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CHAPTER 1

INTRODUCTION

This chapter proves a review of the concept of injected parts and methods of parts

developments. This chapter also relates how parts were produced by using specific tools that

provided in the laboratory. Besides that, this chapter also includes the information about

parameter involves and the material that used in this project. The injected parts also are chosen

so that the sample can be taken nicely to do some analysis.

1.1 HISTORY OF INJECTION MOLDING

Injection is a manufacturing process for producing parts from both thermoplastic and

thermosetting plastic materials. Material is fed into a heated barrel, mixed, and forced into a mold

cavity where it cools and hardens to the configuration of the cavity. After a product is designed,

usually by an industrial designer or an engineer, molds are made by a mold maker or toolmaker

from metal, usually either steel or aluminum, and precision-machined to form the features of the

desired part. Injection molding is widely used for manufacturing a variety of parts, from the

smallest component to entire body panels of cars. (Todd, 1994)

Am injection molding machine, also known as an injection press, is a machine for

manufacturing plastic products by the injection molding process. It consists of two main parts,

an injection unit and a clamping unit. Injection molding machines can fasten the molds either a

horizontal or vertical position. The majority of machines are horizontally oriented, but vertical

machines are used in some niche applications such as insert molding allowing the machine to take

advantage of gravity.

The first man-made plastic was invented in Britain in 1852 by Alexander Parkes. He publicly

demonstrated it at the 1861 international exhibition in London; calling the material he produced

“parkesine.” Derived from cellulose, Parkesine could be heated, molded and retain its shape when

cooled. It was, however, expensive to produce, prone to cracking, and highly flammable.

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In 1856, American inventor John Wesley Hyatt developed a plastic material he named

Celluloid, improving on Parkes’ invention so that it could be processed into finished from.

Together with his brother Isaiah, Hyatt patented the first injection molding machine in 1872. This

machine was relatively simple compared to machines in use today. It worked like large

hypodermic needle, using a plunger to inject plastic through a heated cylinder into a mold. The

industry progressed slowly over the years, through a heated cylinder into a mold. The industry

progressed slowly over the years, producing products such as collar stays, buttons, and hair

combs. (U.S. patent, 1872) The industry expanded rapidly in the 1940s because World War II

created a huge demand for inexpensive, mass-produced products. In 1946, American inventor

James Watson Hendry built the first screw injection machine, which allowed much more precise

control over the speed of injection and the quality of articles produced. This machine also allowed

material to be mixed before injection, so that colored or recycled plastic could be added to virgin

material and mixed thoroughly before being injected. Today screw injection machines account for

the vast majority of all injection machines. In the 1970s, Hendry went on to develop the first gas-

assisted injection molding process, which permitted the production of completed, hollow articles

that cooled quickly. This greatly improved design flexibility as well as the strength and finish of

manufactured parts while reducing production time, cost, weight and waste.

The plastic injection molding industry has evolved over the years from producing combs and

buttons to producing a vast array of products for many industries including automotive, medical,

aerospace and consumer products. (Douglas, 1996)

1.2 INJECTION MOLDING MACHINE

For thermoplastics, the injection molding machine converts granular or pelleted raw plastic

into final molded parts via a melt, inject, pack, and cool cycle. A typical injection molding machine

consists of the following major components:

Injection system

Hydraulic system

Mold system

Clamping system

Control system

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Figure 1.1: Injection molding machine for thermoplastics.

For the machine specification, the clamping tonnage and shot size are commonly used to

quickly identify the size of the injection molding machine for thermoplastics. Other parameters

include injection rate, injection pressure, screw design, mold thickness, and the distance between

tie bars. The major equipment auxiliary to an injection molding machine includes resin dryers,

materials-handling equipment, granulators, mold-temperature controllers and chillers, part-

removal robots, and part-handling equipment. Injection molding machines can be generally

classified into three categories, based on machines function which are:

General-purpose machines

Precision, tight-tolerance machines

High-speed, thin-wall machines

1.2.1 Injection system

The injection system consists of a hopper, a reciprocating screw and barrel assembly, and an

injection nozzle, as shown in Figure 1.2. This system confines and transports the plastic as it

progresses through the feeding, compressing, degassing, melting, injection, and packing stages.

Figure 1.2: A single screw injection molding machine

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I. The hopper

Thermoplastic material is supplied to molders in the form of small pellets. The hopper on the

injection molding machine holds these pellets. The pellets are gravity-fed from the hopper through

the hopper throat into the barrel and screw assembly.

II. The barrel As shown in Figure1.2, the barrel of the injection molding machine supports the reciprocating

plasticizing screw. It is heated by the electric heater bands.

III. The reciprocating screw

It is used to compress, melt, and convey the material. While the outside diameter of the screw

remains constant, the depth of the flights on the reciprocating screw decreases from the feed zone

to the beginning of the metering zone. These flights compress the material against the inside

diameter of the barrel, which creates viscous heat. This shear heat is mainly responsible for

melting the material. The heater bands outside the barrel help maintain the material in the molten

state. Typically, a molding machine can have three or more heater bands or zones with different

temperature settings.

IV. The reciprocating screw consist of three zones which are:

the feeding zone the compressing or transition zone the metering zone

Figure 1.3: A reciprocating screw

V. The nozzle

It connects the barrel to the spure busing of the mold and forms a seal between the barrel and

the mold. The temperature of the nozzle should be set to the material’s melt temperature or just

below it, depending on the recommendation of the material supplier. When the barrel is in its full

forward processing position, the radius of the nozzle should nest and seal in the concave radius

in the supre busing with a locating ring. During purging of the barrel, the barrel backs out from

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the spure, so the purging compounds can free fall from the nozzle. These two barrel positions are

illustrated below.

Figure 1.4: Nozzle with barrel in processing position (a) and nozzle with barrel backed out for purging (b).

1.2.2 Mold system

The mold system consists of tie bars, stationary and moving platens, as well as molding

plates that house the cavity, spure and runner systems, ejector pins, and cooling channels, as

shown in Figure 1.5. The mold is essentially a heat exchanger in which the molten thermoplastic

solidifies to the desired shape and dimensional details define by the cavity.

A mold system is an assembly of platens and molding plates typically made of tool steel. The

mold system shapes the plastics inside the mold cavity (or matrix of cavities) and ejects the

molded part. The stationary platen is attached to the barrel side of the machine and is connected

to the moving platen by the tie bars. The cavity plate is generally mounted on the stationary

platen and houses the injection nozzle. The core plate moves with the moving platen guided by

the tie bars. Occasionally, the cavity plate is mounted to the moving platen and the core plate

and a hydraulic knock-out (ejector) system is mounted to the stationary platen.

Figure 1.5: A typical (three-plate) molding system

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I. Two plate mold

The vast majority of molds consist essentially of two halves, as shown below. This kind of mold

is used for parts that are typically gated on or around their edge, with the runner in the same mold

plate as cavity.

II. Three plate mold

The three-plate mold is typically used for parts that are gated away from their edge. The runner is

in two plates, separate from the cavity and core.

1.2.3 Clamping system

The actual required tonnage depends on a number of factors, including part design, polymer

viscosity, polymer flow length, mating mold surface condition, and mold construction. The mold

should occupy approximately 2/3 of the platen area between the tie bars to prevent possible

damage to the mold from “platen wrap-around” Using the minimum clamp force required to

produce acceptable parts will reduce the center deflection of the mold. Figure 1.6 indicates mold

cavity pressure with in thin walled parts and long flow paths for low to medium viscosity

materials.

Figure 1.6

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1.3 Parameters in injection molding machine

The quality of molded part is greatly influenced by the conditions under which it is processed.

See, for example, the process window shown in figure 1.7. As you lower the temperature, higher

the pressure is needed to deliver the polymer melt into the cavity. If the temperature is too high,

you risk causing material degradation. If the injection pressure is too low, a short shot could result.

If the pressure is too high, you will flash the mold.

Figure1.7: Process window shows the influence of temperature versus pressure

1.3.1 Temperature

Range: 370 to 390°F (190 to 200°C)

The optimum temperature profile depends on many variables, including machine capacity to

shot size ratio, screw design, mold and part design, and cycle time. Generally, barrel temperature

controllers should be of PID type, and set so the material melts gradually, with cooler rear zone

and hotter front zone temperature. For vented barrel machines, a relatively flat temperature

profile is recommended to ensure the polymer is melted by the time it reaches the vent zone

reverse temperature profiles are used occasionally to compensate for improper screw design, to

reduce machine amperage or torque requirements, and to compensate for machines with short

L/D ratios.

1.3.2 Pressure

The injection pressure is the pressure of the melt in front of the screw. The injection pressure

should be low as possible to reduce the part internal stress. On machine, set the injection pressure

to the machine maximum. The purpose is completely exploit the injection velocity of the machine,

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so that the pressure setting valve does not limit the velocity. Because the switch-over to holding

pressure occurs before the mold is completely filled, no damage will be done to the mold.

Figure 1.8 Resin/hydraulic pressure ration for a 30 mm screw

1.3.3 Injection volume

When the process has stabilized (when the same parts are produced each time), adjust the

switch-over position to 99 percent of filling. This will exploit the maximum injection speed in as

large a part of the injection as possible.

1.4 Material used

Many plastics are derived from fractions of petroleum or gases that are recovered during the

refining process. For example: ethylene monomer, one of the more important feedstocks, or

starting materials for plastics, is derived in a gaseous form from petroleum refinery, gas, liquefied

petroleum gases, or liquid hydrocarbons. Although petroleum gas derivatives are not the only

basic source used in making feedstocks for plastics, they are among the most popular and

economical in use today. Coal is another excellent source in the manufacturing of feedstocks for

plastics. From these basic sources come the feedstocks we call monomers. The monomer is

subjected to a chemical reaction known as polymerization; it causes the small molecules to link

together into ever increasingly long molecules. Chemically, the polymerization reaction gas turns

the monomer into a polymer, and thus a given type of plastic resin.

