IMA October 2016 Machinery/Technology at K2016

Injection Moulding Asia Machinery/Technology at K2016 • Austria’s Engel will have eight exhibits at its booth and a further ten at partners. A 500-tonne E-speed hybrid model will be combined with IML, decorating long, thinwall hollow cartridges with extreme L/D ratio and 1.2 mm-wall thickness, said to be a first. The machine now comes with Ecodrive servo-hydraulics as standard and is optimised for additional speed and faster acceleration/ deceleration.

Easicell will be shown in the DecoJect IMD application, to replace painting PP automotive interior parts for cost savings of up to 14%. It involves roll-toroll feeding of a TPO film through the mould, where it is sucked in by vacuum, preheated by a robot carrying an IR panel, and back-injected with PP and trimmed by a punch action in the mould. Another IMD application will be using a paint-transfer film from Kurz, demonstrated with an organosheet composite laptop cover that is both overmoulded and decorated in the same cycle. It will use Engel’s Variomelt hot/cold moulding process, and after moulding, a UV cure fully hardens the paint for scratch resistance.

Machinery • Germany-based Arburg will have 27 machines on show at partner booths, with 12 on its own stand. A 100-tonne electric Allrounder Golden Electric entry level machine series, with a size 290 injection unit, which made its debut in March, will be producing a technical part. Profoam physical foaming will be producing an automotive application. Dynamic mould temperature control will be used to produce a highgloss surface. An innovative cube mould technology designed for multi-component packaging will be presented, as well as the two-component moulding of a wristwatch from two different LSRs. Another highlight will be a high-speed application for medical technology, where a clean room version of an electric Allrounder 470A will be used.

Michael Hehl, Managing Partner and spokesperson for Arburg says the firm will have a whole gamut of machinery including the electric Allrounder Golden Electric entry level machine series that made its debut in March as well as other “surprises that we like to keep an ace up our sleeve”

In many applications, only the integrated moulding process makes it possible to bond thermoplastics and LSR together in stable layers. Pressure reservoir diaphragms used in pressure compensation vessels are an example for this, made using tiebar-less Engel Victory

• Making their debut at Canadian Husky Injection Molding Systems’s booth will be new integrated solutions such as HyCAP 4 that will run 1.25-g 29/25 closures for a mineral water application in a 2.4-second cycle and a speciality closure system producing 6.1-g flip-top closures for shampoo bottles, in under 8.5 seconds. Integrated will be eIMC in-mould closing technology, which enables better part quality and 20% cycle time improvement. At its experience centre it will showcase multi-layer barrier technology, including examples of existing and future applications. Introduced in 2015, the technology is built on the HyPET HPP5 platform, combining benefits of an easy-to-maintain system with precise dosing of the barrier layer. It will also show medical moulds by Schöttli.

• Highlights from German firm KraussMaffei will be the GXW 650-2000 Colorform, combining moulding and reaction process in a single cycle; thermoplastic resin transfer moulding (TRTM) demonstrating an automotive fibre compound structural component with metal inlays under series production conditions. Frames for the roof shell of the Roding Roadster R1 sports car will be created. Also at the show will be its extended CX small two-platen machines with servo-hydraulics, with models from 200-420 tonnes, revamped clamp for up to 40% additional energy savings and a new oil filter said to extend oil life by 25%.

• US firm Milacron Holdings, having re-entered the PET machine market in 2015, will display M-PET 300 servo-hydraulic PET system with its preform tooling.

It will also showcase Klear Can recyclable multi-layer plastic can, running on a Ferromatik 280, integrated with Mold-Masters iM2 48-zone controller, IML from CBW and inspection system from IMD. Meanwhile, its K-tec machine will mould two-component PET preforms with cosmetic finish partnering with MuCell and Foboha cube mould technology. Another upgraded Elektron Evolution will be equipped with the new linear robot and E-multi injection unit to mould a “crinkle box”.

KraussMaffei will show the production of frames for the roof shell of the Roding Roadster R1 sports car

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Injection Moulding Asia Machinery/Technology at K2016 • Swiss firm Netstal will launch a 750-tonne Elios, which according to Euromap offers the fastest dry cycle in its size. It will be shown producing 43,000 domed lids/hour with a part weight of 2.8 g in a 24+24 stack mould and 4 second-cycle. It will also exhibit injection-compression moulding (ICM) with a stack mould on an Elion 280-tonne hybrid press, for thinwall moulding with reduced injection-pressure and clamp-force requirements and stresses and warpage in the parts. Material savings of up to 20% and total unitNetstal is presenting injectioncost reduction of up to 10% compression moulding are claimed. technology in a stack mould

• Sumitomo (SHI) Demag under the Electrified 4.0 slogan will present its smallest 500-tonne allelectric IntElect running a new consumer packaging application, while what it says is the fastest IML exhibit, El-Exis SP200 hybrid press, will be producing four PP cups in less than 2 seconds. An El-Exis SP420 hybrid machine will be producing PP trays on a 2 + 2 stack mould. The company also will show an IMD application for automotive door trim that creates a wood appearance and also allows for backlighting with a film from Kurz.

