It is a hot runner nozzle such as had never been seen before Fakuma 2021: with a honeycomb structure on the outside and, in the nozzle interior, integrated insulation gaps manufactured in one part by the additive SLM process, in which even the fastening nut is captively printed on the nozzle body. The pride of the concept is the special algorithmic modification of the nozzles for any application case.

A mold-making job with up to 30 nozzles is processed in the SLM machine in about 24 hours. 

16:9

The First Additively Manufactured One-Part Hot Runner Nozzle

Spritzgießen

Kunststoffverarbeitung: Verfahren

Doriat, Clemens, Dr.

Selektives Laserschmelzen von Kunststoff, Metall, Keramik

Verfahren für die additive Fertigung

Pulverbettverfahren

Heißkanalsysteme

Kunststoffverarbeitung: Maschinen und Komponenten

Komponenten für die Kunststoffverarbeitung

Additive Fertigung

Algorithmically Modified  Inner Workings

Internal pressure loads are typical for fiber-reinforced plastic components. To increase the burst strength of components, the fiber orientation can be modified in a targeted way during injection molding by means of a rotating mold core. A newly developed simulation method allows this modified fiber orientation to be taken into account at the design stage.

Practical implementation of a mold system with rotating core.

Mold System with Rotating Core Improves Mechanical Properties

Werkstoffprüfung, mechanisch

Messtechnik

Werkstoffprüfung

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Verbundwerkstoffe / Werkstoffverbunde

Kunststoff Werkstoffe

Spritzgießsimulation

Software

Simulation

Faserverbundwerkstoffe

Andere Werkstoffe

Design Methodology for Parts Subject to Internal Pressure

The aim of this joint project is to develop a production cell in which a rear license plate light can be manufactured with hybrid processes without any additional steps such as bonding. Some of the necessary analyses and pre-testing of the material combinations resulting from the structure of the product – plastic housing and optics plus metal conductive tracks – are presented in this article.

Lighting  solutions on various products. 

Manufacture of a Rear License Plate Light in a Highly Integrated Production Cell

LED / OLED-Systeme und Faseroptik

Lichttechnik

Polymethylmethacrylat

Thermoplaste

Hybrid-Spritzgießen (Metall / Kunststoff)

Polycarbonat

What Is the Most Suitable  Material Combination?

Family molds belong to the state-of-the-art in injection molding – at least when wall thicknesses and volumes of individual components vary considerably. Using a trial mold soon ready for series production, Synventive demonstrates that – though demanding – optimal process control can be achieved using the right technology. The filling of each mold cavity is controlled individually and in real time. The Kunststoffe editorial team were among the first guests at the new Tech Center.

View into the mold space of the Engel Duo 2700 at the Tech Center. In the background, a 6-axis robot with 180 kg load-bearing capacity which removes the components.

Single-Shot Injection Molding of Heterogeneous Components

Schröder, Susanne

Leading-Edge Process Control

The plastics processor TKW Molding, which specializes in safety-related automotive components, is responding to the increasing requirements of its tier 1 and OEM customers by extensively automating its injection molding production. This also encompasses downstream process steps, such as integrated component testing, traceable part deposition and packaging. The company has been working closely with Arburg in this field since 2020.

A robotic system removes the parts from TKW’s 8+8-cavity mold.

Fully Automated In-Mold Assembly Process at TKW Molding

Optische Mess- und Prüftechnik

Montage-Spritzgießen

KFZ-Zulieferer

Dienstleistungen

Safely Belted in

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.

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

Spritzgießmaschinen

Arburg Kunststoff Freiformen

Freiraumverfahren

High-End Wherever You Look

The new “Heat-Inject” product from Incoe International Europe stands out in that it uses the hot runner system as a carrier platform, but instead of melt, it brings heat into the cavity.

The heat pulse from heat-inject ensures good surface quality where a weld line may otherwise be visible due to the part geometry and gating.

Targeted Heat Pulses in the Cavity

At the presentation of The Economic Times’ brand awards, Hasco’s Indian subsidiary received the award for “Best Plastics & Polymers Brand 2022”.

Sandeep KP, Technical Sales Engineer and Rajnikant Patel, Business Development Manager / Hasco India (from left)

Special Honor for Hasco India

Pharmaceutical crimp caps generally consist of a thin aluminum sheet and a plastic component, and are used to seal medical vials, for example for vaccines. Through a combined deep-drawing and backmolding process with previous inline laser treatment of the thin aluminum sheet, the process can be significantly shortened. The media-proof joining together of the two materials is carried out through a mechanically interlocking connection.

A crimp cap for injection vials is manufactured in a two-step process.

Combined Deep-Drawing and Backmolding Process with Mechanically Interlocking Joint

Hybridtechnik

Aluminiumlegierungen

Metall Werkstoffe

NE-Metalle

Laserbearbeitungen

Oberflächentechnik

Tiefziehen

Verfahren für die spanlose Fertigung

Spritzgieß-Sonderverfahren

Simulation Stanzen / Umformen

Laserstrukturieren

Medizintechnik

Medizinprodukte

Process Chain for the Production of Hybrid Medical Products

Nowhere are the demands imposed on materials higher than in the area of medical technology. That is understandable because, after all, what is ultimately at stake here is the patient’s health. But any materials manufacturers seeking to use hot runner technology to process polymers in compliance with strict directives and differentiated legal regulations also need the expertise possessed by the hot runner manufacturer’s application engineers.