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Table 1.1 Origin of plastics

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CHAPTER 2

Production Automation - Injection Molding

There is no need to dwell on the challenges facing today’s injection molding industry, in the

last couple of years, injection molders have made sizable capital investments to improve quality

and efficiency in an effort to counter competitive pressures as well as rising material and labor

costs. Now injection machines, advanced automation and inspection devices, to automated

assembly machinery and sophisticated materials handling equipment have enabled molding

plants to significantly increase output with a lower operation cost basis. As a result, they now

enjoy the highest historical productivity rates.

However, in spite of all these advances, the injection molding industry faces its biggest

challenge yet. To further optimize efficiency, there is a need for an integrated approach that

guarantees flawless execution from the conceptual stage of part design, to its high volume

production, to its ultimate delivery to the customer. Unfortunately, the injection molding

manufacturing process is a patchwork of disparate systems with which it is difficult to

intelligently exchange data, making the planning, setup and ramp-up of new production lines

time consuming and plagued by inefficient trial and error and fine tuning methods.

2.1 Set up, Optimize, Control and Monitor

Once the part and the mold designs are optimized and the effects of the molding processes

have been taken into account, the logical next step is to deliver optimal processing parameters to

the primary equipment and other process controls in the manufacturing cell.

Automating the setup process enables production to start more quickly and shortens the time

required to determine and achieve the ideal process parameters such as shot size, injection speed,

temperature and pressure settings. Used intelligently, design analysis simulation (DOE) results

can provide appropriate initial conditions from which to begin the manufacturing process setup

and downstream optimization and control tasks. The more complex the part, the material or the

mold, the narrower is the processing window and the higher is the need for continuous

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monitoring and optimization during production. In a networked environment, monitoring and

optimization can now be handled automatically from a single operator console in a central

location, limiting operator interventions in the production cell to major equipment failures.

2.2 Optimal Temperature and Flow

Production capacity and yield are ultimately determined by the speed, reliability and quality

by which the melt flows from the machine into the mold. This is where advanced hot runner

controls come in, as they assure that materials are kept in an optimal molten state until injected

into the part cavity. This “final controls element” guarantees higher yields, reduced cycle times

and better part quality.

2.3 How Are We Doing Today?

Bringing production equipment into a networked environment does more than just extend the

control and monitoring functionality. It provides access to real-time data that can be used for

production monitoring, work order management, job scheduling, statistical quality control

(SQC), Statistical process control (SPC) production scheduling, preventive maintenance,

production reporting and part traceability.

The instant access to the metrics that define an operation’s performance, give it the agility to

quickly and confidently respond to changing market conditions and competitive pressures.

Can you schedule additional jobs to maximize your capacity?

How aggressively can you price your services?

Can you provide detailed production quality data and assure part traceability to your

customers?

Providing such a capabilities gives an output of effectively and efficiently.

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Figure 2.1 Todays manufacturing process

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2.4 The Knowledge Loop

To accomplish all of the above fig 2.1, a system needs to be totally integrated and balanced.

It has to be a “knowledge loop” that starts with the in-depth profiles of production capabilities

and material characteristics that are used to optimally design a part and mold and determine a

practical processing window. From there the information is used to control and monitor the

optimal settings of the process equipment and the auxiliaries in the manufacturing cell. The

knowledge loop is closed with the validated data serving as the source for future predictive

modeling and design, implementing this knowledge loop requires a technology partner who

understands the complex data interfaces needed to communicate with older as well as today’s

state-of-the art equipment. Turning proprietary signals from a multitude of sources into a

wealth of meaningful and usable information is invaluable.

The knowledge loop needs to be extendable to upstream and downstream process. This can

go from the basic hand-off or exchange of intelligent data between process entities to a superset

of centralized control and monitoring functions that star with the supply management of raw

materials, through automated assembly, and packaging.

The ultimate goal to create a single continuum that is proactive in that it intelligently

determines the fastest and most reliable process steps to produce a product, and reactive to

predictably adapt to erroneous behavior, to expand the body of process knowledge and to

document product genealogy and quality.

2.5 Manufacturing Optimization

Even though design analysis solutions play an important role in this knowledge loop, the focus

of this chapter is on the manufacturing optimization segment. Manufacturing solutions products

comprise a complete suite of tools that can be used for the setup, optimization, and control of the

injection molding process, as well as for the monitoring and monitoring-related tasks associated

with injection molding equipment, as well as upstream and downstream auxiliary equipment. The

primary objective of manufacturing optimization is to achieve and maintain the best processing

conditions, resulting in higher part quality and more efficient use of machine time. In the next

sections, we will cover several important aspects of manufacturing optimization and knowledge

loop can help you accomplish them.

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Fig 2.2 manufacturing optimization

2.5.1 Process Setup

Successful process setup requires an operator to determine a machine-mold-material

combination of processing conditions to achieve acceptable quality parts. Proper process setup

module eliminates the guesswork over process parameter permutations and instead provides an

intuitive, systematic method for establishing the best combination of process parameters that

produce good molded parts. This scientifically created process results in less time spent on setup

and less material wasted on trial-and-error iterations.

2.5.2 Process Optimization

After determining the combination of process parameters that will produce an acceptable

quality part, it is important to further determine or verify a robust processing window.

Knowledge loop process optimization module performs an automated Design of Experiments

(DOE) that builds on the foundation established during the process setup phase. The technology

allows users to further optimize the combination of processing parameters to determine a robust,

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“good parts” processing window. The Predefined DOE runs automatically, so no special expertise

in statistical process control (SPC) is required for a machine operator to determine a robust, “good

parts” processing window quickly. Once this robust processing window has been determine, the

process is less likely to go out-of-control and produce out-of-specification parts.

2.5.3 Process control

Assuming a robust processing window has been determined by using the process setup and

process optimization modules, users can access knowledge loop process control module to

maintain the optimized processing conditions. The process control module allows users to

consistently maintain the production process, resulting in reduced reject rates, higher part

quality, and more efficient use of machine time.

2.5.4 Hot Runner Process Control

The right machine parameters and the wrong process control of the mold will result in slower

cycles, parts out of tolerance, high scrap rates and constant headaches for processing technicians.

It is imperative for the best part-price ratio that the core of a mold, the hot runner when used, be

properly controlled.

Altanium hot runner process controls are the industry’s first and only modular, small footprint

solution that can support from one to 384 zones. Its unique modular control units can be used

freestanding, mounted on the mold or mounted alongside, behind, or even inside the injection-

molding machine. With advanced technology for auto-saving, boost control, standby

management, mold diagnostics and data collection, Altanium controls offer the highest degree of

temperature control accuracy for existing and future low-mass nozzles, featuring user selectable

phase angle or zero cross power control per zone, state-of-the-art “hall effect” current transducers

and enhanced diagnostics and control software.

The increased use of temperature-sensitive engineering plastics, hare-to-mold polymers, and

co-injected materials demands the ultimate in temperature control to assure dimensional

consistency, which is where Altanium hot runner controls come in.

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2.6 High Speed Process Monitoring and Analysis

Once a robust processing window has been established and is in control, it is important to

continuously monitor key process parameters to identify any trends in the process. Using

collected data, process monitoring and analysis module analyze the manufacturing processes to

uncover hidden or latent problems, as well as collect and archive the data for future part quality

conformation.

2.6.1 Statistical process control

Fundamentally, statistical process control (SPC) is a method of monitoring a process during

its operation in order to control part quality during production, as opposed to relying on

inspection to fine problems after the fact. SPC involves gathering and analyzing data about the

process itself in near real time, so that necessary action can be taken. This is done in order to

identify special causes of variation and other abnormal processing conditions, thereby brining the

process under statistical control and reducing cycle-to-cycle part-to-part variation. Because of the

nature of the injection molding process, it is ideally suited for implementing SPC methods.

Therefore, a complete manufacturing solutions systems should include a method for performing

various SPC tasks.

SPC module can be used to apply SPC methods to the injection molding process. Some of its

capabilities include:

Measure and store up to 50 parameters on every machine cycle and then perform typical

SPC treatment of the data.

Activate alarms and part diverters when process limits are violated.

Display run charts to review process parameters and part attributes for up to 100,000

machine cycles.

Display histograms, X-bar and R charts, and scatter diagrams for additional analysis

capability.

These are just some of the SPC capabilities available to help injection molders improve their

process and maintain greater control over it.

2.6.2 Statistical Quality Control

Relative to injection molding, statistical quality control (SQC) is the application of statistical

techniques to measure and evaluate the quality of the part or process. Within SQC, there is the

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concept of acceptance sampling, which is the application of statistical techniques to determine

whether a population of items should be accepted or rejected based on a sample inspection.

Furthermore, “quality measurements” associated with certain characteristics, such as part weight,

part dimensions, part warpage and others, can be assessed. Any or all of these characteristics can

be identified as either acceptable or not acceptable. In combination, the measurement of these

characteristics results feedback and the correlation with SPC data offer valuable tools for

injection molders who aim to achieve or exceed the highest levels of production quality, SQC

module allows SQC data to be entered into the system and recorded in association with shot-

numbered process data for correlation purposes in a statistical process analyzer tool.

2.7 Production Monitoring Technology

Production monitoring is normally associated with tracking data such as part counts, number

of good parts versus number of defect parts, defect causes, machine downtime, and machine

efficiencies.

Production monitoring module includes the previously mentioned features that allow for the

tracking of production data, plus it has mechanisms to input scrap causes, downtime codes, job

start/stop, lot changes, material consumption, and part quantity adjustment. This capability

allows injection molders to measure and track their operations in real time, thereby enhancing

critical decision-making.

2.7.1 Production Reporting

Once a production or process monitoring system is in place, there must be a mechanism for

extracting the data collected in a format that is easily communicated to those who require the

information. This is accomplished using production reporting module, which provides the

following capabilities:

View production process with graphic and tabular reports.

Report real-time status on every job on every machine.

Customize reports.

Create dozens of standard reports that summarize performance by job, machine, mold,

and part number.

Graphically illustrate scrap and downtime using Pareto and pie charts.

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Easily and efficiently interchange information with various databases and other software

packages, such as ERP/MRP systems.

