Pipette tips feature a challenging wall thickness/length ratio, an inner geometry that is key for analysis results, and a tip opening just a few tenths of a millimeter wide. They have been in extremely high demand during the coronavirus pandemic, which is why the mold construction and hot runner specialist Männer has developed a mold with an innovative cluster concept.

At the Männer test center in Bahlingen, Germany: an injection mold for manufacturing pipette tips, shown here in operation. Automation of the system is currently being set up

Pipette Tips: Männer Presents a Mold with Replaceable Clusters

Spritzgießen

Kunststoffverarbeitung: Verfahren

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

Medizintechnik

Medizinprodukte

Maintenance During (Nearly)  Uninterrupted Production

Space-saving machine concepts for demanding production environments are booming. A real-life example of a slit micro-membrane for pharmaceutical glass vials shows how intelligent machine functions make an important contribution to supporting machine operators and continuous documentation of the production process.

Injection molding and slitting of an LSR membrane for a glass-vial closure for pharmaceutical products make high demands on precision

KraussMaffei Delivers a Customized Solution for LSR Processing

Automatisierungszellen

Automatisierungstechnik

Mikrospritzgießen

Silikonkautschuk

Kunststoff Werkstoffe

Kautschuk / Elastomere

Transparency in Production

RKT has been manufacturing plastic products for medical and industrial technology for 45 years. Discs for the rapid analysis of multi-resistant hospital germs are a lighthouse project within the sophisticated product portfolio.

 A six-axis robot picks the molded parts out of the mold under an inert gas atmosphere and conveys them into the cleanroom for further processing and packaging

High-Tech Production of Life-Saving Disks for Fast Analysis of Dangerous Germs

Reinraumsysteme / -technik

An All-Round Winner

Closing the circle: a tool manufacturer with a long track record in injection molding is taking particle foam processing to the next level. A new machine and highly efficient molds are intended to streamline the technology and make it interesting even for injection molders.

Managing Director Stefan Hofmann (left) and Project Manager Johannes Schütz in front of the prototype of the new “<a href="http://Bead.Machin">Bead.Machin</a>e”, the development of which started a good two years ago © Hofmann

On the Launch of a Molding Machine for Particle Foams

Doriat, Clemens, Dr.

Innovationsentwicklung

Wirtschaft

Innovationen und neue Technologie

Partikelschäumen

Schäumen / Reaktive Verarbeitung

Werkzeug- und Formenbau

Dienstleistungen

Werkzeug-, Formen- und Modellbau

The Impulse Machine

In the injection molding of engineering plastics, mold temperature control consumes more than one third of the total energy input. A novel technology offers the opportunity to reduce this continuous major cost factor – and eliminate hotspots.

Fig. 1. The temperature control units have the highest energy share in the injection molding process

Source: M. Schläger et al [2]; graphic: © Hanser

Reduced Energy Consumption and Shorter Cycle Times due to Structurally Integrated  Heat Pipe Mold Cores

Temperiertechnik

Cooling with Heat Pipes

Thermoplastic foam injection molding enables lower melt viscosity due to the addition of blowing agent, which is also attractive for the production of thin-walled packaging. Since injection molded packaging is often decorated through in-mold-labeling, it is important to understand how the blowing agent affects adhesion between the film and the molded part to avoid bubble formation at the interface.

Selecting the right IML film is critical for visually appealing molded parts

How Does the Addition of Blowing Agent Affect Adhesion and Molded Part Properties?

Schaumspritzgießen

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

Properly Foamed with IML

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

Spritzgießmaschinen, allgemein

Spritzgießmaschinen

High-Speed Machine with a  Small Footprint

The resource-economical determination of an optimized operating point in injection molding is still a challenge. Machine learning offers great potential for re-using knowledge from a flow simulation that has already been generated.

Significant reduction of the effort for determining the optimum operating point by machine learning

Machine Learning: Combining Simulation and Experimental Test Data

Spritzgießsimulation

Software

Simulation

DOE-Software

Qualitätsmethoden

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Digitaler Zwilling

Quicker Evaluation of the Optimum Operating Point

Tactotek and Amphenol ICC, a leading global manufacturer of interconnect products, have announced that they are collaborating to develop automotive grade in-mold connectors for Tactotek IMSE technology.

IMSE parts integrate printed electronics and electronic components within 3D injection molded plastics

16:9

Gedruckte Elektronik

Elektronik

Technik Trend

kunststoffe-international.com

KFZ-Schalter für die Autobedienung

Elektromechanik

Elektromechanik für Automobile

Anzeige- und Bedienelemente

Mobile Automation

Automotive

Fahrzeugbau

Amphenol ICC and Tactotek to Create Automotive Connector

In plastics processing, efficient production methods are required, especially for articles with high volumes and exacting quality requirements, and these must be constantly optimized. The container specialist Walther Faltsysteme has been successfully working together with the Austrian moldmaker Haidlmair for many years.

Left: products which are manufactured using the technologies of the Haidlmair Group companies. Right: an application example with folding boxes

Walther Faltsysteme Combines Three Mold Technologies from the Haidlmair Group

Industrie 4.0 für die Qualitätssicherung

Condition Monitoring / Prozessüberwachung

Instandhaltung

Paletten und Behälter

Logistik

Verpackungstechnik

With Broad Sword and Data Collector

In the realm of virtual product development, the idea of the cycle has been around for many years. But where does the cycle begin? When we take a closer look at this concept, new aspects rightly start to emerge.

