Duroplaste

KFZ-Zulieferer

Dienstleistungen

Sprue Recycling Conserves Resources

The transfer of foam injection molding from thermoplastic to thermoset processing has not yet been implemented in industrial practice. IKV Aachen has investigated this transfer and has precisely analyzed the economic efficiency of the process and the potential for lightweight construction.

Foamed thermosets can be used to produce low-density thermally resistant components at low cost

The Qualification of Suitable Foam Injection Molding Processes Enables the Use of Thermosets in Lightweight Construction Applications

Excellent Resistance at Reduced Weight

Thermosets are being increasingly used for packaging electronic devices, and offer good properties for this application. Direct overmolding of the components is particularly interesting here. However, achieving a successful product requires striking a balance between processability, thermal conductivity and reproducibility.

In direct packaging,  the electronic devices or components are directly overmolded with the molding compound 

Thermoset Injection Molding of Packages for Electronic Devices

Elektronik

Kunststoff

Bauwesen

Baustoffe

Duroplastische Werkstoffe

Direct Packaging of Components

In a research project being carried out by the IKV and KTP, the influence of geometric and process parameters on the quality of the screw connection in the direct assembly of thermosetting plastics has been analyzed. The research results show that, in addition to the geometric design, the production parameters offer additional optimization potential for the reliability of the screw connection. The compactness and curing degree of the parts exert the largest influence.

Encapsulation protects the sensitive sensor technology from external influences. The direct screw connection enables secure mounting of the module.

Higher Process Quality through Adjustment of the Production Parameters

Verbindungstechnik

Schraubtechnik

Verbindungstechnik Verfahren

Achieving a More Secure Connection with the Correct Design

Car windows can be framed more economically and more securely with a novel thermoplastic elastomer based on styrene block copolymers (TPS), as opposed to rubber seals. Advantageously, the typically low viscosity of TPS leads to reduced glass breakage and allows thinner glass to be used. 

Novel Thermoplastic Elastomer with Good Flow Behavior and High Surface Finish 

Messgeräte für Viskosität

Oberflächenveredelung

Flexible Auto-Glass Framing 

Engel Austria GmbH, Schwertberg, Austria has developed a new injection moulding machine for the processing of all common rubber compounds and other elastomer materials. The new Engel flexseal 300 T horizontal machine with a clamping force of 3,000 kN has been designed specifically for the needs of international O-ring and flat gasket manufacturers and sets new standards for the industry with its features. 

Injection Molding Machine for O-Rings and Flat Gaskets 

Flexseal 300 T 

At the Deutsche Kautschuk-Tagung DKT 2015 in Nuremberg, Germany from June 29th to July 2nd, Arburg GmbH + Co KG, Lossburg, Germany, presented a compact manufacturing cell for removal suction cups with a threaded brass insert. The system is centered around a vertical injection molding machine (type: Allrounder 275 V) fitted with an elastomer processing package. 

Insert Molding with EPDM 

Inserttechnik

Automated Elastomer Processing 

The lighting industry is going through a technological change – from light bulb via energy saving lamp to the light emitting diode (LED). Especially for high-power LED the limit of the optical materials is reached, which affects the durability significantly. Transparent liquid silicone rubber offers a promising alternative because of its good thermal properties and high UV-stability.  

LED-Lenses Made of Liquid Silicone Rubber for Light Applications in the Automobile 

Optik

Kunststoffe

Silicone in Automotive Headlights 

Industry 4.0, lightweight construction, and combined technology – that is how one could summarize the current trends and challenges that have been the subject of countless injection molding developments during the past years. In their advance releases for the K exhibition, exhibitors clearly indicate that they are continuing along these lines. 

Injection Molding between Industry 4.0, Lightweight Construction, and Combined Technologies 

Verbundwerkstoffe / Werkstoffverbunde

Spritzgieß-Sonderverfahren

Spritzprägen

Folientechnik (IMD, IML, FIM, u.a.)

Hybridtechnik

Reinraumsysteme / -technik

Trip to a Known Destination 

Despite the proven superiority of high-tech rubber injection molding machine models, robust lean-tech alternatives still have a large body of support, even though the available methods for increasing rubber plastication performance have already been successfully used for over ten years. This is demonstrated with a practical report at the North-German rubber and silicone processor Präzisa in Ratekau near Lübeck. 

The Rubber Injection Molding Machine Manufacturer LWB Steinl Is Staging a Sporty Comparison between Two Injection Molding Concepts 

Steuern, Regeln

Manufacturing Quality Parts Faster 

The announcements in the field of injection molding give the impression that the developments of recent years are continuing. These include the increasing digitalization of injection molding production, as well as highly integrated production cells that combine very different competencies. The spotlight shines not only on the machinery, but rather on optimum system solutions for integrating molds and individually configured peripheries in the digital and the real world. 

Fakuma 2018: Injection Molding Networked and Integrated 

Steuerungen (Hardware und Software)

ERP-Systeme

Treibmittel

The Communicative Machine 

The Dow Chemical Company (Dow), Midland, USA, has expanded its elastomer technology platforms and capabilities, including a  range of Silastic silicone and fluorosilicone rubber technologies. For example the Silastic LTC 9400 Liquid Silicone Rubber (LSR) product line is a low-temperature-cure (LTC) LSR solution that enables short cure times at low temperatures and features processing benefits including improved rheology for fast low-pressure injection. According to the manufacturer, that creates new opportunities for part design by enabling overmolding of low-melting-point thermoplastics, actives and electrical components. These LSRs also increase robustness by reducing sensitivity to temperature gradients. 

