Tension strap

Multi-variant on-demand high-volume production

Industry 4.0 in practice: the example of elastic tension straps illustrates how part variants can be cost-effectively produced in high volumes. Due to the clever product and mould design, a flexible turnkey solution as well as direct process control, the products are produced individually on a shot-to-shot basis.

Length, colour and the ends of the tension strap (hook or eyelet) can be freely selected and configured on a terminal according to customer requirements. The order is then transferred directly to the central SELOGICA control system via the OPC UA communication protocol. A compact turnkey system based around a vertical ALLROUNDER 375 V injection moulding machine then produces the part variant on demand – without any need for conversion. In industrial practice, such an application is ideal for cable assembly in the automotive industry, for example.


  • Individual production on demand: variant changes from shot-to-shot without any changeover
  • Digital transformation: customer requirements are integrated into the running injection moulding process online
  • Clever product and mould design: combination mould for all fastening variants
  • Flexible six-axis robotic system: automatic cutting to the required strap length
  • Compact turnkey system: automation integrated in the machine installation area

Basic specifications

Tension strap
Cavities: 4
Part weight: 13.5/14 g
Material: PP GF 30
Cycle time: 35


The tension straps are overmoulded on a vertical ALLROUNDER 375 V. The four-cavity mould has two cavities each for the hooks and eyelets. This allows hook/hook, hook/eyelet or eyelet/eyelet combinations to be produced. The cavities required in each case are filled via hot-runner nozzles.
to the electric machines

Robotic system
Multi-axis robots offer highly flexible perfection in motion and feature high functionality on a small footprint. With the vertical ALLROUNDER V, the use of a robot makes it possible to enter the mould from the rear. For this purpose, the ends of the strap are placed into the cavities in accordance with the order.
to the multi-axis robot

Process and know-how

Overmoulding of inserts
The tension straps are cut from the roll to the length required by the customer and the ends are spliced by means of a plasma process. The flexible inserts are handled by a six-axis robot that is compactly housed within the machine's installation area.
to the process

The top priority is the common goal of always finding the most cost-effective solution. This calls for interdisciplinary expertise. As a technology and systems partner we cover a particularly broad spectrum and can offer you expert support for the implementation of your requirements.
to applications technology
to turnkey consulting


Increased variant diversity, shorter product life cycles, more individualisation: the multi-variant high-volume production of tension straps shows how customer requirements can be integrated and cost-effectively implemented on demand. As a technology and system partner we implement pragmatic Industry 4.0 solutions for your digital transformation.
to the industry

Variant changes from shot-to-shot without any changeover: the fully automatic assembly and overmoulding of elastic tension straps prototypically demonstrates how different cables can be efficiently produced. The compact turnkey solution produces consistent high quality and simplifies logistics.
to the industry


Strap feedingLeicht
Plasma treatmentplasmatreat