AHEAD. Fiber composite solutions for advanced lightweight components. Engineering Passion

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1 Surface RTM Technology Fiber-reinforced, paintable surfaces such as roof elements, door inner panels, trunks or engine hoods AHEAD THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI AHEAD RTM Technology Structural and semi-structural components such as underbody structures, side frames or seat structures Issue Wet molding RTM Technology Semi-structural components made of recycled carbon fibers, e. g. hybrid components THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI INDUSTRIAL (R)EVOLUTION CUSTOM-MADE NETWORKING WITH PLASTICS 4.0 IMC Technology Fiber-reinforced, structural components such as front ends, mounting supports, instrument panel carriers FiberForm Technology Continuous fiber-reinforced components such as crash elements, B-pillar reinforcements or seat structures Fiber composite solutions for advanced lightweight components Engineering Passion WET MOLDING PROCESS MADE READY FOR SERIES PRODUCTION CFRP IN INCREASINGLY SHORTER CYCLE TIMES Issue

2 EDITORIAL CONTENTS COVER STORY 6 Custom-made networking with Plastics Interview: Networking goes far beyond just processing polyurethane BRAND & MARKETS Dear customers, dear readers, Everybody is talking about Industry 4.0. KraussMaffei is working on the vision of completely networking all processes in production. We call this Plastics 4.0. Under this category, we are developing solutions that open up new areas of potential in your production. We bundle our solutions into three areas: Intelligent Machines, Integrated Production and Interactive Services. This issue of AHEAD describes how we offer a custom-configured solution from these intelligent functions. As a global company with comprehensive expertise, exceptional innovative ability and passionate dedication to engineering plastics machines, we offer customized systems consisting of the machine and peripherals. KraussMaffei customers in China now enjoy concrete advantages when purchasing a GX injection molding machine. Production of this machine has now been started at our plant in Haiyan, China. It goes without saying that the same worldwide KraussMaffei standard of quality is applied. Local companies benefit not only from the quality and efficiency of our machines, but from time savings during delivery. For more information about the Chinese market and the GX series for the growing automotive, packaging and medical technology industries, read on in this issue. This issue also features numerous interesting project highlights that repeatedly display our expertise in Trendsetting including the areas of resource conservation, lightweight construction, energy efficiency and surface aesthetics. However, we are not resting on our laurels. In conjunction with our project partners, we are continuing to advance the development of innovative solutions. In doing so, our objective is to offer you new technologies and improved products and services that help make your processes and products better. We will present a few of these areas of progress at the Chinaplas trade show in Shanghai in April. I m particularly looking forward to K2016. Even today, I can promise that you ll have the opportunity to see firsthand high-quality and innovative products and processes of the KraussMaffei brand in Düsseldorf. Be sure to stop by and visit our booth. You have my personal invitation. Have a good read! 12 GX goes East 14 Interview: Growth with quality 16 Interview: Packed full with performance 18 High-performance polyurethane molds and trimming technologies PROCESSES & PRODUCTS 20 Advanced surface effects in the one-shot process 22 FiberForm helps attain the desired weight 24 Up to 30 percent energy savings 25 Gripping carriers from the printer PARTNERS & PROJECTS 26 CFRP in increasingly short cycle times 28 Peak technology for efficient operation 30 All-around lightweight construction talents on a science mission 32 Complexity made easy 34 Fit for large series 36 Streamlined transport crates for South Africa 38 Better light with OptiSys KRAUSSMAFFEI GROUP 4 Change of ownership at the K raussmaffei Group 5 New Vice President Sales at the Injection Molding Machinery segment at KraussMaffei 39 Strong together and unique all over the world Dr. Hans Ulrich Golz Managing Director President of the Injection Molding Machinery segment 39 Imprint

3 KraussMaffei Contents 3 20 DMH technology Complex surfaces created in the one-shot process. 22 Budget-friendly lightweight construction alternative Two LRX-350 linear robots in a CX 300 produce optimum results for auto motive supplier Takata. 26 Wet molding process in auto body construction The BMW Group is setting new standards with the new BMW 7 Series.

4 4 KraussMaffei Group AHEAD Issue KraussMaffei Group CHANGE OF OWNERSHIP AT THE KRAUSSMAFFEI GROUP* EXPRESSING THEIR PLEASURE AT THE CONTRACT SIGNING FOR THE CHANGE OF OWNERSHIP OF THE KRAUSSMAFFEI GROUP (from left to right): Ting Cai, Chairman and CEO of China National Chemical Equipment Co., Ltd. (CNCE), Dr. Frank Stieler, CEO of the KraussMaffei Group, and Chen Junwei, CEO of ChemChina Finance Co., Ltd. The KraussMaffei Group management greets the pending change of ownership enthusiastically*. Our new investor is ChemChina, a Chinese chemicals conglomerate that has been interested in our company for many years now. The company is a strategic and long-term oriented investor, says Dr. Frank Stieler, CEO of the KraussMaffei Group. Strong growth The KraussMaffei Group will accelerate its growth course significantly in light of the possible synergies provided by the planned transaction. ChemChina will enable us to improve our market access in China. We see substantial potential for reinforcing and expanding our market position for the long term, relates Stieler. This will enable us to ensure that we can sustain and grow the high standard of performance and quality of our brands, he continues. Strong brands The strong KraussMaffei, KraussMaffei Berstorff and Netstal brands will be continued and will still also stand for the highest quality, technology and value retention of the machines and systems in the future. The brands will not be watered down, confirms Stieler. We offer our customers the right solutions they need to meet the increasing challenges they face manufacturing their products. Responsibility for production, technology (including patents) and Research and Development will remain in Europe. The existing corporate structure is being maintained, and the headquarters of the KraussMaffei Group will remain in Munich. Customers and suppliers will continue to have the same contact persons. Identity and independence We are growing our company by acquiring one of the world s leading mechanical engineering companies, which boasts a 178-year tradition. We place great priority on making sure that the KraussMaffei Group maintains its identity and independence, says Jianxin Ren, Chairman of ChemChina. We prize the company s vast management and technological expertise and believe that we * The change of ownership is subject to closing conditions including customary regulatory approvals. This is expected in the first six months of (The article reflects events as of press time on March 31, Later news was not able to be incorporated into this issue. For current information, refer to the Internet site.)

5 KraussMaffei KraussMaffei Group 5 ABOUT CHEMCHINA ChemChina is China s largest chemicals company. The group is internationally active, on a worldwide expansion course and, in recent years, has acquired shares in various companies in Italy, France, Norway, the UK and Singapore with a recent example being Pirelli, a tire manufacturer with a rich tradition. Founded in divisions agrochemicals, petrochemicals, specialty chemistry, elastomers (rubber) 140,000 employees 37 billion euros sales volume (2015) 140 countries NEW VICE PRESIDENT SALES AT THE INJECTION MOLDING MACHINERY SEGMENT AT KRAUSSMAFFEI Since January 1, 2016, Nadine Buhmann has been the new Vice President Sales in the Injection Molding Machinery segment for the KraussMaffei brand. She took over these responsibilities from Dr. Hans Ulrich Golz, who performed this role in addition to his responsibilities as the Managing Director of KraussMaffei and as the President of the Injection Molding Machinery segment of the KraussMaffei Group. Buhmann is responsible for the worldwide sales of KraussMaffei brand injection molding machines and systems as well as the associated areas of strategic product management, configuration, application technology, TechCenter and technology development. Buhmann considers the focus of her new position to be on strengthening successful operational sales within the business units and regions by focusing on strategic focal points. She earned her degree in business management and has over 15 years of leadership experience in the international capital goods market. Before joining KraussMaffei, she was the Vice President of Sales at MTU Friedrichshafen/Rolls-Royce Power Systems. can use them for some of our subsidiaries in China. Together, ChemChina and the KraussMaffei Group are ideally positioned for future growth, adds Ren. Accelerated growth will have sustainable positive effects for the company. The bottom line should be net worldwide job creation. Later this year, K 2016 will be another highlight at which the company will shine the spotlight on its innovations. We hope that our customers will visit us at the trade show booth in Düsseldorf in October, says Stieler. NADINE BUHMANN Since January 1, 2016, she has been the new Vice President Sales for the KraussMaffei brand.

6 6 Cover Story AHEAD Issue

7 KraussMaffei Cover Story 7 WITH KRAUSSMAFFEI, PLASTICS PROCESSORS CAN ALREADY TAKE ADVANTAGE OF THE OPPORTUNITIES OF INDUSTRY 4.0 CUSTOM-MADE NETWORKING WITH PLASTICS 4.0 Everybody is talking about Industry 4.0. This technology makes it possible to network machines and production processes. This fourth industrial (r)evolution gives plastics processors tremendous opportunities to increase output and take advantage of potential savings. Plastics 4.0 is the category under which KraussMaffei offers its customers very concrete opportunities to take advantage of Industry 4.0. TEXT: DR. SABINE KOB PHOTOS: KRAUSSMAFFEI W ell-organized small shops with injection molding technology are a model of networking. When everyone knows the entire production process, mutual support can be provided by quickly calling over a colleague, and sometimes without exchanging words at all. Someone sees that the heater is running needlessly and turns it off. Another goes ahead and organizes the individual parts so that things can get rolling faster. Industry 4.0 transfers this idea of continuous networking to the machines in the shop and to manufacturing sequences. In practice, this can mean that the material dryer knows that the machine has only 200 more parts to produce and stops what it is doing in time to save energy and conserve granulate. Another example is when the injection molding machine contacts the mold setter with a notification that maintenance is required soon. The basis for this is that all devices work intelligently, interact with each other and speak a common language. One approach is OPC UA,