Low-Temperature-Cure Silicone  

Silikone

Extended Elastomer Product Line from Dow 

The integration of individual parts to a multifunctional assembly is one of the important innovation potentials of plastic injection molding, e. g. the production of glass window modules for car rear doors, as practiced at Henniges Automotive. They consist of the glass pane, a web strip, and fastening clips, which are overmolded by a TPE frame to a ready-to-install assembly. For the manufacturing the automotive supplier relies on vertical C-frame injection molding machines from LWB Steinl. 

Assembly of Higher Integrated Car Window Modules through Injection Molding 

Montage-Spritzgießen

From the Vertical Machine into the  Car Door 

LSR optics offers a wide range of applications due to the optical brilliance, the possibility to produce undercut shapes not to mention the competitive pricing. The adhesive surface which is almost impossible to clean however makes the LSR parts vulnerable against contaminations. This characteristic however limits the possible application fields. To overcome this limitation Wilhelm Weber has partnered with Fraunhofer IFAM in a recent research project.

Half of the board was treated with VUV while the other half has covered. Afterwards norm dust was applied onto the board uniformly and than knocked off (once) in upright position. The dust sticks to the untreated areas while falls of the treated areas

Surface Modification of LSR Components Hinders Adhesion of Dirt

LED / OLED-Systeme und Faseroptik

Lichttechnik

No Chance for Dust and Contaminations

Ceresana Report on the European Market for Plastic Injection Molding

Last year, nearly 12.9 million t of plastics were processed in Europe using injection molding.

The market research institute Ceresana has studied the European market for injection-molded plastics: last year, nearly 12.9 million t of plastics were processed in Europe using this method.

“3D printing may be faster and does not require expensive molds,” says Oliver Kutsch, Ceresana’s managing director: “But injection molding is still unbeatable when it comes to cost-effectively producing plastic products of virtually any size or shape in huge quantities.”

From raw material directly to finished part: injection molding is one of the most important processes in the plastics industry.

Melting a plastic granulate and injecting it into a hollow mold under high pressure is best done with thermoplastics and thermoplastic elastomers. However, more and more bioplastics are being used in this process. The most important type of plastic for injection molding is polypropylene (PP): Ceresana expects demand for products made from polypropylene to grow by an average of 1.5% per year over the next ten years. Polyethylene-HDPE follows in second place with a market share of around 17%. The current study also analyzes the market for polyethylene-LDPE and LLDPE, polyamide (PA), acrylonitrile butadiene styrene (ABS), polystyrene (PS), polycarbonate (PC) and other types of plastic. There are major differences in the various areas of application: In the packaging sector, for example, polypropylene accounts for around 71% of demand, while it only accounts for 16% in the construction sector.

Mass Produced Products for All Areas of Life

Dashboards and children’s toys, medical syringes and electric switches, toothbrushes and glass-fiber-reinforced aircraft parts: injection-molded plastic products are part of our everyday lives. The most important sales market, with a volume of around 4.5 million tonnes, is the packaging industry, which uses them primarily to protect food products: Containers, cans, trays, boxes and closures of all kinds. Inscriptions and labels can be integrated directly into ice cream cups or other plastic parts using in-mold labeling (IML). Printed films are inserted into the injection mold and then fuse seamlessly with the injected liquid plastic. Keyboards for cell phones and computers are also produced in this way. However, the second largest application area for plastic injection molding is products for the automotive industry. Ceresana expects Europe-wide demand in this sector to increase by 2.1% per year until 2031.

Current Market Analysis on Plastic Injection Molding

Chapter 1 provides a description of the European market for plastics in injection molding – including forecasts up to 2031. Demand and revenues are presented for the countries in Western and Eastern Europe.

Demand for the individual types of plastics is also discussed:

<ul><li> Polypropylene (PP)</li><li>Polyethylene (LDPE/LLDPE)</li><li>Polyethylene (HDPE)</li><li>Polyamide (PA)</li><li>Acrylonitrile-butadiene-styrene (ABS)</li><li>Polystyrene (PS)</li><li>Polycarbonate (PC)</li><li>Other plastic types</li></ul>

The following areas of application for injection-molded plastics are examined:

<ul><li> Packaging</li><li>Construction</li><li>Transportation</li><li>Electrical and electronics</li><li>Industrial products</li><li>Other applications</li></ul>

Chapter 2 provides country-specific market data for 22 European countries, i.e. demand and revenues. Demand is analyzed in detail for various application areas and individual product types.

Chapter 3 provides a useful directory of the 80 most important European companies in the field of plastic injection molding. It is clearly structured according to contact details, revenues, profit, product range, production sites and brief profile. The companies presented include Amcor Limited, Aptargroup Holding GmbH, Bemis Manufacturing Company, Bericap, Berry Global, Inc., ElringKlinger Kunststofftechnik GmbH, Essentra plc, Magna International, Inc., Mauser Group B.V., Röchling SE & Co. KG, and Silgan Holdings Inc.

Further information about the new market study “<a href="https://www.ceresana.com/en/market-studies/industry/plastic-injection-europe/ " target="_blank">Plastic Injection – Europe</a>”.

Ceresana  

https://www.ceresana.com

Ceresana has studied the European market for injection-molded plastics.