Application expertise

Transcription

1 Overview Application expertise Customized use of innovative processes

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3 ARBURG - always the perfect solution Our promise: individual consulting and modern production solutions from a single source. Our home: since 1954, innovative solutions for efficient plastics processing have been developed at ARBURG s headquarters in Germany s Black Forest. From one-off parts to small orders or high-volume series: we are your expert partner for production-efficient plastics processing. Our modular product portfolio can be adapted to every individual need. These range from ALLROUNDER injection molding machines and turnkey systems to industrial additive manufacturing with our freeformer: as a technology and system partner, we always focus on the entire value chain, regardless of the sector you are involved in, the processes you use, or the parts and quantities you want to manufacture. You can always rely on ARBURG to provide the perfect individual production solution. Modular technology made in Germany Ever since ARBURG began processing plastics, this has been done with the aim of perfecting technologies and processes. Our main goal is your production efficiency and therefore your cost-effectiveness. This is made possible by products that we manufacture and continuously develop exclusively at our headquarters in the Black Forest under the most stringent quality criteria. In addition, we always advise you as equal partners with our unique know-how mix. Whether you need injection molding or industrial additive manufacturing, a single machine or a highly automated turnkey system, pragmatic industry 4.0 solutions or a digitally networked smart factory, we are there when it comes to efficient plastics processing. Finding the perfect solution together ARBURG is committed to extensive pre- and after-sales services. An extensive network incorporating the parent factory, subsidiaries and international trading partners brings our technology and services quickly and efficiently to all our customers. Our specialists will support you right from the start - from product and mold design, through the planning, design and commissioning of production technology, through to process integration and production planning. We will be at your side, whether a machine needs to be serviced, you urgently need a spare part, or require support for special challenges. Further information: Image brochure 3

4 Versatile: multi-component technology Adapted: arrangement of the injection units in accordance with the mold concept. Fully hydraulic to fully electric The modular ARBURG product range comprises hydraulic and electric drive concepts. The movement axes, as well as the injection units, can be moved completely independently from one another thanks to hydraulic accumulator technology or servo-electric drive. Reproducible mold filling and particularly high molded part quality are achieved by means of the position regulation of the screws provided as standard. Wide variety of combinations Cylinder modules for thermoset, silicone and micro-injection molding are available, as are screws with special geometries. The processing of all possible material combinations can thus be achieved. In addition to the horizontal ALLROUNDERs, vertical and rotary table machines are also available for the encapsulation of inserts. Opting for multi-component injection molding technology from ARBURG, allows you to draw on an extensive standard range of technology which leaves nothing to be desired, both in terms of clamping force/injection unit combinations and drive alternatives. As a user, you will find the right machine and equipment for your specific part requirements within this broad range. Our offerings are complemented by practice-oriented accessories such as separate rotary or indexing units, integrated robotic systems, as well as comprehensive application technology consulting and project planning. Our competence brings you significantly more success! Further information: Multi-component injection molding brochure 4

5 Flexible configuration Several different positions of the injection units with respect to one another are possible. These are freely combinable, as the mold and process technology requires. Solutions with up to six components have already been realized. Central user interface With the SELOGICA control system, users have direct access to all parameters, including those of all the injection units. All mold functions and robotic systems can be programmed via the graphic sequence editor in the same way as additional machine axes. Complex sequences are made transparent and comprehensive process optimization is ensured. In the case of multi-station molds, for example, start-up and running empty can be programmed both freely and easily. This also applies in conjunction with robotic systems and when not all injection units are in use. For quality assurance purposes, the parts status is communicated from station to station. This allows reject parts to be reliably detected. An additional benefit: there is only one data set for the complete production unit, including accessories such as rotary units or robotic systems. Individual solution: flexible combination of injection units. 03/

