Finished component in a single step

Three into one: a magnetic disc, carrier plate and protective cap are moulded into a functional rotary encoder using the three-component process. The innovative mould concept and the complex automation solution dispense with joining techniques and downstream assembly.

All operations are combined in a single process – including insertion of the sensor and overmoulding with a carrier plate as well as magnetisation and assembly injection moulding directly in the mould. A fully automated production cell built around a hydraulic ALLROUNDER 370 S injection moulding machine featuring three (size 30, 70 and 30) injection units.


  • Fully automated three-component production cell
  • Injection units integrated in SELOGICA machine control system
  • Magnetisation and assembly injection moulding in the mould
  • From production of the individual parts to final assembly in one process

Basic specifications

Rotary encoder
Cavities: 3
Part weight: 1.5 + 1.0 + 0.5 (g)
Material: PA + PBT + MABS
Cycle time: 30 s


A hydraulic three-component ALLROUNDER 370 S machine with a clamping force of 700 kN and size 30, 70 and 30 injection units (EUROMAP) is used. All three injection units are integrated in the SELOGICA control system.
to the hydraulic machines

Robotic system
The highly-flexible MULTILIFT V robotic system in a longitudinal design enables vertical removal, even with the injection unit arranged in the parting line. It also performs insertion of the sensor, transfer of the magnetic disc in the mould and final assembly.
to the robotic system


Overmoulding inserts
The robotic system positions the sensitive sensor on the nozzle side of the mould and the magnetic disc on the ejector side. In order to combine the insert with the magnet, the sensor is overmoulded with a carrier plate.
to the process

Assembly injection moulding
The magnetic disc made from a ferrite-containing PA is rotably mounted onto the spindle of the PBT carrier plate. This is not possible using conventional means. Joining technology and downstream operations are dispensed with, rendering the process cost-effective.


The rotary encoders with magnetised plastic and overmoulded sensor produced using assembly injection moulding are functionalised components for electronic applications. The finished moulded part detects directional changes and is suitable for vehicle navigation systems, for example.
to the industry


Component conceptLTK Erlangen
Hot runnersGünther Heißkanaltechnik
AutomationKiki, Xenon