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Foreshadowings of NPE 2006: Fakuma and IPF

March 5, 2006

21 Min Read
Foreshadowings of NPE 2006: Fakuma and IPF

If what we saw at two major international trade shows was any indication of what IM machine suppliers are bringing to the big show in Chicago this June, you?ll see the most productive, cost-effective injection molding machinery technologies anyone in the world has ever seen before. For example, Toyo/Maruka introduced its new 100-ton Si-100III at IPF?05. It achieves injection speeds of 1000 mm/sec. Equipped with a 12-mm screw and a built-in parts-handling unit, Boy Machine?s Boy 12A molded .0009g gears at Fakuma.

Sodick demonstrated its new side-entry robot by removing .01g gears from its 20 tonner.

JSW?s all-electric 55-ton J55AD-60-US molded polycarbonate light guide panels.A Sumitomo 130-ton all-electric molded PC memory cards, eight per cycle.

Systec and Husky combined to show an inmold-labeling system with a two-cavity mold, though eight-cavity versions are possible.

Engel Speed machines for packaging applications are available in sizes from 150-715 tons.

This 440-ton Arburg is equipped with six accumulators. It made a PP bucket every 11 seconds.

The Niigata MD50X above is a fifth-generation all-electric machine. The cabinet is fully air-conditioned and filtered.

Battenfeld?s re-engineered two-platen HM line.

A Krauss-Maffei 160-750 CX press molded thermoplastic substrates with a sliding-table mold. The substrates were then coated with a PUR skin.

Toshiba?s EC160NII was equipped with a Priamus Fill system and molded three-component parts.

UBE demonstrated its Ecoprest double-layer foam-molding process on its MD450S-IV-i13A/i6.5A press. With Ecoprest, parts are foamed with carbon-dioxide.

Toshiba?s Nano Imprint exhibition included its EC60NII all-electric, which molded thin-wall PC mobile phone screens in two-cavity tooling.

Ferromatik-Milacron?s Elektra Evolution 50 cleanroom molding machine, built with Alpha Ionstatex, has a HEPA-filtered module around the mold area. It molded .58g PS hemoglobin testers in an eight-cavity mold.

Previously direct-drive clamping machines, Meiki?s MU Series all-electrics are now more economical toggles.

Demag?s NC5 machine control guides users through all setup and process optimization stages.

Injection molding machine suppliers at the International Plastic Fair (IPF?05, Sep. 24-28; Makuhari Messe, Chiba City, Japan) and Fakuma (Oct. 11-22; Messe Friedrichshafen, Friedrichshafen, Germany) showed off their latest capabilities in the form of production machines, not just prototypes, as has sometimes been the case in the past.

While there is no guarantee that the builders will bring specific machines to NPE, their staffs will in any case be poised to discuss the advanced technologies?and the machines, with few exceptions, are poised to ship to buyers.

Big Electric Iron

An all-electric, twin-platen, 3300-tonner designated 3000em-470 has been developed by Mitsubishi. It does use a little oil for nozzle-touch force and such, however. Modeled after its small footprint, twin-platen MM3 Series, this 3300-ton giant features an AC servodriven injection unit incorporating four direct-drive servos that?s capable of delivering shot volumes of 2030 cc/sec. Plasticating capacity is 1 ton/hr.

Its motors are coupled directly to the screw drive for quick response, easy serviceability, and to eliminate belt dust generation. It?s equipped with Mitsubishi?s UB MD screw, which is designed for high mixing performance. Three units were already sold in Japan at showtime for automotive molding. A 2000-ton model reportedly will be introduced later this year.Mitsubishi?s FEA-engineered ?center-press? mold clamping unit focuses clamping forces directly on the center area of the platen, increasing the force transmitted to the mold, eliminating parting-line gaps for flash-free molding. It?s got 2050-by-1900 mm between tiebars, 2030 cm3 injection volume, and it consumes 57% less energy than comparably sized hydraulics.