6 Precisely tailored: silicone injection molding Perfect HTV processing The INJESTER tamping devices have been developed for the automatic feeding of paste-like materials. They contribute towards optimum pre-compression and to minimizing air and gas occlusions. This keeps the articles free from voids and their surfaces flawless. Here, ARBURG offers a variety of INJESTER versions with hydraulic pistons and servo-electric conveying screws. Effective LSR processing Additional sealing of the cylinder module ensures the necessary cleanliness during LSR processing. In addition to an open nozzle, a number of needle shut-off nozzles featuring a standardized hydraulic drive are available. A single cold-runner nozzle also enables direct injection and consequently sprue-less part production, without requiring a moldside cold runner system. Bubble-free HTV feed: INJESTER tamping device processes solid blocks. The quality and cost-effectiveness of your production can only be as good as the components you use. You can fully rely on ARBURG injection molding technology for the processing of liquid or solid silicones. Everything from a single source: the ALLROUNDER machine, which is precisely adapted to your LSR or HTV application, plus any dosage, vacuum and removing technology or complete automation solutions that you might require. For this purpose, we work closely with the applicable leading manufacturers within the sector. With our comprehensive process expertise, we can save you a great deal of work. This way, you don t have just any production solution, but the very best one, at your disposal. Further information: Silicone injection molding brochure /2018

7 Adapted plasticizing Special technology is required to ensure correct feed of the LSR or HTV material, as well as precise dosage and injection. For constant thermal conditions, the cylinder module and nozzle feature multi-zone liquid temperature control. Premature cross-linking of the material is thereby effectively prevented. The zero-compression screw with a special non-return valve is adapted to the processing requirements at hand. Reliable evacuation An important technique for smooth silicone processing is air evacuation of the mold prior to injection. With the SELOGICA control system, evacuation can be programmed with great flexibility thanks to dedicated symbols, whereby integration of all common vacuum concepts is possible. Moreover, SELOGICA also utilizes signals from vacuum devices for process and quality control. System solutions for LSR and HTV ARBURG also offers modular system solutions for silicone processing. This ensures the implementation of individually tailored concepts, which are efficient throughout. In some cases, an ALLROUNDER with processspecific equipment might be sufficient. In others, a complex automation cell with quality assurance and/or packaging stations may be the perfect solution. Sophisticated system solution: entire LSR technology from a single source. 03/

8 Suited to specific material: thermoset processing Special: compression-free screws with adapted channel depth. Special cylinder modules ARBURG has introduced adapted injection units for granular thermosets and moist polyesters (BMC) into its modular range of technologies in order to fully meet the requirements for thermoset processing. A high level of production quality is achieved through liquid temperature control with up to four zones and separate temperature control for the feed. Bimetallic cylinders ensure a correspondingly long service life, while special screw geometries ensure optimum preparation of the material. Particular attention has been paid to minimizing return flows during injection and maintain holding pressure. The clearance between the screw and nozzle is adjustable to prevent excess material here. During BMC processing, temperature-controlled cold-runner radius nozzles ensure short sprues. Special materials require special machine technology. The same applies to thermoset processing. Here we offer you an efficient combination of our proven hydraulic ALLROUNDER machines and a practical thermoset package. The addition of the universal high performance of our SELOGICA control system and our extensive experience in application technology enables us to offer you just what you expect from us: perfect technology for smooth production from the start. Further information: Thermoset injection molding brochure 8

9 Gentle BMC feed The INJESTER tamping devices have been developed for automatic feeding of dry materials with a high filler content. They contribute towards optimum pre-compression, thus minimizing air and gas inclusions. This keeps the articles free from voids and their surfaces glossy. Here, ARBURG offers several INJESTER versions with hydraulicpiston and servo-electric conveyor screw. What they all share in common is full integration in the SELOGICA control system. The conveying pressure is programmable and the material reservoir can also be filled without difficulty during production. Furthermore, the delivery pressure in INJESTER screws is regulated. Reliable venting The venting of cavities is crucial during thermoset processing. It provides an effective means of allowing air and cross-linking gases to escape. As a result, the surface is not scorched and complete mold filling for voidfree components is guaranteed. Both single and multiple venting operations can be programmed via the SELOGICA control system, even during the holding pressure phase. Integrated solution: INJESTER screws for high-quality series production. 9

