Getting plastic into shape

Injection molding

The injection molding process is predestined to bring PLASTIC into SHAPE. Many innovations in technical parts are based on combinations of the many different process variants or newly developed special processes. Common to all of them is the process sequence of preparing a plastic melt, injecting the melt into a closed cavity and cooling the material under mold constraint.

We use the extensive experience of our experts and the wide-range equipment of our technical center to examine every component of your injection molding process. We lighten your components, integrate functions cost-effectively and increase the robustness of your processes - making them more energy- and resource-efficient. Together with our experts in component and mold design, we work with you to realize a successful product. In addition to "getting plastics into shape" in line with the material and the process, we focus on the topics of functionalization, lightweight construction and process optimization using appropriate technologies and, above all, combining them.

Plastic innovatively shaped

Injection molding

In addition to other major plastics processing methods, injection molding is one of the most frequently used primary molding processes. The range of molded parts produced fully automatically and cost-efficiently by injection molding extends from simple mass products to complex, technical components and assemblies. Within this spectrum, we can support you with the most diverse issues.

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For more function integration

2K injection molding

With 2K injection molding or multi-component injection molding, assemblies or components that previously existed individually can be integrated into a single part produced in a single manufacturing step. This enables functional integration in a smaller installation space and at lower cost. However, the process is anything but trivial, because the compatibility is important when joining two different melts. With our 2K injection molding machines and the matching 2K molds, we can answer any technical question and find the right combinations for you.

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Zweikomponenten-Sandwichbauteil hergestellt im Schaumspritzguss

Realize lightweight solutions

Foam injection molding

The main advantage of thermoplastic foam injection molding (TFIM) is the reduction in density and thus material. This also has a positive effect on the environment and economy. Density reduction can be achieved by chemical or physical foaming. Chemical foaming as an established process can be realized quickly and easily by metering a chemical blowing agent. For this purpose, a standard injection molding machine is used with minor machine modifications. Physical foaming offers even greater lightweighting potential compared with chemical foaming. Here, the blowing fluid requires special machine technology. The Cellmould® unit of the Battenfeld HM-MK 180/525H/350V is available for this purpose in the technical center of the KUZ. This machine can produce lightweight components in both 1K and 2K operation.

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Spritzgussträger mit Dekorfolie und Hochglanzschicht mittels In Mould Coating

Combination injection molding reaction technology

With the technology platform for the process combination of thermoplastic and reaction injection molding, we bring together two of our technological core competencies to open up new potential for you. This process combination is based on the manufacturing principles of the classic multi-component injection molding process, whereby a reactive PUR or polyurea mixture is introduced into the mold cavity as the second component and bonds firmly with the freshly molded thermoplastic carrier during crosslinking. Visible and functional surfaces of three-dimensionally molded thermoplastic components can thus be efficiently finished with high-quality coatings. The thermoplastic components thus benefit from the noble high-gloss appearance with a good depth effect and from the insensitive surface properties of the crosslinked systems, right through to self-healing in the event of minor damage. As a result of the versatility of the PUR or polyurea systems used for this purpose, hardly any wishes remain unfulfilled.

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Further training on the topic

Nahaufnahme von Personen, die von einem Techniker im Technikum etwas erklärt bekommen.

Seminar

28.05. - 30.05.2024

Fit for the exam! Injection molding practice for trainees

This seminar serves to prepare trainees for the practical IHK final examination part II for Process Technician for Plastics and Rubber Engineering Focus: Shaped Parts. The main focus is on training on the injection molding machine. This takes place in our technical center and is carried out in small groups under the guidance of our experienced technical specialists. Further information on the agenda, travel, parking and an insight into the script can be found in our download box at the top right.

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Anschnitt eines von außen blauen Sandwichformteils mit schwarzer Füllung.