UBE?s got the Model MD3000HWS-IV-i200A/B 3000-ton (29,400 kN) all-electric. It?s equipped with a 150-mm screw and 400-oz shot, and it?s got 3715-by-2600 mm between the bars. UBE sources say that its first customer for it molded a fascia on it in less than 30 sec, mostly by taking advantage of simultaneous cycle-phase overlapping capabilities. It reportedly provides more than a 60% energy reduction vs. a 3000-ton hydraulic.

UBE?s ready to build 2000 to 2200 tonners in Ann Arbor. This spring it?ll be building a 2000 tonner and is adding crane capacity to do so. UBE its very busy building big machines to replace ?ancient fleets? of energy-hogging behemoths.

The Other Extreme: Micromolding

On the small end of the spectrum, Boy Machines molded micro-gears weighing .0009 g each in a two-cavity mold on its Boy 12A, a press equipped with what is reportedly the world?s first 12-mm diameter screw unit. Its design reportedly reduces dwell time 50% when compared to 14-mm plasticating units.

Ferromatik Milacron prefers the 14-mm units, saying they provide both precise shot size control and that they allow the use of standard-sized pellets. Equipped with a 14-mm screw, its little all-electric Elektra Evolution 30 molded ABS microphone parts weighing .7g at 12.6-sec cycles.

Sumitomo?s servomotored, 7-ton SE7M molded micro LCP connectors weighing .035g, a .48g shot, in two-cavity tooling at 3.3 sec cycles. Platen closing speed is 1000 mm/sec, reducing mold opening/closing time to less than 1 sec at full stroke. Its 300-mm daylight accommodates three-plate molds.

Meanwhile, a 20-ton Sodick-Plustech EH2?equipped with Sodick?s own, new, traverse-axis parts removal robot?molded .01g acetal worm gears in a single-cavity mold at 20-sec cycles.

Nissei says it has a new, tabletop, 3.5-ton micromolder in development for low-speed molding of parts such as lenses.Battenfeld?s Microsystem 50 molded bio-absorbable vascular clamps that were .4-mm diameter and .4-mm thick in 5-sec cycles, with quality control by the system?s 100% optical inspection. Also, two Arburg machines?a 170 U (16.5 ton) and a 370 U (77 ton) teamed-up in a cell to perform the micro-inmold-assembly of planetary gears?a .15g part molded in POM and PBT at 15-sec cycles.

Life in the Fast Lane

Toyo demonstrated what could be the fastest all-electric machine ever built. Its 100-ton Si-100III, equipped with the CH 450 injection unit, achieves an injection speed of 1000 mm/sec. Equipped with a heavy-duty, super-high-revolution ballscrew, it molded 2.6-inch light-guide plates. For the time being, it?s only being made available in Japan.

JSW?s new model J55AD-LS-30H is an all-electric 55 tonner with an 800-mm/sec maximum injection speed. It also featured JSW?s new fill-pressure feedback system, enhanced platen parallelism, and improved injection stability. It molded laser collimator lenses in eight-cavity tooling in 55-sec cycles. Another model, designated J55AD-60H-US, molded PC light guide panels in a two-cavity mold. Shot size was 2.2g.

Sumitomo?s new 130-ton model SE130DU-HP all-electric machine also has a maximum injection speed of 800 mm/sec. It molded PC memory cards in eight-cavity tooling at 14.8-sec cycle times. The cards weighed just .21g. ?U? stands for the Ultimate in Sumitomo?s direct-drive technology. It?s belt-free U-Series press has direct-drive injection, plasticating, clamping, and ejection.

It also has a clamp force feedback system?a tiebar sensor measuring actual clamping force closes the loop. It?s unaffected by the mold?s thermal expansion. Meanwhile, though they didn?t have one at Fakuma, Krauss-Maffei says its C3-AP Series of compact, twin-platen presses have all-electric injection units capable of 800 mm/sec injection speed.

