RocTool demos three innovative molding technologies for plastics and composites at K 2016RocTool demos three innovative molding technologies for plastics and composites at K 2016

The new HD Plastics approach developed by RocTool (Le Bourget du Lac, France), a specialist in heating and cooling technology, enables designers and part manufacturers to achieve exceptional part quality and increased performance without secondary operations such as painting or decorative films, according to the company. The technology will be demonstrated live at K 2016 on stand C41 in hall 15 on a KraussMaffei CX 160-750 injection molding machine with a two-cavity tool machined using laser texturing technology from GF Machining Solutions. Laser texturing allows end-production value effects by means of texturing at a sub-micron scale, says RocTool.

“With HD Plastics, our main focus is to evaluate different resin families and to maximize RocTool technology to achieve quality parts that allow designers to expand their choices. The surface quality, color and removal of visual defects are always our priority,” said Mathieu Boulanger, RocTool CEO. “At this year’s K show, we propose three molding demonstrations, plus we have several applications in production today on display and also various highly innovative products in development.”

Among the new parts on display at RocTool’s stand will be parts molded from tooling made in collaboration with ABC Group (Toronto, ON, Canada) and Proper Tooling (Warren, MI), including exterior automotive grilles with molded-in color in multiple textures and a 100% recycled plastic housing. “Being able to get the best quality with 100% recycled materials is a great challenge and also a choice to turn to the most planet-friendly solutions,” said Jachen Mitzler, Head of Strategic Product Management at KraussMaffei.

In partnership with Reichle and KraussMaffei, RocTool presents a complex case with a decorative texture on the mold. The demonstration will also focus on eliminating weld lines, reducing sink marks and achieving faster cycle times. A full replication of tool surfaces will be on display. The demonstration can be found at the KraussMaffei stand, B27/C24/C27/D24 in hall 15.

Another new RocTool process will be presented at the event: Induction Dual Heating (IDH), a combination of plastic and composite materials with a new RocTool heating configuration. In partnership with Flextronics Manufacturing and Arburg, RocTool with present for the first time the IDH process that combines the forming of a composite sheet and injection over-molding thermoplastic in the same process. RocTool will present the process for a hybrid 14-inch, 1-mm-thick computer A cover, bringing the benefits of composites (high modulus and light weight) and plastics (cosmetic integration functions) in a single product while eliminating secondary operations, all in a one-minute cycle time per part and in the same machine.

“What differentiates Induction Dual Heating from other technologies, is predominantly our ability to transfer a cold composite insert, whether woven or nonwoven, therefore erasing any known deficiencies in current processes, such as the transfer and handling of a heated insert, the cooling of the insert during transfer or the precise positioning of the softened insert,” said RocTool CTO Dr. Feigenblum.

IDH technology provides in-situ pre-heating of the composite insert in the tool by combining a heated mold by induction and the preheating of the insert by radiation with a single power source. By definition, IDH is able to control the heating of the two elements intelligently, adapting the heating time and the power injection automatically, said RocTool.

The complete installation can be viewed at the Flextronics stand (C79, hall 8B).