All-round lightweight construction talents on a science mission

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1 All-round lightweight construction talents on a science mission KraussMaffei is inaugurating modular injection molding system solutions at the new MERGE Lightweight Technology Center at the Chemnitz University of Technology Cutting-edge research for the automotive industry intended to advance series production (Munich, December 9, 2015) The Free State of Saxony is investing in the lightweight construction technology of the future as part of the Federal Government's Cluster of Excellence MERGE "Technology Fusion for Multifunctional Lightweight Structures" with the Chemnitz University of Technology. At the heart of the new MERGE Lightweight Technology Center is an MXW 2500 injection molding machine from KraussMaffei that, thanks to a wide variety of technical options, offers maximum flexibility for researching and prototype manufacturing close-to-production in their original size. The ceremonial launch of the new plant took place in October 2015 as part of the 2nd International MERGE Technologies Conference. One-of-a-kind in the German research landscape "The KraussMaffei MXW 2500 injection molding machine 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. Publication free of charge Sample copy requested 1

2 The MXW 2500 is a very compact, high-performance 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 a close-to-production 1:1 scale," says Prof. Dr.-Ing. Lothar Kroll, Director of the Institute of Lightweight Structures (IST) at the Chemnitz University of Technology and Coordinator of the MERGE Cluster of Excellence. 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 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 thermoset matrix materials. An additional mixing and metering system also enables the processing of polyurethanes with fillers and other reactive matrix materials. The 40-15/29 hybrid is equipped with a color-metering unit directly on the mixing head and an additional gas charging unit. This offers maximum flexibility during prototype manufacturing. Even more lightweight foaming with MuCell 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 primary advantages of the foamed components are their light weight, decreased warpage, higher dimensional stability and short manufacturing times. "The MuCell process has become an established technology, particularly in vehicle manufacturing and for Publication free of charge Sample copy requested 2

3 technical components. The trend is moving towards also using this procedure for premium quality surfaces in visible components," explains Holzinger outlining opportunities for possible future research focuses. Prototype manufacturing close-to-production in the field of thermoplastic lightweight construction with fiber-reinforced plastic is possible thanks to the FiberForm process developed by KraussMaffei. New fiber-reinforced thermoplastic composite components can be manufactured with particularly high strengths using material-based and design-based lightweight construction. 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 process is easy to automate and can be used in fully automated production with compact manufacturing cells. Sophisticated automation solutions 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 rearside and the injection molding machine remains completely accessible on the operator side. The sophisticated solution also required the additional injection molding machine bolt-on unit (in the L- design) on the operator rearside. The workstations for feeding insertion parts and the deposit of the finished parts take place on a platform above the bolton 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 Publication free of charge Sample copy requested 3

4 MC6 control system. "This also eases the operation of complex processes tremendously," says Prof. Lothar Kroll. More about the MERGE Cluster of Excellence Merge means to blend, unify, join. In the MERGE Technology Center, previously disconnected manufacturing processes using various materials such as textiles, plastics or metals are merged. The goal is researching and developing energy- and raw material-saving lightweight structures for mass production. The automotive industry in particular is interested in materials that are lightweight as well as durable. Other areas, such as the aviation industry, the transportation sector or the logistics industry can also benefit from these materials. PM_IMM_2015_12_MERGE_01.jpg The grand opening of the new KraussMaffei injection molding system in the MERGE Technology Center (from left): Georg P. Holzinger (Vice President of KraussMaffei Technologies), Dr. Eric J. Amis (Dean, College of Polymer Science and Polymer Engineering, University of Acron), Prof. Lothar Kroll (Coordinator of the 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 Acron) and Stephen Kidder Photo: Chemnitz University of Technology PM_IMM_2015_12_MERGE_02.jpg Components for cars of the future are currently developed on a MXW 2500 injection molding from KraussMaffei at the new MERGE Lightweight Technology Center at the Chemnitz University of Technology Photo: KraussMaffei Enclosure: Pictures and more information can be found at Publication free of charge Sample copy requested 4

5 Press contact: Petra Rehmet Press officer KraussMaffei brand Phone: +49 (0) (Number Words: 1.062/ Number Characters: 7.329) About KraussMaffei The KraussMaffei product brand is internationally recognized for its groundbreaking, multitechnology system and process solutions for injection and reaction molding technology and factory automation. With its standalone, modular or standardized machinery and systems, and a wide, customizable service offering, KraussMaffei is a full-system partner for customers in many industry sectors. KraussMaffei bundles many decades of engineering expertise in plastics machinery and is headquartered in Munich, Germany. For more information: About KraussMaffei Group The KraussMaffei Group is among the world s leading suppliers of machinery and systems for producing and processing plastics and rubber. Its products and services cover the whole spectrum of injection and reaction molding and extrusion technology, giving the company a unique position in the industry. The KraussMaffei Group is innovation-powered, supplying its products, processes and services as standard or custom solutions which deliver sustained added value along the customer s value-adding chain. The company markets its offering under the KraussMaffei, KraussMaffei Berstorff and Netstal brands to customers in the automotive, packaging, medical, construction, electrical, electronics and home appliance industries. Continuing a long tradition of engineering excellence, the international KraussMaffei Group currently employs around 4,000 people. With a global network of more than 30 subsidiaries and more than 10 production plants, supported by around 570 sales and service partners, the company is close to customers around the world. KraussMaffei has been headquartered in Munich since For more information: Publication free of charge Sample copy requested 5