Seminar

29.05. - 30.05.2024

Basics of thermoplastic foam injection molding (TSG)

Demands for more sustainable solutions and increased functional integration can be met by foaming thermoplastics. The resulting lightweight construction due to the lower density is also a topic that is more topical than ever. This seminar will provide an overview of various processes, the associated machine and tool technology, the special process engineering features of foaming compared to classic injection molding and welding as a subsequent process. Further information on the agenda, travel, parking and an insight into the script can be found in our download box at the top right.

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Seminar

10.06. - 14.06.2024

Injection molding compact - in theory and practice

If you are familiar with the basics of the injection molding process, this extension course will provide you with additional knowledge about the injection molding of thermoplastics. We will explain the phases of the injection molding process in detail, look at the input variables and their influence on the quality of the molded part. In an extended practical section, the theoretical content will be illustrated for you in a practical way on an injection molding machine. Further information on the agenda, travel, parking and an insight into the script can be found in our download box at the top right.

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Nahaufnahme eines grünen Fehlerteils aus dem Fehlerkatalog

Seminar

19.06. - 20.06.2024

Injection molding defects: avoidance + elimination

Unfavorable settings and fluctuations in the process parameters during injection moulding result in constellations that can lead to moulded part defects and cause high economic losses. We will provide you with comprehensive knowledge in recognizing and systematically eliminating faults in injection moulded parts. In the practical part, we will deepen the process engineering correlations with you. Further information on the agenda, travel, parking and an insight into the script can be found in our download box at the top right.

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Seminar

04.09. - 05.09.2024

Injection molding thermoplastics | The basics

You will gain the necessary process understanding for the interaction of the various process components machine, tool, setting and material in injection molding. This will enable you to communicate at eye level in everyday operations. This knowledge is rounded off with a practical demonstration on the injection molding machine. After completing the course, you will be familiar with the basics of injection molding in theory and practice. Further information on the agenda, travel, parking and an insight into the script can be found in our download box at the top right.

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Durchsichtiger Prüfstab mit Spritzgieß-Fehler im Gehäuse.

Seminar

10.09.2024

Injection molding defects: Recognition + assessment

Injection molding is comparatively complex due to the many processing parameters. Unfavorable settings and fluctuations in the process parameters result in constellations that can lead to quality defects and damage to injection molded parts. In this seminar, we will give you an overview of error patterns and their causes and discuss the background and possible remedial strategies with you. Further information on the agenda, travel, parking and an insight into the script can be found in our download box at the top right.

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Seminar

24.09. - 25.09.2024

Optimization of the injection moulding process 4.0

How do you achieve the optimum quality component? We will teach you strategies for time- and cost-efficient adjustment and optimization of the injection moulding process, taking into account defined boundary conditions. These strategies will be applied in the subsequent workshop. Further information on the agenda, travel, parking and an insight into the script can be found in our download box at the top right.

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Seminar

21.10. - 13.12.2024

Certified specialist for plastic injection molding

Due to the increasing shortage of skilled workers, companies are increasingly having to recruit employees from other areas or even specialist fields and qualify them for the tasks in their own company in the shortest possible time. The modular seminar provides compact basic knowledge of the injection molding process combined with comprehensive training on the injection molding machines. Participants thus acquire the ability to work consciously on the machines. With this in-service training in accordance with the qualification standard of the GKV/TecPart the graduates receive a qualification certificate that is classified below the vocational training as a process mechanic for plastics and rubber technology. Further information on the agenda, travel, parking and an insight into the script can be found in our download box at the top right.

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Blaues Granulat in einer Hand, das herunterfällt-

Seminar

29.10.2024

Use recycling cleverly!

The recycling of plastics is an essential part of closing material cycles in order to save significant amounts of fossil resources and waste. In times of raw material shortages and rising prices, it can therefore become an integral part of a sustainable and economically viable material supply. For practical implementation in injection molding operations, it is important to know the special requirements of the material and the processing technology. The seminar provides the necessary know-how to find climate-friendly, economically advantageous and process-reliable solutions adapted to the respective application. Further information on the agenda, travel and parking can be found in our download box at the top right.

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