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

Spritzgießen

Kunststoffverarbeitung: Verfahren

Industrie 4.0 für die Qualitätssicherung

Industrie 4.0

Condition Monitoring / Prozessüberwachung

Instandhaltung

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Paletten und Behälter

Logistik

Verpackungstechnik

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Industrie 4.0 für die Kunststoffverarbeitung

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

With Broad Sword and Data Collector

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)

16:9

Personen

kunststoffe.de

Zahoransky Introduces Expanded Management Team in India

A tool logbook on paper is often not to hand just when you need it most. Or it is incomplete, since it is time consuming to keep the information up to date. A cloud-independent, electronic tool log, which is directly integrated into the tool could make all the relevant data available directly.

The installed ImPro module in use on a demonstrator tool under production conditions 

The Electronic Tool Logbook as a Combination of Operating Manual and Check List

Werkzeuginnendrucksensoren

Messtechnik

Sensoren / Messwertaufnehmer

Messdatenerfassung und -verarbeitung

Software

Papierlose QM-Dokumentation

Qualitätsmanagement

Dokumentationsmanagement

Werkzeugkonstruktion

Werkzeugüberwachung

Toolmanagement

Mobile Datenerfassung

Lagertechnik

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Werkzeug- und Formenbau

Fernwartung / Ferndiagnose

Dokumentenmanagement, CAQ

Qualitätssicherung

Data Management at the Tool

Marbling is often a real eye-catcher in plastic components. However, the effect is difficult to create and there are some pitfalls when it comes to reproducibility. Novel nozzles for injection molding machines in combination with a special dosing technology allow marbled molded parts to be produced far more easily in a much more robust process.

Marbling leads to attractively designed molded plastic parts, but is not so easy to implement in production

A 3D-Printed Nozzle and Modified Dosing Method Deliver Reproducible Marbling  in a Robust Process

Kunststoffe

Photonik

Optik

Additive Fertigung

Farben, flüssig

Kunststoff Werkstoffe

Additive

Exciting Design instead of  Exciting Manufacturing

The toolmaker Siebenwurst uses injection molding simulation to optimize part design and production processes in its routine workflows. Among other things, Simcon’s software ensures the quality and dimensional accuracy of the plastic frame for the first series-produced injection molded e-bike.

The frames give the e-bikes an extraordinary design, with robustness comparable to steel or aluminum

Controlling Complex Development and Manufacturing Processes, Using Simulation

Composite-Halbzeuge

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Verbundwerkstoffe / Werkstoffverbunde

Spritzgießsimulation

Simulation

A Bike Frame from an Injection  Molding Machine

At the 2019 K fair, Arburg and Simcon showcased a filling process proceeding in real-time, as a 3D animation, on the display of a machine control panel, for an example of sunglasses, made of PA12. All that was needed to prepare this, was to load the simulation model, as well as the geometry of the part, directly onto the machine controls. This sounds almost too easy to be true. Right?

The Interviewees Dr. Paul Filz (left) an Dr. Eberhard Duffner

Interview with Eberhard Duffner and Paul F. Filz by the Magazine Kunststoffe

Doriat, Clemens, Dr.

Interview

Electrical components are made from conductive and nonconductive materials. Pressure of competition makes it necessary to reduce the number of components and work steps and to streamline assembly. The moldmaker Mühlbeyer uses a hybrid technology for manufacturing stators and rotors, in which the contact material and plastic are permanently bonded in one production step.

Various plastic-coated stators. During overmolding of the sheet components, not only insulation but also technical functions can be incorporated

Overmolding as a Prerequisite for Cost-Efficient, High-Quality Electric Motors

Elektromotoren

Antriebe

Hybrid-Spritzgießen (Metall / Kunststoff)

Injection Molds for Insulating  Stators and Rotors

Aside from offering high mechanical strength, versatility and durability, polymer materials are ideal for applications in the electrical industry because of their ability to isolate electrical current.

For the conduction cooled MicroTCA systems, Harting processes LCP, a material that is flame-resistant, dimensionally stable at high temperatures, chemically resistant, and has only a low thermal expansion

Connectors for Industrial Lifelines: High-Tech Injection Molding at Harting

Hybridtechnik

Polymere, flüssigkristalline

Thermoplaste

Stanzen

Verfahren für die spanlose Fertigung

Schneiden

Steckverbinder

Elektromechanik

Well-Balanced Hot Runner Technology for LCP Processing

Hybrid production chains have been increasingly in the spotlight in recent years. This also applies to the combination of conventional manufacturing and additive processes in tool construction. With the example of an injection molding tool, it is shown how mold inserts produced by additive manufacturing can greatly shorten cycle times, and thereby significantly reduce unit costs. The important thing is to find a suitable combination of processes from the variety available.