Production reporting is a valuable and necessary component of any process or production

monitoring system as it is the mechanism for providing access to critical information in real time

so that informed business decisions can be made.

2.7.2 Production scheduling

As an injection molder increases the number of machines and molds that are scheduled to run

in production, an automated production scheduling systems becomes a necessity. Without a

production scheduling system, molders will ultimately delay or miss product ship dates. When it

happens, the resulting lost time, additional expenses, and dissatisfied customer cost more than

money, it costs their reputation. Production scheduler module provides fast job creation and

efficient schedules. The ability to use previously collected job histories and job templates makes

scheduling new job or job re-runs easy and efficient. The production scheduler module also allows

users to adjust machine workloads to accommodate changes in production or delivery

requirements while eliminating scheduling conflicts.

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Chapter 3

Injection molding Automation

“Flexible automation is the key for the future of the plastics industry”

Straight ahead. And efficient. As a liner robot (from Engel). That’s how to solve the automation

tasks. The intellignet Engel viper linear robot is the solution for the many of the tasks. It is

powerful, dynamic, stable and fast. It features maximum operation convenience.

But the automation does not only think linear. It always see the injection molding process as

the whole.That’s why we can always expect complete system solutions. Highly integreated

system cells. Turn key. In which the individual system components such as the machine. Multi-

axis industrial robots. Linear devices, camera tech-nology, tracing solutions and much more are

perfectly coordinated.

All this is in the interest of efficency. For premium parts quality stable process and increases

overall productivity for injection molding production.

3.1 Growth

Asia has made a significant contribution of this growth in revenue. A further reason is the

successful launch of the energy-saving ecodrive option which has boosted the market share of

tie=bar=less injection molding machines and of big two=platen machines. Today, half of the

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hydraulic injection molding machines delivered worldwide aare equipped with the

servohydraulic eco drive which – depending on the machine type and application – bundling

business. In particular with the automotive industry and the significantly increased demand for

all-electric e-motion injection molding machines,

3.1.1 Plastic processing goes

Milacron LLC is the argest manufacturer of injection molding machines in the western

Hemisphere, particularly known for its medium to large sized injection molding machines.

Products manufactured by these manchines range from automotive parts to surgical instruments

to consumer goods such as cutlery, bucketlids, and cell phone housings.

3.2 Robotics and vision systems combine to improve injection molding processes

Robotics and automted vision systems have been combined to provide innumerable benefits

to manufcturing fcilities for a variety of operations, such as inspection, assembly, and pckaging.

Vision Systems can provide the speed and accuracy that high volume manufactring facilities need

that relies heavily on robotics is injection molding. For some parts, such as beverage bottles,

manufacturing volumes are huge, and robotic systems significantly increase the speed of part

handling. Manufacturing, and inspection, resulting in increased efficiencies and reduced

operationl costs. Suppliers have developed complete systems of robotic hardwre, Vision hardwre

and software, sensors, and analysis tools that can be easily deployed without requiring specialized

expertise.

3.2.1 Complex Geometries of injection molded parts

The injection molding process results in a 3-dimensional part that can often have complex

geometries. Robotic systems rely on Vision hardware to identify the part, identify the orientation

of the part, perform operations on that part, or move the part to a specific location. These

operations can be challenge, because an injection molded prt is 3-dimensional and the robotic

system opertions in 3D, while the imge created by camera is in 2D. For some injection molded

parts, multiple cameras can be employed along with depth sensors to identify injection molded

parts and provide the right instructions on the robotics.

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3.2.2 Robotics and Post-Mold Machining

The injection molding process often leaves thin layer of plastic, called flash, along the part

where the two halves of the mold came together, or around ejection pin points. This flash has to

be trimmed away after molding. The location of the flash on the part is predictble, because it is

limited to fixed points on the mold, so the trimming process can be performed by robotic systems.

A robot arm welding a cold or hot knife can be used to trim the flash awy from the surface of the

part , resulting in a smooth surface. Integrated vision systems can help the robotic arm:

Locate the part on the assembly line

Determine the orienttion of the part

Guide the robotic arm to the srat of a trimming curve

Guide the arm long a pre-programed curve to remove the flash

The feedback from the vision hardware allows the robotic arm to remove the flash accurately and

maintain the required tolerances in the part.

3.3 Purpose of utilizing automation

Quality

A thermal exchange process

Final quality of the injected product depends of the stability of the process

Process stability

Constant cycle time of production

Overall process control

Automated product removal

Produce more injected products with less time

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3.4 TYPES OF ROBOTS

3.4.1 Linear robots

Three-axis electrical motor drives:

AC servo or AC inverter/asynchronous motors and supplementary

rotary axes

Placed either on the fixed part or in the movable side of the injection

machine

Using grippers or vacuum suction

Maximum payloads typically up to 30kg

Reason of utilizing “Pick-and-Place” or Linear robots:

accurate motions

free of vibration

high acceleration and deceleration

precise insertion/removal of pieces

Secure picking and carrying of the injected products.

Fig 3.1 linear robot

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3.4.2 Six-Axis robots

Six degrees of freedom

Axis 1: located at the robot base, allows the robot to rotate from left to right. Rotate a full 180° range from the center point. Axis 2: lower arm of the robot to extend forward and back-ward. Axis 3: vertical reach, allows the upper arm to raise and lower. Axis 4: aids in the positioning of the end-effectors or gripper, which

rotates the upper arm in a circular motion moving parts between horizontal to vertical orientations.

Axis 5: allows the wrist of the robot arm to tilt up and down. This axis is responsible for the pitch and yaw motion.

Axis 6: a twisting motion of 360° rotation clockwise or counterclockwise direction in a circular motion, both to position end effectors and to manipulate parts. Greater flexibility and perform a wider variety of applications

Fig 3.2 six-axis robot

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Fig 3.2.1 simple intergration of an industrial robot and cost-effective implementation of your six-xis robot application in medical

technology particularly in combination with tie-bar-less injection molding machines and filter-fan units, all benefits are combined in

compact production cell.

In addition to the linear robots, the multi-axis industrial robots can also be fully integrated into the system philosophy – without a Euromap 67 interface. This is made possible by Engel easix. With this innovation the Engel RC 200 or CC 200 control unit can control the six rotational axes of industrial robots. The industrial robot is thereby programed with the Familiar and simple graphical instructions of the RC 200 control unit. The additional movement instructions for the industrial robot can be seamlessly integrated into the graphical user interface of the extended view. An operator who is able to prepare the sequences for linear robots can also quickly learn to program jointed arm robots. ENGEL customers are thus perfectly prepared to respond to the demands of the future. The trend towards a higher degree of automation is continuing.

Fig 3.2.2 robo controlor

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3.4.3 3-Axis Robots

Are used for automation on horizontal plastic injection molding machines(top entry

applications) and operations requiring higher spped 3-Axis robots can be used for part picking,

in mold decorating (IMD) and-mold labelling (IML), insert loading, stacking, palletizing

inspection. 3-Axiz robots are simple to operate and maintain and minimize energy consumption.

3-Axis robots are redployable on various types and sizes of plastic injection molding machines

within the robots payload and strength. Robotic Automation Systems integrates both Hahn

Automation (GHS Automation / Geiger Handling) and Wittmann 3-Axis robots.

Fig 3.3 3-Axis Robots

3.4.4 Scara Robots

(Selective complaint Assembly Robot Arm) provide a circular work envelope with broad

range of movement, allowing for added flexmbility. SCARA robots have a small footpring and can

be built on a smaller scale. SCARA robots are typically employed for loading and unloading

vertical injection molding machines, or to present a complement of inserts upstream of a 3-Axis

or 6-Axis robot. Epson SCARA robots offer high spped, heavy payload, high precision, large work

envelopes and fully integrated options. SCARA robots can be used for assembly in high tolerance

applications. Robotic Automation Systems integrates both Epson Robots and Yamaha Robotics

Scara Robots.

Fig 3.4 scara robots

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3.4.5 Side Entry Robots

Are single axis robots dedicated to a specific application. They offer extreme high speed for

applications such as placing decorations / labels for in-mold decorating (IMD) / inmold labelling

(IML) and part removal. Robotic Automation Systems integrates both Hahn Automation (GHS

Automation / Geiger Handling) and Wittmann side Entry Robots.

Fig 3.5 side entry robots

3.4.6 Servo Sprue Pickers

Are simple pick-amd-place robotic devides used for sprue removal or part and runner

separation in plastic injection molding automation. Servo Sprue pickers range in size to fit 15 to

300 ton plastic injection molding machines. The X and Y axis, and A rotation, are all servo driven

for maximum flexibility and programmability. All adjustments are made from a hand held pendant

for ease of use shile maintaining infinite positioning. Servo sprue pickers allow for pre-staging

above the mold, which minimizes action time in and out of the mold. They are flexible allowing

for deposit on both sides of the injection molding machines – runners out on one side and parts

out on the other. Robotic Automation Systems integrates Hahn Automation (GHS Automation /

Geiger Handling) servo sprue pickers

.

Fig 3.6 Servo Sprue Pickers

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3.5 viper

The powerful linear robot maximum stability, impressive dynamics and maximum user-

friendliness. The new Engel viper combines all of these things with ease. It saves weight with its

innovative design using laser- welded steel sections and convinces users with a substan-tially

higher load-bearing capacity.

More efficiency due to intelligence. Clever software such as vibration control and mass

identification, it automatically reduces structure-borne vibration, even with longer axis

dimensions, and optimises its movements and dynamic values to achieve better efficiency. The

impressive results: Ultra-fast cycle times and maximum productivity accompanied by low energy

consumption.

Fig 3.7 viper

3.5.1 Mass Identification

Due to this patented technology the robot detects the working load automatically within a

cycle. And adapts the dynamic values accordingly. Thanks to the dynamic model the Engel viper

ensures a uniform mechanical load. Which means:

The robot moves faster when it has less to carry. Benefit to you: shorter cycle times

and increased productivity.

The robot moves slower when it has more to carry than normal. This protects the

mechanical components. Ensuring an even longer robot service life.

