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Complex surfaces in the one-shot process

14.10.2015
- KraussMaffei is presenting the CX 160 with dynamic, inductive mold heat-balancing at Fakuma
- Two different technical components with precision structures and hologram appearances
Complex surfaces in the one-shot process - Picture Main

(Munich/Friedrichshafen October 14, 2015) Exciting surface effects with precision structures and hologram appearances are being presented at the Fakuma by KraussMaffei (Hall A7, Booth 7303/7304) on a CX 160 – 750 with DMH technology (dynamic mold heating). This is made possible in part by the dynamically inductive mold heat-balancing from RocTool. The APC function (Adaptive Process Control) ensures uniformly high component quality and thus supports zero-defect production.

The application of decorative film inserts is unnecessary

The laser-structured mold inserts have special surfaces with various effects and precision structures (high-gloss, hologram) and thus impressively illustrate the constructive design options for premium quality visible components. "The inductive DMH process we offer in cooperation with our partner RocTool is an excellent example of how customers can increase their production efficiency in injection molding," says Dr. Hans Ulrich Golz, Managing Director of KraussMaffei and President of the Injection Molding Machinery Segment at the KraussMaffei Group. Components with premium quality surfaces are developed in the one-shot process. As a result, additional in-mold decoration steps such as preforming, punching and feeding have been omitted. KraussMaffei is presenting two different design variants using the example of an electronic box cover at Fakuma. The CX 160 produces components with surfaces in a high-gloss finish using structure effects and hologram structures.

"The RocTool induction mold heating technology enables a highly precise replication of the microstructures made on the mold surface using laser technology, all within a one-shot process," explains Stéphane Hersen, CEO of RocTool. The material to be used for this process at Fakuma is a black polycarbonate from Sabic.

But cutting back on additional decorative film inserts is not the only reason why you can increase productivity with the CX 160 DMH. With the new CX series, KraussMaffei has optimized its CX series with clamping forces of 350 to 1,600 kN with regard to energy efficiency, productivity and space requirements. In this way, the drive concept has been energy-optimized and requires ten percent less electricity than before thanks to smart battery management with a disconnectable battery. The BluePower Vario drive option, a variable-speed asynchronous motor, improves efficiency and reduces idling capacity. The longer the cycle times, the greater the savings—up to 30 percent compared to the traditional hydraulic variant.

Space-saving automation and grippers in 3D printing

A suspended Kuka 6-axis robot takes over the demolding process and stores the components inside the expanded machine protection housing. This reduces the production storage space by 25 percent. To guarantee available accessibility to the mold area, for example during the mold change, the conveyor belt moves to the side when the non-operator side doors open. The conveyor belt is centrally operated the same way as the injection molding machine using the new MC6 Multitouch control system.
The removal gripper initially produced through the 3D printing process is especially lightweight and can be manufactured in a weight-optimized way quickly and easily. In addition, the lightweight gripper can be perfectly adapted to the 3D contour of the component. Simple integration of cavities offers additional advantages. In this way, the hose connections can be simplified, for example, producing a compact gripper without protruding edges. The use of cavities for additional rigidity is also possible.

Fewer rejects thanks to APC

The APC (Adaptive Process Control) machine function from KraussMaffei immediately compensates for fluctuations in the injection molding manufacturing process. The results are consistently high component quality and fewer rejects. Overall, substantial savings can be made in regard to time, costs and material.

 
Complex surfaces in the one-shot process - Picture 1
Complex surfaces in the one-shot process - Picture 2