Tool insert for a spacer of a glass fiber-reinforced PA66. The example shows that hybrid manufacturing is suitable and provides added value, even with comparatively simple parts

Additive Manufacturing and Hybrid Molds in Combination with Conventional Machining

HSC- / HPC-Bearbeitung

Spanende Verfahren

Anlagen Additive Fertigung / 3D-Druck, Metall

Anlagen für die Additive Fertigung

The Potential of Redesign and  Part Consolidation

Starting with the systematic design of manufacturing processes and the precise simulation of part manufacture, through smart tooling technology and sophisticated melt guidance, to efficient mold temperature control, numerous exhibitors have many innovations in the field of tooling technology on offer at K 2019.The current debates concerning marine pollution as well as anthropogenic climate change and its consequences seem to be having an effect at this world-leading trade show for plastics processing in Düsseldorf, Germany. A number of companies are noting the growing customer interest in sustainable, carbon-neutral and resource-efficient modes of production, and offering products and services intended to satisfy this interest.

Resource-Efficient and Environmentally Friendly Products Are the Trend in  Tooling Technology

Temperiergeräte

Gießanlagen

Temperiertechnik

Normalien für die Kunststofffertigung

Normalien

Kaltkanalsysteme

Exhibitors See Green

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.

Two thermally separated cube molds rotate in opposite directions at a 90° angle. Bottom: injection and cooling of component 1 (roller made of PP) and component 2 (female connection made of POM), staggered by 180°

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

Montage

Montagetechnik

Steuern, Regeln

Mehrkomponenten-Spritzgießen

Werkzeugtemperatursensoren

Industrieroboter

Spritzgießmaschinen

Reverse Rotation

For a cutlery series made of a new biopolymer, three full hot runner molds with digital process monitoring were developed in close cooperation with mold maker Uniform and hot runner specialist Ewikon.

The 16-drop family mold on the machine. The removal and packaging of the parts are fully automated

Complete Digital Hot Runner Solution for Automated Biopolymer Processing

Biokunststoffe

Virtual Reality für die Qualitätssicherung

Process Reliability Is Crucial

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

Medizintechnik

Medizinprodukte

Maintenance During (Nearly)  Uninterrupted Production

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

Schaumspritzgießen

Künstliche Intelligenz für die Qualitätssicherung

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

Spritzgieß-Sonderverfahren

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 Kunststoff

Kreislaufwirtschaft

There Is More beyond the Horizon

A Polish pharmaceutical company is developing inhalation therapy for the treatment of lung disease and the appropriate drug delivery drug. The inhaler has a complex interior and consists of 14 components. In order to be able to produce these with the required precision, Celon Pharma has formed a partnership with the mold making company Glittenberg and its hot runner sister Witosa.

For its complex functional mechanism, the inhaler requires 14 components

Glittenberg Supplies Tools for Vital Medical Devices to Celon Pharma

Plastic in the Service of Medicine

Molding Solutions – a business within Barnes – is bundling the expertise of its members and will be represented with its mold and hot runner technology and controls at its own booth as well as at those of partners.

Molding Solutions – a business within Barnes – is bundling the expertise of its members Männer, Foboha, Synventive, Thermoplay, Priamus, and Gammaflux and will be represented with its mold and hot runner technology and controls at its own booth as well as at those of partners.

At its own booth in Hall 1, the Molding Solutions network will show how digitization is helping to simplify recycling of packaging materials. Packaging made of a certified bio-based material is given a digital watermark so that recycling centers can automate the separation of these digitally marked products in the waste stream. The mold inserts were laser engraved to apply the digital watermark onto the mold, which then applies it to the part when molded. A special camera detects the watermarks in the plastic part. By scanning the product with a digital watermark app, consumers can access a digital product passport with recycling-relevant information.

moldMind, the „digital cockpit“ of the injection mold, is a recording system that documents relevant process data and events of an injection mold in real-time throughout the entire life cycle of the mold. The intelligent monitoring system detects problems quickly to minimize downtime. The data can be accessed directly on the device or in the Barnes Connectia Cloud, which will celebrate its premiere at the K Show.