All-electric machines rated at 500 mm/sec injection speed also were demonstrated at IPF?05. The 15-ton Toyo Si-15III molded fine-pitch connectors. It accelerates to maximum in .009 sec (the equivalent of 5.6 G) and brakes just as rapidly. And another ultra-quiet Toyo all-electric unit, a 350-ton model Si-350IIIH, dry cycles in 1 sec, has a 160-mm mold stroke, and a 300 mm/sec injection speed. It molded PP cups in a 16-cavity tool at 4.8-sec cycles.

Nissei has upgraded the stability, responsiveness, and injection velocity of 15-, 50-, 80-, and 180-ton models in its Elject NEX Series of all-electrics. A new, low-inertia servomotor increases injection velocity to 500 mm/sec. Another new feature is Nissei?s automatic clamp-force correction technology. Using it, production can start before tiebars reach a constant temperature, the need for excessive clamp force settings is unnecessary, and mold protection functions are improved. It allows Nissei to adapt its traditional belief in the merits of direct-force hydraulic clamping to all-electric toggles.JSW decided that high-speed injection need not be limited to horizontal all-electrics machines. Its new 40-ton all-electric vertical model, designated JT40ELIII-20V-HS, can motor along at 500 mm/sec. It ran small, .270g/.3-mm-pitch nylon connectors in 64-cavity tooling at 18-sec cycles. The connector?s were just .10-mm thick. Weight deviation was ±.00011g.

All-electric machines have come a long way in a relatively short amount of time, but for thinwall packaging speed, you?re still going to need at least a little oil. Husky?s 120-ton Hylectric H120 hybrid press smoothly ran a Husky-valve-gated two-cavity mold in a radically uncomplicated inmold labeling (IML) system every 2.3 seconds. Labels were delivered from an easily refillable magazine rack. A cam-operated swing chute unit inserted the labels into the mold, removed the finished parts, and transferred them to a stacking/counting unit.

The automation was developed by Husky and SysTec (SysTec Komplettsysteme GmbH; Bad Urach, Germany; http://www.systec-komplettsysteme.de/en/05/001.htm). The cell can be scaled-up to handle four-, six-, or eight-cavity molds.

An Engel Speed packaging machine equipped with an Engel ERS 1 Speedy robot for parts removal and an Engel ERC 13 carton stacker stackmolded PP yogurt containers in a six-cavity SysTec mold at cycles around 2.7 sec. Capable of 1.1- to 2.2-sec dry cycle times, Engel Speed hydraulic toggles are available from around 150 to 715 tons, with or without electric screw drives.

Engel has special frame-mounted guides for the moving platen?guides that extend beyond the platen, for handling large, heavy molds?and their tiebars have no direct play in platen guiding. Also Speed Series? inline injection units are designed to reduce mass acceleration during injection, even if they make the machine a little longer. Nearby, an all-electric 60-ton Engel E-Motion TL equipped with Engel?s X-Melt system precision-molded DVD lens holders in a four-cavity mold at 10.7-sec cycles.

In-mold Labeling has Conspicuous Presence

There were notable IML displays at both shows, including the following: Four-cavity, all-electric in-mold labeling of 6g, .40-mm-thin PP yogurt containers was demonstrated on a new 180-ton JSW press (Model J180AD-300H) equipped with a large-capacity injection unit.

Boy Machines demonstrated IML with foils on a 99-ton Boy 90 A. The scratch-resistant foils were automatically inserted by a robot from a dispenser mounted on the rear end of the machine. The 90 A is equipped with a double pump and has a 900-mm extended daylight option, both of which increase performance and expand mold options.

A 220-ton BM Biraghi all-electric press ran IML cups in a two-cavity mold at 3.8-sec cycles in a booth fully automated by Star Automation robotics.

In a somewhat similar vein, JSW?s proprietary ?Die-Slide? technology was used to demonstrate all-in-one inmold vapor sputtering of thin film and inmold assembly of automotive directional signal lamps on a 220-ton model J220ELIII-2M-DSI equipped with two shooters.