3.5.2 Vibration Control

Thanks to this software, structure-borne vibrations are reduced. This substantially increases

path and positioning accuracy. The positive consequence: shorter cycle times are possible. This

software has been filed for patent.

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3.5.3 Viper series

3.5.4 Efficiency Control

According to the motto “as fast as necessary – not as possible”, the robot optimizes the

acceleration and speed values. And it minimizes robot waiting times.

Take-off starts “just in time”

Freely selectable waiting period in take-off position

Avoidance of unnecessary stress for mechanism and drive train

Assurance of a long service lice

Reduced energy consumption, resulting in up to 25% lower costs.

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3.6 Robot Control Unit

Robot Control Unit = Machine Control Unit

Since, injection molding machines and robots from a single source, full integration of the two

control landscapes is guaranteed without the need for a Euromap 67 interface. The RC 200 robot

control unit is integrated into the machine control unit CC 200 as a subsystem.

Fig 3.8 robot control unit

3.6.1 Benefits

Simple operation: Uniform, concise and logical operation of the machine control, also for

robot control

Single data management for injection molding machine and robot

Considerably increased productivity thanks to synchronized movements

3.6.2 Language

It speaks all Languages

A state-of-the-art control unit needs to keep on top of highly processes. While providing for

quick and simple programming. The ENGEL RC 200 fulfils this requirement to perfection. It

speaks the language of the machine operator as well as that of the system adjuster and programer.

The robot control unit speaks the language of the system operator and adjuster

In the so-called simple view the robot sequence is clearly and simply displayed in the form of a

circle. The sequences are graphically visualized in chronological order on the cycle. In addition,

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the operator sees the current working position of the robot. By pressing one of the sequence icons

the adjuster can adapt its function new sequence.

3.6.3 NO Programming Skills Needed

Numerous predefined standard sequences in the control unit are available to the operator

for different applications in automation. The adjuster does not require any programming skills.

He simply selects a sequence and can adjust the process sequences contained therein to current

requirements by exchanging options. All settings (positions, speeds and waiting times) required

for the selected sequence are displayed in a clearly laid out setup page.

This means simple automation tasks can be performed cost – effectively without additional

programming personnel. Furthermore tooling rimes are reduced.

3.6.4 Ideal for System Operators and Adjusters:

The viper wizard guides the system operator through the menu. He only needs to decide yes

or no. Once all questions have been answered, he will be guided through the positions which must

be set for the complete program sequence based upon his choice. The next step is that simple view

As shown in the Figure below.

Fig 3.9 easily operating Robot control unit

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If Complex control tasks are to be performed, the system programer can discharge them quickly

and efficiently with the RC 200 in the extended view. The extended view offers the full spectrum

of functions.

The robots automation is displayed with graphic symbols. To simplify the view, instruction

groups are combined into sequences. This produces a clear overview even of complex sequences.

The zoom function is used to open up sequences and display all instructions of the respective

sequences. Instructions to be inserted are simply selected from an extensive function list and

placed at the appropriate position in the sequences.

Parameters are set directly in the graphic display by processing the instruction graphic in the

sequences. This enables even complex sequences to be configured in the shortest time.

Fig 3.9.1 For programmers – extended view of the RC 200: the parameters a inserted directly into the

Graphic display, so that even complex sequences can be quickly configured

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3.7 Turn Key

Competence for system solutions Turn key.

Highly integrated cells from one source.

Whether multi-component injection molding, inmold labelling or insert technology: the trend

towards integration of several process steps into a highly-automated production cell continues at

a fast pace.

Do you need complex, highly integrated production cells, in which several injection molding

machines produce parts, linear robots interact perfectly with industrial robots and extensive

processing steps such s quality control using state-of-the-art camera technology, selection and

packing?

The specialists at automation systems will handle the overall concept systems and

implementation of your demanding projects. And they will ensure that all parts are precisely

coordinated and mesh seamlessly into one another.

In the service of efficiency. For premium parts quality, stable processes and increased overall

productivity.

Fig 3.10 Turn key

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Turnkey – door panel production at Dura Automotive in strakonice. Czech Republic: two large

Engel duo 900 machines, each equipped with an Engel viper another. Between them are the units

for finishing molded parts: a laser unit two plasma treatment units, two six-axis robots a foam

unit and a hardening oven.

Fig 3.10.1 clean room production of medical valve

Extremely compact design of the overall system – innovative clean room production of a 2K

medical valve. A six axis robot by a staubli removes the parts, using a camera to inspect and

deposits them sorted by cavity. A highlight: the six axis robot control unit is fully integrated into

the CC 200 machine control.

Competence in lightweight construction:

Steering column of PA, reinforced with organic sheeting (replaces steel and aluminium sheets):

the production cell with a duo 500 pico, two linear robots and an industrial robot, as well as a

laser cutting unit.

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Fig 3.10.2 Competence in lightweight construction

3.8 Handling automation process

3.8.1 Flexibility

Flexibility is the ability to produce diverse parts with the same equipment. Greater flexibility

also means moving toward more cells run by 6-axis robots and moving away from the fixed path

of traditionally linear production ultimately, flexibility is all about software, which is one the core

strengths. From the standpoint of production-flow planning, flexible multitasking within cells

can speed overall line efficiency, while also creating possibilities for clever production solutions

when shifting to new products.

3.8.2 Time-consuming reconfiguration

Automation Industries particularly focused on making it easier to program, control and

operate. Bringing to robotics what Apple brought to personal computers – userfriendliness. All

man-machine interfaces are designed to be strongly visual, with god interactivity and feedback on

what’s happening. Since launching of new industrial robot controller, the IRC 5. It features a

highly visual Teaching pendant with a color touch-screen where even untrained users can quickly

supports, what we call Multimove. This is the ability to coordinate the complex movement of two

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robots working rotates a part, another facing robot dispenses a gluing bead, IRC 5 can also run

four robots simultaneously, which reduces space and equipment requirements.

3.8.3 Injection Molding of large tonnages

Robots can be ordered preconfigured for communication between the robot and the injection-

molding machine. Since, work with both SPI and all Euromap protocols and provide a line of

robots that integrate well with machines generating 50 to 5,000 tons of clamp force. For machines

of 1,000 tons and up, also offer solutions with shelf-mounted robots situated on top of the molding

machines for optimal parts handling.

3.8.4 How does more automation affect quality?

Present quality requirements for injection molding might typically accept only about 50

ppm or less in waste. Which is a ratio that can only be achieved with the best automation. To help

support this process there developed advanced vision systems for in-process quality control. The

Dynamic model as mentioned previously also comes into pay here. Robotware Dispense, the

Dynamic model’s optimal track to create a consistent bead by matching glue glow with robot

speed for perfect bead consistency. This naturally saves money for customers in terms of

programming time and waste reduction.

3.9 Reasons Why Automation is Vital for Injection Molding Today

Precision and consistency in plastic injection molding are important quality considerations.

Without having both, you cannot produce high quality injection molded parts.

Measuring quality specifications using fully programmable, automatic CNC-driven quality

inspection and measuring equipment to verify critical dimensions on first article inspections and

production samples or runs enables accurate and reliable data every time. This takes the human

element out of the equation and enables timely corrections in the production process.

Using robotics is a necessary part of current injection molding techniques. Through continued

development and application of automated processes and robotics, your plastic injection molder

can deliver consistent results with greater speed, precision, and flexibility.

Automation has been a worthwhile investment at crescent industries by incorporating multi-

functional robots during the molding process and post molding process to deliver consistent

plastic components.

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CHAPTER 4

INCREASED PRODUCTIVITY WITH AUTOMOTIVE PARTS

The Automotive industry is one of the most important technological drivers for injection

molding technology. Many components in the outer layer of an automobile or truck – the glazing,

the interior, the safety and operation technology and the drive train – can be manufactured only

using injection molding. Now procedures and combinations of these are the constantly growing

demands of the automobile industry and of automobile drivers. Injection molding technology

makes automobiles and trucks more comfortable, safe, economic and environmentally friendly.

This integration ensures the highest quality and optimal manufacturing costs.

4.1 Automation technology – for quality and economy

Engel’s Automation technology headquarters in Dietach/Austria provides a broad range of

robots and peripheral unit equipment for handling molded parts on the injection molding

machine. It also has feed systems for insert parts, robots for inserting and removing, as well as

downstream equipment for processing, loading or storing. Process specific automation concepts

for back injection of textiles or films, for over molding glass or for production in a cleanroom

environment supplement the range of services.

4.2 Attractive and protective: Structural and exterior parts

The first impression is the crucial one – especially for automobiles. The design freedom of

plastic is utilized more and more in order to individually design the outer layer of vehicles.

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Injection-molded exterior parts meet very high demands in terms of the surface and the

dimensional stability. Injection molding machines and technologies ensure the best surface

quality and maximum economy, even for large molded parts and those with long flow paths.

Fig 4.1 Exterior part

4.2.1 Strong in light-weight construction

As an alternative to metal structures, light-weight fiber reinforced designs have increased

in importance. Today, they can be essentially tailored to fit, and laid out according to the

application and safely injection-molding using ENGEL fiber melt.

4.2.2 Large-scale exterior parts

High-performance screws ensure a high degree of plasticization during plasticizing.

Hydraulic or electrical screw drives that can work synchronously with the mold movements

reduce the cycle time, increasing output and economy. Special-purpose screws provide minimal

wear and a long lifetime despite the strong wear and tear in high-performance plasticization.

4.2.3 Automatic post processing

Customer-and application-specific automation of the injection molding machine during the

production of coating friendly bumpers and other exterior parts increases the economy of the

overall system.

Fig 4.2 Bumper production fully automated with six-axis robots

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Automation includes separation of the sprue, flaming to activate the surface, deburring, quality

control and packaging of the component.

4.2.4 Injection-compression molding for increased quality

In the case of injection molding large-exterior parts with long flow paths and large flow

path to wall thickness ratios, injection-compression molding is recommended to safely fill the

molded part, and to cleanly mold the surface and to avoid internal stress. Injection-compression

molding results in highly precise parts with a high cost efficiency.