Focus on hot runner process control at Synventive

Synventive will showcase a new electric valve gate. Synventive’s new compact eGateTM Sync will complement the legacy eGate system. The cost-effective eGate Sync impresses with its plug-and-play installation and simple user interface. Quality is improved by increasing shot-to-shot consistency – all with significant energy savings compared to hydraulic systems.

With the new hot runner configurator, 3D data of 2-, 4-, or 8-drop hot runner systems with top-selling nozzles from Männer and Synventive can be created within minutes. The step-by-step configuration can draw on a material database of more than 12,000 resins. Customers generate customized 3D data easily and quickly through the application check, which includes a follow up with an application engineer for applications outside of guidelines. Männer and Synventive’s configurators are available today, while Thermoplay’s is expected to soon follow.

New and proven hot runner and control technology for multi-cavity applications

Männer is expanding its Packaging and Slimline product range with additional valve gate nozzles. The Packaging range for high-speed molds is complemented by the „MCN-EP,“ with a small diameter and permanently centered valve gate pin. The design of the nozzle tip facilitates high-precision gating and enables the correction of tip protrusion without reworking (patent pending). Like the proven MCN 8 and MCN 6.5, the new MCN 5 valve gate nozzle from the SLIMLINE series is ideal for tight installation conditions in high-cavity molds. Männer has not only the nozzle in mind, but also the optimization of the manifold. A 3D printed manifold designed using artificial intelligence is used to show how the design of flow bore helps a non-symmetrical 6-drop hot runner system achieve perfect balancing.

Thermoplay has added two nozzles to its „TFS“ series – the open nozzle series for side injection – for larger part volumes. Additional Thermoplay innovation is aimed at special applications. For example, Thermoplay has created nozzles for a 45° gate to produce conical parts as well as multi-tip nozzles for small parts that are gated with several gating points. Thermoplay sees 3D printing as an option for fast delivery times and is introducing a new multi-nozzle with an additively manufactured collar.

Gammaflux rounds off the portfolio with its proven hot runner temperature control technology. With its in-house Triangulated Control Technology and up to 192 zones, the G24 is one of the top seller among temperature controllers on the market.

Processing PCR and biomaterials with digital intelligence

Adding digital intelligence to high-precision mechanics is a high priority for Molding Solutions. When processing new PCR and biomaterials, injection molders struggle with material fluctuations, which makes process-reliable production difficult. The Fillcontrol process monitoring system from Priamus identifies and corrects material fluctuations that contribute to decreased quality through dynamic process control by adjusting the manipulated variables of pressure and temperature signals.

<b>Barnes at the K Show 2022: Hall 1, booth C 50</b>

Synventive Molding Solutions GmbH  

https://www.synventive.com

FOBOHA (Germany) GmbH  

https://www.advaltech.com

Gammaflux Europe GmbH  

https://www.gammaflux.de

Otto Männer GmbH  

https://www.maenner-group.com

Thermoplay S.p.A.  

https://www.thermoplay.com

Priamus System Technologies GmbH  

https://www.priamus.com

Barnes Group Inc.  

Digital Watermark Technology: 6-cavity Foboha mold with laser engraved inserts to apply the digital watermark.

Digital Watermark Technology: Closure with digital watermark

2022-09-23 Barnes Group auf der K

Barnes an den Ständen von Partnerunternehmen

The Molding Solutions network will display an additional five molds and several hot runner systems, as well as temperature controllers and process control systems at partner booths.

KraussMaffei will demonstrate how material can run through several product life cycles in the future at its booth in Hall 15. Medical consumables are produced from PP in Männer‘s 96-cavity mold, after which the material is granulated and fed to the production of automotive parts, also at the KraussMaffei booth.

Pipette tips are manufactured and removed under this specification at Netstal in Hall 15. The turnkey system consists of a 64-cavity pipette tip mold with hot runner from Männer, a Netstal Elion 2800–870, and high-speed automation from MA – micro automation. The network of experts show that the close integration and coordination with product specialists can make it easy for customers to configure a high-performance production cell with a clear ROI.

High-speed production with lateral removal

At its booth in Hall 11, Yushin will rely entirely on lateral demolding robots. Blister packs are produced in a 16-cavity Männer mold and removed laterally, in a Netstal Elion 800. Thanks to the cycle time-optimized Männer mold, the performance of the Netstal injection molding machine and the high-speed robot from Yushin, cycle time can be reduced by up to 3.5 seconds.

Balancing and energy efficiency optimization