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

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

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.

16:9

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

Messe K-Kunststoffmesse

kunststoffe-international.com

Condition Monitoring / Prozessüberwachung

Instandhaltung

Biokunststoffe

Kunststoff Werkstoffe

Oberflächentechnik

Digitalisierung

Kunststoff-Rezyklat

Silikonkautschuk

Kautschuk / Elastomere

Kreislaufwirtschaft

Compoundieren

Kunststoff-Aufbereitung

It Can Be Done!

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

Automation cell with SmartPlus 90 for manufacturing a spirit level.

kunststoffe.de

Spritzprägen

Naturmaterialien

Verstärkungsstoffe

Green DC Current for the Injection Molding Machine

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

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

Hybridtechnik

Reinraumsysteme / -technik

Trip to a Known Destination 

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 

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

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Nachhaltigkeit

Umweltmanagement

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.

Polylactid

Thermoplaste

Medizintechnik

Medizinprodukte

Applications in Three Key Sectors

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.

At the heart of the cube machine is a compact cube designed by our partner Foboha which can be easily accessed from above. The rotation of the cube is powered servo-electrically and the horizontal movement relies on rack and pinion mechanisms

Arburg Expands Hybrid Cube Series

“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.

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

Messe Fakuma

Individual Automation and Digitalization

A year to forget is nearing its completion. To brighten up this dreary fall season without a major event like Fakuma, injection molding machine builders have concocted various strategies.

Fig. 1. Ingrinder system solution: the sprue picker guides the removed sprue via vacuum conveyance to the integrated granulator

Injection Molding Machine Builders Are Discovering New Ways to Reach Their Customers

Vernetzung / Cloudlösung für die Kunststoffverarbeitung

Schneidmühlen

What Can You Do at Fall Fairtime,  When There Aren’t Any?

iQ process observer, the new process monitoring platform from Engel monitors hundreds of parameters from the injection molding cell in the background.

The injection molder is truly not a friend of changes – if they occur in the running process. The iQ process observer helps him to keep an eye on the process and thus keep a handle on the quality

A Process Monitoring Platform Monitors Several Hundred Parameters Simultaneously

Prozessvisualisierung

IoT-Plattformen für die Kunststoffverarbeitung

An Eye on the Process –  a Handle on Quality

Arburg will be showing the hybrid high-performance Hidrive series on its stand no. 21B25 in Hall 2, with an Allrounder 520 H producing 32 pipette tips in around 6 s cycle time.

The hybrid Allrounder 520 H on show at Interplastica is equipped with a 32-cavity mold and produces pipette tips in a cycle time of around 6 s.

High-Tech for Medical Technology

From 25 to 28 January, the OOO Engel team presents its booth in Moscow again. The injection molding machine manufacturer and system solution provider headquartered in Austria is making the huge potential of digital solutions tangible by producing technical parts live on a tie-bar-less victory injection molding machine.

Engel victory injection molding machines with tie-bar-less clamping units.

The Benefits of Tie-Bar-Less Technology

Paul Caprio has left Engel North America effective January 31st, 2022. Now the company presents the new management board.

Engel North America Management Board (left to right): Johann Dastl (CFO), Vanessa Malena (COO), Benjamin Lettner (CSO), Mark Sankovitch (CEO).

New Management Board at Engel North America

In the past, relying on vertical injection molding machines instead of traditional horizontal molding machines when it came to the production of 2-component molded parts was a common option for molding small and medium-sized parts but not for large size parts. But when the automotive supplier Eldisy was faced with parts in that segment horizontal injection molding machines proved to be an inaptly alternative as new vertical machine systems proved as more reliable and therefore more productive. In the Bavarian injection molding machine manufacturer LWB-Steinl, the company found a partner to enter this new territory.

A vertical gantry frame machine with two thermoplastic injection units injecting from above proves to be a “gamechanger” for the production of 2-component automotive components at Eldisy in the German Gardelegen.

Eldisy Switches to Vertical Machines for the Production of Large-Size 2-Components

KFZ-Zulieferer

Dienstleistungen

With a System Change  to New Competitiveness

Injection Molding Innovations In-House, Live and in Color

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.

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 special feature is that by limiting the technical options, the manufacturer can offer the machine with short delivery times and an attractive price/performance ratio. According to the company, the new B8X control system with in-house developed control components deserves mention. They allow a higher clock frequency, shorter response times and greater reproducibility of the molded parts, with unchanged operator comfort and the familiar visualization. The SmartPlus, too, is equipped with the energy recovery technology (KERS) developed for the EcoPower series.