• Germany’s Boy will showcase its patent-pending Multi-Drive drive concept on a 24-cavity 100E machine producing caps for mineral water bottles. Features are: two servomotor-driven pumps can be used parallel to or with each other while the interplay of both hydraulic drives can reproduce the functionality of an all-electric machine.

Sumitomo Demag’s hybrid machine will be making IML cups

• Wittmann Battenfeld will present for the first time its Combimould process on a machine from the servohydraulic SmartPower series. A 180-tonne, 8-cavity model will mould caps made of thermoplastic and LSR.

• Austria’ rubber machine maker Maplan will have a new machine design and C6000.web/C600.web controller.

Apart from the aesthetics, making its debut is “Smart light” multi-coloured indicator lights with alarms.

Meanwhile, the MTF1500/250 vertical machine has a reduced height of 935 mm, with better accessibility to tooling, and a new FEM-clamping unit. A new MHF700D/300 horizontal machine will be equipped with a cold runner mould from Stampi, while MTTF-C 30 will be shown with a TPE injection unit that can be pivoted to the side.

This enables the screw to be replaced easily, for fast material or colour changes.

• Haitian China will have three new machines including the “P” (packaging) version of the Venus II all-electric series, with a square platen and a modified machine bed to handle heavy moulds. A 300-tonne model will mould an IML cup in 4.4 seconds. Its new two-platen Jupiter II plus series boasts faster clamp movements, new linear guides that eliminate lubricant and friction on the tie-bars, optimised platen and a new Keba controller.

Meanwhile, its all-electric Zhafir Zeres will make its debut at the K. It has a servodriven-hydraulic pump for core pulls, ejectors and nozzle touch.

• German firm Windsor will present for the first time at K, Taiwanese FCS (Fu Chun Shin) machines, after having entered into an agreement with FCS has committed to build hydraulic and servo-hydraulic machines according to European standards. A 150-tonne servo-hydraulic SD-150SV machine will be producing a transparent assortment box in PP.

Maplan’s vertical MTF range has a reduced operating height plus a new concept for the clamping unit

Windsor will show an FCS servo-hydraulic machine

• Another rubber machine maker Desma will show its S3 series with robot integration and the newly developed e-drive cold runner system. It will also showcase its platform for digital solutions, SmartConnect 4.U, which networks machines, components, applications and systems.

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Injection Moulding Asia Machinery/Technology at K2016 • Italy’s Negri Bossi will show its new-generation allelectric Project ELE, designed for packaging and medical markets. Featuring a new “smart flex 2” clamp, with toggle geometry designed specifically for electric closing, the machines also come with the Tactum multi-touch controller.

• Austrian LSR dosing systems provider Elmet will have a new Top5000P multi-component dosing system at its stand. Elsewhere, Engel will produce a pressure reservoir diaphragm on a tiebar-less Victory multi-component machine. After injection of the core and frame of glass fibre-reinforced PBT, a robot transfers it to Elmet’s LSR tools with needle valve. Momentive will produce a two-colour egg cup, with only one dosing system, on Arburg’s one-component machine. At Boy, Elmet will demonstrate a 128-cavity LSR tool where each cavity is injected by a cold runner nozzle, creating no scrap.

3D printing/Additive Manufacturing • Arburg will present the Freeformer, launched at K2013, with updates such as an optimised build chamber with improved air and temperature control. A material dryer is also optionally available, integrated in the machine control system, plus maintenance intervals for the discharge system have been significantly extended. New applications, materials and parts will be presented on a total of three Freeformers.

• German silicones company Wacker Chemie says up till now “there is no mature 3D printing technology available for silicones”. It will show the Aceo Imagine Series K printer. Based on a drop-on-demand method developed by Wacker, it deposits tiny drops of silicone on a water-soluble substrate. The silicone is formulated so that the Wacker will showcase the droplets flow together prior first industrial-scale 3D to UV-activated curing. printer for silicones The use of water-soluble materials allows overhangs and internal lattices. It is said to print considerably faster and with contact-less technology enables freedom in design. The printer is targeted at healthcare, transportation, rapid prototyping, electronics/optics, automotive and aerospace industries.

Arburg’s Allrounder 470A will be processing in the 4+4 cavity mould, with Elmet’s needle valve and rotating core beam, Momentive’s LSR to produce a two-colour egg cup

• French tooling specialist RocTool will showcase its new HD (High Definition) Plastics approach on a KraussMaffei CX 160-750 with a double-cavity tool from GF Machining Solutions, and with laser texturing. In partnership with Flex and Arburg, RocTool will also present its IDH (Induction Dual Heating) technology that combines the forming of a composite sheet and over-moulding of thermoplastic in the same process. It will be shown producing a 1-mm computer cover, in a supposedly 1 minute cycle/part.

• German firm Ewikon will display its new micromanifold for high-cavity medical and closure applications. The standard main manifold is on one level with each of its drops feeding a balanced micromanifold on a second level with four screwed-in, heat-conductive tip inserts, each having a flow-channel diameter of 3 mm and a melt seal at the gate. The four gates in the micro-manifold have one heating circuit, simplifying wiring and control circuits.

