Arburg Plastic Freeforming is predestined for the additive manufacturing of medtech components. The associated Freeformer-type additive manufacturing systems process the same plastic pellets that are used in injection molding. That makes the open systems very economical to use.

In the AKF process, resorbable original materials such a plate-implants similar to bone, can be manufactured. They are gradually replaced by endogenous tissue

Medical Product Manufacturers Are Processing Original Materials Using the Freeformer

Anlagen Additive Fertigung / 3D-Druck, andere

Anlagen für die Additive Fertigung

Biokunststoffe

Kunststoff Werkstoffe

Additive Fertigung

Medizintechnik

Medizinprodukte

Werkstoffe für additive Verfahren

Andere Werkstoffe

Arburg Kunststoff Freiformen

Verfahren für die additive Fertigung

Freiraumverfahren

New Possibilities for Use  in the Human Body

Up to now, the integration of electronic components and consequently, the production of customized 3D-printed sensors has presented a challenge. Now, together with the companies Arburg and Balluff, Fraunhofer IPA has achieved a breakthrough.

Demonstration model of customized sensor at different production stages: CAD concept (top left), after integrationof the electronic components (top right) and as a finished demonstration model (bottom)

16:9

Technik Trend

kunststoffe-international.com

Sensoren

Logistik

Lagertechnik

Sensors from the Printer

tesa develops e. g. adhesives for smartphone components and investigate the added value that additive manufacturing with plastics freeforming can bring.

“Printed” pressure-sensitive adhesives can be used, for example, to bond smartphone components together, without producing any waste

tesa Uses Freeformer for Novel Bonding Applications

Klebstoffe

Verbindungstechnik Verfahren

Chemisches Fügeverfahren

What Holds the World together

Additive manufacturing has the potential to manufacture tablets individualized for the particular patient, and thereby further digitalize the pharmaceutical industry. In medication development, the properties of a tablet, such as its shape, dosage or release of the active substance, can be individually tailored – by making just a few changes to the digital 3D print file. Merck scientists have used a Freeformer for their lab tests.

Merck researcher Dr. Thomas Kipping (right) and Nabil Lamrabet value the advantages that the Freeformer offers as an open system.

The Freeformer Allows a Tailor-Made Combination of Several Active Ingredients

Anlagen Additive Fertigung / 3D-Druck, Kunststoff

Patient-Specific Tablets

The new injection-molding machine Engel duo speed combines productivity and efficiency with short cycle times in a high clamping force range. The two-platen machine is thus making inroads into a range of packaging applications that were formerly the domain of toggle machines.

If you want a somewhat larger sized pail: the duo speed large machine was developed specifically for manufacturing pails and transport boxes

Engel Duo Speed Expands the Machine Portfolio for Packaging Applications

Spritzgießen

Kunststoffverarbeitung: Verfahren

Spritzgießmaschinen, allgemein

Kunststoffverarbeitung: Maschinen und Komponenten

Spritzgießmaschinen

High-Speed Machine with a  Small Footprint

In the second part of the series, calculations were carried out on the throughput behaviour, pressure build-up capacity and the melting process on the basis of an exemplary geometry. These results are now to be examined in more detail and subsequently optimized.

Through empirical tests and simulation-supported test series, a screw can be designed in a tailor-made manner for the respective application 

Part 3 of the Series Deals with the Tests to Optimize the Screw Geometry

Spritzgießsimulation

Software

Simulation

Schnecken und Plastifiziersysteme

All about Plasticizing Screws

The fifth broadcast by arburgXvision was all about the exciting question of how productivity can be optimized by bringing together technology, organization and digitalization in the ideal manner.

Christoph Kiefer, Team Manager Technical & Commercial Sales Support (left), and Dr Thomas Walther, Head of Application & Process Development (center), had a discussion with presenter Guido Marschall on how to increase production efficiency by taking advantage of “hidden benefits“

Automatisierungstechnik

5. arburgXvision: „Savings through Hidden Benefits!“

With a new process, Engel makes it possible to process plastic waste as flakes in injection molding directly after grinding. Since a complete process step, pelletizing, is eliminated, the innovation significantly improves cost efficiency in plastics recycling.

The aim of the innovation is to process plastic flakes, for example, from post-consumer collection, directly in injection molding without pelletizing

Kunststoff-Recycling

Kunststoff-Aufbereitung

Kreislaufwirtschaft

Processing Plastic Flakes Directly

iQ process observer, the new process monitoring platform from Engel monitors hundreds of parameters from the injection molding cell in the background.