Fig 4.3 Integrated mold change systems reduce the set-up times, increase

the flexibility of the machine and increase the utilization

Fig 4.4 ENGEL duo compounder for preparing and injection molding long glass fiber-reinforced plastics

4.3 Wheel-well liners

Wheel-well liners and cover strips at the engine compartment should have noise-reducing

properties. These are attained by injection molding specifically modified polymers or by over

molding textile material. By combining the ENGEL combimelt multi-component technique and

the ENGEL tecomelt back injection technique in a single injection molding machine, noise-

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optimized products that can be totally adapted to customer requirements in terms of geometry,

mounting elements and acoustic properties, are produced in a single operation.

Fig 4.5 Truck wheel-well liner with acoustic optimization

4.3.1 Special-purpose screw units for gentle preparation

Single-screw systems for long glass fiber-reinforced granulates (LGF) permit processing on

standard injection machines. Using ENGEL fiber melt technology on the ENGEL duo large-scale

machine. It is possible to produce highly stressable structural elements with a lower investment

in production technology. Melt preparation with optimized screw unit geometries reduce the

shear load of the material, providing optimum embedding and distribution of the long reinforcing

fibers in the polymer.

4.3.2 Individual combination of recipes

The injection molding of specific material recipes requires compounding and injection

molding in a special-purpose machine: the ENGEL duo compounder. With this machine. Which

operates in two stages, nearly any mixture-such as those with long glass fibers-can be produced.

With the ENGEL duo compounder, the processor can optimize his variable costs for materials

independently of a supplier.

Fig 4.6 Fiber reinforced part

4.3.2.1 Structural elements with hybrid technique

In the hybrid technique, sheets are inserted into the mold and over molded with plastic to

reinforce it. Engel provide their own automation solutions for inserting and removing the sheets.

The highly precise, self-learning mold protection detects deviations on the inserted part, thus

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providing the highest level of safety from mold damage and ensuring operational safety and

uptimes of the entire plant.

Fig 4.7 Fully automatic production plant for structural parts with hybrid technique

4.3.2.2 A-, B- and C-columns

The ENGEL combimelt multi-component technique integrates assembly, optical and sealing

elements in a single operation. Eliminating sink marks and ensuring the best possible surface

quality, impact-absorbing column elements can be fully over molded with a second plastic in

order to attain can be fully over molded with a second plastic in order to attain highly reflective

surfaces. Furthermore, an additional TPE component seals the chassis and absorbs vibrations.

Fig 4.8 A-column, manufactured by Dura using ENGEL combimelt three component technique

4.4 Glazing and light engineering

Panes of transparent plastics, mainly of polycarbonate, are not heavy and provide designers a

great deal of freedom. Today, complete glazing systems of plastic integrate numerous functions

and lower system costs.

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Lighting engineering, which is now based more than ever on plastics, has the greatest potential.

The classic multicolor technique is supplemented by the use of modern LED technology and the

integration of sealing functions. More and more, optical and glazed parts in automobiles are being

made of transparent plastics instead of glass. On the one hand, injection-molded plastic parts –

due of the fact that several colors can be combined without problems – provide increased design

freedom; on the other hand, they are significantly lighter, thereby lowering the fuel consumption

and CO2 emission of vehicles.

Increasing demands of glazing and lighting engineering also raise the demands in production

technology and the production environment. Therefore, many glazed parts are injection molded

machine-related precautions, such as undirected tie-bars on ENGEL injection molding machines,

provide for very low soiling tendencies.

Fig 4.9 Rear window of a Chevrolet Blazer

4.4.1 Glazing using plastic

Specific equipment for injection molding glazings is available on the dual-plate ENGEL duo

large-scale machine. The compression packages BASIS, PROFI and EXPERT are highly precise

special compression programmes with which large-scale molded parts can be injection molded

with especially low stress. This ensures that the optical properties are constant over the entire

surface of the molded part.

Fig 4.10 Glaze melt for 2K panorama windows

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4.4.2 Compact machines for large parts

Compared to standard two-component machines, the machine concept of an ENGEL duo

combi M with rotary plate technology provides a reduction in the clamping force requirement and

in the investments in machine technology.

Furthermore, both the clamping force control and the process control are simplified because

the injection molding units. Which lie opposite of one another in the center of the machine axis,

cause centric swelling forces. This results in the largest possible component in relation to the size

of the clamping unit.

4.4.3 Tie-bar-less technology for maximum freedom

The tie-bar-less design principle of the ENGEL victory and e-motion small-and mid-scale

machines provide very easy access to the mold installation space and high flexibility in the mold

dimensions due to the great rigidity of the clamping unit. Last but not least, the tie-bar-less

clamping unit simplifies the adaptation of the clean-room technique using the mold.

4.4.4 Gentle plasticization for faultless melts

In order to ensure that molded parts of transparent plastics such as PMMA and PC always

have the highest optical quality, ENGEL provide screws with special geometries and distinct

check valves. These gently prepare the melt and prevent the formation of so-called black spots.

4.4.5 Integration of décor and function

Engel tecomelt in-mold decoration permits the integration of functional elements. Such as

antennae or heating coils, in glazing elements. Furthermore, back injection of transparent firms is

an alternative to a scratchproof coating using varnishing.

Fig 4.11 System for sheathing glass windows at AGC

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4.5 Over molding Windows

Mineral windows can be over molded with thermoplastics or elastomers in order to provide

a sealing and assembly function. The single-step process in injection molding machines with a

horizontal or vertical clamping unit reduces the assembly effort and reduces costs. In its complete

machine program. Automation provide a tailor-made, compact production solution for every size

of window, every over molding material and every process-related requirement. As ENGEL

machines can be plasticizing units for both elastomers and thermoplastics, they provide the

flexibility of changing the injection unit based entirely on customer requirements.

The use of the sensitive mold protection system auto protect reduces glass breakage and rejects

while increasing the up-times and productivity of the over molding system.

Fig 4.12Over molded stationary side window for a Mitsubishi automobile

Fig 4.13 Tie-bar-less injection molding machine with clean-room module for the injection molding of automobile diffusing lenses at ZKW

Slovakia

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4.6 Diffusing lenses

Diffusing lenses for headlamps have the highest requirements regarding optical quality, lack

of distortion and surface properties. Due to their limited size, they are produced using classical

injection molding and not using injection-compression molding.

4.6.1 Highest melt quality due to special non-return valve

In this application, ENGEL screws, with their special geometries and distinct check valves,

ensure gentle material preparation and avoid the formation of “black spots”. After the diffusing

lenses are injection molded, fastening elements are often molded on using ENGEL combimelt.

Fig 4.14 Diffusing lens for the BMW 3 series, produced by ZKW Slovakia

Fig 4.15 4x multi-component mold on an ENGEL combimelt machine with rotary table

4.7 Rear lights

Multicolor automobile tail lights are produced using the multicolor ENGEL combimelt

technique in multiple molds on large-scale ENGEL duo machines with integrated rotary tables.

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Any arrangement of up to four injection units optimally adapts the machine to customer

requirements.

4.7.1 Fiber optics and LEDs

The production of fiber optics and light-emitting diodes poses special requirements in

terms of the lack of stress and on surface quality. Highly precise fully electric injection molding

machines, such as the ENGEL e-motion with its compression function, meet these high demands.

Combined with variothermal mold tempering, even complex geometries and lens effects can be

easily provided at optimum costs.

4.7.2 Reflectors

Reflectors in lamps require a high surface quality so that they can have very specific

properties after metallization. This requires precise molding, if necessary using the ENGEL gas

melt gas injection technique to avoid sink marks.

Fig 4.16 Reflector made of polyether imide (PEI) for an automobile dual headlamp

that will subsequently be enhanced

To produce reflectors from thermoplastics that are resistant against high temperatures, special

screw units provide a long operating life due to low wear. In order to injection mold reflectors

made of thermosets, ENGEL BMC injection units are designed specifically for processing wet

polyester.

4.8 Decorative and of high quality:

Panels and interior parts

A large variety of plastic components can be found in a vehicle interior. Dashboards and

consoles hold countless functional elements and have a pleasant look and feel. This also applies to

door and pillar panels that hold airbag systems for protection against head-on or side impact,

requiring precisely defined characteristics.

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Door panels cover power window systems, seals, speakers and cables, and their surfaces have

a high-quality look and feel. Technologies such as ENGEL tecomelt and Dolphin provide comfort

and safely in automobiles.

Whether you need the compact injection molding of panels or interior parts, back injection using

soft foam films, the transfer of injection molded structures in a polyurethane shaped foam plant

or the injection molding of highly stressed structural parts and load-bearing elements from long

glass fiber-reinforced plastics using the inline compounder. ENGEL provide all single-stage

processes on a multitude of injection molding machines in economic production cells with a high

degree of automation.

Fig 4.17 Instrument panel for pickup truck molded in two-component

technology by Visteon US on an ENGEL duo combi M machine

4.9 Dashboards

While dashboards of economy cars are usually made using standard injection molding, a

multitude of ENGEL special purpose procedures is used for soft or decorative surfaces in vehicles

with higher requirements.

Fig 4.18 Dashboard support made of glass fiber-reinforced plastic

4.9.1 Fit for just-in-sequence

In the case of the injection for soft foam film backings in the ENGEL tecomelt procedure. It

is possible to switch the color or surface structure from cycle to cycle, as is required in just-in-

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sequence production. ENGEL automation solutions for a corresponding injection molding

machine makes such a production job rational and inexpensive.

4.9.2 Dashboard supports

A dashboard support made using ENGEL fiber melt has the required combination of

strength, rigidity, and the required resistance against impacts.

Weight optimization can be attained using a combination of coinmelt compression technology.

4.9.3 Dolphin: wide range of properties in a single operation

As the most up-to-date alternative to established technologies, ENGEL offer the singe-stage

Dolphin procedure. Here, ENGEL use the combimelt technology to enhance a compact support

with a foamed soft component. The ENGEL combi M machine is used here. With two horizontally

opposite injection units and an integrated horizontal rotary table, the polyester-based TPE is

foamed directly on the support, which was made immediately beforehand from glass fiber

reinforced PBT. Cycle for cycle, a part ready for installation exists the injection molding cell.

