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Batch-related process deviations are commonplace in thermoset injection molding. With the help of a learning quality model, the target component mass can be kept constant even in the event of process fluctuations.

The screw speed is controlled predictively based on a physical process model.

16:9

Werkzeuginnendrucksensoren

Spritzgießen

Prozessregler

Industrie 4.0 für die Kunststoffverarbeitung

Duroplast-Spritzgießen

KI (Künstliche Intelligenz)

Process Reproducibility  Due to Model-Based Control

Reinforcement learning (RL) offers great potential for automating quality control in the injection molding process. The holistic approach of the Institute for Product Engineering (IPE) enables the adaptation of machine parameters to react dynamically to disturbances.

Inline quality control with camera system and precision scales for recording product dimensions, surface quality, and weight as the basis for implementing the RL approach.

Machine Learning

Automated Quality Control in the Injection Molding Process

Based on initial injection molding tests, machine learning models can precisely map complex relationships between machine settings and product quality. Quality predictions  lead to optimized settings with reduced testing effort.

Two injection-molded sensor housings from Sick: With surface defects (streaks, left) and after optimization of machine settings (right).

Optimal Machine Settings  in Just a Few Clicks

Kistler has revised its proven solutions for process control in injection molding. The hot runner control system with ComoNeo and the AkvisIO process data management software have been optimized. The latter ensures traceability for every molded part produced and also allows quality data to be integrated into the user’s IT landscape.

The histogram function supports statistical process control for evaluating production batches in injection molding regarding process capability within the desired intervention limits.

Digitalized Quality Assurance in Injection Molding

Engineering meets freerider: OST develops virtual model for the development of alpine skis.

The right mix of flexibility, weight and rigidity is essential for a freeride ski to cope well with difficult terrain. The geometry determines the lift in deep snow.

Messtechnik

Finite Methoden

Faserverbundwerkstoffe

Sportgeräte

Simulation instead of Field Tests

The choice of temperature control unit has a major impact on costs and sustainability. With the Series 6, HB-Therm relies on durable technology, energy efficiency and digital innovations.

HB-Therm temperature control technology of the last three generations (in each case next to the machines).

Temperiergeräte

Temperiertechnik

Energieeffizienz

Digitaler Zwilling

Temperature Control Units that Pay Off

StrömungsRaum Framework cloud-based platform from Ianus Simulation makes it possible to carry out simulations without the need for prior knowledge or hardware.

Various process steps in plastics processing combined in a single cloud framework – StrömungsRaum.

Spritzgießsimulation

Extrusionswerkzeuge

Heißkanalsysteme

A Pioneer in Digital  Process Optimization

With the duo 5500 combi M technology center machine, Engel offers the opportunity to implement a variety of injection molding technologies for large components.

32 m long, 13  m wide, 6.8 m high and weighing 545 t: The large Engel duo 5500 combi M machine with a clamping force of 55,000 kN has recently been installed at the Technology Center in St. Valentin, Austria, for customer trials.

Composite-Halbzeuge

Schaumspritzgießen

Mehrkomponenten-Spritzgießen

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

Elektromobilität

Spritzprägen

Verbundwerkstoffe / Werkstoffverbunde

Nachhaltigkeit

Oberflächentechnik

Spritzgießmaschinen

Injection Molding Technologies  on a Mega Scale

The cloud-based platform Stadler Connect provides central access to the plant manufacturer‘s digital products and uses machine and material data to optimize sorting plant performance.

Stadler Connect uses machine and material data to optimize sorting system performance.

Digitale Transformation

Vernetzung / Cloudlösung für die Kunststoffverarbeitung

Recycling

Kunststoff-Recycling

How Data Improve System Performance

At Fakuma 2024, SimpaTec presented Moldex3D software an essential tool for sustainability and cost-effectiveness.

Moldex3D 2024 enables users to make progress in terms of sustainability and cost-effectiveness.

Messe Fakuma

Precise, Detailed, High-Performance

Companies must become more sustainable. A PLM system covers the entire product lifecycle and therefore provides the ideal basis for greater sustainability.