8 8 Cover Story AHEAD Issue which has established itself as an international standard for machine-to-machine communication, explains Dr. Rainer Schiffers, Head of Machine Technology and Project Manager for Industry 4.0 at KraussMaffei. The connection with the master computer takes place via a corresponding interface. This currently is Euromap 63, which is to be replaced by Euromap 77, which will then use the OPC UA protocol. KraussMaffei plays a leading role in the Euromap committee. Günther Grimm, Head of Software/Control Engineering, explains, Euromap 77 makes data exchange even faster and easier. KraussMaffei is bundling its Plastics 4.0 activities into three categories: Intelligent Machines, Integrated Production and Interactive Services. Intelligent machines is the name for machines that optimize themselves to improve productivity and part quality. One example of this is the APC (Adaptive Process Control) function, which continuously measures melt viscosity and adapts the switchover point from the injection phase to the holding pressure phase to ensure uniform part quality. This makes it possible to compensate for batch fluctuations or changes in ambient conditions. Another function that enables systems to act intelligently is the KraussMaffei Weekly Timer. Until now, machine operators determined the starting point of the preheating phase of the plasticizing unit and hydraulic system, usually the same for all machines together and independently of how long they needed for this phase. Machines that heat up quickly would spend time idling before the actual start of production. This wasted energy. The Weekly Timer now enables each machine to define the desired beginning of production. Since each machine knows the specific amount of time it requires, it will start at the right time in order to be ready for use immediately. The program is integrated into the MC6 machine control system free of charge and is a truly one-of-a-kind product on the market. Real-world example: Monday morning When starting up production, such as on a Monday morning, the communication chain is as follows: The Weekly Timer tells the injection molding machine when it wants to begin production and passes this information on to the material dryer. Because the material dryer knows how much time it needs, it starts up the heater in a timely manner so that it is available exactly when it is needed. The dryer, in turn, is selected in accordance with the required throughput so that no capacities are wasted here either. The combination of the Weekly Timer with an energy management system in place within the building gets into the area of Integrated Production. The energy costs for buildings are often measured according to consumption peaks that are measured by the quarterhour. This means that in some cases, it can be worthwhile to start the machine two minutes later to ensure that a certain peak is not The basis for this is that all devices work intelligently, inter act with each other and speak a common language.

9 KraussMaffei Cover Story 9 exceeded. If the machine receives a signal indicating not yet from the energy management system and transmits this signal to the connected material conveyor, the entire system waits until the critical period is passed. This saves costly electricity. Real-world example: mold change The seamless networking of injection molding machine and material supply is also helpful for other scenarios. An impending mold change is one of these. When the dryer knows that only a few more parts are being produced, it stops working in a timely manner to save energy and prevent the material from drying out excessively. If there is a problem with the material supply, the injection molding machine can get help in a timely manner before it runs dry itself. This boosts availability. For these cases, the production does not have to be connected to the Internet, but doing so opens up many other additional options. Interactive services include monitoring, diagnostics and remote configuration using Remote Manager. The KraussMaffei solution is integrated into the company network as a preconfigured system. This makes it possible to monitor and control all systems, including status messages and process parameters, remotely. The more rapid the advance of collecting production data and the connection to the Internet, the more relevant security considerations become. Schiffers comments, Data protection is, and will remain, an extremely important topic. Another critical We re doing active research and development work and have access to future-proof solutions. question is who stores the data where. We re doing active research and development work in this area and have access to reliable and future-proof solutions. Plastics 4.0 offers plastics processors major opportunities, whether they are regional companies or conglomerates with global production. The degree of networking can be selected individually based on requirements and customized to the individual company. KraussMaffei supports its customers and stands by them, providing the entire bandwidth while also taking regional differences into account. For example, in China with its great enthusiasm for technology, the trend towards Industry 4.0 is accelerating in leaps and bounds. YOUR CONTACT: Dr. Reinhard Schiffers Head of Machine Technology reinhard.schiffers@kraussmaffei.com

10 10 Cover Story AHEAD Issue INTERVIEW WITH NICOLAS BEYL ON THE OPPORTUNITIES AND POTENTIAL OF INDUSTRY 4.0 FOR REACTION PROCESS MACHINERY NETWORKING GOES FAR BEYOND JUST PROCESSING POLYURETHANE Intelligent Machines, Integrated Production and Interactive Services are the buzzwords with which KraussMaffei is advancing the vision of Plastics 4.0. What does this mean for customers in reaction process machinery and what does it mean for production? Nicolas Beyl, Managing Director of KraussMaffei and President of the Reaction Process Machinery Segment, explains. INTERVIEW: PETRA REHMET PHOTOS: KRAUSSMAFFEI

11 KraussMaffei Cover Story 11 AHEAD: The topic of Industry 4.0 is being talked about mostly in Injection Molding Machinery. What specific possibilities do you see for Reaction Process Machinery? Beyl: Industry 4.0 also offers great potential for Reaction Process Machinery. This involves closely networking the individual production systems but also goes beyond the limits of strict polyurethane processing. Take, for example, the production of instrument panels in vehicle manufacturing. This involves various technologies, including injection molding, thermoforming, polyurethane back-foaming, punching or milling, or various automation technologies. An increased level of networking, meaning intercommunication, provides a large amount of potential for optimizing the processes. Concretely speaking, if the injection molding carrier and the surface skin are handed over to a polyurethane system for back-foaming, the data that accrues in each production step is collected and passed on to the higher-level data management system. This data capture continues during the punching or milling of the instrument panels. Using a continuous process data entry system, the production data can be read out in bundled form, analyzed and used to optimize the entire system. At KraussMaffei, we bundle these activities under the category of Integrated Production. AHEAD: What is the ideal implementation of Integrated Production? What are the advantages for the customer? Beyl: The networking of the individual system parts is being implemented on a customerspecific basis nowadays. By introducing more standardized protocols, the trend An increased level of networking provides a large amount of potential for optimizing the processes. NICOLAS BEYL, MANAGING DIRECTOR OF KRAUSSMAFFEI AND PRESIDENT OF THE REACTION PROCESS MACHINERY SEGMENT in coming years will go more and more towards plug and play. These will very likely be based on the OPC UA report. In injection molding technology, KraussMaffei is currently drafting the Euromap 77 recommendation in conjunction with other manufacturers. Of course, reaction process machinery is a more diverse field than injection molding technology. Despite this, we are following the development of this guideline very closely to draw some conclusions for Reaction Process Machinery. AHEAD: What is your definition of Interactive Services? Beyl: Interactive services are another important pillar in implementing Industry 4.0. Even today, many of our customers have decided in favor of installing what is known as a web box on the Reaction Process Machinery systems. After being given access by the customer, our service and software technicians can access the systems via the Internet and carry out service work. At the same time, the customer can access this web portal to query the status of its systems from central locations. The next step will be a service portal solution on which the entire system data is stored along with the history, documentation or system-specific spare parts catalogs. We at KraussMaffei are working intensively on creating genuine added value for our customers. For us, the topic of data security is of utmost importance it will be ensured under all circumstances. AHEAD: What do your customers think about the vision of Industry 4.0? Do you ask them specific questions? Beyl: Much of the technology we summarize under the general term of Industry 4.0 is not new. Customers have been asking questions about individual, specific topics from the area of Industry 4.0 for a while. As we just mentioned, we also offer these solutions. How ever, the new, one-of-a-kind feature is the CPU power we now have available to advance these ideas into new dimensions within the entire process chain. As a result, it makes sense to take a closer look at these new opportunities as a part of the discussion on Industry 4.0.

12 12 Brand & Markets AHEAD Issue Brand & Markets KRAUSSMAFFEI EXTENDS ITS PRODUCT RANGE AT THE SITE IN HAIYAN GX GOES EAST KraussMaffei customers in China now enjoy concrete advantages when purchasing a GX injection molding machine. Production of this machine has now been started at our plant in Haiyan, China. It goes without saying that the same worldwide KraussMaffei standard of quality is applied. There is no need for costly and timeconsuming ocean transport. TEXT: DR. SABINE KOB PHOTOS: KRAUSSMAFFEI

13 KraussMaffei Brand & Markets 13 F or Jörg Wittgrebe, Sales Director at KraussMaffei, local manu facturing is an important prerequisite for offering his customers even more attractive delivery times. The deadline pressure is tremendous, because mold makers in China now supply entire series of molds within one to two weeks and end customers of plastics processors also act on ever-shorter timelines. Absolute platen parallelism The GX series is directed towards the growth sectors of automotive, packaging and medical technology with its clamping force range of 4,000 to 9,000 kn and high basic speed (dry cycle time of just 2.3 seconds). It thus complements the large MX, which has been produced successfully in Haiyan since June The most important features of the GX series include the compact twoplaten design, which allows for fast clamping movements and modularity that can be used to select the necessary plasticizing unit, for example, as though it were being selected from an assembly kit. The specially developed GuideX guide shoe which carries the moving platen, guarantees absolute platen parallelism even for heavy molds and has a force- absorbing effect increasing the service life of the molds. The smooth movements also result in very low energy consumption. These inner values make the GX series suitable for both high-volume projects with aggressive cycle times and technically sophisticated applications, such as those in lightweight automotive construction. Today, more electric vehicles are currently on the road in China than in Europe and an increasing number of weight-saving procedures are in demand for increasing their range in the future. The GX can, for example, be combined with FiberForm technology, which involves back-injection of thermoplastically impregnated fiber-reinforced composite materials (refer also to p. 20), or with the MuCell/CellForm physical foaming process, also with compression injection stroke if necessary. In the packaging industry, larger objects such as transport crates, buckets and even disposable products such as end caps for shampoo bottles, can be produced on the machine using multi-cavity molds. The medical sector benefits from the clean room compatibility of the GX series. For example, one customer produces disposable syringes in a stack mold. Customized solutions In addition to the time saved during delivery and during spare parts procurement, another advantage of producing locally in Haiyan is being able to offer prospective Chinese customers customized packages made of machines and peri pherals. For the less technically advanced components of a manufacturing cell such as conveyor belts, the team can make use of local manufacturers and thus offer highly attractive terms and conditions. The cycle time-relevant core components of an automation system, such as the LRX linear robot, will continue to be produced by KraussMaffei. Expanding local sourcing and guiding suppliers towards compliance with the KraussMaffei quality standards is a goal for the next few years, specifically expressed by Sales Director Jörg Wittgrebe. Chinese customers will then receive the best of East and West. YOUR CONTACT: Jörg Wittgrebe Sales Director, KraussMaffei China joerg.wittgrebe@kraussmaffei.com

