You produce components for the automotive sector? Then ARBURG is the expert partner for you. See here how you can produce high-strength lightweight parts, create hard/soft combinations, cost-effectively overmould small batch parts or perform foaming within an injection moulding cycle.
FIM technology for ‘smart’ component surfaces
The night light example shows how multi-functional surfaces can be produced using Film Insert Moulding (FIM). This process is ideal for high-quality touch functions for digitalization, for example, in car interiors as well as the electronics industry, white goods and medical technology.
The pre-formed 3D films with integrated electronic functions and five LEDs are fed from the trays from outside. The films are cleaned beforehand under controlled production conditions, in-mould laminated and their electronic function is checked one hundred percent in the clean room cell around an electric injection moulding machine ALLROUNDER 470 A.
Lightweight construction with fibre reinforcement
ARBURG offers the new ProFoam process for the physical foaming of thermoplastics. The plastic granules are mixed with a blowing agent in a granulate lock upstream of the injection unit. This means that fibre-reinforced plastics are no longer subject to additional shearing.
ProFoam enables lightweight, robust and low-distortion parts to be injection moulded with a homogeneous foam structure. When glass-fibre reinforced materials are used, a longer average glass-fibre length is generally produced in the component than with conventional compact injection moulding. One efficient example is a kinematic housing for a automotive interior application, which, weighing 361 g, is around 13% lighter than a comparable compact part.
Functional part in a single step
The cost-effective manufacture of functional components in a single step is a domain of plastics processing. Thumb wheels for passenger car interiors are a good example: Thanks to a targeted combination of materials, high-quality plastic parts with a soft-touch surface are produced.
The thumb wheels can be produced in a fully automatic process sequence on a hydraulic three-component ALLROUNDER 570 S injection moulding machine. This enables efficient high-volume production of these sophisticated functional components. Initially, the translucent main body is produced from PC, then an electroplateable visible surface is added in ABS before a third, attractively tactile TPE component is injected.
LSR coupling cushion
Liquid silicone compensates for curvature: thanks to an LSR coupling cushion, a rain/light sensor can be optimally attached to a car windscreen. A multi-component machine moulds a low-viscosity liquid silicone (5 Shore A) onto a PBT frame, in which the sensors are inserted.
The production of hard-soft combinations with a silicone component represents a significant challenge in terms of machine and mould technology because thermal isolation is required within the mould. The coupling cushion is produced from PBT and LSR on a fully-electric two-component ALLROUNDER 570 A with a clamping force of 2,000 kN. The four pre-moulded parts and four finished components with a part weight of 4.53 g are produced in a cycle time of 38 s.
Foaming within the injection moulding cycle
As a main contractor, ARBURG has, jointly with its partner Sonderhoff, developed the inline MOLD’n SEAL process, which combines injection moulding with subsequent PUR foaming. This allows you to save time, costs and space, as well as significantly increasing your production efficiency.
A six-axis robotic system removes the still-warm housing covers from a hydraulic ALLROUNDER 570 S injection moulding machine and moves the seal contour under a foam dosage unit, which applies the foam seal. No intermediate storage is required and the curing time is reduced significantly.
to the moulded part
Manual filter production
A vertical ALLROUNDER 375 V injection moulding machine shows how fuel tank strainers can be produced cost-effectively and to high quality standards in small batch volumes by integrating manual operations and using innovative working methods. A total of seven production steps take place within a total cycle time of 50 s.
The strainers are produced extremely flexibly to a very high level of quality in unit volumes of up to 3,000. The machine and operator are both used to full capacity. In a cycle time of around 35 s, the upper and a lower sections of the filter are injection moulded while the two parts from the previous cycle are joined mechanically. The operator simultaneously performs finishing operations, including assembly of the finished component. In this manner, approx. 85 units are produced per hour.