10 Cost-efficient: powder injection molding Cost saving: short sprues thanks to extended nozzle length. Reproducible operation Reproducible mold filling and particularly high molded part quality are achieved by means of the unique position regulation of the screws. This minimizes reject parts. With ARBURG, the non-return valve can be configured according to the relevant particle size of the powder, ensuring a high degree of process stability, even in the case of coarse powders. The geometry of the PIM screws is always designed for the necessary low compression. Overheating and decomposition of the feedstock is thus reliably prevented. Sprues are kept short through extension of the PIM nozzle length. The expensive feedstock is optimally utilized and the molded parts are always perfectly compressed. Owing to the abrasive properties of the powder/binder melt, the injection unit is designed to be extremely wear resistant. With the injection molding of powdered materials (PIM) you have access to a technology that offers new design options for highly complex components made from metal (MIM) or ceramics (CIM). The process technology does not differ significantly from the processing of filled plastics. This especially applies to consistently high-quality during volume production. Faults in the molded part such as cracks, for example, can no longer be remedied during subsequent debinding and sintering. We consequently place great value on reproducible, flawless injection molding production. Only then you as a PIM producer can be on the safe side and smoothrunning production be ensured. Further information: Powder injection molding brochure /2018

11 Wide variety of options In principle, all ALLROUNDERs are suitable for powder processing. The machines can be individually adapted by means of different hydraulic and electric expansion stages various arrangement options for the injection units, e.g. for multi-component injection molding task-specific equipment packages e.g. for gas injection molding technology or in-mold lamination of green sheets. Complete solutions precisely adapted to the applications are created by means of integrated robotic systems, e.g. for gentle handling of the fragile molded parts, the socalled green compacts. In-house PIM laboratory At ARBURG s unique PIM laboratory, all the important process steps from feedstock mixing and testing, preparation and injection molding through to debinding and sintering of the molded parts can be carried out under practical conditions. Furthermore, detailed consultation is available from our experienced specialists e.g. on suitable powder/binder mixtures. Integrated solution: production cell for first rate powder processing and gentle handling of the sensitive green compacts. 11

12 Multi-faceted: clean room technology Low-emission technology The high-grade standard equipment of the ALLROUNDER effectively combats contamination and emissions. The machines come with an abrasion and scratch-resistant powder-coating as standard. Liquid-cooled drives and control cabinets prevent air turbulence and heat dissipation. A wide range of individual features are also available for optimum clean room production. These include, for example: stainless steel sorting unit for the reliable separation of good and reject parts mobile clean air module for fast, convenient setup stainless steel clamping unit and nickelplated mounting platens with covered bores for the best cleaning conditions in compliance with GMP A and ISO 5 Practice-oriented: equipment packages for clean room concepts. Does your medical clean room application require you to meet all the necessary standards and guidelines? Do your own quality standards necessitate a technically clean production environment? In both cases, we are the right partner for you. In order to exclude sources of contamination and to establish a sufficiently clean production environment, our ALLROUNDER injection molding machines can be adapted individually by means of highly-flexible expansion options. Perfectly molded parts from the clean room - we make it happen! Further information: Clean room technology brochure 12

13 Ionized clean air Clean air modules with ionization ensure clean production conditions. Electrostatic charging is prevented and the number of particles on the molded parts is reduced significantly. The permanent air flow leads to a high level of air circulation in the production area, preventing the ingress of particles. Clean room concepts The range includes machines or production cells docked onto the clean room, ALLROUNDERs that operate completely in the clean room, as well as customized clean room cells as turnkey solutions. As a main contractor, ARBURG cooperates closely with the leading manufacturers of automation solutions and clean room technology here. Qualification and validation Comprehensive qualification documentation is available for all ALLROUNDERs as standard in order to meet the documentation requirements of ISO and GMP. The test log may also be included as evidence of machine capability. Regular qualified re-validation is also possible with the ARBURG inspection contract. Clean solution: special equipment meets the highest requirements in clean room production. 13

14 Efficient: micro-injection molding Homogenous material preparation ARBURG s developments are aimed at maximum efficiency: the existing hydraulic and electric standard machine technology is combined with optimized injection units, which makes the technology highly cost-effective. All the injection units operate according to the screw/piston principle, all screw geometries are adapted to optimum material preparation with minimal dwell times. The screw and the cylinder can be designed to be highly wear-resistant in order to be able to process the abrasive materials often used in micro-injection molding. Modular design: Micro injection module enables flexible machine use. Thanks to our modular ALLROUNDER machines, the manufacture of micro components with weights under one gram today represents the state of the art. Furthermore, there is no need to resort to expensive and complicated special machines. Both your production facility and our ALLROUNDERs remain free for a host of other applications. Our range extends from screws with a diameter of 12 or 15 mm through a special micro-injection module with 8-mm injection screw for extremely small shot weights, through to your individual system solution for micro components. Homogeneous material preparation based on the principle of first-in, firstout as well as high reproducibility are a matter of course at ARBURG. Further information: Micro injection molding brochure /2018

