New concept for multi-component molding

Working together, Boucherie and KraussMaffei have collaborated to deliver a unique manufacturing system utilizing the Boucherie patented Flexi Cube Molds and KraussMaffei molding machines for a multinational consumer products company located in the USA. This is a further development utilizing the patented Flexi Cube Mold Technology introduced by Boucherie in 2017.

The mold can be seen in the Boucherie Booth at the K Show (Hall 1 Stand D13)

The core of this ingenious mold is a stack design with a central, stationary cube. Surrounding its circumference various stations are provided which are linked by a transport-system that travels around this cube.

For this purpose, a solid track is installed around the cube on which holders with molded parts are traveling. These holders are moved by means of servo- motors allowing the holders to travel over different distances at very fast transfer times - as low as .7 seconds. As such, the number of stations, their individual positions and their function can be selected as needed. This results in maximum mold layout flexibility.

Versions for 1, 2, 3, 4 or more components can be built with or without intermediate cooling stations between injection stations where desired or further with one or more ejection stations or positions where premade structures can be inserted.

More simple applications include two-component molding, with maximum cavitation in stack configuration, or combined with any of the extra functions described above.

Because the central cube is stationary, the interface with the injection molding machine can be kept simple. It is comparable to a regular stack mold, in this respect. The stationary central part also allows easy and ample supply of cooling water, compressed air, electronics, etc. without need for delicate rotating couplings.

The valve gated hot-runner system is standardly equipped with a hydro-mechanical activation system for the valve pins, a system Boucherie has been using in all its molds for over 25 years.

Utilizing the Boucherie Flexi Cube Mold, mass production can be realized with a very simple, easy to maintain, manufacturing cell.

The Boucherie Flexi Cube Mold will produce in a KraussMaffei model GX W 650-1400-750 SpinForm machine. The machine was designed with high- performance screws and increased drive power for faster cycle times. The machine will be equipped with KraussMaffei‘s SmartCube High performance industrial PC with integrated OPC UA interface. The machine is equipped with integrated sliding table and servo frequency converter to support and turn the Flexi Cube Mold System.

Come by the Boucherie Booth (Hall 1, Stand D13) and see a 4 station, 32 cavity mold for a 2-component consumer product.