14 14 Brand & Markets AHEAD Issue JÖRG WITTGREBE TALKS ABOUT TRENDS IN CHINA GROWTH WITH QUALITY Major opportunity for premium suppliers: Plastics processors in Asia are becoming increasingly conscious of quality and actively requiring high-tech features for increasing efficiency and user-friendliness. KraussMaffei s locations in Haiyan and Shanghai, headed by Sales Director Jörg Wittgrebe, are taking advantage of this trend for their own growth. INTERVIEW: DR. SABINE KOB PHOTOS: ISTOCK, KRAUSSMAFFEI AHEAD: How do you feel the Chinese market is developing for KraussMaffei? Wittgrebe: We couldn t be happier. We re finding that even local Chinese companies are placing increasing value on the quality and efficiency of machines. This opens up great potential for additional growth. International customers who, for reasons of consistency, want to run KraussMaffei machines at their Chinese plants, are already familiar with us and what we do. To ensure that we can offer a more comprehensive product range and additional service offerings in the future, we have boosted staffing levels and want to grow even further. AHEAD: What are some special demands that Chinese processors make for their equipment? Wittgrebe: One example is that the desire for an easy-to-use control system is more widespread. Of course, our MC6 control system is a response to this request. It is clearly arranged, user-friendly and features

15 KraussMaffei Brand & Markets 15 intuitive operation. In China, there is no structured training system with different qualification levels like that in Germany, where almost all machine operators have completed apprenticeships. AHEAD: How great is the desire for energy efficiency and sustainability? Wittgrebe: The topic of energy consumption is of primary importance to our customers, because electricity now costs nearly as much there as in Germany. At Pudong Airport, you see power plants everywhere. There is an energy efficiency label for machines similar to the one we have from Euromap, and even local providers are making increasing use of servomotor technology to lower consumption rates. Therefore, processors have a great awareness of the topic and place high value on functions like the Eco button on the MC6 machine control system, which makes it possible to configure the injection molding machine s settings for optimum energy efficiency. AHEAD: Industry 4.0 is a hotly discussed topic in the German-speaking plastics industry. To what extent is the topic also relevant in China? Wittgrebe: I d say that here in China, it s even more firmly established in peoples minds than in Germany. The customers ask us about it and want to know what specific solutions we can provide for networking production JÖRG WITTGREBE, SALES DIRECTOR, KRAUSSMAFFEI CHINA Major opportunity for premium suppliers. systems. Some are focused on the coupling of machine and material supply, as we presented it at the Fakuma trade show. One motivation for Industry 4.0 is increasing wages, but another is the automotive industry s desire to save all process parameters for five to ten years, to enable production to be traced after the fact in the case of damage. This is a great opportunity to position ourselves as a premium manufacturer, because Industry 4.0 requires both first-class machines and correspondingly high-performance control systems and interfaces. We have all that. AHEAD: What are your goals for KraussMaffei China in the next three to five years? Wittgrebe: One milestone will be the opening of our new TechCenter, which will offer training courses and a range of other services to bring us closer to our customers and their processes. In terms of production, after starting with modular machines in standard configuration, we are now able to provide customized Engineered Machines. The next item on the agenda is multicomponent technology. Industry 4.0 requires not only firstclass machines, but the corresponding high-performance control systems and interfaces. We have all that.

16 16 Brand & Markets AHEAD Issue THE MARKET FOR LOGISTICS AND LARGE PACKAGES IN FOCUS PACKED FULL WITH PER- FORMANCE Whether pallets, large bins, crates or buckets the market for logistics and large packages features an incredible level of variety. In making a selection, processors often have entirely different requirements for the injection molding machine and the associated technology. Klaus Zeiler, Head of the Logistics/Packaging (LOG/Pack) Business Unit, talks about current trends and developments. INTERVIEW: PETRA REHMET PHOTOS: KRAUSSMAFFEI

17 KraussMaffei Brand & Markets 17 large number of materials that off-gas aggressively. Here, KraussMaffei offers custom solutions in the area of plasticizing units that offer a high level of protection for the mold and barrel and thus provide extended service life. KLAUS ZEILER, HEAD OF THE LOGISTICS/PACKAGING BUSINESS UNIT The distinguishing feature of the market for logistics and large packages is continuous growth. AHEAD: What industries is the LOG/Pack Business Unit targeted towards? Zeiler: Our customers primarily come from the packaging and logistics industry. Our customer base includes all different types of companies, from small and medium-sized enterprises to large key accounts. What they value most about KraussMaffei is its system expertise, which offers injection molding and automation solutions from a single source. We can also draw from a wide network of mold makers and peripherals suppliers, as necessary. This benefits our customers around the world. AHEAD: Let s stay on the topic of logistics. What do your customers expect in this segment? Zeiler: For logistics applications, such as pallets or large bins like trash containers or containers, for example, it is essential for products to fulfill the required mechanical properties. This requires especially highperformance large machines with fast cycle times. In the MX series, KraussMaffei has one of the fastest large machines on the market, with clamping forces of up to 55,000 kn. With the exceptional repeat accuracy it provides for filling behavior and precision replication, the MX series offers ideal prerequisites, particularly in the high-performance area. AHEAD: What is most important in terms of packaging solutions? Zeiler: In terms of the packaging area, the primary emphasis is on smaller transport packages such as boxes or buckets. Compared to large articles, this area is mostly focused on low item costs. This is where the GX series, the fastest global two- platen machine in the mid-range clamping force segment with forces from 4,000 to 9,000 kn, shines. This enables us to offer short cycle times, thanks to the best machine dynamics and the shortest dry cycle times. Rugged screws also ensure consistently high plasticizing performance. AHEAD: What role does recycling play? Zeiler: The use of recycled materials surely plays an important role in the logistics and packaging industry. For example, trash containers are often produced in sandwich construction, meaning with a core of recycled material and inner and outer shells made of new materials. For this application, KraussMaffei offers solutions perfectly tailored to customer needs with the MX series in a multicomponent design with two or more injection units. For pallets or small transport packages, manufacturers often use recycled material, often as much as 100 percent. The difficulty is that recycled materials include a AHEAD: What markets do you currently believe to have the greatest growth? What are the growth drivers here? Zeiler: In general, we can say that the distinguishing feature of the market for logistics and large packages is continuous growth. High peaks and deep lows, such as those encountered in the automotive industry, are less typical. On a global level, Europe surely provides greater growth opportunities as part of the new hygiene requirements when transporting foodstuffs. In this area, plastic pallets offer significant advantages over wood and thus will replace them to an increasing extent. The standardized Euro crates for transporting meat and sausage products will propel demand. We expect continued strong growth in the US, particularly in the area of logistics. We also expect high demand in the Middle East, Southeast Asia and China. KraussMaffei is in an extremely good position worldwide with its tightly knit sales and service network. YOUR CONTACT: Klaus Zeiler Head of Logistics/ Packaging Business Unit klaus.zeiler@kraussmaffei.com

18 18 Brand & Markets AHEAD Issue KRAUSSMAFFEI CELEBRATES 10 YEARS OF EXISTENCE AT THE VIERSEN AND GEORGSMARIENHÜTTE LOCATIONS HIGH-PERFORMANCE POLY- URETHANE MOLDS AND TRIMMING TECHNOLOGIES Cutting, punching and robotic milling of complex plastic components and premium quality molds for pouring, foaming and back-foaming these are the trademarks of the KraussMaffei locations in Viersen and Georgsmarienhütte, Germany. In the ten years since their founding, they have experienced constant growth and made a name for themselves worldwide. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI I t all started back in October The Reaction Process Machinery department of KraussMaffei decided to build up its own mold area with molding tools and trimming technology. That is how mold toolmaking developed in Georgsmarienhütte, a town in the state of Lower Saxony, and trimming technology developed in Viersen in neighboring North Rhine- Westphalia. Since then, KraussMaffei has been providing its customers with turnkey solutions for automotive interiors and can actively partic ipate in the project management during the vehicle development at a significantly earlier stage. This was the right step and is confirmed by our strong growth. We are globally present with our mold and trimming technology in all automotive markets not only in Europe, but also in China and the US. Today, every two out of three foamed instrument panels, for example, are trimmed using technologies of KraussMaffei from Viersen, states Nicolas Beyl, Managing Director at KraussMaffei. Both locations have continuously expanded in the course of the continuously growing market penetration. Thus, today there are approximately 70 employees working in Viersen and approximately 60 in Georgsmarienhütte. CUTTING, PUNCHING, MILLING The Viersen location of KraussMaffei Reaction Process Machinery features technologies for machining complex plastic components.

