Multi-component molding is key to cost reductionMulti-component molding is key to cost reduction

Production cells that are highly integrated and automated reduce the amount of factory space required to produce parts in part because there is no need to inventory components in intermediate stages of assembly. Process quality may also be improved.

As a demonstration at the show, Engel will be producing auto-injector parts using two-component technology.

ABS and TPE will be processed in a single step, using a servoelectric 16+16x index platen mold on an Engel e-motion 80H/80W/180 T WP combi designed fo cleanroom operations. System partners for the collaboration include Hack Formenbau, SHL (Scandinavian Health), Piovan, Max Petek Reinraumtechnik and Stäubli.

The parts will be moved by an easix multi-axis robot that is integrated with th machine's control unit. Robot instructions for the robot are built into the machine control so that the machine operator no longer needs to know two separate control logic approaches.

Another benefit of robot/control integration is the optimization of machine efficiency. In one example, the robot can start to take off molded parts before the mound is fully open, reducing cycle time.

Another productivity innovation is a recently developed approach called iQ weight control. Patent-pending software detects and compensates for fluctuations in ambient conditions and raw materials in the same shot. The pressure profile of screw positions in real time are analyzed and compared to the measured values with an online reference.

Based on the results, the system computes a new set of process parameters that allow changes in the melt volume and material viscosity, which Engel says are the two most important factors impacting quality. Relevant process parameters are readjusted automatically as required, avoiding any impact on mold filling.

Engels says that its all-electric injection molding machines are can achieve cycle times under three seconds, and injection speeds of more than 500 mm per second. Machines with 160 and 220 tonnes clamping force a tonnagere now part of the medium range.