The injection molder is truly not a friend of changes – if they occur in the running process. The iQ process observer helps him to keep an eye on the process and thus keep a handle on the quality

A Process Monitoring Platform Monitors Several Hundred Parameters Simultaneously

Steuerungen (Hardware und Software)

Industrie 4.0 für die Qualitätssicherung

Industrie 4.0

Prozessvisualisierung

Condition Monitoring / Prozessüberwachung

Instandhaltung

Industrie 4.0 für die Kunststoffverarbeitung

IoT-Plattformen für die Kunststoffverarbeitung

An Eye on the Process –  a Handle on Quality

The area of application of cube molds has expanded to take in the production of technical parts. The new Allrounder Cube 1800 from Arburg with a clamping force of 1800 kN is providing the response to this trend. With its compact cube, this machine completes the portfolio of products at the lower end of the range.

At the heart of the cube machine is a compact cube designed by our partner Foboha which can be easily accessed from above. The rotation of the cube is powered servo-electrically and the horizontal movement relies on rack and pinion mechanisms

Mehrkomponenten-Spritzgießen

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Arburg Expands Hybrid Cube Series

Moldmakers and manufacturers of injection molding machines or peripheral equipment will present some of their collaborations.

Werkzeug- und Formenbau

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Messe Moulding Expo

form-werkzeug.de

Betriebstechnik für Kunststoffverarbeitung (Peripherie)

Production Concepts for Moldmaking

At Fakuma 2021, Engel is expanding its product range of intelligent assistance systems. The new iQ motion control allows Engel viper series linear robots a reliable early start combined with fully automatically optimized motion planning. Users benefit twofold: from a time-saving in teach-in and shorter production cycles.

iQ motion control operates with automatically optimized motion planning

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

Messe Fakuma

Handling, Handhabungstechnik

Linearroboter für die Kunststoffverarbeitung

Optimized Motion Planning for Shorter Cycle Times

“At our trade show presentation this year, we are concentrating on the automation and digitalization of our injection-molding machines,” says Alfred Schiffer, marketing partner at Dr. Boy GmbH & Co. KG, explaining the activities planned for Fakuma. Three of the four applications at its own tradeshow booth – four more can be seen at its partners – are equipped with Dr. Boy’s own LR 5 linear handling unit.

On the Boy 35 E, the LR 5 compact telescopic handling system is use for a medical LSR application

kunststoffe.de

Elastomer-Spritzgießen

Individual Automation and Digitalization

After a year’s forced break of Fakuma, Wittmann Battenfeld is announcing the new servohydraulic SmartPlus machine as the highlight of this year’s trade show. It is claimed to be characterized by high economic and energy efficiency and repeat accuracy.

The new SmartPlus machine is equipped with the HiQ Flow software and the CMS Light condition monitoring system

Schaumspritzgießen

Mikrospritzgießen

Spritzprägen

Injection Molding Innovations In-House, Live and in Color

Emilio López has been appointed as the new managing director of Engel de Mexico SA de CV. He succeeds Peter Auinger, who retired on 1st September 2021.

Emilio López is the new managing director of Engel de Mexico SA de CV

New Managing Director in Mexico

Arburg presents a total of four Allrounder exhibits and two Freeformers on show. All machines will be connected live to the Arburg host computer system ALS for demonstration purposes and to the arburgXworld customer portal, another focus of the trade fair display. Detailed information on the arburgGreenworld environmental and recycling program will round off Arburg‘s involvement in Chinaplas.

Zhao Tong, Director of Arburg‘s organizations in China, notes the importance of the event in Shanghai (25 to 28 April 2022): „Chinaplas is the most important trade fair for us in the entire region. It is important that we showcase cutting-edge technology here, because the high-end market in China is also constantly growing and gaining in importance. Arburg has chosen the focal points of its trade fair activities accordingly. With our injection molding machines and automation systems, we offer optimal solutions for individual series production, and with the Freeformers, further solutions for the production of prototypes and small series. Then there are tools like arburgXworld and the ALS host computer system for supporting service and production management, and the arburgGreenworld environmental and recycling program for greater resource conservation and production efficiency.“

Zhao Tong sees the electric Allrounder 470 A with 1000 kN clamping force, size 290 injection unit and Gestica control system as an important highlight. A Multilift Select with a load capacity of six kilograms completes the configuration. The powerful injection unit with 35 mm three-zone screw can produce even complex parts in multiple molds quickly and to a high standard without any problems. As a sample for the trade fair, the electronic ‚connector‘ part will be produced on this machine in a 16-cavity mold. Each part weighs 0.59 g, and the 16 connectors will be produced in a cycle time of around six seconds. The machine‘s energy requirement is very low, which increases economy and efficiency. This means that the Allrounder also fits in very well with the company‘s efforts as part of the arburgGreenworld program.

