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

Spritzgießen

Kunststoffverarbeitung: Verfahren

Spritzgießwerkzeuge

Kunststoffverarbeitung: Maschinen und Komponenten

Werkzeuge für die Kunststoffverarbeitung

Heißkanalsysteme

Komponenten für die Kunststoffverarbeitung

Medizintechnik

Medizinprodukte

Maintenance During (Nearly)  Uninterrupted Production

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.

16:9

Combined Deep-Drawing and Backmolding Process with Mechanically Interlocking Joint

Hybridtechnik

Aluminiumlegierungen

Metall Werkstoffe

NE-Metalle

Laserbearbeitungen

Oberflächentechnik

Tiefziehen

Verfahren für die spanlose Fertigung

Spritzgieß-Sonderverfahren

Simulation Stanzen / Umformen

Software

Simulation

Laserstrukturieren

Hybrid-Spritzgießen (Metall / Kunststoff)

Process Chain for the Production of Hybrid Medical Products

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

Werkzeug- und Formenbau

Dienstleistungen

Werkzeug-, Formen- und Modellbau

Mold Platforms for IVD Consumables

Otto Klumpp GmbH has for many years processed, for example, highly transparent PC and high-performance plastics such as PPSU into sophisticated medical products. Since cleanliness and hygiene are essential for implants or blood-carrying systems, injection molding production and parts assembly are performed in the cleanroom. DLC-coated components also play an important role in in-house mold production. 

Otto Klumpp: DLC-Coated Standards in Cleanroom Production 

Handling, Handhabungstechnik

Polysulfone / Polysulfide

Normalien und Heißkanaltechnik

Reinraumsysteme / -technik

Cutting Edge Technology 

Jako meditec specializes in the injection molding of tubes, with closure caps and racks, in which blood samples from blood donors are kept deep-frozen for many years. Each sample can be uniquely traced thanks to a DM code. The two-component tubes are produced using a special, patented wet-in-wet injection molding process. 

Jako meditec: Patented Wet-in-Wet Process for Freeze-Stored Blood Sample Tubes 

Mehrkomponenten-Spritzgießen

Industrieroboter

Blood Samples with Origin Code 

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

Zahoransky Automation & Molds GmbH has entered into a partnership with the Swiss company Kebo AG. The result of this collaboration is a new mold concept for the production of pipette tips, which features a double quick-change system.

If a core breaks during production, it can be replaced quickly

Messe Fakuma

kunststoffe-international.com

Double Quick-Change System Speeds up Production

The Institute for Plastics Processing (IKV) at RWTH Aachen University is investigating a new control approach for injection molding in which the cavity pressure is controlled by different positions of the hot runner valve pin. The influence on the cavity pressure of different strokes in the holding pressure phase is investigated.

The experimental mold with the cavity of a bicycle saddle has a servo-electrically driven hot runner

20:7

Cavity-Specific Pressure Control to Increase Process Consistency

Steuern, Regeln

Mess-, Steuer- und Regelgeräte

Qualitätssicherung

Qualitätssicherung Kunststoff

The Hot Runner Valve Pin  as Actuating Variable

In contrast to recent years, when particular key themes often dominated the fair exhibits of the leading injection molding machine builders, this year’s Fakuma will present more combinations of many different competences in complex production cells. Thus, Industry 4.0 not only takes slowly concrete shape, but is put into context with peripherals and controls in the development of new series. 

Re-Inventing Injection Molding Holistically  

Servomotoren

Instandhaltung, Wartung in der spanenden Fertigung

ERP-Systeme

Industrie 4.0

Polyurethan

Additive Fertigung

Spritzgießmaschinen

Gasinjektionstechnik

Schaumspritzgießen

Temperiertechnik

Machines as the Heart of Production 

It is familiar to every eyeglass wearer: Just a tiny spec on the glass ruins your vision. And there may even be a safety risk if car headlamps scatter the light in the wrong direction. The manufacture of optical parts by injection molding is therefore a serious and demanding task affecting the entire process chain.  

