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.

Injection Molding Trends at K 2019

Spritzgießen

Kunststoffverarbeitung: Verfahren

Schaumspritzgießen

Smart Factory

Energieeffizienz

Mikrospritzgießen

Mehrkomponenten-Spritzgießen

Spritzgießmaschinen, allgemein

Kunststoffverarbeitung: Maschinen und Komponenten

Spritzgießmaschinen

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Fließpressen

Handling, Handhabungstechnik für die spanende Fertigung

Automatisierungstechnik

Handling, Handhabungstechnik

Spritzgieß-Sonderverfahren

Spritzgießsimulation

Software

Simulation

Elastomer-Spritzgießen

Linearroboter für die Kunststoffverarbeitung

Industrieroboter

Montagetechnik

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Montage-Spritzgießen

Knickarmroboter

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Hybrid-Spritzgießen (Metall / Kunststoff)

Ressourcenmanagement

Produktion

Technical Excellence thanks  to Digital Assistance

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.

Messe Fakuma

kunststoffe-international.com

Spritzprägen

Injection Molding Innovations In-House, Live and in Color

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

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

Temperiertechnik

Reinraumsysteme / -technik

The Communicative Machine 

The new Reverse Cube developed by Foboha manufactures various components or multi-component parts from varying materials in one step and assembles individual parts into finished products independently from the cycle time using an integrated handling robot. The automated process improves quality, accelerates cycle times by up to 40 % compared to separate injection molding and assembly processes, and thus enables substantial productivity gains at lower costs.

Manufacturing and Installing Multi-Component Parts on a Two-Part Cube Mold

Montage

Steuern, Regeln

Werkzeugtemperatursensoren

Messtechnik

Sensoren / Messwertaufnehmer

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

Reverse Rotation

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.

Arburg Expands Hybrid Cube Series

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.

Medizintechnik

Kreislaufwirtschaft

Optimized Motion Planning for Shorter Cycle Times

iQ motion control from Engel now allows reliable early start combined with fully automatically optimized motion planning. The assistance system has been part of the standard kit of all new Engel viper-type linear robots since October 2021.

iQ Motion Control Brings the Injection-Molding Machine and Robot Closer together

A Production Cell with Fluid Movements

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.

Innovative Injection Molding in Times of Pandemic

Künstliche Intelligenz für die Qualitätssicherung

Industrie 4.0 für die Qualitätssicherung

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Biokunststoffe

Kunststoff Werkstoffe

Nachhaltigkeit

Umweltmanagement

Schnecken und Plastifiziersysteme

Machine Learning / Künstliche Intelligenz für die spanende Fertigung

Industrie 4.0 für die spanende Fertigung

Kunststoff-Recycling

Kunststoff-Aufbereitung

Lasermarkieren

Oberflächentechnik

Laserbearbeitungen

Inline- / Online-Messsysteme

Qualitätssicherung

Qualitätssicherung Kunststoff

There Is More beyond the Horizon

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

Trip to a Known Destination 

6700 guests from over 50 countries – once again the Technology Days, held from March 15 to 18, 2017 at Arburg, confirmed the company’s strategy. Roughly 50 exhibits were on display, covering all major topics such as lightweight construction, medical technology and packaging. Situated in the Black Forest in Germany, Arburg followed a "pragmatic" approach to "Industry 4.0", this year.  

Arburg Technology Days: From Prototyping Center to Turnkey Injection Molding Solution 

Additive Fertigung

Magnet for Visitors 

In contrast to recent years, when particular key themes often dominated the fair exhibits of the leading injection molding machine builders, this year’s Fakuma will present more combinations of many different competences in complex production cells. Thus, Industry 4.0 not only takes slowly concrete shape, but is put into context with peripherals and controls in the development of new series. 

