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

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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

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

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

Spritzgießen

Kunststoffe

Photonik

Optik

Additive Fertigung

Farben, flüssig

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

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

Anyone seeking to replace a metal component by a plastic one, to reduce the number of component parts from eight to three and simultaneously cut both the weight and manufacturing costs needs to take great care to ensure that all specifications are met – especially if the component is used in a hot gearbox and is subject to high mechanical stress.

The shifter fork creates a positive lock between the gear wheel and the shaft so that the engine power can be transmitted to the wheels

Production-Ready Plastic Shifter Fork Offers a Maximum of Functional Integration

Kohlenstofffasern / -matten

Produktentwicklung (F+E)

Innovationsentwicklung

Inserttechnik

Hybrid-Spritzgießen (Metall / Kunststoff)

Replacing Metal in the Gearbox

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

Schaumspritzgießen

Smart Factory

Energieeffizienz

Mikrospritzgießen

Mehrkomponenten-Spritzgießen

Spritzgießmaschinen, allgemein

Spritzgießmaschinen

Fließpressen

Handling, Handhabungstechnik für die spanende Fertigung

Automatisierungstechnik

Handling, Handhabungstechnik

Spritzgieß-Sonderverfahren

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)

Ressourcenmanagement

Produktion

Technical Excellence thanks  to Digital Assistance

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

Medizinprodukte

Medizintechnik

Mold Platforms for IVD Consumables

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

Industrie 4.0 für die Qualitätssicherung

Condition Monitoring / Prozessüberwachung

Paletten und Behälter

Verpackungstechnik

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

With Broad Sword and Data Collector

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

Stanzen

Verfahren für die spanlose Fertigung

Schneiden

Steckverbinder

Elektromechanik

Well-Balanced Hot Runner Technology for LCP Processing

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

Vorbeugende Instandhaltung für die Qualitätssicherung

Datenanalyse

Toolmaking of the Future –  Digitalized and Sustainable

The aim of the project was clear: a highly automated turnkey system must replace several decentralized, operator-guided machines in order to be able to mass produce enclosures for a vacuum sensor with three inserted pins in a way that is smooth, automated and therefore faster than before in large-scale production, and error-free. The plastics processor Goerlich chose the machine manufacturer Arburg as a partner in its goal of achieving greater production efficiency.

All upstream process steps are integrated in a very small space: after the pins have been  punched out (right), a Scara robot places them in the correct position on a loading plate (left) so that the Multilift V robotic system can pick up 24 pins and insert them into the mold

At Goerlich, a Turnkey Plant Replaces Two Machines with a Vertical Clamping Unit

Automatisierungszellen

A Machine Strategy with  Extra Automation

HeiQ – Heitkamp Kunststofftechnik took over sales responsibility for injection molds from Rouxel Mold in Germany, Denmark and The Netherlands.

The French manufacturer of injection molds wants to expand into international markets thanks to HeiQ.

French Rouxel Mold Expands Market

Pharmaceutical crimp caps generally consist of a thin aluminum sheet and a plastic component, and are used to seal medical vials, for example for vaccines. Through a combined deep-drawing and backmolding process with previous inline laser treatment of the thin aluminum sheet, the process can be significantly shortened. The media-proof joining together of the two materials is carried out through a mechanically interlocking connection.

A crimp cap for injection vials is manufactured in a two-step process.

Combined Deep-Drawing and Backmolding Process with Mechanically Interlocking Joint

Aluminiumlegierungen

Metall Werkstoffe

NE-Metalle

Laserbearbeitungen

Oberflächentechnik

Tiefziehen

Simulation Stanzen / Umformen

Laserstrukturieren

Process Chain for the Production of Hybrid Medical Products

Injection Molds for Insulating  Stators and Rotors

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

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.

In our modern world, if something is caused to rotate or move at the push of a button, electrical drives are usually involved. Electric motors make manufacturing processes effective and efficient in many industries – e. g. machinery, apparatus, material processing, chemicals, plastics, paper, textile, foods, stone/earths. Electric motors are also indispensable in transport (rail, automotive, marine, air), household appliances, agriculture and consumer goods. In the mass production of electric drives, too, electric motors permit highly efficient manufacturing, enabling a very good price-performance ratio.

The key elements of a simple electric motor are:

<ul><li>rotor (rotating electromagnet),</li><li> stator,</li><li>commutator (only for d. c. motors),</li><li> brushes,</li><li>coil, and</li><li> shaft.</li></ul>

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