Optical Components Place High Requirements on the Entire Process Chain 

Kfz-Leuchten, Beleuchtung

Polyacrylate

Polycarbonat

Spritzprägen

Optik

Keeping a Sense of Perspective  

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)

Treibmittel

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

Elastomer-Spritzgießen

The Communicative Machine 

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.

Tools for wet razors operate  in very narrow tolerance windows and their requirements are comparable to those in the medical and pharmaceutical industries 

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

Mikrospritzgießen

Innovationsmanagement

Produktentwicklung (F+E)

Projektmanagement

Wirtschaft

Automatisierungstechnik

Produktmanagement

Trend Setting or Following?

The switchover process from the injection phase to the holding pressure phase is frequently the cause of reduced part quality in injection molding.

Typical injection molding defects, caused by incorrect switchover from injection to holding pressure phase (© IKV)

Phaseless Process Control Should Revolutionize the Switchover Process

Prozesssimulation

Mess- / Regel- und Prozessleittechnik

Prozessautomation

Spritzgießsimulation

The Switchover Problem and  its Consequences

SPS – Industrial Automation Fair (SIAF) Guangzhou and Asiamold, the first China fairs to be hosted by Messe Frankfurt in 2021, concluded on 5 March after three days, with the visit number increasing an impressive 27% to 63,968.

Sensorik für Werkzeugmaschinen

Industrie 4.0 für die spanende Fertigung

Verfahren für die additive Fertigung

Kunststoffverarbeitung

Lohnfertigung

SIAF Guangzhou and Asiamold Conclude Successfully

In the injection molding of engineering plastics, mold temperature control consumes more than one third of the total energy input. A novel technology offers the opportunity to reduce this continuous major cost factor – and eliminate hotspots.

Fig. 1. The temperature control units have the highest energy share in the injection molding process

Reduced Energy Consumption and Shorter Cycle Times due to Structurally Integrated  Heat Pipe Mold Cores

Cooling with Heat Pipes

Real-Time Process Monitoring in Cleanroom Environments

In the production of plastic parts for the medical and pharmaceutical industry, the requirements for cleanroom environments are becoming increasingly stringent. In this area, not only the demand for all-electric injection molding machines is increasing. There is also an increasing use of electric drives for the implementation of mold movements, which meet the high requirements for cleanliness and reliability.

Compared to hydraulic or pneumatic systems, electric drives offer high cleanliness and virtually maintenance-free operation over millions of cycles. In cooperation with Husky Injection Molding Systems, Schöttli AG, Diessenhofen, Switzlerland, a Husky Company, offers fully integrated complete solutions for electric mold movements and valve gate actuation in high-cavity injection molds.

The performance of electric drives is constantly evolving and opening up new areas of applications and uses. In combination with efficient control technology, the actuators offer great advantages over alternative systems from the hydraulic sector in terms of cleanliness and energy efficiency. In addition, individually programmable motion profiles, for example when actuating valve gate systems, can increase the quality of the molded part and the durability of the injection mold.

The vast experience of Schöttli AG, a Husky Company, in the design of electric actuators ensures that the ideal actuator is selected for every injection mold and every application. In addition to the maximum force, the acceleration of the movement is also taken into account in order to achieve the shortest possible cycle times. The applications are varied and include not only unscrewing and ejection movements but also combined movements, which are realized for example in compression molds and electric valve gate systems.

For example, Schöttli has designed and manufactured a 72+72 cavity stack mold for a medical locking cone, which ensures the unscrewing movement of the thread cores and demolding through ejection sleeves via four individually controlled electric drives (Fig. 1).

Dynamic mold movements impose high demands on the regulation and control technology of the actuators. The acceleration of the mold components in combination with the demolding of the plastic part requires a high moving force, which the actuator must apply. This force is generated by a servo motor and is transmitted over a gearbox into the core puller.

At this point, high torque means extensive power consumption, which the controller must provide via the power and control electronics. The high current consumption of the servo actuator within short time intervals represents a demanding task in the dimensioning of the electronic components.