15 Micro injection units and modules Special micro injection units and modules combine an 8 mm screw for injection with a second screw for melting the material. The perfect interaction of the two screws continuously feeds the melt from the material inlet to the tip of the injection screw in a pressure-controlled manner. With this pioneering technology, the first-in, first-out principle is fully ensured. A homogeneously prepared, newly dosed melt is always available for every shot. Moreover, extremely small shot weights of under one gram are achieved with great precision and with the longer required travel distances. Optimum process control The SELOGICA has innovative control systems that permit precise position, speed, temperature and pressure control. Special dosage control ensures a homogeneous melt feed for the micro-injection module, while the position regulation ensures precise screw movements. Finally, adaptive temperature control achieves high tem perature stability. System solution for micro components: implement extremely small shot weights under a gram with high reproducibility 03/

16 High performance: packaging technology Fast, precise, and energy efficient: servo-electric toggle-type clamping unit. Servo-electric toggle system The servo-electric toggle-type clamping units of the hybrid and electric ALLROUNDER machines save a lot of time and energy in comparison with the hydraulic clamping units, also making them more cost-efficient. The cycle times can be reduced thanks to extremely fast mold movements. Features such as energy recovery during braking ensure that the energy applied is used more efficiently. High plasticizing capacity So-called barrier screws, in which the compression zone has been replaced with a barrier zone, ensure homogeneous melt preparation. The servo-electric direct drive permits dosage across cycles, precise dosage volumes and energy-efficient operation. High-performance drives with high screw circumferential speeds permit minimal dosage times. The requirements are complex: maximum productivity allied to high energy efficiency are the key in the packaging sector. Here, every hundredth of a second and every kilowatt-hour represent hard cash for you. That s why we have consistently further developed ALLROUNDER injection molding technology in the direction of an energy-efficient complete solution. With the special Packaging (P) version, we guarantee you short cycle times and a high level of process reliability: around the clock, 365 days a year. In short: maximum productivity with low energy requirements, throughout the entire volume production. From closures weighing only one gram, to large-capacity containers, you can rely on our support as a partner perfectly positioned in the global market. Further information: Packaging technology brochure /2018

17 Dynamic injection Highly dynamic filling during injection molding is decisive for thin-walled items. This is the only way to achieve the shortest injection times on a reproducible basis. As well as high acceleration, active braking is also important. This is assured by the unsurpassed, position-regulated screw from ARBURG. Synchronous ejection The combination of servo-electric toggletype clamping unit and servo-electric ejector is extremely powerful and results in short opening and closing times thanks to the precise, reproducible dropping of molded parts. The hydraulic booster function means that even shrunk-on closures can be demolded with ease. System solutions for packaging As a system service provider, ARBURG also handles the project planning of complete systems, commissioning at the customer s premises, CE labeling, as well as training and support. This is made possible through close co-operation with leading manufacturers of molds, automation solutions and peripherals. Technical details are always adapted in a customized manner, e.g. cooling water distributors with feed lines measuring up to two inches. Complete solutions for high performance: the entire injection molding technology is adapted to short cycles and high process reliability in accordance with the application at hand. 03/