Fig. 1. Stress-strain diagram as a function of microstructure. Shown are three different porosities (5 to 15 %) relative to the compact material

When Traditional Approaches Meet their Micromechanical Counterparts

Werkstoffprüfung, mechanisch

Messtechnik

Werkstoffprüfung

Analysetools, FEM

Produktentwicklung(sprozess)

Qualitätsmanagement

Cracking Product Development

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

Schnecken und Plastifiziersysteme

All about Plasticizing Screws

In the injection molding process, the screw-in blind rivet is one joining element with adequate one-sided accessibility, high strength properties and good economic efficiency. But what factors influence the strength of the bond between the semi-finished product and the molded-on blind rivet?

Fig. 1. The three steps of the joining process for a screw-in blind rivet connection

Study of the Factors Influencing the Strength of the Bond between a Thermoplastic Composite and a Screw-in Blind Rivet

Verbindungstechnik

Chemisches Fügeverfahren

Verbindungstechnik Verfahren

Universal-Prüfmaschinen für Zug, Druck und Biegung

Organobleche (gewebeverstärkte Thermoplast-Halbzeuge)

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Molding on a Joining Element

The XPlanar motor system combines the advantages of conventional transport systems with magnetic levitation technology. This opens up completely new possibilities for handling and positioning products in the machining process. The floating effect obviates the need for mechanical guiding components and helps Plasmatreat to simplify the system configuration for plasma treatment.

A floating planar mover carries the workpiece exactly into position for surface treatment 

XPlanar Transports Workpiece during Plasma Surface Treatment Process

Automatisierungskomponenten

Förderanlagen und -geräte

Oberflächentechnik

Fördersysteme

Kunststoff-Aufbereitung

Nozzle in Protective Position

With the increasing digitalization of injection molding, new process parameters are coming under the spotlight. Engel, together with the Polymer Competence Center Leoben and Montan University Leoben, Austria, is using machine-learning methods to explore the potential of mold breathing for quality assurance in rubber injection molding. This research project was supported by the partner company SKF Sealing Solutions Austria.

The collection and interpretation of process data supports producers of safety-relevant rubber products in ensuring a constant high quality

Automatic Process Monitoring with iQ Clamp Control and Machine Learning

Steuerungen (Hardware und Software)

Mess-, Steuer- und Regelgeräte

Qualitätssicherung

Qualitätssicherung Kunststoff

Elastomer-Spritzgießen

Machine Learning für die Qualitätssicherung

Rubber Injection Molding with  Quality Recognition

Over the last few months Wittmann Battenfeld has succeeded in winning new customers in many markets with its SmartPower injection molding machines.

Over the last few months Wittmann Battenfeld has succeeded in winning new customers in many markets with its SmartPower injection molding machines. The appealing design of the SmartPower, its near-silent operation, the highly repeatable process capabilities, wide platens and class-leading compactness are perhaps some of the main factors influencing a purchase. However, once in operation, the bonus of the SmartPower’s extreme energy efficiency performance also becomes an inescapable fact, says the company.

In numerous meetings with customers held by Dan Williams, Managing Director of Wittmann Battenfeld UK following the installation of SmartPower machines, energy efficiency has come up as a topic of particular significance. According to the company, the magnitude of actual savings realized on the production floor by comparison to similar machine models has exceeded expectations and surprised many users.

A typical example is White Horse Plastics (WHP) based in Oxfordshire, which recently ordered a SmartPower 60. WHP Managing Director Paul Bobby says that “after labor and raw material costs, energy and utilities present us with the next most significant overhead. I always expect to see some significant improvement when comparing old to new, but these outcomes were far more impressive than could ever have been hoped for. In fact, the greatly reduced running costs from the SmartPower machine were so incredible that it led to us repeating the exercise in order to check our methodology. But when repeated these results were exactly the same. These machines are called SmartPower for a very good reason” says Bobby “and the energy savings achieved are truly world class.”

At Thomas Dudley-owned Rugby Plastics similar experiences have emerged: Dr Steven Pepper has been leading the company drive towards factory efficiencies. In this case a SmartPower 50 injection molding machine was the basis for the energy measurement work. The machine was supplied with servo power and a HiQ quality control package and it also deployed the regenerative KERS braking system so effectively used by the Wittmann Group.

The SmartPower was compared to a machine that had been supplied in the early 1990’s. Unsurprisingly perhaps the test results were astounding, revealing that the SmartPower injection molding machine was six times more energy efficient and six times less costly to run than the older machine.

Joint Wittmann Battenfeld UK Managing Director Tracy Cadman says that “my accounting background and expertise tells me that the low running costs of Wittmann Battenfeld designed equipment has to be a primary consideration for our customers in any purchasing decision. Customers are increasingly factoring these numbers into a lifetime of machinery performance – over ten, fifteen, twenty years.”

Tracy also notes that the company is able to confidently model and forecast the reduced energy cost they will save prospective customers with SmartPower based technology. “Our leading customers in the UK and Ireland are increasingly realizing that low energy production is helping to future proof businesses, not only for cost but also in terms of transparent Industry 4.0 production and securing a low environmental footprint.”

Wittmann Battenfeld GmbH  

https://www.wittmann-group.com

Tracy Cadman and Dan Williams in front of a SmartPower 90 (f. l.)

2021-09-01 Wittmann

issue 04/2022

issue 03/2022

issue 02/2022

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