The Element of Surprise

Arburg, once exclusively a supplier to the small-machine market, showed a 440-ton unit equipped with six accumulators. The press produced 545g PP buckets every 11 seconds. Fakuma was the first public display of Arburg?s new fully accumulator-assisted press, the Allrounder 820 S 4000-3200.

Its accumulators allow for fast axial movements and reduce cycle times. All machine movements are individually controlled through servovalves. Its big, servomotored 25:1 L/D injection unit housed a 90-mm barrier screw. The opening stroke was 650 mm.

Arburg also demonstrated its Alldrive Series? high-speed packaging capabilities on a 110-ton Allrounder 420 A 1000-400. It ran 8.6g PP cups in a two-cavity mold at cycles well under 2.5 sec. Only the nozzle touch was hydraulic?the rest was all electric.

Netstal has long been associated with speedy operation. At Netstal?s booth a press running a two-cavity mold produced thinwall PP cups at 2.5-sec cycles?2800 cups/hr on its standard Synergy 1200-460, a 120 tonner. Nearby, Netstal?s all-electric Elion 500-130, 55-ton model precision molded connector housings in a four-cavity tool. Company sources say 40 Elions have been sold since their introduction at K?04, mostly in Europe. Its latest model is a 175 tonner.

At the IPF, Sodick-Plustech?s Model HSP100EH2, a 100-tonner equipped with an accumulator-assisted plunger on its signature, used a check-ring-free, two-stage injection unit. It was remarkably quiet, while precisely molding .6g PC optical guide plates in two-cavity tooling at 30-sec cycles.

Sodick debuted its direct linear drive technology. Designed for plungers of 16-mm diameter, or less, Sodick has developed and patented this proprietary direct linear servomotor technology to combine the features and benefits of its linear direct-drive technology with hydraulic pressure. It reduces fill time by reducing the time it takes to go from zero to maximum speed and back again to zero, rather than by increasing the machine?s maximum injection speed. A 5-ton model LDO5EH2 with a maximum 450 mm/sec injection speed demonstrated this new technology, precision molding challenging .1g LCP technical parts in two-cavity tooling at 6.5-sec cycles.

A high-speed, all-electric, 120-ton Ferromatik Milacron Elektra Evolution 110 also stopped folks in their tracks. It was used to demonstrate the company?s new Hi-PM software, which monitors the closing of the non-return valve as a process reference point, calculates injection stroke, and controls the injection process from there. The press precision-molded small medical tubes in a 16-cavity mold?a total shot weight of 7.85g. Injection speed reportedly was 80% faster than a similar machine running a similar part without Hi-PM software.

Updated Technology

Battenfeld unveiled its fully re-engineered mid-range HM Series of variable-volume full-hydraulic machines at Fakuma with a two-platen press with retractable tiebars. Designated HM 400/2250, company sources say that, ton-for-ton, its 420-ton HM Series machines, now in full production, are the shortest full hydraulic machines on the market, but that they combine this small footprint with generous tiebar spacing. A mold that normally runs in a 500 tonner reportedly could fit in the HM400/2250. It ran bottle caps in a 32-cavity mold at Fakuma in 7.5-sec cycles.

Battenfeld?s closed-loop HM machines are designed for easy serviceability and maintenance. Their tiebars have high-pressure sealing to reduce any possible damage and it?s a snap get at its ejector. Its oil and electric systems are built into its base. Battenfeld?s Unilog B4 controls are standard. Plans call for these twin-platens to be made available in 320-, 420-, and 500-ton models.

Niigata introduced its fifth-generation all-electric at IPF?05 with its MD50X:1.0, a 55 tonner with 320-by-320 mm between the bars, a 45g shot weight, and a brand-new injection system design. It?s equipped with the company?s new ?X-Generation? control, built with USB and flashcard porting for data storage. And its cabinet is fully filtered and air-conditioned. Niigata?s MD-X machines use a new servo system, photoelectric cabling, and high-performance/low-noise load cell technologies. Ballscrews, gear motors, and inverter controls are digital. The show unit molded .5-mm fine pitch/200-core LCP connectors in two-cavity tooling.