18 Other processes: widely diversified range Reel-to-reel process: perfect encapsulation of leadframes. FDC unit: cuts continuous fiber strands and adds them to the melt. Band feed: reliable processing of strip materials. In order to be able to produce costeffectively in the long term as a trendsetter, your manufacturing processes must be constantly reviewed and further developed. New processes and plastics, as well as the use of innovative machine and system technologies also play a significant role. Here, we offer you comprehensive support in applications and process technology, support that is particularly critical in the initial stages of new processes in your company. Thanks to our close cooperation with the leading manufacturers of materials, molds and peripherals, we implement even complex production processes in a very short time. Our modular ALLROUNDERs coupled with the universal SELOGICA control system provide the ideal platform. 1 Encapsulation of inserts Whether inserts are to be encapsulated with thermoplastics, thermosets or liquid silicone, the combination of plastics with metals to produce hybrid parts can be reliably implemented in a customized manner using ARBURG s modular vertical and rotary table machines. A good example here are turnkey reel-to-reel systems for automated inline production. These permit the encapsulation of leadframes in short cycles in order to create top-quality parts. 2 Fiber Direct Compounding (FDC) With the FDC process, fibers up to a length of 50 mm can be fed directly into the liquid melt. This achieves greater part resilience and reduced wall thicknesses. 3 Elastomer injection molding The injection units of the ALLROUNDERs are additionally equipped with a band feed for the injection molding of elastomers, i.e. elastic, malleable plastics. Special conveying screws process the base materials in continuous lengths. 4 Hotmelt processing Hotmelt is an adhesive used to encapsulate electronic components or connectors with a perfect seal, reliably protecting them from splash water. Precision adapted cylinder modules ensure high processing quality. 5 Wood polymer injection molding Wood plastic composites (WPC) materials can be processed on ALLROUNDER injection molding machines without difficulty. The screw and non-return valve are adapted in accordance with the filler content of the material /2018

19 6 8 9 PCIM: six-axis robotic system links foaming system and ALLROUNDER. ProFoam granulate lock: constant feed of material and liquid propellant. IMD: gentle part removal via linear MULTILIFT robotic system. 6 Particle-foam Composite Injection Molding (PCIM) With PCIM, a foamed molded part is permanently bonded to plastic. This allows the positive properties of particle foaming such as EPP or EPS to be combined with thermoplastics such as ABS, PP or TPE. 7 Compression injection molding Compression injection molding is characterized by a change in cavity volume during the ongoing injection and/or holding pressure phase. This process enables the production of low-stress, thick-walled components without sink marks. The complex process sequence, however, requires in-depth process expertise and machine technology with high repeat accuracy. With the SELOGICA control system, compression injection molding becomes freely and universally programmable without the use of special programs. 8 Foam injection molding With the physical ProFoam foaming process and MuCell, a homogeneous, gas-filled plastic melt is created which forms extremely fine cell structures in the component. In this way, more lightweight molded parts can be produced. Moreover, sink holes can be prevented and shrinkage and distortion minimized. 9 In-mold decoration (IMD) The IMD process allows plastic parts with high-quality surface decorations to be produced. An image printed on a flat polyester film is transferred to the molded part during injection molding. Like the robotic systems, the pay-off and take-up device for continuous decorative films are supplied from a single source, by ARBURG. 10 In-mold labeling (IML) The IML process is suitable for high-speed packaging, as well as technical applications, in order to e.g. label thin-walled components directly in the mold. For this purpose, prefabricated films are inserted in the mold by robotic systems or IML systems configured for extremely short cycles. As a main contractor, ARBURG provides all the technology. 11 Fluid injection molding technology (FIT) Targeted hollow spaces can be produced in the part during the injection molding process through the introduction of gas (GIT) or water (WIT) into the cavities. The SELOGICA control system enables switching from material injection to gas or water injection as a function of time, distance or pressure. This means that all the FIT processes can be reliably implemented. 03/

20 Individual: consulting and design 1 2 Well-founded expertise: practical first-hand knowledge of all questions relating to injection molding technology. Customized: full support for tailored production solutions. Optimum customized solutions call for interdisciplinary expertise. We are consequently particularly broadly positioned here. Our expertise ranges from machine, robotic and control technology as well as application engineering, through to computer-aided production planning. We are a competent partner at your side who will help you increase the success of your company. We can offer you detailed consulting on all injection molding processes throughout the entire value-added chain: from detailed design through purchasing and commissioning to production optimization. Our common goal: always to offer the most cost-efficient production solution for smooth series production. 1 Applications technology As a technology partner, ARBURG provides detailed consulting services for injection molding and applications technology. Our experts devise customized solutions concepts and specialize in finding the most efficient alternative for the production of molded parts. All customers can call on the same level of comprehensive know-how from help with molded part design and the choice of material, through to mold and machine configuration and production optimization. The ARBURG Customer Center, which has its own laboratory, and the worldwide ARBURG technology centers and demonstration rooms provide the perfect environment for in-depth testing and trials. 2 Turnkey projects Projects or production cells are individual, customized solutions, which cover a variety of requirements in terms of the combination of ALLROUNDER injection molding machine, robotic system and peripherals. Upstream and downstream production steps can be fully automated. At the same time, however, injection molding can also be linked to other processes. As a general contractor with overall responsibility, ARBURG can offer its customers in this area individual support for the complete planning process, as well as on-site installation and commissioning through to all the necessary services. Close cooperation between the project department and custom /2018