Tooling • Mold-Masters’ new, premium hot runner line Summit is said to have four times less thermal variation from set point, compared to the typical thermal variation seen in a nozzle with a heater band. The nozzle profile positively affects balance and is especially effective for medical sectors where precision is paramount. It has also enhanced features in the Fusion G2 series for automotive and large-part moulding. An extended nozzle length range provides more flexibility while the compound nozzle can be used to avoid interferences with cavity cooling lines, and position nozzles in very tight pockets.

New additions to Fusion G2 include high performance water-cooled gate inserts plus additional new gating methods designed specifically for certain resins.

Furthermore, its new Dura+ hot runner for lighting applications features smarter angled manifold designs for easier installations and reduced cost on mould machining.

• Heitec Hot Runner Systems will showcase the X-Slim nozzle for larger shot weights, compared to its SlimLine nozzle, while retaining a small installation bore diameter. It is also said to have the largest ratio of flow channel diameter to installation bore diameter on the market. Three models have flow channels from 4.5-8 mm and installation bore diameters of 11-20 mm, with hot tip or valve gates from 50-300 mm.

• Italy’s HRSflow, which is part of Inglass, will show its latest Ecoflow hot runner boasting 25% reduced energy use and system size, in terms of weight and volume.

Others are the Flexflow electric servodriven-valve gate system where a control unit is not required.

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Injection Moulding Asia Machinery/Technology at K2016 • PSG Plastic Service presents its ProfiTemp hot runner control, with a small footprint, extended range of functions and touchscreen operation. It also has a new reflector nozzle for narrow cutouts, supplementing the previous cascade control Variofill and offers benefits of a sensor and variable opening speed of needles for better process control.

it will have a new linear robot LRX TwinZ for complex stack mould applications, the servopicker SPX 10, as well as a mobile industrial robot integrated with Multisubmit control function.

KraussMaffei’s LRX Twin for complex stack mould applications

• Wittmann Battenfeld will display its new R9 robot controller and a re-engineered IML work cell for fast label changes.

PSG Plastic Service will present the new hot runner control

• Swiss firm Priamus System Technologies says in its Fillcontrol automatic valve gate control for hot and cold runners it is possible to position and control the pins in the corresponding valve gates directly as a function of melt flow. Thus, multi-cavity moulds can be balanced without having to change the nozzle temperatures of hot runners, especially for LSR material. The automatic detection of the melt front enables the different filling times for each cavity to be analysed and balanced. A precondition is the connection of the system via an interface. For the balancing of thermoplastic multi-cavity moulds, valve gate controls of Synventive are suitable while for applications in LSR moulding, it recommends ACH Hefner’s servo-shot system.

• French supplier Sepro will have eight robots including a new 7X-100XL five-axis Cartesian beam robot and 6X-400 six-axis articulated-arm robot, developed in a partnership with Japan’s Yaskawa Motoman. It’s the largest of four models introduced recently for machines from 800-5,000 tonnes, completing four smaller six-axis models developed with Staubli. Two new small robots to Sepro’s new five-axis Cartesian beam be featured include robot a three-axis robot called the Success 5, and an S5 servodriven-sprue picker.

Automation/Robotics • With the focus on Industry 4.0 at the show this year, Arburg will present a smart factory linking a vertical Allrounder 375V, a Freeformer and a seven-axis robot.

A number of its exhibits will have robots, from simple pickers to six-axis robots featuring the Selogica user interface and complex turnkey systems. A new Multilift robot will also be introduced.

• In a team up with Hekuma, Engel will show an automation cell for a new interdental brush process, with up to 500 bristles moulded, in a shot weight of 1.93 g, in single-component moulding together with the core and grip. Until now, interdental brushes have consisted of three component moulding of the grip, wire mesh, and filaments. Now, it’s done in one shot with no metal insert. The compound contains glass fibres that stiffen the grip and core but do not penetrate the very delicate bristle areas. Hekuma’s Hekuflex automation demoulds the brushes, presents the parts for camera inspection, packs them into retail sales bags, 16 pieces each. Engel will use its 170-tonne all-electric Emotion with eightcavity mould from Hack Formenbau; iQ weight control to analyse pressure profile at screw positions; iQ clamp control to monitor mould breathing for each shot and adjust clamp force as well as e-flomo for constant temperature control.

• Engel will introduce a four-axis Scara robot, an extension of the easix line, which previously consisted of six-axis models. Advantages are higher speed at lower cost for pick-and-place, stacking, and palletising. Based on Staubli hardware, it can be integrated with Engel’s CC300 machine controller. Also new is a servosprue picker based on the e-pic robot from 2014. It combines a linear vertical axis with a vertical swivel arm, but has no horizontal axis like the e-pic. Instead, it rotates up to 110 degrees on its pedestal.

• KraussMaffei will highlight its expanded APC (Adaptive Process Control) Plus, which detects process fluctuations caused by changing ambient conditions or fluctuating viscosity, and takes measures. It is now suitable for multi-component moulding and LSR, as well as provides new features, such as taking into account specific behaviours of raw materials. In terms of robots,

Engel will team up with Hekuma in a brush application, said to be a world’s first

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