Smart Molding International 1-2023

molding outlook 20 smart_molding international 1/2023 Saving resources and reducing weight with alternative materials and ultra-modern technologies At the K 2022, WITTMANN BATTENFELD presented an ap- plication which makes a substantial contribution to climate protection especially due to its light weight, achieved by ma- terial savings on the one hand, and on the other hand by using alternative materials. With a MacroPower1100/12800 fitted with an energy-sav- ing, speed-controlled servo motor and a constant displace- ment pump, WITTMANN BATTENFELD demonstrated produc- tion of an indoor panel which stands out by its light weight, using a single-cavity mold supplied by FRIMO, Germany. The panel consists of an extremely light natural fiber material onto which a map pocket made of Borcycle TM EE1300SY supplied by Borealis is over-molded, which is a mineral-reinforced PP for car interior applications with 30% PCR (post-consumer recyclate) content. Borcycle TM EE1300SY meets the most stringent requirements in terms of odor neutrality and emissions for vehicle interiors set by various OEM’s and is also available in light colors. In order to achieve an extra high reduction of material input and weight, the Cellmould structured foam technol- ogy developed and patented by WITTMANN BATTENFELD is used. In this process, nitrogen is added to the plastic melt during metering. This is carried out via a gas injector mounted on the plasticizing barrel. Thanks to the special Cellmould screw geometry, the gas is then dissolved and finely distributed in the plastic material. During injection into the cavity of the mold, the gas then separates itself again from the plastic and forms a fine-celled foam struc- ture inside the molded part. Further advantages of structured foam technology apart from cost cuts through less material input are a reduction of warpage and sink marks as well as more freedom of design for mold makers. Consequently, using the Cellmould pro- cess makes it possible for customers to combine economic with technological benefits. The reduction of material input achieved in this way also benefits the environment in several respects. Firstly, valuable resources are saved, and secondly, the parts are lighter, which reduces the car’s fuel consump- tion and/or extends the battery range in electric vehicles. In this application, the pre-cut natural fiber mats are picked up from a buffer stack and inserted into an IR heating station by a WX152 robot from WITTMANN. Next, the heated mats are placed into the mold on the fixed mold half by a combina- tion gripper, formed, cut to size and over-molded. For this ap- plication, the mold is fitted with a hot runner system specially equipped with needle shut-off nozzles for compatibility with the Cellmould process. Prior to insertion of the next natural fiber mat, the finished part and the trimmings are removed from the fixed mold half and subsequently transported to the storage position. Campetella Robotic Center: a new concept of automation From 19 to 26 October 2022 Campetella Ro- botic Center welcomed K 2022 visitors to guide them through their most advanced automa- tion, result of a sustainable innovation based on the customer’s real needs. Both at Campetel - la’s and Demag ’s booths, visitors had the op- p o r - tunity to check out the new Modula W X-Series, core of a fully automated system managing the IML production of margarine tubs. Born to fit IMMs up to 4.500 kN clamping force, this high-speed side-entry robot boasts a peculiar and innovative "W" structure that allows it to operate on a 2-level stack mold, which is also specifically designed to double productivity. The Campetella product develop- ment team has been focusing on the shared ever-growing need to increase the production systems’ efficiency in the food-packaging industry. Minimizing footprint on the ground while maximizing pro- ductivity. This is what Campetella was able to achieve by creating this newModula. Its main transversal axis, located on the upper side of the robot, makes it possible for the discharge conveyor belt to be placed at the bottom, thus ensuring a significant space optimization. WITTMANN BATTENFELD Cellmould technology, developed to save material and reduce weight (picture: WITTMANN GROUP) Innovative carbon-fibre arm with twisted profile (picture: Campetella)