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.

16:9

Combined Deep-Drawing and Backmolding Process with Mechanically Interlocking Joint

Hybridtechnik

Kunststoffverarbeitung: Verfahren

Spritzgießen

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Aluminiumlegierungen

Metall Werkstoffe

NE-Metalle

Laserbearbeitungen

Oberflächentechnik

Tiefziehen

Verfahren für die spanlose Fertigung

Spritzgieß-Sonderverfahren

Simulation Stanzen / Umformen

Software

Simulation

Laserstrukturieren

Hybrid-Spritzgießen (Metall / Kunststoff)

Medizintechnik

Medizinprodukte

Process Chain for the Production of Hybrid Medical Products

For the first time a readable digital watermark, imperceptible to the naked eye, has been incorporated into an injection-molded flip cap.

On the flip cap, the digital watermark is not visually perceptible, but can be read like a code by specialized high speed camera

Integration of Digital Watermarks in Complex Injection Molded Packaging Products

Bildverarbeitung

Fertigungsautomation

Barcode-Systeme

Identtechnik

Inspektion, Analyse und Sortierung von Rohmaterial

Qualitätssicherung

Qualitätssicherung Kunststoff

Kreislaufwirtschaft

Key to Purity of Recycled Resins

The article demonstrates the use of digital twins for molds in injection molding through the integration of track-and-trace technologies for data collection.

An RFID reader records whether a mold is ready for the setup process

How Track-and-Trace Technologies Can Support Mold Management

RFID

RFID Teileidentifikation

Digitaler Zwilling

The Digital Mold Twin

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

Verbundwerkstoffe / Werkstoffverbunde

Kunststoff Werkstoffe

Spritzgießsimulation

Faserverbundwerkstoffe

Andere Werkstoffe

Design Methodology for Parts Subject to Internal Pressure

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

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

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

The Zahoransky subsidiary in Coimbatore, India, has been managed by a new dual leadership team since March 1, 2022. For the first time, there is also a woman in the top management circle, Sathyapriya Balakrishnan.

The new dual management team for India: Sathyapriya Balakrishnan (Managing Director) and Reinhard Schnurr (Managing Director)

Werkzeug-, Formen- und Modellbau

Personen

kunststoffe.de

Zahoransky Introduces Expanded Management Team in India

Arburg has adopted a clear message for its trade fair appearance at the K 2022 in Düsseldorf: „There is only a Plan A“.

In the arburgGreenworld pavilion of the VDMA Circular Economy Forum, an Allrounder 370 A with recyclate package is manufacturing “Greenline” wall plugs from Fischer.

Messe K-Kunststoffmesse

kunststoffe-international.com

Mehrkomponenten-Spritzgießen

Nachhaltigkeit

Umweltmanagement

Energieeffizienz

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Sustainability thanks to Digitalization

Rodinger Kunststoff-Technik supports their customers all the way from product development and prototype molds to a product ready for serial production.

Tiny structures in the cavity of a Lab-on-a-Chip cartridge: complex and filigree geometries such as these can be efficiently manufactured by injection molding thanks to high-precision mold technology and special plastics.

Manufacturing Materials to Laboratory Standards

Reinraumtechnik

Betriebsausrüstung / Betriebsmittel

Medizintechnik (KU)

Kunststoffverarbeitung

Plastics: the Obvious Choice

At K 2022, Engel, with its partners Alpla Group, Brink and IPB Printing, is presenting a quantum leap for the packaging industry. Thin-wall containers can for the first time be produced from PET directly by injection molding in only one process step.

Fig. 1. The thin-walled containers are injection molded from rPET.

Schmelzefilter

Kunststoff-Aufbereitung

Polyethylenterephthalat

Thermoplaste

Spritzgießmaschinen

Kunststoff-Rezyklat

Processing rPET by Thin-Wall  Injection Molding

With the MicroJect Advanced, Faurecia, a company of the Forvia Group, is presenting a new manufacturing process for foam injection molding.

Single-source component: the door panel comes directly from the injection-molding machine as a ready-to-install visible component with different grains.

New Injection Molding Technology for Foamed Parts with Class A Surfaces

Schaumspritzgießen

Werkzeugbeschichten

Dienstleistungen in der Metallbearbeitung

Design Surfaces thanks to Innovative Mold Coating

With Hekutip QC, a quality control assistant for pipette tips, Hekuma and Ziemann & Urban have developed a standalone solution that covers wide-ranging testing requirements fully automatically, as well as being compact and swift to deploy.

Hekutip QC covers wide-ranging testing requirements fully automatically, as well as being compact and swift to deploy.

Messe Fakuma

Prozessautomation

A Standalone Measuring Station with a Wide Testing Range

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.

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

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

Doriat, Clemens, Dr.

Solar / PV

Energieerzeugung

Erneuerbare Energie

Temperiertechnik

Condition Monitoring / Prozessüberwachung

Instandhaltung

Biokunststoffe

Handling, Handhabungstechnik

Automatisierungstechnik

Elastomer-Spritzgießen

Digitalisierung

Silikonkautschuk

Kautschuk / Elastomere

Compoundieren

It Can Be Done!

Injection molding cell combines high article variance with automated product changeover.

With the turnkey solution, 159 product variants can be manufactured.

Flexible Production Concept Combines High Article Variance with Automation

Automatisierungszellen

Automatisierungskomponenten

Inserttechnik

Linearroboter für die Kunststoffverarbeitung

Multiaxialroboter für die Kunststoffverarbeitung

One System, 159 Variants

Production systems for large molded parts can be flexibly and economically reconfigured or expanded using hot runner adapter plates.

Melt transfer from two on the side injection units of an Engel v-duo 2300 RTM into the middle of the hot runner intermediate plate mounted on the sliding table. 

Economical Solution for the Production of Thermoplastic Large-Structure Components

Normalien und Heißkanaltechnik

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Flexible Injection Solutions  with Adapter Plates

Double Quick-Change System Speeds up Production

Zahoransky Automation & Molds GmbH has entered into a partnership with the Swiss company Kebo AG. The result of this collaboration is a new mold concept for the production of pipette tips, which features a double quick-change system.

Both 8x8 modules on the nozzle side and the cores on the ejector side can be changed in just a few steps to allow production to be resumed immediately when mold cores and wear bushings are replaced. Michael Schmidt, Managing Director Zahoransky Automation & Molds GmbH, comments: “Pipette tip molds are ‘divas’ from a production point of view – very sensitive in the process – and require precise handling: The challenge is that long thin cores are immersed in a counter-bearing and injected on one side. With our new design, all maintenance activities can be completed in a few minutes on the injection molding machine thanks to these quick-change systems on our mold.”

The new 64-cavity pipette tip mold with double quick-change system was developed together with Swiss-based Kebo AG. The company, based in Neuhausen am Rheinfall, has more than 40 years of experience in developing hot runner technology solutions. Says Gerold Keller, owner and CEO of Kebo AG: “We are very pleased with this special partnership between two mold makers who complement each other ideally for this project. As a result, we were able to achieve our common goal in a short development time and improve the technology for manufacturing pipette tips in a way that significantly reduces production costs and significantly improves service life for manufacturing companies.”

KEBO AG Formenbau  

https://www.kebo.com

Zahoransky Automation & Molds GmbH 

https://www.zahoransky-group.com

If a core breaks during production, it can be replaced quickly

2021-08-10 Zahoransky_Kebo

Each heating element can be removed individually in a few simple steps

The new pipette tool from Zahoransky powered by Kebo – 64 cavity

The heater can be disconnected via the cable and the block including the heating element can be removed