Susanne Schröder will become editor-in-chief of the magazines Kunststoffe and Kunststoffe international on December 1, 2020. The current editor-in-chief Dr. Karlhorst Klotz will leave the company by mutual agreement.

Susanne Schröder will become editor-in-chief of the magazines Kunststoffe and Kunststoffe international on December 1, 2020. Until now she has been editor-in-chief of the trade journal FORM+Werkzeug

16:9

Werkzeuge für Leichtbauwerkstoffe

Präzisionswerkzeuge

Tiefziehwerkzeug

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Werkzeugüberwachung

Toolmanagement

Werkzeugwechselsysteme, Spritzgieß

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Spritzgießwerkzeuge

Werkzeug- und Formenbau

Modulare Werkzeugsysteme

Absaugungen für Werkzeugmaschinen

Betriebsausrüstung / Betriebsmittel

Absaugvorrichtungen

Fluorkunststoffe

Kunststoff Werkstoffe

Thermoplaste

Werkzeugverwaltungssoftware

Prüfen von Kunststoffen

Messtechnik

Biokunststoffe

Presswerkzeuge, Kunststoff

Werkzeugreinigung, Kunststoffe

Standardkunststoffe

Kunststoffverarbeitung

Lohnfertigung

Technische Kunststoffe

Füllstoffe für Kunststoffe

Kunststoff

Bauwesen

Baustoffe

Kunststoffhandel

Handel

Betriebstechnik für Kunststoffverarbeitung (Peripherie)

Kunststoffverarbeitung: Verfahren

Kunststofffasern

Verstärkungsstoffe

Kunststoff-Recycling

Kunststoff-Aufbereitung

Hochleistungskunststoffe

Qualitätssicherung Kunststoff

Qualitätssicherung

Change in the Chief Editorial Office of Kunststoffe

The consumables required for In-vitro diagnostics are manufactured in a production process that is subject to high requirements in terms of precision and quality, but also the complex cleanroom manufacturing environment. This has implications for the entire plant technology – especially toolmaking.

64-cavity tool for pipette tips. The hot runner system is balanced across all cavities

Strategic Approach through Classification according to Product Groups

Spritzgießen

Medizinprodukte

Medizintechnik

Mold Platforms for IVD Consumables

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

Sensoren / Messwertaufnehmer

Messdatenerfassung und -verarbeitung

Software

Papierlose QM-Dokumentation

Qualitätsmanagement

Dokumentationsmanagement

Werkzeugkonstruktion

Mobile Datenerfassung

Logistik

Lagertechnik

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Fernwartung / Ferndiagnose

Instandhaltung

Dokumentenmanagement, CAQ

Data Management at the Tool

Unforeseen downtimes in serial production are always accompanied by high costs, making it essential for machines to be serviced in time. Because sensor, transmission and data storage technology have taken a big leap forward in recent years, predictive maintenance has already been realized in some industries, demonstrating a tangible benefit of Industry 4.0. The WZL and the WBA have developed a guideline for this.

Fig. 1. The guideline for the development of predictive maintenance solutions is divided into three phases: analysis, design and implementation

Guideline to the Development of Predictive Maintenance Systems for Serial Producers and Toolmaking Companies

Industrie 4.0 für die Qualitätssicherung

Industrie 4.0

Condition Monitoring / Prozessüberwachung

Sensoren verschiedener Messverfahren

Fertigungsautomation

Sensorik / Aktorik

Machine Learning

Datenanalyse

Dienstleistungsqualität

Industrie 4.0 für die Kunststoffverarbeitung

Instandhaltungsmanagement (TPM)

Vorbeugende Instandhaltung für die Qualitätssicherung

Werkzeugbau

Machine Learning für die Qualitätssicherung

Symbiosis of Toolmaking and  Serial Production

At HRSflow‘s headquarters in San Polo di Piave, Italy, a new production facility for hot runner systems based on lean manufacturing principles was recently completed.

The new HRSflow hot runner plant in Italy

3000 sqm for Lean Manufacturing

Normalien und Heißkanaltechnik

Komponenten für die Kunststoffverarbeitung

HRSflow Expands Headquarter

The toolmaking industry of the future is facing significant changes in its range of services and its value creation processes. It is difficult to predict exactly how the collaboration of German tool manufacturers with series production will be structured in the future. However, it can be assumed that digital networking and sustainability will play a key role.

What the Two Trend Topics Mean for Collaboration between Toolmaking and Series Production

Nachhaltigkeit

Umweltmanagement

Energieeffizienz

Ressourcenmanagement

Produktion

Toolmaking of the Future –  Digitalized and Sustainable

Maintaining competitiveness while producing in Germany requires not only cost-efficient production, but also high-quality products. Vorwerk Elektrowerke is accepting this challenge. In collaboration with the Institute of Product Engineering at the University of Duisburg-Essen, Germany, the company is testing a 100 % inline quality monitoring system as well as a quality prediction using machine learning.

Customers who choose the Kobold VK 200 vacuum cleaner expect top quality. To ensure this, efforts for the introduction of Industry 4.0 measures are taken in the production plant in Wuppertal, Germany

Successfully Managing Digital Transformation with Automation and Artificial Intelligence

Künstliche Intelligenz für die Qualitätssicherung

Mehrkomponenten-Spritzgießen

Kameras, intelligente

Bildverarbeitung

Machine Learning / Künstliche Intelligenz für die spanende Fertigung

Industrie 4.0 für die spanende Fertigung

Inline- / Online-Messsysteme

Inline Quality Monitoring and  Data-Based Quality Prediction

Closing the circle: a tool manufacturer with a long track record in injection molding is taking particle foam processing to the next level. A new machine and highly efficient molds are intended to streamline the technology and make it interesting even for injection molders.