19 KraussMaffei Brand & Markets 19 CUSTOMIZED POLYURETHANE MOLDS In Georgsmarienhütte, KraussMaffei develops and manufactures solutions for pouring, foaming and back-foaming polyurethanes. Custom solutions Viersen, the location responsible for trimming, supplies not only the conventional punch press (TrimStar), but also flexible technologies as robot-guided milling and cold-knife solutions (Routing Star). KraussMaffei is one of the few providers on the market that can supply both variants or combinations of them from a single source. In recent years, these technologies have been advanced through intensive development. The TrimStar 3 and Routing Star 4 versions came about this way. Today, every two out of three foamed instrument panels are trimmed using technologies of KraussMaffei from Viersen. NICOLAS BEYL, MANAGING DIRECTOR OF KRAUSSMAFFEI KraussMaffei builds special molds for foaming and back-foaming automotive parts at its location in Georgsmarienhütte. These can be used to implement corresponding processes such as flexible foam, rigid foam, semi-rigid foam and flexible integral foam. Individually designed molds made of various materials are used, depending on the foam application. Investments in the future The success of recent years is paying off, and of course, efforts are being made to ensure that it stays that way. We are happy that for ten years now, we have been able to provide our customers with a very competitive complete package for automotive interiors. To further support the mold making growth, in Georgsmarienhütte we have just invested in an additional 5-axis machining center. Together with our professional team, which we will also be adding to in 2016, we will further expand our position in the automotive interior sector, states Beyl. YOUR CONTACT: Georgsmarienhütte: Volker Krausmüller Plant Manager, KraussMaffei Harderberg/Georgsmarienhütte volker.krausmueller@kraussmaffei.com Viersen: Udo Hafer Plant Manager, KraussMaffei Viersen udo.hafer@kraussmaffei.com

20 20 Processes & Products AHEAD Issue Processes & Products DYNAMICALLY INDUCTIVE MOLD HEAT-BALANCING MAKES IT POSSIBLE ADVANCED SURFACE EFFECTS IN THE ONE-SHOT PROCESS Exciting surface effects with features, such as micro-structures or holograms, are created on injection molding machines from KraussMaffei with inductive DMH (Dynamic Mold Heating) technology from RocTool without the need for any additional film decoration. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI GREATER DESIGN FREEDOM IN DESIGNING COMPONENTS DMH technology ensures perfect surfaces, with features such as hologram structure or glossy appearance.

21 KraussMaffei Processes & Products 21 W hether matte, glossy, structured or with a hologram appearance the design and creative options provided by DMH technology are extremely varied. This provides virtually unlimited freedom for designing and shaping surfaces. The technology is ideally suited for premium-quality visible components such as technical components in the entertainment and household industry or in the vehicle interior, for example. The critical advantage is that the components with the advanced surfaces are created in a one-shot process, without any additional film decoration whatsoever. As a result, additional in-mold decoration steps such as preforming, punching and feeding have been omitted. This not only reduces cycle times, but also cuts running production costs for the film, which are usually higher than the additional energy cost of the DMH technology, says Andreas Handschke, Product and Technol ogy Manager at KraussMaffei. The cavities of the mold inserts feature special laser-applied nanostructures. These provide the desired effects on the surfaces of the later components with corresponding dimensional accuracy of the plastic melt, which is produced using the DMH process. Furthermore, the DMH technology from RocTool, which is part of the company s strategic market campaign HD Plastics (High Definition Plastics ), enables very high temperatures that extend far beyond 400 C. Thus, there are virtually no limits in place for processing poly carbonate. The inductive heating system enables very quick heating phases and, therefore, does not require any close- contour tempera ture control channels. Water is used as a cooling medium via standard heat- balancing units. The water does not generally have to be recirculated from warm to cold and can be supplied via normal coolant holes in the cavity. As a result, energy requirements are low and cycle times do not increase, explains Mathieu Boulanger, CEO at RocTool. Short cycle times, less material consumption this sums up the economic advantages of DMH technology nicely. Although the purchase price of an injection molding machine with DMH technology is higher than that of a film decorating system, the investment pays off very quickly. For example, if we assume a film price of 10 euros/m², the new acquisition will be amortized within a year or two. YOUR CONTACT: Andreas Handschke Product and Technology Manager andreas.handschke@kraussmaffei.com

22 22 Processes & Products AHEAD Issue KRAUSSMAFFEI CUSTOMER TAKATA REDUCES COMPONENT WEIGHT FROM 560 TO 275 GRAMS FIBERFORM HELPS ATTAIN THE DESIRED WEIGHT Lightweight construction technology has never delivered this much weight reduction by over onehalf, with associated shorter cycle times and lower manufacturing costs per component. Automotive supplier Takata attained this in an airbag housing using the FiberForm technology from KraussMaffei. TEXT: DR. SABINE KOB PHOTOS: KRAUSSMAFFEI, ISTOCKPHOTOS EVEN LIGHTER WITH FIBER-REIN- FORCED THERMOPLASTICS The airbag housing produced by Takata using the FiberForm process. F iberform stands for thermoforming and back-injection of thermoplastic semifinished products, known as composite sheets. These semifinished products are first heated, reshaped in the injection mold and then also back-injected with fiber- reinforced materials in this process. The process combines the high amount of design freedom from the injection molding process with the enormous strength provided by fibers made of glass, carbon or aramid that are present in the organic sheet as a roving or mesh. The result is an extremely rugged yet lightweight component that can be produced in short cycle times. The airbag housing contains both the folded airbag itself and the gas generator, and, in case of an accident, must withstand the explosion and the pressure when the airbag inflates. Therefore, parts manufactured in a compact injection molding process need wall thicknesses of up to 3 millimeters. A wall thickness of just 0.5 to 1 millimeter is sufficient using FiberForm. In a period of just one year, a joint project team of Takata and KraussMaffei completely redesigned the housing in three development steps, enabling a weight reduction by one-half. A compact reference part made of polyamide 6 with 40 percent short glass fiber and a part weight of 560 g was the starting point. In the first step, the team used an organic sheet with a polyamide matrix and fiberglass reinforcement to reduce the weight to 330 g.

23 KraussMaffei Processes & Products 23 In a period of just one year, a joint project team of Takata and KraussMaffei completely redesigned the housing in three development steps, enabling a weight reduction of one-half. An additional 55 grams were cut by switching to polypropylene as a material for the organic sheet matrix and injection molding, and by switching from short glass fiber to long glass fiber reinforcement (LGF). This made it possible to reduce the glass fiber content from 40 percent to 30 percent. The scale now reads a fantastically low initial weight of 275 grams. The last goal was an additional cost reduction during injection molding, because longfiber granulates are expensive. This is true of granulates of almost any fiber content. In October 2015, therefore, KraussMaffei introduced an integrated solution at the Fakuma trade show that enables the plasticizing unit to feed equal portions of highly concentrated PP granulate with 60 percent LGF and a polypropylene dilution polymer, and meter it accurately. This alone enables plastics processors to save percent in material costs, while also providing flexibility for adapting the fiber content and developing proprietary recipes. The scale and the conveyor belt are integrated into the CX 300 injection molding machine s standard protective housing in a space-saving manner, as is the organic sheet feeder. Compared to the previous version of the system with LRX-150 handling, the installation area required for the system decreased by 25 percent thanks to the mechanical coupling of both linear robots to a common Z-axis and a longitudinal discharge for the finished parts. The MC6 control system now operates both the scale for checking the shot weight consistency and additionally the infrared oven. It is no wonder that Udo Gaumann, Manager Core Engineering Materials at Takata, evaluated the entire project that redesigned the component and used longfiber granulates positively. In conjunction with the great potential for lightweight construction that the FiberForm technology offers, the invest ment pays off very quickly and can therefore be considered a cost-effective lightweight construction solution. Space-saving multiple kinematics If we consider the manufacturing sequence and the handling of the FiberForm airbag housing, the two robots LRX-350 linear come to mind immediately. They work in parallel and assume the tasks of heating up semifinished fiber components (composite sheets) and demolding the finished components. This cuts cycle times. In addition, a weighing process for checking the shot weight consistency and the placement on a conveyor belt were implemented. YOUR CONTACT: Stefan Fenske Product and Technology Management stefan.fenske@kraussmaffei.com COMPACT PRODUCTION CELL Integration of organic sheet feeder, scale and conveyor belt within the standard protective housing of the CX 300 injection molding machine.

24 24 Processes & Products AHEAD Issue BRIDGING DOWNTIMES IN POLYURETHANE PROCESSING SAFELY AND RELIABLY UP TO 30 PERCENT ENERGY SAVINGS KraussMaffei offers its customers the BluePower product line, a comprehensive concept that gives a lasting boost to processing polyurethane (PUR) and other reaction systems. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI D owntimes are cost drivers, though they are also characteristic features of processing polyurethane and other reaction systems. In many cases, the systems are used to produce components in relatively short runs. Additionally, production is only partially automated in many cases. As a result, the manufacturing process has to be stopped, the component has to be removed from the mold manually and the mold must be cleaned. The mold change also results in frequent production interruptions. During these downtimes, the energy requirement of the system should be reduced as much as possible, says Herbert Adolf, Head of Technology and Service Reaction Technology at KraussMaffei. During regular operation of the system, the energy requirements can be decreased even more by making the process of mixing the reaction components as efficient as possible. The priority now is to bridge these downtimes in the most energy-efficient manner possible. This is exactly where the BluePower program from KraussMaffei proves its benefits. The systems switch the metering pump drives to low-pressure output immediately after the filling process. Furthermore, the complete switch-off of the pump drive occurs after a preconfigured time span if the system is idle. The machines are equipped with a control function for fast pressure build-up so that the complete operating performance can be reached again in almost no time. The agitators and the heat-balance of the container can also be further operated in order to condition the components during pauses in production. Here, KraussMaffei systems provide an adjustable interval mode, which ensures that the temperature and homogeneity of the components remain constant while insuring minimum energy consumption. Optimized mixing heads KraussMaffei also takes advantage of the energy-saving potential present in the mixing heads area. The mixing head hydraulics can be moved or switched off, depending on the process requirement in the bypass operation if the required pressure is reached. The flow-optimized mixing heads and mixing head nozzles from KraussMaffei achieve the highest mixing quality, even with minimum power consumption. The respective mixing head that is optimally adapted to the application is selected from the versatile product range of mixing heads, says Adolf. Motors with IE2 efficiency classes have been used since 2015 (IE3 starting in 2016) in mixing and metering systems from KraussMaffei. There motors achieve the Premium Efficiency value corresponding to the IEC standard. It was possible to reduce the connected load of the drive motors by up to 30 percent through the consistent optimization of the metering pumps and the hydraulic concepts. A pump capacity of 16 liters/min. reduced the connected load from 11 kw to 7.5 kw, for example. The extensive measures that KraussMaffei applies to increase energy efficiency offer great potential. It is possible to attain energy savings of up to 30 percent in specific areas by optimally adapting the machine s individual power requirements to current processes, he explains. Overall, this reduces not only the CO₂ load during production, but manufacturing costs as well. YOUR CONTACT: Herbert Adolf Head of Technology and Service, Reaction Process Machinery herbert.adolf@kraussmaffei.com

