FRIEDRICHSHAFEN, GERMANY (Dec. 12, 12 p.m. ET) — Injection machinery maker Ferromatik Milacron GmbH has created a way of manufacturing lightweight car door handles by combining monosandwich technology with a gas injection process. The process creates a part with a hollow centre, reducing weight by 25 percent - from 107 grams to 79 grams.
“From the outside of the part you can't see how the interior was created,” said Rüdiger Saum, manager of applications and consulting. “By combining the monosandwich and gas injection processes, we are able to produce parts that look and feel fantastic, but are lighter and stronger at the same time.”
During the monosandwich part of the process, the core material is plasticized in the main injection unit. Then the secondary extruder introduces the skin material into the barrel of the injection unit. The two materials are injected with a single stroke into the mold cavity. During the cooling time, gas injection takes place, using Maximator Cinpres technology to create the hollow area.
At the Fakuma trade show this year in Friedrichshafen, Ferromatik Milacron demonstrated the technology using a black nylon 12 with glass spheres for the skin, and a 30 percent glass fiber nylon 6 for the core material. EMS supplied the materials.
“Opening and closing the car door puts a lot of stress on the handle, so the part has to be able to withstand that,” said Saum. “And if you think of extreme situations, such as an accident, the part has to work under duress as well.”
At Fakuma, shot weight was 246 grams and cycle time was 79 seconds.
Huf Hülsbeck & Fürst GmbH & Co. KG supplied the mold.