Fast: Medical Technology on a Hybrid Machine

On a hybrid Allrounder 470 H with a clamping force of 1000 kN, size 400 injection unit with 35 mm standard screw and Gestica control system, pipette tips will be produced from PP in a 64-cavity mold. The cycle time for this high-speed product is only seven seconds, which is partly due to the machine being equipped with powerful memory technology and the aXw Control ScrewPilot for reproducible injection and high molded part quality. The shot weight is 64 grams. The complex automation comes from regional Chinese manufacturer Ningbo Welllih Robot Technology Co, LTD. In addition to a Luxor80 granule feed from Motan, a hot runner system from Husky and two HB-Therm temperature control devices are also used.

A face mask will be injection molded in a 4-cavity mold from Polarform Werkzeugbau GmbH. The sample part will run on a 570 E Golden Electric Allrounder during Chinaplas. The high-end system with this machine for LSR processing is a novelty in Asia. The Allrounder 570 E Golden Electric is defined here as an entry-level machine with maximum precision for the special application of LSR injection molding. It has a clamping force of 2000 kN and a size 800 injection unit with a 45 mm LSR screw and no mixing or compression zone. A special non-return valve is also used for low-viscosity material.

A Wacker Chemie AG LSR optimized for medical technology is processed. The molded part weight is around 42 grams and the cycle time some 60 seconds. The extreme undercut of the mask and different wall thicknesses with the very thin lip make the injection molding of these parts highly complex. The gripper on the Multilift Select robotic system with a 15-kilogram load capacity in transverse design ensures precise, smooth removal. It comes from Barth Mechanik GmbH, and the dosing system from Chinese manufacturer Mucomac in Shenzhen.

The system is completed by a CoolShot cold runner system from Ewikon with electrically needle-type shut-off system and a cooling unit from Shini in Taipei. For medical technology, which is also one of the most important industries in this region, clean production with maximum process control is indispensable. Arburg can fully guarantee this with this configuration.

The largest Arburg machine at Chinaplas will be a hydraulic Allrounder 820 S optimized for fiber direct compounding (FDC). The machine has a clamping force of 4000 kN and a size 3200 injection unit equipped with a 70 mm special screw for long glass fiber processing. The aXw Control ScrewPilot, which allows reproducible mold filling via the control of injection pressure and speed is also included as necessary basic equipment. A platform will be produced with a PP as base material. The single-cavity mold has a hot runner with needle-type shut-off nozzles. The molded part weight is 700 g and the cycle time some 80 seconds.

The FDC lightweight construction process is characterized by high material availability and up to 40 per cent lower costs compared to special long-fiber granules. FDC molded parts are used in all innovative sectors of plastics processing, such as automotive construction or the aerospace industry. The physical properties that can be achieved are due to the individually adaptable long fibers. The FDC unit directly on the injection unit is integrated into the Selogica control system, as is the entire process, and includes a servo-electric lateral feeder with built-in cutting device, an adapted cylinder, and special screw geometry.

The molded parts are removed from the single mold via a Multilift Select robotic system with a load capacity of 15 kg. Downstream, the items are weighed inline via a scale automation system for quality assurance, entered into the process documentation, and then deposited on a conveyor belt.

Business Potential in China and Asia Remains High

According to Zhao Tong, the exhibits at Chinaplas 2022 are a perfect match for the current market requirements in China: „The automotive industry is becoming increasingly energized by developments and applications in the field of e-mobility. In medical technology, Arburg can make an important contribution to more stable supply chains thanks to its central production, its on-time delivery, and the high reliability of its Allrounders. More and more companies are also looking to IT solutions such as the arburgXworld customer portal and the ALS host computer system to increase their production efficiency. With our products and technologies that are ‚Made in Germany‘, we are in the right place at the right time. Because – and this is also demonstrated by our involvement in Chinaplas – we can offer our customers regionalized services to fully support them in increasing quality, efficiency and resource conservation in their companies.“

Shanghai venue: 25 to 28 April 2022, Hall 2.1, booth G62

ARBURG GmbH + Co KG  

https://www.arburg.com

A highlight at Chinaplas 2022 is an electric Allrounder 470 A with Gestica control system.

Arburg will be demonstrating the potential of freeformers for additive manufacturing on two exhibits at Chinaplas 2022.

Zhao Tong, Managing Director Arburg China

2022-03-23 Arburg Chinaplas

issue 03/2022

issue 02/2022

issue 01/2022

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