Nissei introduced its new ONX Series of hybrids. They feature Nissei?s new, quiet-running X-Pump, which combines a servomotor with a conventional hydraulic pump, uses 55% less oil, and reportedly reduces energy consumption 40% vs. conventional straight hydraulic pumps. Pump cooling water reportedly is virtually unnecessary.

PNX presses are engineered to be highly responsive, to provide excellent resolution and reproducibility in the low-velocity/low-pressure range, and to cost less than all-electrics. They also allow Nissei to return to its central-clamp cylinder, direct-pressure, hydraulic clamping system, a Nissei tradition. One of the three running at the show, a 41 tonner designated PNX40-5a molded .4-mm-thin PC light-guide plates in single-cavity tool.

New Hybrid Breeds

Sodick Plustech displayed its second-generation TR-EH2 series of hybrid presses, which feature stylish see-through safety gates and an attractive new machine control. The Model TR-EH2 features the company?s check-ring-free, two-stage, V-Line injection unit, with servomotored fixed-screw plasticating on top of a servohydraulic plunger, which now can be accumulator-assisted. The clamping unit has direct-drive electrically powered open, close, and ejection. Lock-up is hydraulically powered.

Fu Chun Shin brought a 100-ton model in its latest AF Series of hybrid toggles to IPF. AF?s feature a servodriven shooter reportedly capable of delivering up to a 700-mm/sec injection speed. FCS reportedly has improved the rigidity of their clamps by 30%. Moog servovalves are used for closed-loop control. A servo-powered check ring eliminates product weight fluctuations.

Injection-compression molding capabilities are standard. Servomotored cycle phase overlapping of feeding and mold movement reduces power consumption 15-20%, while speeding cycles. They?re also available in 30- and 800-ton models. The 100 tonner molded lenses at IPF.

Toshiba supplies hybrids from 650 to 1800 tons. A new 850-ton Model ED850 molded a structural foam automotive part in PP and a blowing agent, demonstrating its precise core-back capabilities. Proper blowing agent expansion and surface cooling was accomplished by opening the mold precisely, shot after shot.

Also, Sumitomo ran a 250-ton model in its SE-HY line of accumulator-assisted, toggle-clamp hybrids. With an 800-mm/sec injection speed, its SE260HY hybrid ran PP parts in an eight-cavity hot runner mold in 3.2-sec cycles. Fill time was .07 sec.

More New Lines

Systec?that?s the name for the brand-new standard line of fully modular hydraulics designed with custom molders in mind that Demag launched worldwide at Fakuma. Company sources say customers can start with a basic, standard machine and pick from any number of functional modules?such as electric screw drives, or high-speed options?to suit a Systec machine to practically any application. Systecs range from 50 to 200 tons and feature another new Demag standard, its NC5 control system.

The show machine was equipped with the first of a new line of Demag parts removal robots. Its control was integrated into the NC5. Also an all-electric Demag Intelect 50/330-45 ran PPA parts.

Krauss-Maffei showed two models of its EX Series of direct-drive all-electrics, each featuring the company?s distinctive Z-toggle clamping system design, which has fewer moving parts and, subsequently, fewer maintenance headaches. An 80-ton KM80-380 EX ran mobile phone covers in two-cavity tooling and a 160-ton KM160-750EX ran food container closures in a stack mold. It launched a 160-ton EX in January.

A representative model of Engel?s updated, tiebarless, Victory Standard series of economical, precision molding machines was shown at Fakuma, equipped with an all-electric drive. It was a Victory Standard 200/500, a 55 tonner. Standard machines?22 to 132 tons?feature new outward-curving glass safety gate exterior styling.

Footprint and machine weight have been reduced, injection units are fully modular and maximum daylight and opening strokes have been increased for larger and stranger-shaped molds. Engel?s latest CC 200 control is a standard on Standards. The show machine molded glass-reinforced PBT connectors in two-cavity tooling at 12-sec cycles.

