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.

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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!

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

Mikrospritzgießen

Spritzgießmaschinen, allgemein

Messe Fakuma

Spritzprägen

Injection Molding Innovations In-House, Live and in Color

Over past months, many in-house workflows and development processes have slowed down and also changed. Nevertheless, time has not stood still, also not in injection molding technology. The debate and development have been shaped by two themes: digitalization and the circular economy. Below are some examples of developments and projects that underpin this trend.

Two displays are seamlessly integrated into the continuously 3D-formed instrument panel

Innovative Injection Molding in Times of Pandemic

Künstliche Intelligenz für die Qualitätssicherung

Industrie 4.0 für die Qualitätssicherung

Steuern, Regeln

Software

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

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Spritzgieß-Sonderverfahren

Nachhaltigkeit

Umweltmanagement

Spritzgießsimulation

Simulation

Schnecken und Plastifiziersysteme

Machine Learning / Künstliche Intelligenz für die spanende Fertigung

Industrie 4.0 für die spanende Fertigung

Kunststoff-Recycling

Lasermarkieren

Laserbearbeitungen

Inline- / Online-Messsysteme

Qualitätssicherung

Qualitätssicherung Kunststoff

There Is More beyond the Horizon

Three solutions for increasing the productivity in the automotive, medical and packaging industries are presented by Tederic at K 2022 with the Neo injection molding machine series. T

The Neo·Ec combines electrical and hydraulic drives.

kunststoffe.de

Polylactid

Thermoplaste

Medizintechnik

Medizinprodukte

Applications in Three Key Sectors

The exhibitors at K 2022 showed ways and means of achieving special surfaces by injection molding. A small selection.

The material mix of the “rear-end cover” allows backlit elements to be generated with selective light barriers – with no undesirable light scattering.

State-of-the-Art Injection Molding Solutions at K 2022, Part 4

Plasmabehandlung

Reinigen und Vorbehandeln

Dynamische / variotherme Temperierung

Polycarbonat

Impressive Results

In foam injection molding by the ZiFoam principle, gas is added to the pellet stock while it is still in the solid range.

Small pores, big difference (micrograph): Foaming makes the manufactured parts much more lightweight, consumes less resources and improves the CO2 balance.

Flexible Retrofit Set for Thermoplastic Foam Injection Molding

Leichtbau

Physical Foaming Made (More) Easy

Material and manufacturing process optimized, CO<sub>2</sub> saved: recycled wash cap from Pöppelmann K-Tech closes the loop.

Material and manufacturing process optimized, closed loop: Recycled wash cap for the automotive industry. 

Sustainable Wash Cap

Investigations show the positive effects resulting from the combination of thermoplastic foam injection molding with post-consumer recyclate.

Double benefit: Reducing part weight and processing recyclate by the MuCell process.

Werkstoffprüfung, mechanisch

Messtechnik

Werkstoffprüfung

Saving CO<sub>2</sub> Twice Over

Once again, the K 2019 in Düsseldorf, Germany, lived up to its claim to be the leading trade show for plastics technology. At least in the field of injection molding, there were exciting global innovations to see – if you looked closely.

Fig. 1. Smart Operation – the machine is operated with only four buttons (© KraussMaffei)

Injection Molding Trends at K 2019

Smart Factory

Fließpressen

Handling, Handhabungstechnik für die spanende Fertigung

Linearroboter für die Kunststoffverarbeitung

Industrieroboter

Montagetechnik

Montage-Spritzgießen

Knickarmroboter

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Hybrid-Spritzgießen (Metall / Kunststoff)

Ressourcenmanagement

Produktion

Technical Excellence thanks  to Digital Assistance

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

Hybridtechnik

Reinraumsysteme / -technik

Trip to a Known Destination 

Swiss toolmaker Georg Kaufmann and Germany-based Daimler AG have developed a multifunctional,  production-ready injection compression mold in a project aimed at making the rear door trim of an SUV by a technology that is more lightweight, more cost-effective and utilizable all around the world. 