Fig 4.19 All-thermoplastic dashboard, injection molded in one operation using Dolphin

As it is a single-step procedure. Dolphin is more economical than established processes,

requires less space and can produce recyclable all-plastic dashboards in a single operation.

4.10 Column panels

Today, textile-decorated column panels are produced by back injecting textile structures

in the injection mold-usually on mid-sized injection molding machines. During the fully

automatic insertion and securing of the textile cuts, the tie-bar less clamping units of the ENGEL

victory machine series provides the unique advantage of access to the mold without any obstacles

at all. Robots and grippers can use the entire available space and are not inhibited by tie-bars;

molds can be changed quickly and easily. This ensures shorter cycle times and improved economy.

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Fig 4.20 Production of back-injected column panels on a tie-bar-less ENGEL injection molding machine lntier head inserts a dual

gripper textile cuttings in the mold and removes the finished parts

4.10.1 Use of entire mold fixing plates for highest degree of economy

As back injection occurs at relatively low pressures in the first place, the entire surface of

the mold fixing plate can be used for bulky molds on tie-bar-less machines. Compared to normal

machines the entire surface of the mold fixing plate can be used for bulky molds on tie-bar-less

machines. Compared to normal machines with tie-bars, tie-bar-less injection molding machines

take full advantage of their higher production efficiency during back injection.

Fig 4.21 Back-injected panels for the A-, B- and C-columns of the Audi A4, produced at Magna Intier

4.11 Door panels

The ENGEL duo series is used for large door panels. The Significance of compression

increases with larger molded part surfaces and longer flow paths. The ENGEL injection

compression programmer protects the material during injection, permitting very low clamping

forces. Platen parallelism control ensures a uniform wall thickness distribution over the entire

surface of the molded part, as well as minimal mold wear.

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Fig 4.22 Complete interior door panel of the BMW 6 series, produced by back-pressing decorative soft foam film material

Very large parts with textile decoration that are produced in low numbers can be made on

injection molding machines with a vertical clamping unit in the ENGEL tecomelt procedure.

Here, the melt is inserted into the open mold using injection units that can be moved in three

dimensions and is gently pressed onto the textiles at a very low internal pressure. In this

technique, significantly simpler and less expensive molds can be used without a hot runner,

providing an economic advantage for low and mid-sized batch sizes.

4.11.1 Speaker covers

Low-viscosity, easily flowing plastics are usually used to precisely shape, gird-shaped

speaker covers with many delicate holes. Fully electrical machines such as the ENGEL e-motion

provide sensible process control: they precisely maintain the tight processing window, provide

the best surface shape and prevent over molding and burr formation. If a molded part gets stuck

during removal from the cavity, the reactive mold protection of the ENGEL machines, with its

numerous sensitive pins, protects the mold from damage, which could be expensive.

4.11.2 Map pockets on the insides of doors

Map pockets on the insides of doors also usually have a thick-walled area that can be shaped

using gasmelt.

Fig 4.23 Production system for large-scale, textile-decorated parts using ENGEL tecomelt technology

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4.12 Door handles

Thick-walled molded parts such as door handles are often made with the ENGEL gasmelt gas

injection technique. This technology maintains the post-injection pressure longer than in

conventional injection molding, thus ensuring well-shaped surfaces and molded parts with low

mold shrinkage and high dimensional stability. This is a requirement for subsequent metallization

or electroplating, which would make surface defects very apparent.

Fig 4.24 Arm rest for front doors of the Mercedes

A class, made by Johnson Controls using

the Dolphin procedure

4.12.1 Arm rests

The option of the Dolphin procedure for making panels entirely with thermoplastics instead

of with the film back injection method will become more popular, not least because tight radii can

be executed better than with the back injection method. Likewise, the significant logistics and

post-processing costs that are usual in the most common soft foam films are not necessary.

Fig 4.25 Two-component machine with integrated bar code printing

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4.13 Airbag covers

Airbags covers must have specific break-open properties during a crash, but must also

perfectly adapted to the look of the vehicle interior. ENGEL machine, procedural and automation

technologies ensure the process stability required for this.

4.13.1 Stability in the process – safety for the passengers

Various options in the ENGEL CC 200 machine control unit and the modular ENGEL e-

factory software solution analyse and document all relevant process parameters.

Fig 4.26 Airbag cover for the VW Tiguan, manufactured by TRW using the

ENGEL foammelt technology and MuCell® physical foaming

Fig 4.27 Fully automatic production system for airbag covers of BMW models at HTP

4.13.2 Support structure for backrests

A support structure that has been invisibly integrated into the seat and that has been made

using the ENGEL insert vertical machine represents one of the most important transitions from

the driver to the vehicle. The movable structure of plastic-over molded metal rods is manufactured

in an injection molding cell. The ENGEL combimelt technology is used to combine the desired

rigidity with excellent antifriction properties.

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Fig 4.28 Metal rods over molded with plastic form the “backbone” of an automobile seat

4.13.3 Decorative trim and backlit apertures

Backlit apertures with a day/night design and decorative trims that usually have an

limitation wood, carbon or aluminium design are produced using in-mold decoration. As is the

case with textile decorations, the decoration or structure can be changed cycle to cycle in the

ENGEL foilmelt procedure, enabling fully automatic just-in-sequence production.

Fig 4.29 Decoration trim with wood look

4.13.4 Vent grilles

Air vents have gone down in the history of injection molding as the “classic” movable part

in multi-component molding. Today they are usually produced in multiple molds. Depending on

the dimensions of the mold part and the number of bars, various injection molding machines serve

as the basis of multi-colored component injection molding: ENGEL victory, ENGEL e-motion.

Both can produce the vents in a single operation. Climate control vents for the VW Golf and Audi

A3 are produced in a 4+4 mold by combining ENGEL foammelt strucrural foam molding with the

ENGEL combimelt multicomponent technology to form a sealing lip.

Fig 4.30 Vent grille with movable air guides

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4.14 Reliable and safe:

Safety, clamping and operation technologies

Not only active and passive safety equipment, such as ABS, ESP, seat belts, headrests, seat belt

tensioners and airbags, consist mainly of injection molded components today. Driver assistance

systems, steer-by-wire and break-by-wire systems also require plastics. Particularly in the case of

these safety-relevant parts, with their sensors, switches and plugs, the automobile manufacturer

requires documentation of the production data for reproducible product quality.

Both mechanical as well as electrical and mechatronic components of safety equipment are

produced by over molding insert parts in the ENGEL insert vertical machine. The self-learning

and highly sensitive ENGEL auto protect mold protection program provides the lowest possible

mold wear. This reduces maintenance costs to a minimum.

4.14.1 Seat belts, belt buckles, belt tensioners and belt deflectors

Safety elements from over molded metal parts are usually produced on small horizontal or

vertical injection molding machines. Modular automation systems for entire families of parts

ensure the fastest possible adaptation capability with replaceable mold cavities: molds do not

have to be removed. Machine and automation technology that are adapted to one parts, keeping

insertion and removal times to a minimum.

Fig 4.31Over molded belt buckle

4.14.2 Lock housings

Lock housings are complex, highly precise functional parts whose production can combine

a number of technologies. In the insert vertical machine, metallic parts are inserted into the mold

and integrated into the injection molded part as function elements. The required seal is

economically implemented either as a thermoplastic or elastomer component using ENGEL

combimelt multi-component technology combined with the elast rubber machine within an

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overall system. Furthermore, foammelt structural foam molding makes low-distortion, weight-

optimized thermoplastic structures possible.

Fig 4.32 Lock housing with dual-component technology

4.14.3 Circuits and connectors

Electric and electronic safety elements from thin, over molded metal parts are usually

produced on small horizontal or vertical injection molding machines as well. As is the case with

mechanical safety parts modular automation systems for entire families of parts ensure the fastest

possible adaptation capability: with replaceable mold cavities molds do not have to be removed.

A large rotary table diameter permits the use of several work-stations that can also be equipped

with different molds.

4.15 Injection molding of elastomers and liquid silicon

As classic elastomers, liquid silicons (LSR) or thermoplastic elastomers (TPE), runner like

materials can be used in many components for sealing purposes or as noise and vibration

dampeners.

A complete range of vertical and horizontal injection molding machines to process cured

elastomers. Plasticizing units to process ribbon-shaped prepared rubber compounds according to

the first-in first-out principle are marketed as elast. Screw or piston plasticizing machines, as well

as plasticizing and conveying technologies for liquid silicon are specified as lim.

Important application for classic elastomers in automobiles are engine and body supports, seals

for windows, media lines and electrical systems as well as bellows. Insulation and sealing

components for electrical plugs as well as sealing rings and sealing membranes made of LSR

provide especially high resistance against heat and cold, an excellent ageing behavior and very

good resistance against weather.

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4.15.1 Skids and guide rails

Combimelt unites the optimum sliding properties of polyoxymethelene (POM) with the

high rigidity of polyamide (PA) to form a precise component with defined friction properties for

the highest possible operating comfort.

In the case of window guide rails, the TPE component provides optimum positive damping

between the window pane and the POM guide element.

Fig 4.33 Guide skid

4.15.2 Switches and buttons

Switches and buttons with functions and a label or icon are produced using the ENGEL

combimmelt multi-component technique. For example, a 130-tone ENGEL victory machine with

an ENGEL ERC 63 parts removal robot can produce switches of polyamide and two POM types

in 4+4+4 mold. The functionality of flexible plastic parts is provided by cost optimized assembly

injection molding.

Fig 4.34 Switches for automobile electrical systems using three component technology

4.15.3 Parking brake levers

ENGEL combimelt combines a comfortable look and fell with high-quality mechanical

properties. Large molds with low clamping force requirements-the tie-bar-less ENGEL victory

machine is predestined for such injection work.

Fig 4.35 Parking brake levers

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Fig 4.35.1 Production of automobile parking brake levers in a multiple mold

4.16 Airbag igniters

The injection molding procedure is also used to manufacture pyrotechnic components to

protect passengers and pedestrians. To do this, the pyrotechnic material is over molded directly

on a fully electrical tie-bar-less precision ENGEL e-motion machine. The machine increases

production by reducing the cycle time due to optimum conditions for automation. It provides the

injection precision and mold protection required for working with highly explosive material.