A brand-new series of Fanuc all-electrics is coming. They?re called the Roboshot S-2000iB Series and they?ll be available in four sizes ranging from 50 to 300 tons. More than 23,000 Roboshots were sold worldwide by IPF?05. More details on them are expected to be released to the North American molding public before NPE time.

Their clamping units have been redesigned to focus more clamping pressure on their platens? center, and the platens are wider. Their shooters are more rigid and are designed for more precise control of injection pressures. And a directly coupled servomotor/screw option will be available. It eliminates the belt and more than doubles acceleration. The new Roboshots also are capable of smoothly interpolating position and pressure in microseconds.

A Multimolding Multitude

Owing to its growing popularity everywhere, multicomponent molding was well represented at both shows. Battenfeld displayed its HM 270/1330H/ 525V equipped with a horizontal and a vertical injection unit, and a servo-driven rotary table for molding two-component sealing caps in 30-sec cycles. A new side-entry Battenfeld servorobot was part of this display.

Krauss-Maffei produced automotive seatbelt buckle covers that changed colors each shot with a system that combined not only different colors, but different materials and manufacturing processes as well. Thermoplastic substrates were molded on a K-M 160-750 CX press with a sliding-table mold and then were coated with a PUR skin shot through K-M?s multicolor RIM mix head. K-M had another of its CX Series of multimolding machines at its booth in Friedrichshafen. An 80-ton K-M 80-180/180 CX with horizontal and vertical shooters and equipped with the company?s own electrically powered turntable molded PP/TPE connector sockets every 30 seconds. Its CS Series and its large-tonnage MX twin-platens both can be equipped with the company?s "Economiser." This device uses the reactive power generated by the pumps and screw motors to help power machine operations.Ferromatik Milacron had two all-electric twin-shooters on display. A small, 82-ton Elektra evolution 75 MSW equipped with the company?s ?Monosandwich? coinjection molding system was one. The other was a 198-ton Elektra evolution 180-2F equipped with enough space between the bars?630 by 630 mm?to accommodate a Foboha turntable. PP perfume bottles coated with color-matched TPE were run in a four-cavity Foboha "rotomold" at 25-sec cycles.

A Two-Shot Throng

A 75-ton Sumitomo SE75D-CI all-electric machine equipped with a small, two-cavity rotomold multimolded micro parts, 1.8g PC/TPE, at 29.7-sec cycles.

At Nissei?s stand a 140-ton model of its recently upgraded DCE series of all-electric two-shot machines molded two-color cups in a two-cavity rotary mold that spun into position in just .9 seconds. This press demonstrated Nissei?s latest high-speed/shock- and grease-free mold rotation mechanism, which uses a high-torque servomotor. The machine also showed off Nissei's new ?double-flat clamp,? which is designed so both sides of the mold offer equally high performance, even when molding parts with an unbalanced projected area.

Toshiba had two multimolding versions of its latest EC-NII Series of all-electrics on show. An EC100NII-2C flawlessly performed two-shot insert molding, and an EC160NII equipped with a Priamus Fill system molded three-component parts.

Meiki demonstrated a different kind of two-component processing. Its new 350-ton MU 350 model equipped with a 60-mm diameter screw ran HIPS that Meiki mixed with EPS recyclate which had been ground, crushed, and pelletized along with a proprietary rubber compound. It molded computer keyboards with this material on its MU 350, using its proprietary gas-assist process to maintain the part?s 3-mm thickness.

Meanwhile, UBE demonstrated its "Ecoprest" double-layer foam-molding process, a low-cost alternative to overmolding, on its all-electric, 450-ton MD450S-IV-i13A/i6.5A press. With Ecoprest, parts are foamed with carbon-dioxide, which is returned to atmosphere after foaming. Designed for producing automotive interior parts, the clamp is programmed to breathe to precise dimension to allow for gas expansion. The coating feels like an overmolded elastomer. The key reportedly is the servo-driven clamp control provided by UBE?s all-electric machine technology.