25 KraussMaffei Processes & Products 25 LAYER FOR LAYER, AN OPTIMIZED COMPONENT GRIPPING CARRIERS FROM THE PRINTER Single-part production at close-to-series costs the dream of every mechanical engineering company that offers its customers customized solutions. KraussMaffei is making this dream reality thanks to an innovative production technology: 3D printing. The process of selective laser sintering makes it possible to manufacture highly complex components in one-off production. TEXT: JOACHIM WEBER PHOTOS: KRAUSSMAFFEI T he gripper unit in accordance with the old concept is classic mechani cal engineering. Four grippers installed on the metal plate in the desired positions, with safe and reliable function and a weight of 1,400 grams. In accordance with the new concept, the grippers are at exactly the same positions. However, the plastic carrier is a sweeping, elegant design, a customized design part that is free of excess material, with an appearance that is both airy and lightweight. This appearance is completely true. At 720 grams, the entire gripper unit weighs only slightly more than half its fully metallic counterpart. The component was created by 3D printing in a selective laser sintering process. In this process, the parts are built up in layers. To do so, powdered material plastic (polyamide), metal (such as aluminum or titanium) or ceramics are applied in a thin layer to a base plate. Now, a laser (selectively) sinters exactly the area of the powder that corresponds exactly to the desired part form in this layer. This means that it solidifies this area by partially melting the powder particles. After each sintering procedure, the construction platform is lowered by an amount equivalent to the thickness of one layer to apply a new powder layer, which is then also sintered. One advantage of this procedure is complete freedom when designing the workpiece. Cavities and undercuts that are very difficult to access when machining materials can be made as desired. Controlling the process requires only a CAD file that describes the component with three-dimensional geometric data. In addition to the weight and material savings, other advantages make 3D printing attractive for KraussMaffei: The functionally oriented design engineering without technical machining limitations enables new types of optimization, even with highly complex geometries. The new design options make it possible to integrate function elements such as drill holes, threads or channels for the media supply including compressed-air hoses in the case of the gripper directly into the component. The resulting decreased number of subcomponents reduces the installation times of the gripper. Even small quantities can be produced cost-effectively. Depending on the component size, the 3D printer can simultaneously produce many identical, but also different, parts. The nesting of different parts on the pro duction area of the printer results in an additional improvement in the performance. The amount of time required for manufacturing complex parts is reduced drastically. This ensures they are available quickly, even in the event of reordering. 3D-PRINTED GRIPPER The focus here is on the optimized, space-saving design engineering of the gripper geometry. All of these benefits can be attained without sacrificing product quality. KraussMaffei has been working with 3D-printed components since early They have success fully passed their long-term testing including with cyclical tensile and pressure loading of the gripper. Additionally, the components are clean room-compliant and highly temperature-resistant. The 3D-printed parts also impress with high levels of form accuracy and reproducibility. For the time being, however, 3D printing will not be the standard manu facturing process at KraussMaffei. We see it as a very promising alternative to conventional gripper design, which we can use for specific applications and components. YOUR CONTACT: Michael Flurl Product Management michael.flurl@kraussmaffei.com

26 26 Partners & Projects AHEAD Issue Partners & Projects WET MOLDING PROCESS MADE READY FOR SERIES PRODUCTION IN THE NEW BMW 7 SERIES CFRP IN INCREASINGLY SHORTER CYCLE TIMES The new 7 series is the BMW Group s flagship in auto motive lightweight construction. Innovative technologies made it possible to make it 130 kilograms lighter than the previous model. One reason is high-performance carbon elements manufactured in the KraussMaffei wet molding process. Roof bow finisher Rear roof support TEXT: DR. SABINE KOB, PETRA REHMET PHOTOS: BMW, KRAUSSMAFFEI C arbon-fiber reinforced plastic (CFRP) features exceptional rigidity at a very low dead weight. Even where they are exposed to high forces in case of a crash, they comply with the highest safety standards and are an ideal complement to metallic materials such as steel and aluminum. They also demonstrate these ideal properties in the new BMW 7 Series. It is the first vehicle in the BMW Group s classic model portfolio in which industrially produced carbon-fiber reinforced plastic is used in auto body construction not as a visible external skin material, but in the body structure itself in conjunction with high-strength steel and aluminum. Parts made of carbon-fiber reinforced plastic include the roof supports and the reinforcement of the roof frame, the B and C pillar, the spoiler and the center tunnel, as well as the upper luggage compartment divider. The BMW Group entered uncharted territory not only in the body structure, but in other areas as well. The company used a new technology, the wet molding process from KraussMaffei, in mass production for the first time when manufacturing the individual carbon- fiber reinforced plastic components. In comparison to classic RTM processes (resin transfer molding) like HP-RTM (high-pressure RTM) and C-RTM (compression RTM), wet molding is characterized by a simpler process chain in which the preform process is omitted completely. For this reason, wet molding is a cost-effective alternative for manufacturing new lightweight components in vehicle manufacturing. Wet molding offers a cost-effective alternative to manufacturing new lightweight components in vehicle manufacturing. Simplified process chain The process is based on a common feature of conventional production methods for manu facturing fiber-reinforced thermoset in the RTM process. The carbon semifinished product is first given the desired threedimensional geometry in a preforming station, the preform created in this process is then inserted into the mold, into which the low-viscosity plastic usually epoxy resin or polyurethane is injected in the third process step. The fibers are infiltrated with the matrix resin using high pressure (HD-RTM) or compression (C-RTM). During the wet molding process, the sequence is reversed, simplifying the process chain. First, a mixing head applies the resin (usually epoxy resin) onto the flat- lying semifinished fiber product in continuous strips. The fiber product is then passed on to the mold, where it is molded. This process has two decisive advantages. It saves valuable cycle time, because the resin can be applied to one component while the other is simultaneously curing in the mold. It is also possible to use

27 KraussMaffei Partners & Projects 27 WET MOLDING A cost-effective alternative to manufacturing new lightweight components in vehicle manufacturing. a width of 80 and 150 millimeters) in a way that is gentle on the material and without causing fiber to be displaced on the semifinished product. A volume flow meter records the applied quantity precisely. This is important to ensure the required strength of the CFRP components. recycled fibers. Mats made of recycled fibers are similar to a nonwoven material, because the individual fibers are not oriented uniformly as they are in a fabric, but rather distributed in an undirected manner. This random arrangement increases the flow resistance that the ultrasonically welded roving provides to the penetrating resin and closed cavity. This makes wet molding an excellent option for the industrial processing of recycled fibers in the RTM process and, as such, is an ideal fit for the claim of sustainable production. Thus, for example, three standard carbon parts on the 7 Series are made from recycled fibers and 100 percent of the energy required for production is from renewable sources. Center tunnel reinforcement Strong network KraussMaffei delivered a total of five double systems with two mixing heads each, and a complete tank unit for the manufacturing of the 7 Series at the BMW location in Dingolfing. These systems can be used to operate multi-cavities, for example. Highly reactive epoxy resin systems with extremely short curing times additionally require faster application precision and place high demands on pumping and metering technology. KraussMaffei is one of very few providers on the market that produces its own highpressure pumps. This allows the company to adjust the pumps to individual customer requirements optimally. The resin is applied using self-cleaning flat sheet dies (with But technological expertise is not the only key factor for developing groundbreaking system solutions. A well-functioning, global network of sales and service partners is needed as well. For this purpose, KraussMaffei maintains highly strategic partnerships, like with Dieffenbacher for instance, a developer of high-performance compression molds for wet molding and other RTM processes. Erich Fries, Head of the Composites/Surfaces Business Unit in the Reaction Process Machinery segment, is also excited about excellent future prospects, stating that, the demand for lightweight construction solutions ready for series production based on carbon-fiber reinforced plastics is running at full speed, even at the international level. Environmental regulations regarding CO₂ reduction are becoming more and more strict, which increases demands even further. The process of developing new materials and processes is still far from being complete. And KraussMaffei is playing a leading role in all of this. YOUR CONTACT: Erich Fries Head of the Composites/Surfaces Business Unit erich.fries@kraussmaffei.com

28 THE GLOBAL PARTNERSHIP BETWEEN KRAUSSMAFFEI AND SHELL LUBRICANTS PEAK TECHNOLOGY FOR EFFICIENT OPERATION Lubricants and hydraulic fluids are extremely hard at work even if they do not show it out in the open. When two global market and technological leaders get together to continuously further develop products from this group, it is not always because requirements are continuing to grow. Together, Shell and KraussMaffei are always looking for new technical solutions. TEXT: JOACHIM WEBER PHOTOS: SHELL, KRAUSSMAFFEI V irtually no unplanned standstills, long maintenance intervals and a high service life for the systems. That goes without saying for KraussMaffei customers. They can always rely on the robust design engineering that the injection molding mechanical engineering company offers. But design engineering features alone are not enough. The carefree package for system safety also includes a complete package for supplying the system with high-performance hydraulic fluids and with services that make the entire system even more reliable. It is crucial to minimize any kind of friction in the system during daily operation under extreme conditions, with high temperatures and pressures as well as with mechanical movements at high speeds. This is the only way to ensure that forces are transmitted to where they are needed unabatedly and the only way to prevent wear and tear. For centuries, oils and grease have been used to varying degrees of success. Today, highly specialized lubricants and hydraulic fluids are what keep machines running as smoothly as possible. Shell is the international market leader and technological pioneer in this business. The company s incredibly broad product range serves customers in over 100 countries. Moreover, Shell has a network of highly skilled employees with many years of expertise in the industry and extensive knowledge of its applications. Shell s presence on the market and the expertise it has gained over the course of 70 years makes it the ideal partner for KraussMaffei for regarding all lubrication and hydraulics questions, says Harald Tiran from the KraussMaffei Group s Indirect Procurement sector. This is all the more true, because the partnership is not a one-way street. Part of Shell s tradition is collaborating with renowned machine and component manufacturers, who provide input in the form of their own experience as well as expertise of the latest developments and trends in their field, explains Shell Lubricants Expert, Jörg Spanke, Cluster

