PlastiVation (B3-321) is returning to Fakuma, this time with two second-generation electric injection molding machines from Tederic's Neo series. The second-generation Neo machines have undergone a technology upgrade claimed to put these on a par with European-made injection molding machines.
At the stand, an electric Neo-E160/e620 with a clamping force of 160 tons and a screw diameter of 42 millimeters will be running in an automated production cell, producing a cup holder with three cups made of PC-ASA. The shot weight is around 150 grams, and the cycle time is 42 seconds. The cup holder weighs 74 grams; each cup weighs 23 grams.
A 3+1 hot runner family tool from Incoe International Europe, equipped with a pneumatic four-way needle valve system and Incoe's Heat-Inject temperature control technology, enables the cup holder to be produced with three openings for the cups with no weld lines appearing on the surface behind the openings.
The second machine, a Neo-E60/e110, will be producing a PP prototype part using a 3D printed mold from SK Industriemodell GmbH. xMOLD resin has been used to print the mold, which means it is compatible with most off-the-shelf injection molding materials. Moreover, it allows for the production of complex components with undercuts to be manufactured more cost-effectively. The tools are fully soluble, eliminating all tool storage and maintenance costs.
Energy-efficient injection molding technology is the main theme at the Wittmann Battenfeld stand (B1-1204) as well. In addition to all-electric machine models from the EcoPower and MicroPower series, a servo-hydraulic SmartPower with an electric injection aggregate will also be shown for the first time.
The machine, a SmartPower B8X 120/350H/130S with an electric injection unit, will be producing a bottle opener made of PC and TPE, using a mold supplied by FKT Formenbau und Kunststofftechnik, Germany, with a W918 robot from Wittmann and a conveyor belt integrated in the work cell. The robot inserts the metal parts fed from a magazine into the mold, where they are overmolded with polycarbonate. The resulting base body is passed on to the second station by a rotary unit and overmolded with TPE, for a better grip. The finished parts are then deposited on the conveyor belt of the Insider cell.
Wittmann has also taken the use of DC energy as a power source for injection molding systems a step further. Last year, the company showed a machine with a robot operating on direct current; this year, the temperature controller, too, can run on energy from the machine's DC intermediate circuit. Further DC-compatible auxiliary appliances are planned. The EcoPower B8X 180/750 DC Insider cell with an integrated WX142 robot in DC version from Wittmann and a DC-compatible Tempro plus D temperature controller will be molding the housing of a plug-in connector for DC technology using a two-cavity mold supplied by Harting, Germany.
A Harting connector is also built into the machine to connect the Tempro plus DC appliance. Power is supplied by an ecological salt battery technology on a sodium-nickel basis from innovenergy. The battery has a total capacity of over 45 kWh, more than sufficient for uninterrupted machine operation throughout an entire eight-hour trade fair day. In addition, electrochemical capacitors, known as supercaps, will be used to complement the sodium-nickel storage units by balancing out short-term load peaks.
Amid the celebrations of the 40th anniversary of Fanuc's high-performance Roboshot fully electric injection molding machine, the company is set to present the latest solutions in injection molding technology and automation, with particular focus on sustainability, energy efficiency, compact design, reliability and the industry's lowest total cost of ownership (TCO) at this year's Fakuma (B3-3211).
Among many highlights will be a fully automated production cell comprising a Roboshot a-S150iB with a clamping force of 150 tons and an LR-10iA compact six-axis robot, demonstrating the efficient and precise processing of biopolymers. Longitudinally mounted on an additional linear axis, the complete footprint of the exhibit has been minimized.
Artificial intelligence is the heart of the latest a-iB series Roboshot. The injection unit, for example, includes AI metering that uses torque — rather than speed — control to compensate for changes in material viscosity such as drying conditions and variations in regrind.
In addition, Fanuc AI mold and ejector protection prevents mold damage and costly repairs/downtime if an event occurs during the opening and closing cycle. It even indicates when greasing is necessary or if the mold is showing signs of wear. The same technology also protects the ejector's forward and reverse movement.
Also on show, demonstrating that third-party robots can be seamlessly integrated with Fanuc injection molding machinery, is a Fanuc Roboshot a-S100iB, equipped with a Sepro Success 11 robot. To help users maximize the available savings, Roboshot machines feature a power consumption screen as standard. This includes an energy analysis page to identify where energy consumption takes place during the cycle, aiding optimization.
According to Fanuc, its Roboshot machines enable reductions in electricity consumption of up to 70 percent compared with hydraulic injection molding machines — and 5-10 percent less than other electric injection molding machines — due to the advanced servo technology used and an intelligent energy recovery system, plus the need for oil treatment and disposal are a thing of the past.
KraussMaffei (A7-7303) is demonstrating the high precision and efficiency of its all-electric PXZ 121-380-180 Multinject machine, which will be producing a small blue turtle with a black core made of mechanically recycled PC/ABS and a high-quality outer layer made of chemically recycled ABS.
The cold runner sprue is removed, shredded and fed directly back into the production process for the core material.
Numerous features of the PXZ 121, such as the new sandwich panel, near-contour mold temperature control from partner Contura MTC and the APCplus machine function, which now also uses individual characteristic values of different material types, make the multicomponent process even more efficient and economical.
Part removal, separation from the sprue, separation into the grinder and depositing on the belt are the automation tasks of the new LRXplus linear robot, which is celebrating its premiere at Fakuma together with the MC7 control system.
The new LRXplus from KraussMaffei offers numerous new functions that make production even more flexible and economical. Thanks to its compatible interfaces, the LRXplus can be combined with almost any system – whether with KraussMaffei injection molding machines, injection molding machines from other manufacturers or as a standalone solution for all other automation tasks.
This year, Engel (A5-5203) is launching its fully electric e-mac 500 injection molding machine, with a clamping force of 5000 kN, combining high performance with energy efficiency and a compact design. Featuring a high-performance clamping drive and the iQ motion control digital assistant, the machine, which will be producing 4-liter containers using in-mold labeling, achieves faster cycle times and reduces energy consumption by up to 30 percent compared with hybrid or hydraulic machines.
The company is also unveiling the latest generation of its Wintec t-win machines, with more than 20 new options, including iQ clamp control, which optimizes clamping force to reduce scrap, energy consumption and tool wear, and iQ hold control, which adjusts holding time for faster serial production.
Additional options, such as proportional valves for core pulls and servo valves for injection, will be available by the end of 2024. The t-win 5500-4900 will produce battery box lids and back panels from ABS.
A tie-barless victory 160 producing fittings is also displayed. The machine features a short cycle time of around 40 seconds and a larger platen for quick mold changes. The integrated digital setup assistant supports operators during tool changes, minimizing errors and boosting overall equipment effectiveness. Live demonstrations at the fair will highlight the machine's rapid tool-changing capabilities.
Engel's digital assistance systems, offering comprehensive monitoring, control and automatic process optimization with real-time feedback, are the company's answer to labor shortages and rising energy costs. Key highlights include the setup assistant and the AI-powered Engel spare parts app.