Production-Ready Process Development for Making Large Interior Parts 

Losing Pounds and Cutting Costs with  Injection Compression Molding 

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 

Foam injection molding is a processing technology to produce foamed plastic parts in serials production, attaining an increasing interest and use in industry. However, the applications are limited due to insufficient knowledge of processing and mechanical properties, limited use of light-weight potential as well restricted surface qualities. All these drawbacks are associated with the cellular structure. The structure characteristics like skin layer thickness, cell size, density and uniformity are developed during procedure. Thus, controlling the cell formation process is the key to work against the restrictions and optimize mechanical properties.

Schaumstoffe

Schaumstoffe und Vorprodukte

Schäumen / Reaktive Verarbeitung

Controlling cellular structure in thermoplastic foam injection molding – influence of processing and mold technologies

In a joint application center for thin-wall packaging, companies Sabic and Netstal have optimized the materials, equipment and process of the technology.

Injection Compression Molding of Down-Gauged Packaging Applications

Verpackungsmaterial

Logistik

Verpackungstechnik

Verpackungsmaschinen

Thinner Packaging Items  without Loss of Quality

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

Werkzeugbeschichten

Dienstleistungen

Dienstleistungen in der Metallbearbeitung

Design Surfaces thanks to Innovative Mold Coating

Green DC Current for the Injection Molding Machine

Under the motto “It‘s all Wittmann”, Wittmann Battenfeld is presenting its machines and systems in the new Wittmann design for the first time.

Wittmann Battenfeld is presenting its machines and systems in the new Wittmann design for the first time. Thereby the group is presenting much more clearly than ever as a single source for the entire injection molding line.

Under the motto “It‘s all Wittmann”, Wittmann Battenfeld is presenting its machines and systems in the new Wittmann design for the first time – and thereby the group much more clearly than ever as a single source for the entire injection molding line, from the machine via automation through to the ancillary equipment with the option of networking via Wittmann 4.0. The exhibitor is offering an innovation that is a perfect fit for the times.

The question of how DC current produced with solar cells on the company roofs can be used to drive injection molding lines directly, and without losses from the circuitous route of inverters, transformers and transmission via high-voltage lines, is answered by Wittmann Battenfeld at its booth. Using a concept study with a model of the all-electric EcoPower series, the machine manufacturer presented the solution and applied for a joint patent with Wago. A DC-operated EcoPower 180/750+, with a 24-cavity mold from Wago, produces a component of its traditional terminal block from a flame-retardant polyamide. The parts are removed with a modified Wittmann robot WX142 in DC design, which is supplied directly via the DC intermediate circuit of the EcoPower, and likewise feeds the excess energy from a delay of the axes into the intermediate circuit.

With this concept, the energy costs can be kept low due to the direct use of solar power. On the other hand direct current can be readily stored in conventional batteries and thus used to cover current spikes. If required, the machine can be switched over to AC operation.

The EcoPower 180 is equipped with the new B8X control unit, which contains in-house developed control components. They allow a higher clock frequency, shorter response times and greater reproducibility of the molded parts, with unchanged operator comfort and the familiar visualization.

In a manufacturing cell conceived and built by Wittmann Battenfeld Deutschland around a SmartPlus series machine, a spirit level is produced in a fully automated process. The new servohydraulic series with B8X control system, which is available with proven technologies and selected options, is, according to the manufacturer, characterized by a high degree of economy, energy efficiency and repeat accuracy. The new injection molding machine, in this case a SmartPlus 90/350, is fitted with the “Wittmann CMS Lite” condition monitoring system.

The spirit level of ABS is produced in a 1+1-cavity mold from Sola. In a first step, the upper and lower parts of the housing are molded. The upper part is deposited in a laser station and printed. At the same time, the lower part deposited on a holder is equipped with spirit levels from Sola. Then the upper part is printed with a predefined force on the lower part. The manufactured parts are conveyed to a test station, where the position of the spirit levels is checked by means of a vision system.

With applications in which renewable raw materials are used, Wittmann Battenfeld demonstrates the processing of alternative materials. Both systems are equipped with the HiQ Flow software, which compensates for viscosity fluctuations in the material.