Things Are Looking Up

New vertical clamp presses and new applications for them were demonstrated at the two big shows by a number of prominent suppliers, including the following:

  • Arburg: Making its world premier at Fakuma, Arburg?s full-hydraulic 175V 125-30, a 13.75-ton C-frame, is the company?s first standard vertical press, since one of its very first machines.

  • Battenfeld: A model in its Vertical R line of hydraulic rotary-table/three-tiebar machines (40 to 200 ton) was used to demonstrate its inline integration into a fully automated production cell. The cell produced ready-to-ship, ultramodern versions of the Nine Men?s Morris game.

  • Boy: Boy?s 35VV, equipped with both vertical injection and clamping, is a 38.5-ton two-platen press that encapsulated knife blades. A multiaxis robot placed knife blades into its two-cavity mold. The blades were automatically overmolded and removed. Auxiliaries were integrated onto the machine table, saving floorspace. The press dimensions allow for its direct integration into production lines.Boy?s brand-new, all-vertical, four tiebar 55MVV, which ran an eight-cavity mold at Fakuma, has a low, 39-inch height and a very compact footprint. It has a table for the mounting of auxiliaries at its back. The 60.5-ton 55MVV with 360 by 360 mm between the bars expands the line upward for Boy?s encapsulation and insert molding press offerings. Its table height is only 975 mm.

  • Niigata: Two all-electric verticals were shown, designated MDV50STs-IV and MDVR50S-IV. One molded a magnifying lens; the other molded lens bodies. One has a rotary table; the other a slide.

  • Nissei: Its Elject TNS50RE is a new three-tiebar all-vertical, all-electric with a big rotary table for large molds that?s targeted at automotive molders. Equipped with NEX Series shooters, Nissei builds them up to 150 tons.

  • Sumitomo: The Model SR50D, a new all-electric rotary-table vertical, precision molded 6.7g PBT coil bobbins at 24-sec cycles.

  • Sodick: A low-table/low-height, 75-ton vertical designated TR75VRE molded 29.3g PPS mechanical parts at 30-sec cycles. Sodick also demonstrated insert molding on a horizontal press, a 140-ton, 500 mm/sec TR140EH2 model, molding 22.4g nylon-66 automotive coil bobbins in a two-cavity mold at 55-sec cycles.

  • Toyo: An all-vertical, all-electric, and robotized 40-ton model ET-40V molded syringes. Another model designated ET-80VR2m equipped with a servo-rotary table, molded magnifying glasses. It had a low, 959-mm table height and featured Toyo?s triple nozzle-touch technology.

High-Tech Highlights

JSW demonstrated all-electric MuCell molding of automotive connectors on a J85AD-110H-MuCell machine, a 350 mm/sec model with 410 X 360 mm between the bars, and a 49-cm3 injection capacity. Another J-AD Series machine, a 180 tonner, used a novel injection-compression technique to precision mold helical POM gears. To improve its cylindrical profile accuracy, partial compression of the part was done by the ejector pin.

A vented screw cylinder on its 140-ton J140AD-Vent model allowed JSW to mold 1-mm-thick PMMA light-guide panels for PDA?s in two-cavity tooling, a 5.5g shot, without the use of a dryer. Meanwhile, Sumitomo?s 75-ton SE75DU press molded PC light-guide plates with a very fine-patterned stamper Sumitomo developed with LIGA processing technologies. The press was equipped with Amotec?s flow-enhancing CO2 processing system.

As part of Toshiba?s Nano Imprint exhibition, a 60-ton, 425 mm/sec model EC60NII all-electric molded 35g, very thin-wall PC mobile phone screens in two-cavity tooling at a 23-sec cycle. Toshiba?s new EC-NII?s feature newly developed low-inertia injectors with high-performance, low-inertia servomotors for quick response and enhanced holding pressure performance. Its low-inertia injection unit is designed to enhan

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