29 Partners & Projects 29 CUTTING-EDGE TECHNOLOGY Shell is continuously investing in the development of even better lubricant solutions. A SUCCESSFUL PARTNERSHIP From left to right: Alfred Rott, Account Manager Shell, Harald Tiran, Strategic Purchase Indirect, KraussMaffei, Nadine Herzog, Account Manager B2B Industry, Shell. Technical Manager North West Europe. This enables Shell to implement current, practical experiences such as information regarding future requirements into its own product develop ment. The fact that KraussMaffei can access Shell s development laboratory for lubricants and hydraulic fluids in Hamburg is an additional advantage that makes this cooperation so appealing. Global presence, product availability and technical support KraussMaffei customers benefit primarily from this close cooperation. In conjunction with the services and consultations that KraussMaffei offers, Shell s lubricants are a key factor for ensuring that all machine and system parts remain in optimum working conditions, that performance and efficiency increase and that operation and maintenance costs are lowered as a result. This high level of quality is also the case worldwide. Hydraulic fluids by the Shell Tellus are only one example. They are available to all KraussMaffei customers worldwide as part of the global partnership between the two market leaders. The Tellus fluids offer a wide variety of special properties. All of them share the ability to keep the hydraulic system clean and to minimize the risk of valve blockage. Additionally, they are extremely resistant to thermal and chemical decomposition. Shell Tellus S2 MA 46 also features a particularly high level of filterability, even among extremely fine filters, a long fluid service life and consequently long fluid change intervals as well as excellent wear-resistance. This hydraulic fluid has been tried and tested and proven itself for years in machines and systems from KraussMaffei. For this reason, it is now the only commissioning fluid for new injection molding machinery systems, explains Gernot Huster, Head of Development for Hydraulic Systems and Measuring Technology at KraussMaffei. We consider lubricant to be an important component of our overall product. Consequently, KraussMaffei recommends hydraulic fluids from Shell to its customers. Analysis, optimization and savings Furthermore, KraussMaffei is offering its global customers yet another special service. LubeAnalyst is a health check to inspect the condition of the lubricants and thus the condition of machines and systems. It is particularly important as an early warning system, due to the fact that analyzing lubricants and their conta minations enables conclusions to be drawn about potential faults. The procedure is simple. KraussMaffei removes a fluid sample from the customer s machine, which is then analyzed in an independent, certified and specialized lab. The customer receives a diagnosis specifically for its machine as well as recommendations on how to proceed. The basis for both come from experiences saved in the central database, which go back several years. The high number of samples enables comparable patterns to be detected. TECHNOLOGY The Shell Lubricants Research & Development centers focus on four technological core areas: Efficiency Reducing maintenance expenses Increasing the service life of components Cleanliness of machines and systems Overall, Shell and KraussMaffei share the same goals, emphasizes Huster. We are both interested in achieving a high level of efficiency for the machines and systems, reducing maintenance expenses, increasing the service life and ensuring clean operation to the highest degree possible. These form a good basis for a successful partnership. YOUR CONTACT: Gernot Huster Head of Development for Hydraulic Systems and Measuring Technology gernot.huster@kraussmaffei.com

30 30 Partners & Projects AHEAD Issue MODULAR INJECTION MOLDING SYSTEM SOLUTIONS AT THE NEW MERGE LIGHTWEIGHT TECHNOLOGY CENTER ALL-ROUND LIGHTWEIGHT CONSTRUCTION TALENTS ON A SCIENCE MISSION The Free State of Saxony is investing in the lightweight construction technology of the future as part of the German Federal Government s Cluster of Excellence MERGE of Chemnitz University of Technology. An MXW 2500 swivel-plate injection molding machine from KraussMaffei is at the heart of the new MERGE Lightweight Technology Center. Thanks to a wide variety of technical options, it offers maximum flexibility for research and close-to-production prototype manufacturing in the original size. TEXT: PETRA REHMET PHOTOS: CHEMNITZ UNIVERSITY OF TECHNOLOGY, KRAUSSMAFFEI M erge means to blend, unify, join. That is the motto of the German Federal Government s Cluster of Excel lence MERGE Technology Fusion for Multifunctional Lightweight Structures of Chemnitz University of Technology. Its focus lies on merging previously disconnected manufacturing processes using various materials such as textiles, plastics or metals. The goal is researching and developing energy- and raw material-saving lightweight structures for mass production. The new MERGE technology center has been relying on a large machine from KraussMaffei since October The MXW 2500 is a true all-round talent in the area of lightweight construction with its numerous options in material, mold or process selection, and it is certainly unique in the German research landscape in this design and size, explains Georg Holzinger, Vice-President of Technologies at KraussMaffei. Above all, this machine is to be used for conducting research for the automotive industry. The aim is to produce parts of a vehicle with a lightweight design, in an energy-saving way and in serial production. These prototype components can be produced in their original sizes. This is particularly important for industry clients who can test the properties of the parts at a 1:1 scale. The MXW 2500 is a very compact, highperformance production system that is characterized by short machining times, fast cycles and a high output. The series has a modular design and offers a wide range of configuration options. We were deliberate in choosing a large machine with a clamping force range of 25,000 kn, to be able to represent large components with measurements of up to 1.5 m x 1.5 m at its original scale, says Prof. Dr.-Ing. Lothar Kroll, Director of the Institute of Lightweight Structures (IST) at Chemnitz University of Technology and Coordinator of the MERGE Cluster of Excellence. THE GRAND OPENING OF THE NEW KRAUSSMAFFEI INJECTION MOLDING SYSTEM IN THE MERGE TECHNOLOGY CENTER (from left): Georg P. Holzinger (Vice President of Technologies KraussMaffei), Dr. Eric J. Amis (Dean, College of Polymer Science and Polymer Engineering, University of Akron), Prof. Lothar Kroll (Coordinator of the German Federal Government s Cluster of Excellence MERGE and Dean of the Department of Mechanical Engineering), Eberhard Alles (Chancellor of the Chemnitz University of Technology), Dr. Micaela Schönherr (CFO of the KraussMaffei Group), Samuel D. DeShazior (Deputy Mayor of Economic Development, City of Akron) and Stephen Kidder. Custom-made multi-component injection molding The W in the MXW 2500 machine designation stands for Wendeplattentechnik ( swivel plate technology). A significant increase in cost-effectiveness in multi-component injection molding can be achieved using the SpinForm design from KraussMaffei. This allows you to double your output of multi-component parts compared to turntable molds at the same clamping force. Even new components with particularly large dimensions

31 KraussMaffei Partners & Projects 31 PARTS FOR THE CARS OF TOMORROW are created on an MXW 2500 injection molding machine from KraussMaffei at the new MERGE Lightweight Technology Center of the Chemnitz University of Technology. The MXW 2500 is a true all-round talent in the area of lightweight construction and its design and size is certainly unique in the German research landscape. can be functionalized this way. With the TwinForm variant, KraussMaffei created an additional solution with a special multi-daylight mold that also ensures noticeably higher production. An additional bolt-on unit in an L design enables the flexible, additional metering and processing of thermoplastics as well as thermo set matrix materials. An additional mixing and metering system also enables the processing of poly urethanes with fillers and other reactive matrix materials. The system is equipped with a colormetering unit directly on the mixing head and an additional nucleation unit. This offers maximum flexibility during prototype manufacturing. Even lighter with MuCell and FiberForm The new MERGE research system is also designed for what is called the MuCell process. The MuCell process is a physical foaming process with nitrogen or carbon dioxide. The advantages of the foamed components are their light weight, decreased warpage, higher dimensional stability and short manufacturing times. Close-to-production manufacturing of prototypes in the field of thermoplastic lightweight construction with fiber-reinforced plastic is possible thanks to the FiberForm option, which was installed as an add-on by KraussMaffei. In this process, impregnated fabric or roving made out of continuous fiber, what are called fiber components, are heated, shaped in the injection mold and subsequently back-injected with a thermoplastic matrix. Like injection molding, the FiberForm technology from KraussMaffei is easy to automate and can be used in fully automated production. A sophisticated automation solution The streamlined automation solution conceptualized by KraussMaffei for this system offers a high degree of flexibility and support for this process. Four LRX robots have been replaced by two LRX500-TwinZ robots. This type of robot (TwinZ) couples two x/y kinematic units each to the z-axis mechanically. Both robots can be programmed and operated using the multiple kinematics control concept. Integration of up to 24 axes is possible. Despite the size and complexity, this automation solution has been implemented in a way that optimizes the available space and enables a high degree of operating convenience. This enables the robots to discharge the parts on the operator rear side and the injection molding machine remains completely accessible on the operator side. This sophisticated solution also required the additional injection molding machine bolt-on unit (in the L design) on the operator rear side. The workstations for feeding insertion parts and depositing the finished parts are located on a platform above the bolt-on unit. This spatial separation enables both systems to be operated optimally. All processes whether SpinForm, TwinForm, MuCell, FiberForm or automation as well as the MXW 2500 can be operated centrally via the MC6 control system. This also eases the operation of complex processes tremendously, emphasizes Professor Kroll. YOUR CONTACT: Georg Holzinger Vice President of Technologies georg.holzinger@kraussmaffei.com

