To manufature ducts that have a chemical resistant inner layer, Engel combines co-injection molding with water assisted injection molding to achieve its hollow 2 layer part. The major innovation here is that the water acts like a third injection unit that displaces the first two components, cools and packs the material into the cavity before ejection.

This new micro-injection molding process technolgy from the IKV - Aachen, Germany, uses ultrasound to melt the shot that is subsequently injected into the micro-cavity. This ultrasonic plasticating is an alternative method to melt small volumes of thermoplastics. A significant reduction of the plasticating time (3-5 s) is achieved, thanks to the high energy input of the ultrasound. A homogeneous polymer melt can be delivered due to constant absorption of ultrasound in polymers.

One of the new exciting items in blown film extrusion is Kiefel’s Perfect Cool system. This new technology allows rapid cooling inside the bubble with a patented system, resulting in a significant increase in productivity - doubled up to 800 kg/h when using a 400 mm die.

Kiefel’s Perfect Cool system (Photo Erik Foltz)

At the Dieffenbacher booth, the Direct SMC automotive hood is still warm from the molding process - A new development that promises a leap forward to the SMC industry. Dieffenbacher, together with M-Base, VW, Reichold, the Institute Chemische Technologie of the Fraunhoffer Institute, Johns Manville, BYK, Forschungszentrum Jülich and Polytec Group have developed DUROVISION a Direct SMC technology. Under the title Innovative parts development for the production of leight-weight components made of fiber-reinforced thermosets by direct process. These key players developed a technique where dosing and homogenization of the raw material, integration of the fibers and compression of the parts is integrated into a continuous process chain. This results in a fully automated system that leads to shorter cycle times, eliminates the maturation step of traditional SMC charge manufacturing, at a lower cost.

A VW hood molded using the Direct SMC DUROVISION technology (Photo Erik Foltz)

The increasing amount of companies offering machines for polymer recycling in K2007 speaks for itself: not only are efficient machines now available, but recycling has become a profitable businesses for both producers and consumers.

One such example is X:GRAN by NGRM. With this machine virtually any thermoplastic can be recycled into granulate. The novel feature of this machine is integrating cutting, conveying and extruding with degassing (if needed) in an integrated single process unit, reducing material storage. In addition, the shredded material is immediately fed to the extrusion process, hot due shearing, reducing energy requirements for material melting.

(Photo Erik Foltz)

With 200 tons weight, 21 meters lentgh and 9 meters width, KraussMaffei is showing an impressive Skin-Form molding process. The process is used to mold inner door panels in one step. First, the thermoplastic (PC-ABS) is injected to mold the carrier, followed by three different types of PUR that are injected to create the skin of the door module.The PUR is injected through mixing heads which are mounted on the mold sides. After demolding the part is placed into a laser cutting cell where sprue and selected parts of the molded part are cut by a 300W CO2 laser system from Robot Technology.

Bayer is actively researching ways of keep us safe. They have developed a method of stacking plastic plates which allows them to be classified as bullet-proof. Bayer stacks several layers of plastics and bond them together using a TPU. This combination of layering allows the structure to absorb the bullet’s energy without shattering. The outer 1.0 cm thick plastic plate absorb the energy, while the TPU layer allows the structure to stretch without shattering. Bayer is using both Makrolon (PC), for bullet proof shields, and Baytec (PUR), as an anti-theft protection panel for these applications. Currently the Makrolon shields are used on the HMMV windshield, and are sure to be seen in our lives in the future.

3.44 Magnum bullet impacts on a Makrolon 750 shield (Photo Erik Foltz)

Withe their new IME5000 solution, Siemens offers a system to fully automate electric injection molding machines. Benefits of using the new Siemens’ system is flexible scaling, simple operation and easy mold changes. This ready-to-use technology encompases all major features of electric injection molding machines and consequently will help increase productivity.

Vitro laser GmbH, a manufacturer and supplier of laser systems for industrial applications is introducing Vitro Laser, a technology that makes possible the engraving of 3D images in glass objects. The process is divided into two phases, (1) a 3D scan or “picture” is taken and (2) the image is engraved into a volume of glass by focusing a laser that changes the structure of the glass in a small point. The beam is computer controlled, and an image is made of thousands of small points. To capture the images the 3D cameras were developed for three-dimensional portraits. In less than a second faces are reproduced in detail. Current applications for this technology include advertising and any type of glass substrate engraving.

At the K in Düsseldof, Germany, Gammaflux is introducing a new process control package that combines the best of its hot runner temperature control technology with the PRIAMUS Fill & Cool system. The result is an integrated package that helps molders achieve balanced fill in their multi-cavity hot runner molds. With this system Gammaflux, with its tradition in research and development, has taken the next step in hot runner process control. www.Gammaflux.com