Smart Molding International 2-2025

17 machinery sensitive gas diffusion layers (GDL) for fuel cells. The LSR seal is applied with absolute platen parallelism directly in the machine, inspected in the mould and the component is immediately removed. The automation system, featuring ENGEL easix articulated robot and a rotary table mould supplied by ACH, ensures short cycle times and high process reliability. To save space, the control cabinet is integrated directly into the machine frame. ENGEL is showcasing a highly cost-efficient solution for fully automated overmoulding with thin LSR layers in a compact footprint. Lightweight, strong, sustainable: bicycle handlebars with fluidmelt and organomelt A nove l b i cyc l e hand l eba r i s manufactured as a hollow component on a tie-bar-less ENGEL victory 180 injection moulding machine with 1800 kN clamping force. The fluidmelt process is used to create the hollow structure, while unidirectional continuous carbon fibre tapes are simultaneously integrated using the organomelt process. This innovative combination of technologies enables maximum part performance with minimal weight and a short cycle time of just one minute. The process is fully automated with an easix articulated robot. With these technologies, ENGEL once again sets new benchmarks in production efficiency and sustainability – opening up new markets for plastic components in applications traditionally dominated by metal. Cost-efficient and ready for series production: Physically foamed B-pillar trim using MuCell A B-pillar trim component is produced in just 50 seconds using the ENGEL foammelt technology on a t-win 6500 two-platen injection moulding machine from the WINTEC brand, part of the ENGEL Group. The foamed part, weighing 290 g, is made of mineral- filled PP from Sabic. ENGEL’s foammelt technology reduces weight and cuts material and production costs while achieving excellent surface replication. Automation is handled by a highly integrated viper 20 robot. WINTEC here demonstrates a cost-effective solution for producing visible interior automotive components. High-precision manufacturing for medical products: Cell culture plates with accelerated validation I n t he Med i c a l a r e a , ENGE L showcases a highly efficient injection moulding cell built around an all- electric e-motion 260 combi M injection moulding machine equipped with two injection units and a central rotary platen. Using a stack mould from Hack, 24-well cell culture plates and matching polycarbonate lids are produced simultaneously in a single shot – with a cycle time of just 11 seconds. The additional injection unit is arranged at an angle to shorten the hot runner path, enable central injection without weld lines and improve material protection. This manufacturing solution, featuring a side-entry robot from Ilsemann, delivers the entire process including assembly and packaging in a compact, ergonomic setup. A key highlight is the validation solution jointly developed by ENGEL and toolmaker Hack. This system enables structured and digital documentation of all validation phases – from Design Qualification (DQ) to Performance Qualification (PQ). Machine- and tool- integrated sensor technology, combined with products from the ENGEL iQ family and standardised documentation modules, significantly reduce the effort required. As a result, the time- and personnel-intensive validation process is substantially shortened. Precision LSR seals for fuel cells are produced on the vertical ENGEL insert 150 – fully automated overmoulding with maximum accuracy in a minimal footprint www.smart-molding.com