Günther has recently installed two new injection-molding machines for customer trials in its technical center.

Testing the Processing Limits of Modified POM Copolymer

Polyoxymethylen

Normalien und Heißkanaltechnik

Looking over the Application  Engineer’s Shoulder

Pipette tips are small and relatively simple components that are now in high demand. One might think  producing large quantities of these products is a simple task. It is not. The requested high quality can only be reached by using complex automation. To meet these challenging requirements, MA micro automation has developed a modular solution: Centauri IVD.

The Centauri IVD production system can be adapted to meet specific pipette tip manufacturing requirements.

Automated High Volume Consumables Production

Handling, Handhabungstechnik

Automatisierungstechnik

Prozessautomation

From Tool to Blister

Anybrid GmbH has succeeded in transforming the usually rigid injection molding machine into a mobile machine that can move freely in the room and can be used to overmold profiles, etc. The company is thus serving a steadily growing market for the production of hybrid components. For the first time, the advantages of plastics processing are combined directly with the flexibility of robotics. In close cooperation with Rehau, extensive studies on an extrusion line were recently successfully completed.

The Robin injection molding system can be swiveled freely on the arm of a six-axis robot to the particular application points.

Automated Lightweight Module for Functionalization and Hybridization of Components

Mikrospritzgießen

Rohr- und Profilextrusion

Extrusion

Industrieroboter

Montagetechnik

Injection Molding on the Fly

Injection, holding pressure, cooling phase – injection molding is a sequential process with individual steps that are usually optimized. Therefore, they offer little more potential for improving the cycle time. But what about the automation system?

With the synchronous motion function, the gripper of the robot starts faster, saving valuable cycle time.

Lucrative Early Start

Multiaxialroboter für die Kunststoffverarbeitung

Synchronous Motion Shortens Demolding Time up to 35 %

Thin wall packaging manufacturers think in terms of efficiency gains in tenths of a second. Every cycle time reduction leads to increased productivity. Another factor influencing part costs is the energy efficiency of the production equipment. In these two key dimensions, Netstal was able to optimize the smallest model in the Elios series with 4500 kN clamping force.

The optimized Elios 4500 with electrically operated toggle levers enables users to achieve cycle time reductions and savings in power consumption (the photo shows the previous variant).

Higher Output and Reduced Energy Consumption

Energieeffizienz

Elektrische Antriebe für Spritzgießmaschinen

Antriebe

Elektrische Antriebe

Clamping Unit of the Elios 4500 with Fully Electric Drive Concept

Techniplas and KraussMaffei are focusing on sustainability in the production of high-quality automotive components with an MXW ColorForm system. Flow-coating with PU directly in the injection mold saves working steps and CO2. With this system, KraussMaffei is demonstrating its expertise both in injection molding as well as in reaction process machinery.

The project team in front of the new MXW 1000 ColorForm injection molding machine (from left): Peter Giessmann (KraussMaffei), Eric Jan Frijters (Techniplas), Philipp Strasser (KraussMaffei), Michael Fuchs (KraussMaffei), Rene Rudolf (Techniplas) and Sarah Seidel (Techniplas).

Combination of Injection Molding and Polyurethane Processing

Schäumen / Reaktive Verarbeitung

No Grain of Dust in the Coating

Frank Schuster, Regional President Metai, takes over the management of Engel Machinery India. Stalinjose Selvanayagam is the new Sales Director.

1 July 2021 will see Engel complete the generation change in the management of its sales and service subsidiary in Mumbai. Frank Schuster, Regional President Metai, takes over the management of Engel Machinery India Pvt. Ltd. Stalinjose Selvanayagam is the new Sales Director. Jitendra Devlia, the previous managing director and sales manager, is retiring.

“The introduction of this management duo is our response to the significance of the growing Indian market. We are simplifying communication with headquarters for our customers in India, and this in turn will speed up project planning for customized system solutions,” says Dr. Christoph Steger, CSO of the Engel Group. Frank Schuster will remain at the headquarters in Schwertberg, Austria, while Stalinjose Selvanayagam will move from Austria back to his home country for his new responsibilities. “We are pleased to have gained a highly experienced injection molding expert for this strategically important position, in the form of Stalinjose Selvanayagam who is at home in both European and Indian culture.”

Stalinjose Selvanayagam first studied electrical engineering in India and later global sales and marketing in Austria, before joining Engel Machinery India in 2005 as a service engineer. Most recently, he was a project manager in the Packaging business unit at Engel in Austria where he looked after key accounts.

Frank Schuster brings a total of 25 years of experience in the plastics industry to the table. He joined Engel in 2016 and was Vice President Packaging before being appointed Regional President of the Metai (Middle East, Turkey, Africa, India) region in spring 2020.

Jitendra Devlia took over as Managing Director of Engel’s Indian subsidiary in 2009. He also previously lived in Europe for many years.

The Austrian company has been engaged in India since 1998. The subsidiary has 21 employees today.

Frank Schuster, Regional President Metai, is the new Managing Director of Engel Machinery India

Stalinjose Selvanayagam is moving from Engel’s headquarters as Sales Director to the Indian subsidiary

2021-07-01 Engel India

issue 04/2023

issue 03/2023

issue 02/2023

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