Reducing CO2 emissions requires a new way of developing, producing and recycling products.

Sustainability: PLM enables transparency across the entire product life cycle

Digitalisierung

The Backbone of Sustainable  Product Development

The mold breathing signal provided by the iQ clamp control digital assistance system can serve as an effective instrument for process optimization and quality monitoring – provided that one knows how to interpret it.

With the aid of the iQ clamp control assistant, the mold breathing is measured and analyzed to determine the optimum clamping force.

iQ clamp control digital assistance system can serve as an effective instrument for process optimization and quality monitoring 

Sensorik für Kunststoff-Verarbeitungsmaschinen

Spritzgießwerkzeuge

Mold Breathing as the Key to Process and Product Quality

Interview with Dr. Stefan Glaser, Vice President Simulation Engineering & Ultrasim at BASF, about 25 years of Ultrasim

The app “molded”, which is part of the Ultrasim Web Services, provides insights into the filling behavior of molds and an understanding of the interplay between design, material selection, and manufacturability.

Doriat, Clemens, Dr.

“The Integrative Aspect Is  Our Great Advantage”

A case study for microphone manufacturer Lewitt shows how simulation software can influence the development of a product without delaying the launch date.

“Connect 2” audio interface: The top housing (upper and bottom view, left) and a set-up example (right).

Weld Lines and Sink Marks – Just a Question of Visual Appearance?

The crystallization of the plastic is an important criterion for the warpage of components. This can be determined inline using a special sensor.

Picture of the IR combi sensor in comparison with a 2 euro cent coin: In the background the sensor (red circle) is integrated in an injection mold.

Qualitätssicherung

Kunststoff Werkstoffe

Materialcharakterisierung

Determining Crystallization Inline

PLA is rarely used in technical applications. The polymer is considered to be very sensitive to hydrolysis. A research project is now showing just how much.

Disposable cutlery and packaging are a classic area of application for PLA. In more demanding areas, however, the biopolymer is only used very rarely.

Polylactid

Biokunststoffe

How Sensitive Is PLA to Hydrolysis?

An MES such as the Arburg host computer system supports the planning, control and monitoring of manufacturing processes. A plea for economy and high efficiency.

Transparency and efficiency: The Arburg host computer system ALS assists with the planning, control and monitoring of production processes. 

Planungssysteme / Leitstand

Kennzahlen, Q-Leitstand, Q-Monitor

Digitally Interlinked:  A Quick Route to Measurable Success

Artificial intelligence methods and digital material characterization are revolutionizing process simulation for composite materials.

Particularly in the field of material and process development, there is an increasing shift of experimental work into the virtual space. The combination of conventional numerical methods with machine learning techniques offers great potential. Click for full view.

Simulation Produkt- / Formteildesign

Prozesssimulation

Analysetools, FEM

From Fiber to Component – the Vision of Digitized Process Development

AI improves product design for plastic components with recycled content.

Artificial intelligence is used to optimize product and process parameters to ensure consistently high product quality. This makes it possible to use recycled materials for technically complex applications with minimal risk.

Produktentwicklung (F+E)

Kunststoff-Rezyklat

Kreislaufwirtschaft

Produktentwicklung(sprozess)

Achieving Sustainable Product Design Using Artificial Intelligence

Automotive supplier Friedrich Deutsch Metallwerk has combined the die casting of a metal insert and its overmoulding with plastic in a single tool.

A new combination of conventional processing methods – high-pressure die-casting and injection molding – could lead to a more efficient process.

Simulative combination for the production of metal-polymer-composite parts

Hybridtechnik

Gusswerkstoffe

High-Pressure Die-Casting  and Injection Molding in One Mold

Over 1000 participants accepted the invitation to the Wittmann Competence Days 2024 and gained an impression of the company’s current products.

In the Smart WorkCell, all components of the production cell exchange information and coordinate their work processes with the aim of maximizing overall efficiency.