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.

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

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.

Successfully Managing Digital Transformation with Automation and Artificial Intelligence

Spritzgießen

Industrie 4.0 für die Qualitätssicherung

Industrie 4.0

Künstliche Intelligenz für die Qualitätssicherung

Mehrkomponenten-Spritzgießen

Digitale Transformation

Wirtschaft

Innovationen und neue Technologie

Kameras, intelligente

Fertigungsautomation

Bildverarbeitung

Industrie 4.0 für die Kunststoffverarbeitung

Machine Learning / Künstliche Intelligenz für die spanende Fertigung

Industrie 4.0 für die spanende Fertigung

Datenanalyse

Inline- / Online-Messsysteme

Inline Quality Monitoring and  Data-Based Quality Prediction

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 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

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.

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

Condition Monitoring / Prozessüberwachung

Sensoren verschiedener Messverfahren

Sensorik / Aktorik

Machine Learning

Dienstleistungsqualität

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.

3000 sqm for Lean Manufacturing

Normalien und Heißkanaltechnik

Komponenten für die Kunststoffverarbeitung

HRSflow Expands Headquarter

With the Corona pandemic sweeping the world, considerable energies are being freed up and focused on developing and manufacturing urgently required medical equipment. Working under extreme time pressure, the OKE Group GmbH, based in Hörstel, Germany, has developed a concept for a full-face mask that can be quickly implemented and, according to the manufacturer, offers reliable basic protection. 

Implementing a Face Mask Concept in Record Time 

Heißkanaltechnik

Medizintechnik

Small Injection Moldings for Protection against Corona 

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.

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

Kunststoffe

Photonik

Optik

Additive Fertigung

Farben, flüssig

Additive

Exciting Design instead of  Exciting Manufacturing

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?

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

Doriat, Clemens, Dr.

Spritzgießsimulation

Simulation

Interview

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.

Controlling Complex Development and Manufacturing Processes, Using Simulation

Composite-Halbzeuge

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Verbundwerkstoffe / Werkstoffverbunde

A Bike Frame from an Injection  Molding Machine

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.

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

Mit dem Jahreswechsel 2020/2021 hat Daniel Sieberer vom bisherigen Alleineigentümer Julian Götzfried einen Geschäftsanteil von 80% an der GIWA GmbH mit Sitz in Westendorf übernommen. GIWA entwickelt und produziert mit rund 200 Mitarbeitern anspruchsvolle Kunststoffteile.

Personen

kunststoffe.de

Neuer Mehrheitseigentümer für die GIWA GmbH

Tool and mold makers are detail oriented and innovative. Prof. Thomas Seul and Fabian Diehr met with some industry players to explore different paths they have taken through the thicket of this industry-jungle they have to deal with.

A Journey through the Landscape of the Tool and Mold Making Industry

Mikrospritzgießen

Innovationsmanagement

Produktentwicklung (F+E)

Projektmanagement

Handling, Handhabungstechnik

Automatisierungstechnik

Reinraumsysteme / -technik

Produktmanagement

Trend Setting or Following?

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.

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

Zahnräder

Verschleißprüfgeräte

Werkstoffprüfung

Zahnradmessgeräte

Form- / Oberflächenmesstechnik

Inline-Messtechnik

Micrometer Accurate Measurement  of Tooth Wear

The mechanical properties of plastic compounds are an important quality criterion. At present, however, they can only be determined by laboratory measurements with a time delay. Online measurement procedures during compounding save time and prevent errors during the production process. A research project shows how the impact strength and hardness of the compound strand can be measured online.

Recording of Mechanical Properties during Compounding

Compound

Industrielle Messtechnik

Fertigungsmesstechnik

Compoundieren

Determining Mechanical Properties  at Every Stroke

Toolmaking plays an important role as the link between product development and series production. Competition in the sector has been intensifying since toolmaking companies in high-wage countries have faced rivalry from new suppliers from low-wage countries. Since international competitors catch up quickly, differentiation with higher-value technical products will probably not be sufficient in future to ensure a competitive edge. Action is required. 

Operational Excellence: Toolmaking in Transformation 

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

Each tech center at the respective locations plays a key role. The four qualification locations in China, Germany, and the USA employ experienced process engineers and high-performance machinery. A total of 37 injection molding machines with clamping force ranging from 700 kN to 5000 kN, including machines for multicomponent and cube molds are available. Beginning in 2021, an additional injection molding machine for the automotive sector with 27,000 kN of clamping force and an injection molding machine featuring high-speed automation will go into production.

For sensitive customer development, production cells can be installed at all locations, with the complete handling process restricted to closed-off areas with separate office units. The extensive calculating technology used for assessing quality parts includes measuring machines for optical and tactile testing, thermal imaging, hydrological measurement, high-speed camera systems, and flow rate meters. After completing the “SAT ready” qualification (ready for site acceptance test), customers receive complete documentation and optimal process parameters, which allows them to begin with site acceptance testing and start production promptly.

The local application engineers then accompany the physical start-up of production. Nobert Scheid stated, “A smooth start-up of production is essential for the processor to prepare for contract manufacturing with defined delivery quantities and times. With our global toolmaking resources in engineering, project management, and lifecycle services, we ensure that our customers can carry on their operations.”

Due to global travel restrictions, the method was expanded to include “Online Mold Qualification” (Fig. 3). DOE (Design of Experiments) and FAT (Factory Acceptance Test) can occur using high-resolution camera technology, without the customer having to travel.

A Holistic Technology Approach and One-Stop Specialist

The basis for economic high-end mold concepts is the elaborate interplay between the mold, hot runner system, temperature control, and process control as a comprehensive system. Process control is becoming increasingly important in this regard. “Today, molds are intelligent process units and include automated sensors for keeping a process stable,” said Norbert Scheid. “Barnes Molding Solutions combines all components into a single high-performance production system. The customer benefits from not only a mold but also a reliable, overall solution. The low total cost of ownership this approach facilitates adds up to the highest level of customer satisfaction.”

Otto Männer GmbH  

www.maenner-group.de

Barnes Group Inc.  

Ausgabenartikel

Tool qualification in the test center in Bahlingen, Germany. After that, the tool is ready for the “site acceptance test”, i . e. for the acceptance on site directly at the customer

Fig. 1. “Seal of Quality” stands for global quality standards of Barnes Molding Solutions

Fig. 2. Norbert Scheid, President of Barnes Molding Solutions 

Fig. 3. The “Online Mold Qualification” is transmitted from the test center by a high-resolution camera without the customer having to travel

Name - Hauptartikel

Guido Radig is the owner of the Provvido editorial office; <a href="mailto:radig@provvido.de">radig@provvido.de</a>

Barnes Group Inc. is a global company whose products and services are used in many different applications and end markets, including aerospace, transportation, manufacturing, automation, healthcare and packaging. Barnes Molding Solutions Group is a strategic business unit within Barnes Group, which includes renowned brands in the areas of mold making, hot runner technology and temperature and process control. Synventive, Thermoplay, Männer, Foboha, Priamus and Gammaflux deliver a comprehensive portfolio of solutions to meet the demanding requirements of global customers in the injection molding industry (figure: © Männer).

The global network of Barnes Molding Solutions includes production sites in Germany, Switzerland, Italy, China and the USA as well as four qualification sites in Bahlingen, Haslach, both Germany, Suzhou, China, and Lawrenceville, USA. <a href="http://www.BGInc.com">www.BGInc.com</a>

Guido Radig is the owner of the Provvido editorial office; radig@provvido.de