Re-Inventing Injection Molding Holistically  

Servomotoren

Instandhaltung, Wartung in der spanenden Fertigung

Polyurethan

Gasinjektionstechnik

Machines as the Heart of Production 

Making a racket is part of the trade. In the past, tradesmen would do this at markets by swinging wooden rattles to attract attention. Today, instead, it is the industry which is trying to make its developments heard and accepted, for example at trade fairs and in the media. What has injection molding technology had to offer recently, aside from Industry 4.0? The answer is process developments that in the main expand the range of applications for plastic parts, mechanical assistance systems that enable consistently high part quality to be achieved more reliably, and the huge field of temperature control. 

New Ways to Attain Special Part Properties Are Advancing the Art of Injection Molding 

Making a Racket for Plastics  

The integration of individual parts to a multifunctional assembly is one of the important innovation potentials of plastic injection molding, e. g. the production of glass window modules for car rear doors, as practiced at Henniges Automotive. They consist of the glass pane, a web strip, and fastening clips, which are overmolded by a TPE frame to a ready-to-install assembly. For the manufacturing the automotive supplier relies on vertical C-frame injection molding machines from LWB Steinl. 

Assembly of Higher Integrated Car Window Modules through Injection Molding 

KFZ-Zulieferer

From the Vertical Machine into the  Car Door 

Single-serve capsules as used, for example, for coffee, are a booming product in the packaging sector. The latest generation of capsules is injection molded and includes an integrated barrier layer to conserve flavor and aroma while saving material compared to alternative manufacturing processes. These complex injection molding parts are produced in high volumes by a Swiss company using Arburg machines.

Lapp Tec Employs Sustainable, Efficient Solutions for Barrier Capsules

Aroma-Tight and Cost-Effective

In injection molding, the component weight reflects the process consistency and the component quality. Components are therefore often weighed manually after production or automatically placed on a scale and picked up again. Engel has now developed a high-precision load cell for inline weight measurement that can be integrated directly between the rotary axes and the end-of-arm tooling of a linear robot.

Weight Measuring System Directly on the Robot Ensures Process Quality

Automatisierungskomponenten

Wiege- und Dosiersysteme

Logistik

Verpackungstechnik

Weighing without Time Overhead

“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.

In a fully automated production cell, a Boy 80 E hybrid, in conjunction with a Boy 2C S injection unit, will produce a wine pourer. Besides the energy-efficient servo drive, the hybrid machine is equipped with an optional electromechanical drive for the injection unit (eSP). The rotational and axial movements of the Servo-Plast unit are executed by two servo motors, completely detached from the machine hydraulics. The LR 5 handling unit removes the final two-component part and feeds it to an ultrasound welding unit, where a plastic decanting insert is welded into the pourer.

The biggest of the Boy injection-molding machines, a Boy 125 E with 1250 kN clamping force and only 5.22 m² footprint – demonstrates its effectiveness in producing stacking boxes. The stacking boxes, weighing 77 g, are injection molded in a cycle time of 17 s, and removed by the gripper hand of the LR 5 handling unit and fed to a printer. After marking, the stacking boxes are laid on an integrated conveyor belt.

A Boy 35 E manufactures dental caps from a 2-component liquid silicone. The vertical Boy LR 5 extremely compact telescopic handling unit takes the LSR caps from a four-cavity mold and places them on a conveyor belt. The four tie-bar machine is impressive for its large-dimensioned twin-platen clamping unit and comparatively inexpensive machine-hour rates. The removal handling device of the fourth exhibit, a Boy 25 E, is completely integrated under the safety cover. In the medical application, the side window parts of a respirator mask are removed from the mold by the picker and placed on a small conveyor belt that is also integrated under the safety cover. With a footprint of only 1.9 m², this automated system is among the most compact manufacturing cells at Fakuma 2021.

Dr. Boy GmbH & Co. KG  

https://www.dr-boy.de

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

2021-09-24 spritzgießen Boy

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FACHARTIKEL_2021, FACHARTIKEL_2020, FACHARTIKEL_2019, FACHARTIKEL_2018, FACHARTIKEL_2017, INTERVIEWARTIKEL_2021, INTERVIEWARTIKEL_2020, INTERVIEWARTIKEL_2019

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