32 32 Partners & Projects AHEAD Issue POLYTEC PLASTICS RELIES ON THE SYSTEM EXPERTISE OF KRAUSSMAFFEI COMPLEXITY MADE EASY A sophisticated production system needs is to be created. Injection molding with various metal inserts and downstream in-line quality checks for flashing to ensure the seal is good. A project such as this can involve contacts with many companies. Or just one, if you take advantage of the system expertise of KraussMaffei. The automotive supplier POLYTEC PLASTICS GmbH & Co KG in Lohne, Germany, a POLYTEC GROUP company, has done just that and is thrilled with the 25 percent efficiency increase. TEXT: DR. SABINE KOB PHOTOS: KRAUSSMAFFEI T he POLYTEC GROUP, which has about 4,200 employees at 25 locations in twelve countries, manufactures components for the automotive industry and, in the process, has gained a great deal of expertise in the area of the engine bay. The technological demand in the powertrain area is substantially higher than in the interior, because the complex interaction of temperature resistance, weight, acoustic capacity and modular design in the narrow engine bay repeatedly presents great challenges to the development and production of functional plastic parts. POLYTEC operates as a successful development partner and system provider for large automakers; the largest customer is the VW Group. Significantly increased productivity At the Lohne location in Lower Saxony, another production cell was needed for manufacturing oil pans, but a significantly higher level of productivity was desired compared to their existing system. As a result, the requirements specifications required a high degree of automation combined with low space requirements and robust processes. Accordingly, the KraussMaffei project team collaborated with the customer POLYTEC to develop a process in which six-axis robots feed and load various sleeves, threaded pins and bushings, and then prepare them on a rotary table with correct mold spacing. There, an LRX-1000 linear robot takes them and places them into the mold, which is installed in a GX from KraussMaffei. The LRX removes the finished oil pan, the sprue is separated and the component is transferred to another six-axis robot. An in-line camera check is carried out there. All sleeves and bushings are checked to make sure they are present and to detect flashing. The latter could impair the seal of the oil pan. A conveyor belt with a cooling section then transports the OK parts to the area for further processing. A critical timeline The concept was appealing and so was the flexibility of the KraussMaffei employees because, as is so often the case, the timeline was critical. Concerning this, Michael Benzien, Head of Purchasing at POLYTEC PLASTICS, said, The long procurement times on the market are a big challenge for us. We need providers with pro-active sales, to whom we can say, We are planning a new system concept; start thinking about potential ways of using it, because by the time we are able to set the specific order, it is usually too late for the start of production defined by the customer. KraussMaffei supported us greatly in this. Now the system runs in three-shift operation and autonomously for up to three hours. Our availability is at 96 percent; the increased productivity we hoped for has been met. Jörg Kippermann, Head of Operations at POLYTEC PLASTICS explains, Our productivity has increased by 25 percent. The optimum coordination of all individual components is a major factor here. They work together like clockwork. Even the control panel of the PLC control system was adapted to the MC6 control system design to give the user a comprehensive feeling of control. Complex processes In the case of such complex manufacturing sequences, injection molding itself represents just one, however critical, step, which is why the requirements for employees change. Gerd Tönjes from Launch Management at POLYTEC PLASTICS explains, We are increasingly Three-shift operation up to 3 h autonomously 96% availability 25% increased efficiency GOOD COLLABORATION The teams from POLYTEC and KraussMaffei worked hand in hand from the start.

33 KraussMaffei Partners & Projects 33 requiring our colleagues to understand the complex processes of injection molding, and when it comes to readjustments, we now rely more on mechatronics and electronics engineers than on just process engineers. This is because the productivity of the systems can be utilized optimally only if you are able to understand and control the entire sequence. Systems that are extremely productive, awaken the desire for more. As the logical consequence, the successful model will be multiplied. At the POLYTEC location in Tianjin, China, the same production line is currently being built without sacrificing automation, as one might expect considering lower employee wages. The desire for process reliability and guaranteed functionality at POLYTEC exceeds the striving for savings, especially since it pays off when in-house technicians worldwide find a trusted standard. The oil pan is delivered to a global model platform, and the demand for international delivery capability placed by the OEM on its first-tier POLYTEC is also conveyed to the machine partner. Michael Benzien explains, The fact that KraussMaffei is globally represented with manu facturing and support was extremely important for us. In the future, processes are to be developed jointly with the employee team in Tianjin as well as in Lohne, and then be installed on-site locally. For that, POLYTEC needs partners who are positioned just as strongly in the target markets. Providing added value Hiltrud Wilke-Bröring from Central Purchasing Investments knows that the collaboration between POLYTEC and KraussMaffei has stood the test of time since the company s founding in the 1980s, and states, We especially value the good service and the procurement of spare parts at very short notice. KraussMaffei provides a clear added value with services like that. YOUR CONTACT: Michael Flurl Product Management michael.flurl@kraussmaffei.com

34 34 Partners & Projects AHEAD Issue AUTOMOTIVE SUPPLIER FRITZMEIER RELIES ON HP-RTM TECHNOLOGY FROM KRAUSSMAFFEI FIT FOR LARGE SERIES Producing CFRP components in large-scale series is a standard made possible thanks to the market launch of electric cars such as the BMW i3, as well as many other factors. The HP-RTM process (high-pressure resin transfer molding) from KraussMaffei supports processors on their path towards increased automation and short cycle times. TEXT: PETRA REHMET PHOTOS: KRAUSSMAFFEI WHEN THE CHEMISTRY IS RIGHT (from left.): Wolfgang Rößler (KraussMaffei Sales), Florian Kirschner (CFRP Production Area Management at Fritzmeier) and Stephan Fraunhofer (Development Management at Fritzmeier) with the cowl from a BMW i3.

35 KraussMaffei Partners & Projects 35 KraussMaffei produced a system solution perfectly designed to our requirements. STEPHAN FRAUNHOFER, HEAD OF DEVELOPMENT AT FRITZMEIER F ritzmeier Composite GmbH & Co. KG relies on increased automation and short cycle times. The auto motive supplier develops and produces a wide variety of top-class components based on fiber- reinforced composites at its Bruckmühl location in Bavaria. The list of well-known references includes large automakers such as BMW (particularly the BMW i3 and the Mini) Mercedes-Benz and Rolls- Royce. In 2014, the company invested in another HP-RTM machine from KraussMaffei and produced, among other creations, carbonfiber- reinforced components for the bodywork of the BMW i3. Very short cycle times were a requirement for the design of the new HP-RTM machine. KraussMaffei produced a system solution perfectly designed for our requirements, explains Stephan Fraunhofer, Head of Development at Fritzmeier. The result is a customized HP RimStar Compact in the design of a four-strand machine with four mixing heads. Two presses can be operated at a time using this machine. By using switchover units, two presses with dual cavities can be operated by using a single four-component machine. This prevents the need to invest in an additional metering system. Highly reactive epoxy systems An additional challenge was the matrix material used, which is a highly reactive and particularly corrosive epoxy system. The special distinguishing characteristics start with the selection of the axial piston pumps, which move the material to the mixing and metering systems. Here, Fritzmeier benefited from the inhouse pump manufacturing of KraussMaffei. By manufacturing our own pumps, we are able to adapt them directly to the customer s requirements so that the machine can operate with a higher level of efficiency, explains Erich Fries, Head of the Composites and Surfaces Business Unit at KraussMaffei. As the only provider on the market, KraussMaffei has been producing the pumps in-house since 2010, allowing for a quick, individualized response to the needs of a customer. station, complete the efficient mixing head system. Systems with demanding processing temperature requirements can be metered to perfection with RimStar high pressure RTM metering machines. High-pressure engineering ensures that the components are thoroughly mixed in the mixing head. Many years of experience and expertise are paying off Fritzmeier benefited from both the technical advantages of the RimStar systems as well as KraussMaffei s many years of the experience and expertise when designing the suitable HP-RTM system. We appreciate the many years of experience and highly skilled consultation services that KraussMaffei provided throughout the entire project phase. As a result of their efforts, we have received a customized system solution that gives us a clear competitive edge, says Florian Kirschner, Head of Production at Fritzmeier, in praise of the close collaboration. The RimStar series mixing and metering systems from KraussMaffei are also optimally designed for processing of fast-reacting epoxy systems. The specific defining features are the flexibility and high product quality with low scrap rates. High-pressure injection using the RimStar series enables fast-reacting resin systems to be processed. This makes it possible to quickly fill the mold for fiber-reinforced components to the benefit of shorter cycle times, explains Fries. The RimStar Compact 8/4-8/4 HP-RTM at Fritzmeier is equipped with four MK 102K-RTM mixing heads. This allows for the perfect premixing of resin and hardener and works according to the self-cleaning principle. Release-agent metering at the mixing head, including the corresponding release agent READY FOR SERIES PRODUCTION Fritzmeier uses the HP-RTM machine from KraussMaffei to produce a variety of products, including carbon-fiber reinforced components for the bodywork of the BMW i3. YOUR CONTACT: Erich Fries Head of the Composites/Surfaces Business Unit erich.fries@kraussmaffei.com

36 36 Partners & Projects AHEAD Issue ACHIEVING PEAK PERFORMANCE AS A TEAM HIGHLY EFFICIENT PRODUCTION STREAMLINED TRANSPORT CRATES FOR SOUTH AFRICA MCG Industries is one of South Africa s leading suppliers of rigid plastic crates mainly for the brewing, beverage and dairy industries. By acquiring three MX injection-molding machines from KraussMaffei, MCG significantly improves cycle times and energy consumption, which ultimately improves its competitive advantage. TEXT: JOACHIM WEBER, PETRA REHMET PHOTOS: KRAUSSMAFFEI A s a result of the continuous increase in raw material prices, due mainly to weakening exchange rates, and an increase in overheads such as energy and labor costs, South African manufactures are struggling to meet customer expectations on price. With antiquated machines that are unable to run modern twin-cavity molds, little can be done to reduce the cost of the crates. Further more, energy costs, especially electricity prices, have increased dramatically over time due to the unrealistic low prices South Africa benefited from over the years Schoeller Allibert, KraussMaffei and its South African representative, P&CT, developed a solution perfectly tailored to our requirements. IAN VICTOR, MANAGING DIRECTOR AT MCG and capacity constraints, which has led to major upgrades and new investment requirements. Based on these facts, MCG has put a strategy together to not only invest in the machines but also in more sophisticated molds, which should allow MCG to manufacture crates far more efficiently. Due to the considerable investment of buying these machines and molds, it was important to ensure maximum value be extracted from this acquisition. Therefore, MCG decided to dedicate a machine to a new, highly sophisticated twin dairy mold as a pilot project, which would evaluate the success of the strategic objective. The services of Schoeller Allibert and KraussMaffei were required for this specific pilot project. The specifications for this new injection-molding machine needed to meet the objective of more output for less cost without ignoring quality, longevity, being fit for purpose or having a more modern look. SHORT DISTANCES The mold s optimized media supply with water and fluid. The first milestone For this reason, the mold was the first area under scrutiny. The guideline read, We want the best, most productive mold available for these types of applications. This is where mold maker Schoeller Allibert, a company known around the world for developing innovative reusable packaging products, entered the picture. Schoeller Allibert proposed a twin-cavity mold similar to those used in the brewing business to achieve this objective. This type of mold was a first for MCG dairy products and would ultimately improve MCG s market share.

