Foam injection molding
The main advantage of thermoplastic foam molding (TSG) 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 1C and 2C operation.
- Use our 2K injection molding machines Battenfeld HM-MK 180/750H/350V with Cellmould® unit and ENGEL Victory 330H 80V / 80 Combi for compatibility testing of your materials or also for sampling your 2K molds.
- We support you in material selection and offer our extended material compatibility table as an aid
- Examine the filling behavior of the material components meeting each other with our 2K cup.
- Check adhesion and compatibility with the 2C tensile bar (link to molded parts catalog) or the 2C roller peel test specimen (link to molded parts catalog).
- If you only have small quantities of material available, special 2C micro-molded parts and test specimens (link to molded parts catalog) are available in our micro injection molding department.
Use our possibilities for damping characterization by means of dynamic-mechanical-thermal analysis (link to magazine) with our new test rig!
Foam injection molding and sandwich effect combined
The sandwich effect causes the layers of a component furthest from the neutral axis to absorb the most bending forces. The closer the material layers are to the neutral axis, the lower the bending stresses and the lighter the foam can become in terms of lightweight construction. Ideally, the largest bubbles are located in the area of the neutral axis. In the direction of the edge layer, they become continuously smaller. Such a foam structure is called integral skin foam. Integral foam often forms during the chemical or physical foaming of thermoplastics: during injection, the melt solidifies immediately at the cavity wall, which impedes the formation of bubbles. The melt inside the component, on the other hand, cools only slowly, which promotes the formation of larger bubbles. A particularly rigid design using 2-component foam injection molding is possible with a combination of metal substitute plastic in the stiffness-relevant skin layer and a lightweight foam core, which acts as a shear-resistant spacer. The sandwich components can be mass-produced using a one-shot process and thus at low cost. The constructive application of the sandwich effect allows a lower weight for components that are mainly exposed to bending loads. As a special contribution to the circular economy and thus to sustainability, recycled material can be used in the core layer (2-component injection molding), as this is encapsulated by the compact, visually flawless skin material.
21.02. - 22.02.2023
Plastics selection in product development
Plastics are highly interesting materials with further increased potential for product development. A multitude of requirements to which the product is subjected in the application must be reconciled with the most efficient processability possible and a limited cost budget for the material. This seminar explains some basic tools for solving this complex problem. The content of the seminar is to underline the practical approach from the material selection to the real use of the product. Using a housing made of semi-crystalline material with/without filler and a lens made of amorphous material, the seminar content will be taught in a practical way. For further information on the agenda, how to get there, parking facilities and an insight into the script, please see our download box at the top right.
27.02. - 03.03.2023
Injection molding compact in theory and practice
If you are familiar with the basics of the injection molding process, this extension course will give you additional knowledge about injection molding of thermoplastics. We will explain the phases of the injection molding process to you in detail, look at the input variables and their influence on the molded part quality. In an extended practical part, the theoretical contents will be illustrated for you in a practice-relevant way on an injection molding machine. You will find further information on the agenda, how to get there, parking facilities and an insight into the script in our download box at the top right.
Multi-component injection molding
Various special injection molding processes can be used to produce more complex components that not only offer cost advantages but also higher-quality features compared with individual components, e.g. through increased functional integration. For example, multi-component injection molding can produce composites from several components of the same or different types. A key quality feature in the injection molding of two or more components is the adhesion between the different materials. For this reason, material selection and molding design are particularly important. In this seminar, we will teach you the basics of multicomponent injection molding technology and demonstrate technical approaches to solutions. For more information on the agenda, how to get there, parking facilities and an insight into the script, please see our download box at the top right.
07.03. - 08.03.2023
Injection molding defects: avoid + eliminate
Unfavorable settings and fluctuations in process parameters during injection molding result in constellations that can lead to molded part defects and cause high economic losses. We provide you with comprehensive knowledge in the recognition and systematic elimination of defects in injection molded parts. In the practical part, we will deepen the process-engineering correlations with you. You will find further information on the agenda, how to get there, parking facilities and an insight into the script in our download box at the top right.
07.03. - 08.03.2023
PUR chemistry - from raw material to material
In this seminar, you will acquire chemical knowledge of raw material production and reactions of isocyanates with regard to the production of polyurethanes and polyurethaneureas. Since most polyurethanes are chemically cross-linked, we will introduce you to network formation and its effect on processing and end product properties. For more information on the agenda, travel and parking, please see our download box on the top right.
14.03. - 15.03.2023
Mold sampling: systematic and efficient
Injection molding is highly efficient in the production of large quantities. To reduce time and costs, we will explain the systematic procedure for mold sampling and give you practical instructions for action, which we will illustrate in the practical part in our technical center. For more information about the agenda, how to get there, parking facilities and an insight into the script, please see our download box at the top right.
16.03. - 17.03.2023
ONLINE - Injection molding beginner course
You don't have the opportunity to attend our beginners' course on site but would still like to learn the basics about thermoplastic injection molding? Then book our online seminar and get an overview of the aspects plastics, machine, process and mold. You can find more information about the agenda in our download box at the top right.
20.03. - 31.03.2023
Expert knowledge: Injection molding
If you are familiar with the basics of the injection molding process, in this intensive course we will illustrate all phases of the injection molding process in compact form - from the plastic to the finished molded part. The topics of systematic setup and the analysis and elimination of injection molding errors are covered in particular depth. In the integrated 5-day machine training, the knowledge is applied and practiced. For more information on the agenda, how to get there, parking facilities, an insight into the script and information on TrainingPlus, please see our download box at the top right.
28.03. - 29.03.2023
Dimensional accuracy of molded parts
The special structure of plastics, which results from their molecular structure and essentially determines their properties, gives rise to some special features for the dimensioning and tolerancing of plastic parts compared to other construction materials. If these are not taken into account in molded part and tool design, this inevitably leads to disputes between plastics processors, toolmakers and OEMs. Get fit and use the plastics technology know-how of the new standard for effective project processing! For more information on the agenda, how to get there, parking options and an insight into the script, please see our download box at the top right.
Plastic innovatively shaped
Injection molding, along with other major plastics processing methods, is one of the most widely used primary molding processes.
Polyurethane - plastic with many faces
Whether as flexible, rigid or integral skin foam, as a coating or a varnish - polyurethane systems offer a wide range of applications. As your partner, we have extensive equipment in our independent technical center to enable you to process almost all polyurethane systems.