Managing Director Stefan Hofmann (left) and Project Manager Johannes Schütz in front of the prototype of the new “<a href="http://Bead.Machin">Bead.Machin</a>e”, the development of which started a good two years ago © Hofmann

On the Launch of a Molding Machine for Particle Foams

Doriat, Clemens, Dr.

Innovationsentwicklung

Partikelschäumen

Schäumen / Reaktive Verarbeitung

The Impulse Machine

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

Paletten und Behälter

Verpackungstechnik

Heißkanalsysteme

With Broad Sword and Data Collector

The spring clamping cylinder ESZS for a nominal clamping force range from 16k N to 350 kN enables hydromechanical clamping.

The ESZS spring clamping cylinder can be used wherever shiftable or movable machine parts have to be fixed or clamped

Werkzeugspanntechnik

Spanntechnik

Robust and Reliable Clamping

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

Moldmakers and manufacturers of injection molding machines or peripheral equipment will present some of their collaborations.

Messe Moulding Expo

form-werkzeug.de

Spritzgießmaschinen

Production Concepts for Moldmaking

Since many years, the South German plastics processor/finisher Varioplast Konrad Däbritz GmbH has focused on the subject of resource conservation. At the Fakuma, Varioplast will present its latest inline production options.

Networked processes reduce the number of rejects, cut energy demand, and shorten transport routes, thereby contributing towards resource conservation

Beschichten (CVD, PVD)

Oberflächentechnik

Chemisches Bearbeiten (Auftragen)

Messe Fakuma

kunststoffe-international.com

Lackierroboter

Montagetechnik

Industrieroboter

Lackieren

Automatisierungstechnik

Resource Conservation with Networked Process

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

Steuern, Regeln

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

Spritzgieß-Sonderverfahren

Spritzgießsimulation

Simulation

Schnecken und Plastifiziersysteme

Lasermarkieren

Laserbearbeitungen

Kreislaufwirtschaft

There Is More beyond the Horizon

Until now, the dimensioning of plastic gear required the measurement of the tooth selectively and manually before, during and after a transmission test. A newly developed in-situ transmission test bench makes it possible to investigate tooth deformation and wear behavior quasi-continuously during the transmission test, thus reducing effort and operator influence. Non-linear behavior can also be better detected.

Gear tooth wear: representation of material removal on the tooth flanks of a gear pairing in accordance with VDI 2736, size 1

Application-Specific in-situ Transmission Testing of Injection Molded Plastic Gears

Zahnräder

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Verschleißprüfgeräte

Werkstoffprüfung

Zahnradmessgeräte

Form- / Oberflächenmesstechnik

Inline-Messtechnik

Micrometer Accurate Measurement  of Tooth Wear

The Advantages of a Network for Global Qualification for Injection Molding

During this year’s pandemic, maintaining supply capability has become a key necessity among processors. Closer involvement of suppliers is only logical in these circumstances. In toolmaking, new challenges are emerging for services related to molds. This is where the global, high-performance infrastructure of Barnes Molding Solutions enters the picture. The slogan here is “globally qualified local manufacturing.”

During this year’s pandemic, maintaining supply capability has become a key necessity among processors. Closer involvement of suppliers is only logical in these circumstances. In toolmaking, new challenges are emerging for services related to molds.

The so-called “Global Hybrid Qualification” offered by Molding Solutions, a strategic business unit within Barnes Group (see Box p. 8) involves technology transfer based on global manufacturing capability, for which all units are tailored and harmonized for qualification of customer molds (Fig. 1). The activities involved in the process were further extended and refined during the pandemic in 2020. Norbert Scheid (Fig. 2), President of Barnes Molding Solutions, stated, “The key focus is to stay in close contact with customers all across the globe. The goal is the highest process reliability and availability of molds, regardless of where the customer manufactures.” The concept is related to all high-performance mold systems within Barnes Molding Solutions, including customer-specific hot runner systems, control technology, and process control.

The Strategic Approach of Standardized Quality Guidelines

Global Hybrid Qualification is based on two underlying principles. On one hand, customers can receive faster and more qualified support if an entire global network is utilized for the project. On the other hand, many customers are globally positioned and want to use production molds at different locations, according to defined quality standards. “The toolmaking industry must meet global demand with global solutions,” said Norbert Scheid. “Barnes Group supports this conceptual approach of global customer proximity through group-wide technology transfer.”

The most important criteria for global cooperation between Barnes Molding Solutions’ companies in Europe, the USA, and Asia are standardized quality guidelines related to CAD/CAM processes, our fleet of machine tools, and qualification. The qualification process can be carried out according to customer specifications or according to our uniquely-developed Barnes Molding Solutions benchmark. The “Molding Solutions Qualification Standard” was developed following strict scientific molding criteria.

Molds can be built in the Barnes Molding Solutions plant in China and prepared for sampling and qualification. In Suzhou, a pre-qualification routine – the FOT process (First off Tool) – is initially carried out. These molds are then subject to final qualification testing at group network locations in Europe or the USA. During the current pandemic, however, the model for developing and manufacturing molds in Europe (Germany and Switzerland) and finally qualifying them in the USA is also becoming increasingly important.

Tech Centers Bring together Qualification Expertise

Name - Hauptartikel