37 KraussMaffei Partners & Projects 37 A SOPHISTICATED COMBINATION In terms of a twin-cavity mold, the large MX machine offers optimal utilization of platen dimensions and clamping forces. As a result of the type of mold that Schoeller Allibert was proposing, a special molding machine was required with a higher than usual specification. Schoeller Allibert recommended KraussMaffei as the machine supplier for this project, due to their long-standing working relationship and its confidence in KraussMaffei s capability to meet the specifications required to achieve the objectives. The large MX type offered by KraussMaffei fit the bill perfectly. In terms of a two-cavity molds, this injection molding machine offers optimal utilization of platen dimensions and clamping forces at an excellent price/performance ratio. The on-site service and a training concept required for MCG employees, ranging from the operator to the Production and Engineering managers, was an important key element for KraussMaffei to consider when choosing the machine. The target-oriented solution The additional non-standard technical components supported MCG s requirements and allowed for very short cycle times and low energy consumption. These components, such as the HPS barrier screw being installed in the MX machine, provide exceptionally high throughput with excellent melt quality and shorter cycle times with 20 percent lower energy consumption. The insulating sleeve around the injection unit offers even more potential for energy savings. It reduces the heat-up time by 20 to 30 percent. The total heat energy required drops by 20 to 40 percent. Schoeller Allibert, KraussMaffei and its South African representative, P&CT, developed a solution perfectly tailored to our requirements. We were amazed at how effectively they worked together, says Ian Victor, Managing Director at MCG. The combination of a precisely configured machine and a high-tech mold allowed us to implement a wide variety of objectives simultaneously, such as short cycle times without warpage or sink marks. Warpage and sink marks can only be eliminated by a very uniform melt flow with very short injection time. The machine from KraussMaffei played a significant part in making this possible, says Stefan Scheuerer, Director of Sales Africa for Schoeller Allibert, in lauding his project partner. The success could be measured readily because MCG had specified a cycle time of 30 seconds, quite a challenge for a product this size (424 x 334 x 310 millimeters). At machine acceptance, KraussMaffei was able to run a stable process at a cycle time of 28 seconds. This investment has already paid off. This molding machine as well as the other two have become a success story for MCG, said Victor. Victor has nothing but praise for the machines, the new system has given us a true leap forward in technology. In the future, MCG will expand the production of milk crates, as well as other sectors, to new countries and is looking forward to once again utilizing proven expertise in mold making and injection molding technology provided by Schoeller Allibert and KraussMaffei. ON THE ROAD TO SUCCESS TOGETHER The teams of MCG, KraussMaffei, Schoeller Allibert and P&CT. YOUR CONTACT: Fabian Lewicki Regional Sales Manager at KraussMaffei fabian.lewicki@kraussmaffei.com

38 KRAUSSMAFFEI IS RESPONSIBLE FOR A RESEARCH PROJECT ON OPTICS MANUFACTURING BETTER LIGHT WITH OPTISYS Anyone who wears glasses is aware of this phenomenon: the higher optical power required or the larger the frames, the thicker the lenses. The automotive industry faces similar problems. Steadily increasing sales figures and headlights with more and more advanced shapes pose new manufacturing problems. For this reason, KraussMaffei is the coordinator of the OptiSys research project. TEXT: DR. SABINE KOB PHOTOS: FOTOLIA F unded by the German Federal Ministry of Education and Research, the OptiSys project, which began in June 2015, researches how to manufacture thick-walled optics in a cost-effective manner by using multilayer, multi- material injection molding and by implementing optically functional microstructures with high aspect ratios (height to width) on the lens surface. The reason for this project is the impending spread of LED headlight in the automotive sector. It will be necessary for future developments to set themselves apart from the international competition by providing complex, visual components with new functions. At the same time, it must be possible to produce these components in a highly costeffective manner, especially for the large market of middle-class cars. Optically superior lenses are now to be created using multiple layers with different refractive indexes. For this purpose, each of the six OptiSys project partners are addressing and researching questions for which they have gained the necessary expertise during their day-to-day business. Hella, global supplier of lighting technologies for the automotive industry, is carrying out a requirement analysis and is responsible for the visual design of the planned demonstrator as well as the required light and application tests. In the next step, injection molds and production systems are being conceptualized. FWB Kunststofftechnik is providing the component design that is suited for plastics and is designing the multi- cavity mold. Kugler is responsible for implementing visually effective high-aspect structures with its experience in the area of ultra-precision and micro-processing. Simcon, the renowned manu facturer of simulation software, is investigating the layer structure and process parameters in simulations. The Fraunhofer Institute for Mechanics of Materials IWM is researching how thin-layer thermocouples can be applied and be used for process monitoring. The Institute also supports Kugler in the direct diamond processing of steel. KraussMaffei is configuring an integrative manufacturing cell for manu facturing the multilayer lenses in a two-component injection molding process. Moreover, it is devel oping the fundamentals of the process for optics production and is supporting the project partners in coordinating all individual steps. The goal is to work together and produce a demonstrator that can be manufactured in a cost-effective manner, thanks to its multilayer design while simultaneously being superior to lenses that are available currently as a result of its optical characteristics. These characteristics could be, for example, an improved cut-off line or the light remaining more consistent in its color mixture when heating up the lens compared to earlier. OPTISYS Run time: June 1, 2015 May 31, 2018 Sponsor: VDI Technologiezentrum GmbH Project partners: KraussMaffei, Hella KGaA, Hueck & Co, FWB Kunststofftechnik GmbH, Kugler GmbH, Simcon kunst stofftechnische Software GmbH, Fraunhofer Institute for Mechanics of Materials IWM YOUR CONTACT: Martin Würtele Head of Technology Development martin.wuertele@kraussmaffei.com

39 KraussMaffei Imprint 39 STRONG TOGETHER AND UNIQUE ALL OVER THE WORLD The KraussMaffei Group is among the globally leading manufacturers of machines and systems for the production and processing of plastic and rubber. IMPRINT Publisher: KraussMaffei Technologies GmbH Krauss-Maffei-Strasse Munich Germany Phone Fax BRANDS The KraussMaffei Group, with its three product brands KraussMaffei, KraussMaffei Berstorff and Netstal, can thus cover the complete range in machine construction for the plastics and rubber processing industry and serve customers on an individual basis The fascination and passion for mechanical engineering can be traced back continuously through the history of the KraussMaffei Group to Responsible: Imre Szerdahelyi (responsible for content according to German media law) Editor-in-chief: Ashenafi Shawl Editorial team: Stefan Fenske, Michael Flurl, Erich Fries, Manfred Holzner, Dr. Sabine Kob, Anna-Maria Meyer, Jochen Mitzler, Petra Rehmet, Dr. Reinhard Schiffers, Joachim Weber Photo credits: BMW, Fotolia, istockphoto, KraussMaffei, Shell, TU Chemnitz Automotive Construction Major appliances Chemicals industry Our international customers come from an extremely wide variety of industries. Electrical and electronics Consumer goods Medical and pharmaceutical 10 PRODUCTION FACTORIES KraussMaffei 4,500 PEOPLE KraussMaffei Group KraussMaffei Berstorff 1,200 PATENTS Netstal Concept and design: Kirchhoff Consult AG, Hamburg, Printing: omb2 Print GmbH, Munich The customer magazine is published twice a year in German and English. The magazine may only be reprinted with the written permission of the publisher. APRIL OCTOBER 2016 TRADE SHOW CALENDAR Chinaplas, Shanghai, China KraussMaffei Group Plastpol, Kielce, Poland KraussMaffei Group Open House KMC, Florence, USA KraussMaffei Group PU China, Shanghai, China KraussMaffei China Composites Expo, Shanghai, China KraussMaffei Colombiaplast, Bogotá, Columbia KraussMaffei K2016, Düsseldorf, Germany KraussMaffei Group

40 Surface RTM Technology Fiber-reinforced, paintable surfaces such as roof elements, door inner panels, trunks or engine hoods AHEAD THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI AHEAD RTM Technology Structural and semi-structural components such as underbody structures, side frames or seat structures Issue Wet molding RTM Technology Semi-structural components made of recycled carbon fibers, e. g. hybrid components THE CUSTOMER MAGAZINE OF KRAUSSMAFFEI INDUSTRIAL (R)EVOLUTION CUSTOM-MADE NETWORKING WITH PLASTICS 4.0 IMC Technology Fiber-reinforced, structural components such as front ends, mounting supports, instrument panel carriers FiberForm Technology Continuous fiber-reinforced components such as crash elements, B-pillar reinforcements or seat structures Fiber composite solutions for advanced lightweight components Engineering Passion WET MOLDING PROCESS MADE READY FOR SERIES PRODUCTION CFRP IN INCREASINGLY SHORTER CYCLE TIMES Issue