The new machine is currently undergoing practical tests with selected customers. As of the 4th quarter of 2021, it will be available as a first series with clamping forces from 600 to 1800 kN. Its advantages will be showcased in Friedrichshafen, Germany, with a SmartPlus 180/750. The system is equipped with the HiQ Flow application software and the new CMS Light condition monitoring system for monitoring extended, service-relevant machine parameters. An Easy Cell developed and produced at the company’s Nuremberg site in Germany is used for automation with a Primus 26T robot from Wittmann. The cell, mounted on rollers, does not require a safety door, and thereby only takes up a small space beside the injection-molding machine. Despite the compact design, the customer still receives all the CE-compliant safety equipment.

The exhibit is shown manufacturing wheel trims for lawnmowers (mold: Uralan). A mixture of virgin and recycled material is used in the interests of sustainable production. To ensure the quality of the parts, the software HiQ Flow is used. This is an injection controller, which compensates the influences of temperature and batch on the material’s viscosity.

In the manufacture of a medical tube clamp using an 8-cavity mold from Wilamed, digitalization takes center stage. An EcoPower 55/350 all-electric machine is used, which is equipped with the software packages HiQ Flow (for compensating viscosity fluctuations), HiQ Melt (for monitoring material quality) and HiQ Metering (for actively closing the nonreturn valve). The Unilog B8 machinery control integrates a robot, a segmented wheel dryer and three temperature-control units – all from Wittmann as a single source – as well as the Temi+ MES system. The electronic mold data sheet is also stored in the control system. The production cell, networked by means of Wittmann 4.0 routers, can use it to check whether the connected ancillary equipment is adequate for the preselected product data record or whether further equipment is required.

The production of a support ring from PC with a silicone membrane shows how Wittmann-Battenfeld combines its skills in the fields of LSR processing and micro injection molding. For this purpose, a MicroPower 15/10H/10H of multicomponent design (Combimould) is equipped with two horizontally oriented injection units and a turntable. The machine is designed for cleanroom injection molding. The turntable is completely encapsulated; all the connections for heating, temperature sensors, water temperature control, core-puller pneumatics and sensors, as well as relief valves, are provided on the turntable. As with the standard machine, the injection units of the 2-component machine are also implemented in the form of two-stage screw-plunger units with a shot volume of 4cm³, which, with short flow paths, ensure the melt is thermally homogeneous melt, thus provide high part quality. The LSR dosing system, like the mold, comes from Nexus, and is equipped with a new Servomix dosing system with OPC UA interface (Euromap 82.3).

All the machines shown at the Wittmann booth are equipped with Imagoxt, an add-on module for the Temi+ MES. The software allows the energy consumption or energy flow to be visualized and monitored. Imagoxt allows a detailed energy cost analysis for the connected machines to be prepared. User-defined KPIs can subsequently be output, personalized reports and alarm displays generated and the company’s energy performance monitored.

However, “live” this time means more than just having a local presence. In addition to the systems shown at the tradeshow booth, the new Wittmann Interactive media technology will give visitors an insight into further exhibits, with live link-ups to the sites in Kottingbrunn, Austria, Meinerzhagen, Germany, and Nuremberg. For example, Wittmann Battenfeld demonstrates the manufacture of a sports car seat carrier of PP with the lightweight technology Cellmould, a variant of physical foaming and a towel holder of polystyrene with the Airmould Next enhanced gas assist technology.

Wittmann-Battenfeld presents injection compression molding (ICM) technology by live stream from its pilot plant on a high-speed machine EcoPower Xpress 160/1100+. The melt is injected into the mold before it is completely closed and shaping takes place after complete mold closing. The mold can thereby be filled with lower pressure, which reduces the warpage in the part. Thin-walled cups are produced here in a short cycle time with a 4-cavity mold from Glaroform. The dynamic EcoPower Xpress drive technology can deliver, in particular, the short injection times necessary for the ICM process.

And finally, in a joint project with Leonhard Kurz, a manufacturer of functional films and film-feed equipment, and Syntech Plastics, the machine manufacturer is pressing ahead with the promising topic of decorated and functionalized surfaces, for both the automotive industry and white goods. They are working on a plant concept that provides all the essential elements for four different decoration processes, and can be adapted to the specific applications. It can be seen via Wittmann Interactive with the example of manufacturing an interior part with a functional surface. The part itself is exhibited at the tradeshow booth.

Wittmann Battenfeld GmbH  

https://www.wittmann-group.com

The new SmartPlus machine is equipped with the HiQ Flow software and the CMS Light condition monitoring system

Airmould Next, the next generation of a gas-assist module is used in the manufacture of this towel holder

A medical tube clamp is manufactured with a production cell fully networked via “Wittmann 4.0”