Fig 4.36 Explosive capsules manufactured by Hirtenberger

4.17 Ventilation and air-conditioning technology

The pleasant interior atmosphere of the vehicle is a major convenience factor. Actuators and

controls, compressors, and heat exchangers, along with air baffles, air baffle controls and vents

rely on a large number of plastic parts that all need to as light and compact as possible. Therefore,

many components are weight-optimized and foamed using ENGEL foammelt technology.

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4.17.1 Electric engine supports

Drive elements should neither produce noise nor transfer oscillations or vibrations to other

structures. Therefore, they are acoustically insulated and mechanically decoupled. In a holder for

a blower motor, the mounting point-over molded with TPE using ENGEL combimelt-dampens

vibrations and thus also the emitted noise.

Fig 4.37 Receptacle for a Valeo electric motor using two-component technology

4.17.2 Housing parts, air baffles and fan impellers

As the market leader for the mucell physical foaming procedure. ENGEL have successfully

produced a number of components. In the case of housing parts for the rear climate control system

in the Mercedes - benz s-class, developed and produced by behr, ENGEL foammelt structural

foam molding results in an improved molded part quality at a reduced cycle time.

Fig 4.38 Reduced-weight fan impeller using MuCell® technology

Fig 4.39 Valeo air flap with sealing function using two-component technology

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4.18 Plastic engine components

There is an increasing trend towards manufacturing engine components and engine-related

subassemblies from plastics. Today, custom-built injection moldable plastics are designed to

withstand high operating temperatures and for contact with fuel, oil, coolant and brake fluid.

As a result, new components with very high performance and low weight are continuously

being developed for very tight spaces in the engine compartment. The range of applications

extends from decorative cylinder head hoods to suction pipes and suction modules, plugs for the

electrical systems and parts of the fuel systems to flaps and valves for head management and

climate control.

More and more, new production solutions with ENGEL machines and technologies are

replacing metal parts with injection molded ones of plastic.

4.18.1 Engine covers

Although they are purely design parts, engine covers are subject to high temperature

stresses. Therefore, they are injection molded from glass fiber-reinforced plastics. Design or

sealing elements often require the use of the ENGEL combimelt multi-component technology.

The high process capability of ENGEL injection molding machines permits the production of

high-quality surfaces that permit refining not only using hot compression or varnishing, but also

with electroplating.

Fig 4.40 Decorative hood for a VW automobile

4.18.2 Valve lids

This valve lid of glass fiber-reinforced polyamide is used for Audi engines. It is manufactured

on an ENGEL duo with a clamping force of 700 tonnes.

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Fig 4.41 Valve lid for an Audi engine

4.18.3 Air intake manifolds

In compact injection molding on a 1500 tonne ENGEL duo large-scale machine, the parts of

an air intake manifold are made of PA66-GF; these parts are then welded together. Variable mold

tampering achieves an optimum mold wall temperature, which ensures the tight tolerance range

for the component geometry, as is necessary to weld half bearings. The use of group mold ensures

uniform manufacturing conditions for the two individual parts that are to be subsequently welded

together.

Fig 4.42 Air intake manifold for an 8-cylinder engine, manufactured by Mahle

4.19 Air intake flaps

In the production of air intake flaps, ENGEL demonstrate that the combination of the two-

component technique and multicomponent molding attains the highest possible technical level:

two connected injection molding machines produce a set of air intake flaps with ready-to-mount

flap systems for V6 and V8 engines using multi-component molding. Complete assembly and a

100% test.

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Fig 4.43 Switching flaps manufactured by Schneegans

4.19.1 Pick & place and over molding

In the first 300-tonne ENGEL victory combi injection molding machine, the body is first

made of PA46-GF 15 in a 2+2 mold: after pick & place using a linear robot, this is over molded

with PPS in the second mold position. The robot of the second ENGEL victory 130 combi injection

molding machine picks up these set of two and positions them in the first injection station of the

mold, where a lever of the same PA is molded. After pick & place, a rubber seal is vulcanized onto

the flaps.

Fig 4.44 Tumble flaps manufactured by Schneegans

4.19.2 Easy access of the mold

Advantage of ENGEL victory: the design of the tie-bar-less clamp unit provides increased

space in the mold mounting are for complex two-component injection molds and the overhanging

end of arm tooling of the robot.

4.20 Support for air intake controls in a turbocharger

Temperature stresses, media effects and a low idling drag require vulcanizing rubber to be

used as a sealing element. In order to manufacture this support, ENGEL combined the dual-

component processing of rubber and thermoplastic in a single mold that has both a hot area and

a cold area using thermal separation. The two component are connected without any bonding

agent.

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Fig 4.45 The thermal separation of thermoplastic and elastomer in

the same mold permits the production of air controls at KBS

4.21 Suction pipe of NBR/HNBR

The combination of an ENGEL elast rubber injection molding machine with the most up-

to-date robot technology resulted in a one-of-a-kind suction pipe production cell for the

automobile industry at AR-TEX spa in Italy. The two machines can be connected or they can

produce fully automatically, independently of one another. The heart of the system is the high-

demand molded part removal system. Only the optimum interplay of a gripping function,

sufficient compressed air and the part removal system, which is based on the movement of a

human hand, permits to be pulled off the core without damage.

Fig 4.46 A six-axis robot operates two ENGEL elast rubber injection molding

machines at AR-TEX, who manufacture suction pipes for the automobile industry

4.22 Oil dipsticks, media pipes

Spatially bent oil dipstick guide pipes made of PA66-GF are manufactured using the

ENGEL watermelt water injection technique. Even media lines with branchings and several layers

can be produced economically, fully automatically and quickly in a single operation with a

combination of ENGEL combimelt and ENGEL watermelt. Although glass fiber-reinforced

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plastics are used, the pipes have a smooth interior surface. Lines for coolants also have a media-

resistant inner layer.

Fig 4.47 All-plastic oil dipstick, produced by Schneegans

4.22.1 Increased precision due to integrated piston unit

ENGEL are the first provider to integrate a water injection unit with piston injection in the

injection molding machine, namely in the machine frame below the clamping unit, thus saving

space. Thanks to reduced pressure losses, this mechanical and control-related integration

provided more precise controllability and better reproducibility over conventional system.

4.23 Oil pans

The first truck oil pan made of plastic, for the Daimler Actros truck with a V6 engine, was

manufactured on a vertical machine ENGEL insert using fiber-reinforced polyamide PA66-GF35.

Compared to the classic tin variant, the plastic oil pan has significant weight savings.

Fig 4.48 Oil pan using fiber-reinforced polyamide PA66-GF35

4.24 Inlet water headers

Highly complex functional parts for the engine compartment require injection molds that are

just as complex. A number of solenoids and media connections increase the space requirements

in the injection molding machine, although little clamping force is required. Injection molding

machines with a tie-bar-less clamping unit provide the advantage of high accessibility for the

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mold mounting surface. This helps in “downsizing” the machine equipment as well as during mold

changing.

Fig 4.49 Complex inlet water header for an automobile engine, manufactured by Plastic-Concept

Fig 4.49.1 Overhanging mold for the complex inlet water

Header in a tie-bar-less injection molding machine

4.24.1 Switching levers

In order for the operating forces and the operating feel to be the same in all the gears in an

automobile series, switching levers must have especially steady, uniform quality. By over molding

two metal parts with glass fiber-reinforced plastic, an opening for attaching a cable (among other

things) can be integrated in metal pipes. For this purpose, ENGEL supply a complete solution

consisting of a vertical machine and a robot: the pipes and the cable attachments are inserted by

the robot and the finished parts are removed automatically.

Fig 4.50 Multilayer media pipe, manufactured using ENGEL fluid melt

Fig 4.51 Production cell with a 90-tonne ENGEL insert vertical machine with

Automatic insertion, removal and post-processing

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4.25 Pedal bearing blocks

So-called pedal bearing blocks support the brake and clutch pedals in automobiles and

trucks. They are currently manufactured with a hybrid method from plastic and galvanized with

sheet metal. In completely automatic manufacturing cells surrounding an ENGEL injection

molding machine, the three dimensionally shaped and contoured sheet is inserted into the

injection mold and over molded with plastic.

Fig 4.52 Pedal bearing block with hybrid technology for a Mercedes model

4.25.1 Hybrid technology integrates fastenings for attachments

The attached plastic ribs stiffen the construction and prevent the galvanized sheet from

collapsing if it is overloaded. The high E-module of the metal permits a delicate overall

construction, and the ductile behavior of the sheet prevents the component from breaking or

failing apart during a crash. Furthermore, because of the plastic over molding, fastenings for

attachments such as switches and sensors can be integrated.

4.26 Clutch pedals

The pedal itself consists of PA66-GF30 and is manufactured using the ENGEL insert

vertical machine by over molding the metal block. The pedal pad is rubber that is injection molded

on an ENGEL elast vertical machine.

Fig 4.53 Clutch pedal of plastic with over molded bearing

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4.27 Damping elements and spark plugs boots

The ENGEL elast and ENGEL insert machines are combined to manufacture shock

absorbers for an automobile axle. Modified PPE-GF20 replaces the metal that was formerly used.

It is over molded with an elastomer and fulfils the same functions as a heavy molded part of metal

and rubber.

Fig 4.54 Metal-elastomer composite as a damper

Fig 4.55 Spark plug boot

4.27.1 Economic mass production

Air hoses, spark plugs boots and sealing elements such as O-rings on moving parts and

single-conductor seals in automobile electrical systems are produced from classical cured

elastomers using ENGEL elast and ENGEL LIM machines or from cured liquid silicon (LSR) on

ENGEL vertical and horizontal injection molding machines.

Fig 4.56 Reduced-weight shock absorbers by

Barre Thomas, MuCell®-foamed from

TPE on an ENGEL insert machine

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4.28 Results & visualization

Automakers have been using plastics as an affective material in the making of

automobiles. Apart from providing fuel-efficiency and safety, it also helps reduce cost and

increased profits. The other advantages are that they can be molded into any shapes quickly.