Schöttli already includes the control manufacturer during the development period of the injection mold and defines the expected requirements on the actuator, which allows a perfect adjustment of the power electronic components. This close coordination between mold- and control supplier guarantees, that the complete system works reliable in operation and a competent assistance in case of incidents.

After the development and production phase of the injection mold, the injection molding machine, controller and injection mold must harmonize perfectly for a stable process. Communication between the devices takes place via predefined interfaces. Schöttli provides preconfigured interface cables which can be used for commissioning according to the plug-and-play principle. Furthermore, the operation with Husky ASC-controllers offers the customer the possibility of a continuous process monitoring and process interruption, when significant process parameters are out of tolerance.

The efficient Husky ASC controller in combination with a highly dynamic servo motor offers a large variety of advantages. The exact control of up to seven drives (six Servo-axes and one axis for the valve gate UltraSyncE) in combination with the path and force detection by the controller offers extensive possibilities to optimize the process.

The Husky system also offers the possibility of continuous process monitoring and can be integrated into the safety system of the injection molding machine (Fig. 2).

The new generation of Husky controllers allows users to evaluate process data in real time to optimize the process. This is particularly necessary for sensitive processes where the individual mold and machine movements must be coordinated (Fig. 3).

In cooperation with Husky, an injection compression mold with UltraSync-E valve gate system was realized, in which the interaction of

<ul><li>injecting the melt,</li><li>closing the gate by needle movement and</li><li> compression via the mold movement</li></ul>

can be perfectly coordinated. The precise positioning of the mold components by the electric drives ensures that production is continuously within a stable process window and a maximum output with minimum cycle time.

In addition to local data acquisition, the Husky controller allows customers to analyze this data in a central location and get an overview of the current production status of multiple manufacturing cells. The ShotScope NX program is used to capture process data, such as current energy consumption, and record it over the production cycle. In this way, deviations in the system are quickly recorded and production losses are minimized. The evaluation of the data can also be used to localize and optimize processes with high energy consumption in the system to increase the energy efficiency of production (Fig. 4).

Direct Replacement for Existing Molds with Hydraulic Cylinders

A cost- saving solution is guaranteed by the Schöttli E-Drive system. The simple operation combined with a reliable actuator makes this system attractive for prototype molds and unscrewing molds up to 64 cavities. As the controller is already integrated in the actuator housing, this system can also be used as a direct replacement for a hydraulic solution. Existing production molds with hydraulic cylinders can be converted to an electric drive without additional investments in complex control technology (Fig. 5). Especially in the field of unscrewing molds, Schöttli can draw on a wealth of experience gained over more than ten years. This helps to define a tailored solution for the customer and ensure reliable operation. In this context, the company offers safe and efficient solutions for complex applications in the medical and pharmaceutical industries with combined movements, including the conversion of existing molds to electric drives.

Husky Injection Molding Systems Ltd. 

Ausgabenartikel

Fig. 2. The Husky-ASC system offers the possibility for a realtime process monitoring 

Fig. 3. Signal sequence of a combined mold movement consisting of screw position, valve gate and compression position

Fig. 4. With the program ShotScope NX, process data like current energy consumption are recorded over the production cycle 

Fig. 5. The E-Drive system is suitable for prototype molds and unscrewing molds up to 64 cavities

Fig. 1. Solutions for electrical mold movements, for example a 72+72 cavity stack mold for the closing cone production

Schöttli - Hauptartikel

The <b>Schöttli AG</b>, Diessenhofen, Switzerland, is a globally acting injection mold manufacturer focused on medical and pharmaceutical applications. Established in 1952 and “a Husky Company” since 2013, Schöttli-molds stand for precision and high performance in the production of medical and pharmaceutical applications. With ten production sites and 30 aftermarket locations, Husky offers a globally organization for the injection mold market.

<a href="http://www.schoettli.com">www.schoettli.com</a>

<b>Stefan Schneidmadel</b> is Development Engineer of Schöttli AG, Diessenhofen, Switzerland.