For the manufacture of a biodegradable ice cream cup with a 6-cavity mold from the precision mold maker Precupa, a material from HopeTree (type: Baopap) is used. This consists of water, vegetable oils and fats, starch, vegetable thickeners and swelling agents as well as natural fibers, and is free of chemicals. According to the manufacturer, it is disposed of in the normal domestic organic waste bin, where the material ought to have degraded completely with no residues after 50 days at most. The material, which is similar to cardboard in terms of its properties can be fed directly to the injection molding machine, in this case an EcoPower 110/750, without prior drying. Post treatment is also not necessary.

In the second application, to be found in the Circular Economy Forum of the VDMA (open air), an EcoPower 110/350 machine with an 8-cavity mold from Bioblo processes the material Fasal into bio-building blocks. This material, produced by Fasal Wood, is a compound of wood flour and post-industrial polypropylene from Borealis. The system is designed as an insider cell, i.e. the Wittmann Robot W918, a conveyor belt, a Wittmann S-Max 3 screenless granulator, as well as the protective housing, are integrated into the production cell.

The injection molded parts are removed including the sprue and the sprues are conveyed directly into the granulator. Here, the sprues are ground and returned to the process. The finished parts are conveyed to a tubular bagging machine and packaged. To ensure the quality of the parts, two further software packages – besides the HiQ Flow assistance system – are used: HiQ Metering for active sealing of the non-return valve as well as HiQ Melt for determining the flowability of the material (MFR, melt flow rate), are used.

Conservation of Resources and  Weight Reduction

A type MacroPower 1100/12800 machine equipped with an energy-saving speed-controlled servo motor and a constant pump, with a one-cavity mold from Frimo, manufactures a door trim that is characterized by its low weight. The module consists of a particularly lightweight natural fiber mat onto which a map pocket of a recycled polypropylene from Borealis is molded. To achieve an additional material and weight reduction, the Cellmould structural foam technology developed and patented by Wittmann Battenfeld is used.

At the beginning of the cycle, a Wittmann Robot WX152 picks up the cut-to-size natural fiber mats from a buffer stack and places them in an IR heating station. Then the heated mats are placed in the injection mold with a combination gripper (removal and insertion gripper), formed, trimmed and overmolded. The finished part and the trimming waste are removed from the fixed mold half before insertion of the natural fiber mat and subsequently conveyed to the deposition position.

Injection-Compression Molding for Reduced Wall Thicknesses

During injection-compression molding (ICM), the melt is injected into a mold that is not completely closed. The final shaping is performed after complete closure of the mold by displacement of the melt into the cavity. The mold can thereby be filled with lower pressure, which reduces the warpage in the part. The ICM process permits processing of a wider material range with high material and energy efficiency and additionally also permits very low and precisely reproducible wall thicknesses and a precise reproduction of surface structures.

With the trade show exhibit, a high-speed EcoPower Xpress 160/1100+ injection molds 230 ml cups of polypropylene with a wall thickness of 0.28 mm in a 4-cavity mold from Glaroform. Due to the highly dynamic drive technology of the injection molding machine, it can achieve the injection times necessary for the ICM process. The machine is equipped with a 4-cavity IML system from Beck Automation. A special feature of the system consists in placing each label, irrespective of its position in the magazine, always at exactly the same position on the IML core. On one hand the number of rejects and on the other hand the operating effort are reduced, since the label magazine no longer has to be manually adjusted. The quality check of the cups is performed by a vision system with ten cameras integrated into the system.

All machines are equipped with the Imagoxt energy management software, an own development by Wittmann Digital Srl., formerly ICE-Flex Srl. This permits the scalable display and visualization of the energy consumptions of the connected machines and equipment. Likewise, the program directly calculates the CO2 consumption and the energy savings already achieved. All the calculated values can be saved in reports and are available for long-term analyses.

Wittmann Battenfeld GmbH  

https://www.wittmann-group.com

Automation cell with SmartPlus 90 for manufacturing a spirit level.

Biodegradable ice cream tray of Baopap and bio building blocks from Fasal.

Door trim of natural fiber mat and recyclate, manufactured with the Cellmould structural foam technology.