Smart Molding International 1-2024

32 smart_molding international 1/2024 molding technologies Sustainable and lightweight: efficient production of thermoplastic composite parts With its many years of experience in injection moulding and its high level of automation expertise, ENGEL develops highly cost-effective production concepts for the manufacture of composite parts in large quantities. At JEC World 2024 in Paris, France, the machine manufacturer was demonstrating how high production efficiency and cost effectiveness can be combined with sustainability for both the aerospace and automotive industries. I n the ENGEL organomelt process, thermoplastic fibre com- posite preforms - for example thermoplastic sheets and UD tapes - are formed and functionalised in a single inte- grated process step. For example, reinforcing ribs or assembly elements are moulded immediately in the same mould after thermoforming using a thermoplastic from the same matrix material group as the thermoplastic sheet. This not only enables a highly efficient and fully automated production process, but also contributes to the circular economy. The consistent thermoplastic mono-material approach facilitates subsequent recycling of the parts. At its stand in Paris, ENGEL was demonstrating the huge potential of organomelt lightweight technology with a live machine exhibit. An ENGEL victory 660/160 injection moulding machine and an ENGEL easix articulated robot were being used to automate the production of inspection flaps for the fuselage of passenger aircraft. The production cell also included an IR oven, which also comes from ENGEL in-house development and production. To enable a sustainable and cost-effective process, a composite material with a recycled long-fibre core was used in combination with fabric-based cover layers. The thermoplastic sheets were heated in the IR oven, taken into the mould by the robot, formed in the mould and immediately overmoulded. The reinforcement ribs and a mounting clip were formed. Heating up the thermoplastic sheet is a process step which determines the cycle time and is also relevant to quality. The thickness of the preform defines the heat-up and cool-down times. Heating up the material quickly without damaging is important, as are short paths for transporting the heated thermoplastic sheet to the mould, to avoid the sheet cooling down again on the way to the mould and losing its malleability. This is where the tie-bar-less technology of the victory machine plays to its strengths. Barrier-free access to the mould area makes it possible to position the IR oven very close to the mould. And the robot can take the shortest path to the mould without working around interference contours. Both factors accelerate hot handling and ensure process consistency and high component quality. In integrated ENGEL system solutions, the robot and the IR oven are integrated into the injection moulding machine’s