Plastics certainly have a good future. There is no doubt that plastics will be used more and more

by the automobile industry. In the future we can see almost 90% of the vehicles we drive to be

made of plastic. Plastic will certainly become the "metal" of the future. Plastic composites are really

strong and thus a good substitute to metal. Use of plastic is good but it should be reusable

otherwise it may be a very serious environmental issue.

Since plastic is relatively low cost than metal and weighs far less then metal, it improves fuel

efficiency. The versatility of plastic also makes it easy to mold in any shape. Moreover it does have

to be painted, which further reduces its cost. Another advantage is that plastics are corrosion

resistant against metals that are prone to oxidizing attack which can prove to be expansive

especially in salty conditions. Plastics indeed offer greater advantages in automobile industry.

I think after the industrial revolution, plastic has created another revolution. It can be used

to make cars which also make it safer due to its impact absorbing capability. Plastic cars are

certainly the way to the future. I totally believe that plastic is a better substitute for metal.

Advantages of plastic are it is cost efficient, light yet very strong and durable. Also it helps in fuel

efficiency.

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Chapter 5

Conclusion

To maximize capacity utilization and production efficiency, while improving quality,

manufactures need integrated manufacturing solutions that facilitate continuous process

improvements and ultimately make them more competitive.

A “best-in-class” products allow manufactures to optimize operations, drive down costs and

increase profitability with end-to-end solutions that optimize the entire design-through-

manufacturing process.

Automation in injection molding projects minimizes hands on involvement, resulting in

improved consistency, repeatability, product quality and ultimately the best value for the

customers.

Robotics can be used throughout the injection molding process during the insert molding or

over molding process, helping to assist in secondary operations and quality inspections. Using

automation process can eliminate waste, produce consistent quality components and at a faster

cycle time. Reducing the need for manual intervention in the molding process

To make the insert molding and over molding process more efficient, robotics are often utilized.

Injection molders make use of robotics to place the metal components in a molding machine

before the insert molding process and then perform secondary operations like part trimming and

packaging.

Injection molders can take advantage of the use of robots in the over molding process by

removing a molded part or substrate from one injection molding machine and then placing it into

another injection molding machine for the over molding process.

Using robotics to complete as many tasks as possible frees up time and resources for any

required hands-on processes. It also makes it possible to repeat those tasks over many cycles with

consistency and predictability. Robots are also used for secondary operations in the injection

molding process. Some samples of use of robotics in secondary operations are for part trimming,

drilling or clipping. As well as in assembly of injection molded components either by welding,

bonding or adhesives. Automation is also used for sorting of product for further processing and

packaging components to be shipped to customers.

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5.1 Injection molding technology for the mobility of the future

Complete range of Injection molding machines for every size

Turnkey systems consisting of machine, process and automation for cost-optimized

solutions, flexibility adapted to individual customer requirements

Wide-ranging competence in all injection molding technologies and customer processes

Fundamental application-related know-how

Many years of experience in the branch of automotive technology

Close network with competent system partners

Extensive customer service facilities and fast spare parts supply for minimum plant

downtime

5.2 Advantages of plastic

They can be easily molded and have excellent finishing.

They possess very good strength and toughness. They possess good shock absorption

capacity.

Advantages of plastic are corrosion resistant and chemically inert.

They have low thermal expansion of co-efficient and possess good thermal and electrical

insulating property.

Advantages of plastic is very good water resistant and possess good adhesiveness.

Plastic is strong, good and cheap to produce. Advantages of plastic are light in weight.

Plastic is a recycling process and it does not decompose.

Plastic bottles can be reused and restored over again and again.

Plastic is one of the unbreakable.

Plastic is an odour less.

Plastic is used for building, construction, electronics, packaging (gladwrap) and

transportation industries.

Used to make - Water bottles, pens, plastic bags, cups etc.

Advantages of plastic are Very cheap to make.

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Durability

Strength

Chemical resistance.

Advantages of plastic are used to produce another product.

Used to reduce soil and wind erosion.

Benefits of thermoplastics versus metals

When auto engineers design cars today, they are looking for a couple of key attributes in

addition to attractive looks and functionality. These are fuel-efficiency and safety. Plastics win

over metals in both of these attributes. Carbon-fiber reinforced plastics and other innovative

plastics are strong and light and can be molded into virtually any shape. Since they are light, they

increase fuel efficiency as well as range of the vehicles. The toughness of carbon fiber increases the

safety of these vehicles. In fact, today it is possible to make a car almost entirely of plastic. An

example of a car that is almost completely reinforced plastic.

Lightweight and high-strength reinforced plastics were designed by chemical engineers

and are a tribute to chemistry. They were first used in the aerospace industry. Today they are

widely used in automotive doors, fenders, and chassis and also in hoods and support frames for

the engine and transmission. More than 40 million hybrid components in 70 vehicle classes can

now be found on roads around the world. The main benefit of this plastic-metal hybrid technology

is its excellent integration and weight-reducing potential. In addition to car front-ends made of

lightweight nylon composites in combination with aluminum, plastic-metal hybrid technology is

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now also used to make roof frames and break pedal blocks. We foresee a day in the future when a

car could be made of nothing but plastic.

Automakers have been using plastics as an affective material in the making of automobiles.

Apart from providing fuel-efficiency and safety, it also helps reduce cost and increased profits.

The other advantages are that they can be molded into any shapes quickly. Plastics certainly have

a good future. There is not doubt that plastics will be used more and more by the automobile

industry. In the future we can see almost 90% of the vehicles we drive to be made of plastic. Plastic

will certainly become the "metal" of the future. Plastic composites are really strong and thus a good

substitute to metal. Use of plastic is good but it should be reusable otherwise it may be a very

serious environmental issue.

Since plastic is relatively low cost than metal and weighs far less then metal, it improves

fuel efficiency. The versatility of plastic also makes it easy to mold in any shape. Moreover it does

have to be painted, which further reduces its cost. Another advantage is that plastics are corrosion

resistant against metals that are prone to oxidizing attack which can prove to be expansive

especially in salty conditions. Plastics indeed offer greater advantages in automobile industry.

I think after the industrial revolution, plastic has created another revolution. It can be used

to make cars which also make it safer due to its impact absorbing capability. Plastic cars are

certainly the way to the future.

I totally believe that plastic is a better substitute for metal. Advantages of plastic are it is cost

efficient, light yet very strong and durable. Also it helps in fuel efficiency.

5.3 Plastics in the Automotive Industry Today

Although plastics have been used in automobiles since the 1940s,1 the use of plastics and

polymer composites in automobiles is typically viewed as a modern innovation, as many of the

materials that are considered “plastics” are a recent development. These advanced materials have

benefited vehicle appearance, performance, and safety, and continue to offer the automotive

industry new ways to improve its vehicles today. The creation of this growing range of new

materials has even forced a shift in the label “plastics” to the more accurate “plastics and polymer

composites.” (In order to maintain a concise narrative, both labels are used in this roadmap [see

sidebar]).

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As the development of innovative plastics and polymer composites has impacted the

automotive industry, so has the changing automotive market impacted the focus and priorities of

the plastics industry. While many of the same forces, such as consumer demand and global

competition, continue to shape the automotive market, the marketplace of today is very different

from what it was only a few years ago. In order to remain competitive and prosperous, both the

plastics and automotive industries need an integrated strategy for the future, one that aligns the

interests of both industries and effectively leverages the full potential of plastics and polymer

composites. These industries must also seek to work in partnership with state and federal

governments and non-governmental organizations (NGOs) to further advance the shared goals of

addressing global climate change, ensuring security of energy supplies, and reducing U.S.

dependency on foreign oil.

This roadmap uses a variety of terms to refer to full range of materials that are most

accurately referred to as plastics and polymer composites. Alternative labels include polymers,

plastics, and composites.

5.4 Plastics in the Future Automotive

Analysts predict a V-shaped growth pattern for the automotive sector globally. Yet,

despite market-imposed capacity constraints, anticipated production is expected to increase

from 11 million units in 2010 to 15.5 million units by 2011. While the U.S. vehicle sales forecast

is encouraging, healthcare and pension costs threaten margins for U.S. automakers.

This year, the U.S. vehicle sales recovery has been driven by fleet sales — sales of a large

number of vehicles to companies such as rental car agencies and commercial truck operators.

This demand is defined by the miles driven per year, the average age of the fleet (9 years),

population growth rates, and the age of drivers. Slowing the demand for new vehicles

domestically is the growing rate of the retired population, who will drive their vehicles 40

percent less and make fewer new vehicle purchases.

As automakers gear for the next-generation industry transformation, panelists cited a

number of factors that will be affecting the resurgence of original equipment manufacturers

and suppliers alike.

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These include increasingly rigorous legislative mandates on emissions, safety and quality;

intense pressure to scale, particularly for the emerging markets; new or evolving joint-venture

business models due to all the recent mergers and acquisitions in the industry; and narrowing

product portfolios. All of this must also be tied to a myopic focus on taking the number-one

or number-two market positions and delivering best-in-class project margins.

Speaking about the future of the American automotive industry, Retired Vice Chairman

of General Motors Company Bob Lutz delivered a riveting, sharp-tongued criticism of

automakers. Lutz proclaimed that graduates of U.S. Ivy League business schools — including

himself — have contributed to the demise of economic growth and product excellence in the

United States. According to Lutz, MBAs don’t understand the power of image, style or fashion

trends on vehicle sales and the driver experience. Instead, he said, MBA-produced analysis and

profit optimization models focus only on short-term internal targets, and are not driven by

the consumer market. In a plea for corrective action, Lutz demanded renewed focus on long-

term product, service and customer experience excellence. He said General Motors’

management should be less concerned with cost and more concerned with whether the

vehicle is selling in the market. Lutz concluded with a mandate for the industry to correct its

numbers-driven myopia with a broader perspective and corporate culture based on a long-

term vision of consumer-driven product excellence.