21 Know-how 3 ers and machine, robot, application and control technology provides the starting point for all turnkey systems. This results in automated production cells for maximum production efficiency from a single source. Layoutbilder Modular: the right technology for every injection molding task. 3 Comparing cost-effectiveness With the modular ARBURG technology range, any injection-molding task can be implemented in a customized manner. In order to determine the most efficient solution for the application at hand from the many products on offer, a machine comparison and cost-effectiveness calculator is used. Automation solutions are becoming increasingly important in order to reduce unit costs. As a system supplier, ARBURG has comprehensive experience in this regard. Examples of automated operating steps or linkage with other processes include: Positionally-accurate preparation Feed or part removal via rotary or sliding table Pick-up from or set-down in trays Stacking of crates or trays Preheating Cooling Inspection (optical, mechanical, electrical, sealing) Packaging Printing (hot stamping, pad printing, digital print) Laser engraving Laser cutting Deburring Milling Stamping Bending Brushing Assembly Welding Ionizing PUR foaming Extrusion 03/

22 ARBURG Customer Center 1 2 Competent support: the customer is always the main focus. In good hands: jointly finding the best solutions. You require individual support? Our Customer Center in Lossburg offers you a unique range of options over an area of 2,100 m²: more than 30 injection molding machines from all series and processes are permanently available to the customer for mold tests, process optimization and machine comparisons. The facilities range from practical material preparation and production under logged clean room conditions through to quick quality assessment on site using suitable measuring technology. You can process multi component blends, as well as thermosets, elastomers, silicones and powder materials at the Customer Center. Take advantage of our know-how and individual support for your success. 1 Equipped to perfection Whether it be mold prototyping, comparing machine concepts, verifying processes for their practical feasibility or evaluating and discussing test results: the equipment at the Customer Center leaves nothing to be desired and is well thought-out down to the last detail. Molds, for example, can be delivered directly and transported safely to the relevant machine via crane systems, no matter how large or heavy they are. 2 Professional trials and tests The ARBURG specialists ensure the smooth progress and detailed documentation of trials. Because the sales and technical organizations are located near to the Customer Center, communication channels are kept short. In order to solve problems, all the ARBURG expertise is immediately available: from machine, robotic and control technology through to applications technology and project competence or production planning software /2018

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24 Distance between tie bars from 6.69 x 6.69 inch to x inch Clamping forces from tons Injection units from 0.5 to 94.3 oz, hybrid, hydraulic and vertical injection molding machines Film ARBURG GmbH + Co KG Arthur-Hehl-Strasse Lossburg Tel.: contact@arburg.com With locations in Europe: Germany, Belgium, Denmark, France, United Kingdom, Italy, Netherlands, Austria, Poland, Switzerland, Slovakia, Spain, Czech Republic, Turkey, Hungary Asia: People s Republic of China, Indonesia, Malaysia, Singapore, Taiwan, Thailand, United Arab Emirates America: Brazil, Mexico, USA For more information, please go to ARBURG GmbH + Co KG The brochure is protected by copyright. Any utilization, which is not expressly permitted under copyright legislation, requires the previous approval of ARBURG. All data and technical information have been compiled with great care. However we accept no responsibility for correctness. Individual illustrations and information may deviate from the actual delivery condition of the machine. The relevant valid operating instructions are applicable for the installation and operation of the machine. ARBURG GmbH + Co KG DIN EN ISO certified _EN_US_ Subject to alterations Printed in Germany