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A modular drive design is at the heart of Arburg’s Allrounder 420A hybrid injection molding machine. The machine, which will be featured at the Arburg exhibit at Plastec West 2004 in January, is part of the company’s Alldrive series of presses, incorporating modular principles in drive design. In the Allrounder 420A, the modular technology distributes machine functions between both electric and hydraulic axes. The functions of the machine, mold opening and closing, injection and dosing, are controlled by electric drives. Ejection and other in-mold operations can be controlled either hydraulically or electro-mechanically, depending on requirements. The configuration enables the 420A to have sufficient hydraulic power at its disposal when it is needed, and a high level of electro-mechanical accuracy coupled with energy efficiency.

The Allrounder 420 A has 88 tons of clamping force and 16.54 in. clearance between tie bars. Arburg also offers the Allrounder 520A as part of its Alldrive series of injection presses.

Hamilton Avtec, Inc. 905-568-1133

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New in-mold decoration technology eliminates time-consuming and costly post-mold trimming. The result of a cooperative venture between Battenfeld and the German moldmaker Summerer Technik, patented IMCore technology combines two-component molding and in-mold textile trimming in a one-step, complete production process. The technology minimizes waste of plastic and textile materials, as excess textile material is trimmed inside the mold.

A Midwest molder is manufacturing a ready-to-install, in-mold decorated B pillar with a molded-on sealing lip using the IMCore process on a Battenfeld HM 3500/1900 + 130L B4, a hydraulic, multi-color machine in L-configuration. First, textile material, fed from the roll by a special conveyor belt, is cut to size by a laser cutting unit. A Battenfeld Unirob R 15 robot places the material inside the mold, where it is secured on a special frame while the mold is closed. The textile is overmolded with polypropylene, and excess decoration material is trimmed directly inside the mold. In the final step, a TPE sealing lip is molded on to the part.

A key feature of the of the work cell is the textile trimming operation. A laser cutting unit is integrated with an IRB4400 ABB robot. The laser unit has variable settings ranging from 100 to 600 Watts. The length of textile and cutting settings can be freely programmed. The laser robot is also capable of punching and trimming finished in-mold decorated components when required.

Battenfeld Canada Ltd. 905-670-9384

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An improved PET preform platform, HyPET injection molding systems provide higher output at lower costs. The systems are highly flexible platforms that use single-face molds and feature new cooling and handling technologies.

HyPET’s Reflex platens permit molds to run at lower tonnage, resulting is less mold wear. The moving platen is mounted on linear bearings, which further improves alignment and perpendicularity. A new platen-mounted robot, which is faster, more compact and incorporates a simplified hose and cable arrangement, also features an integrated CoolJet system that no longer uses expensive compressed air. HyPET machines also have a narrower footprint that takes up 20% less floor space.

The HyPET platform will eventually replace the G-PET preform system. According to Mike Urquhart, Husky Injection Molding Systems vice president, PET systems, users of HyPET systems will be able to achieve approximately 5% faster cycle times. Other benefits of HyPET systems include lower energy usage and wider tiebar spacing to accommodate high-cavitation molds with larger pitches, Urquhart reports.

Husky Injection Molding Systems Ltd. 905-951-5000

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With a good price/performance ratio, Van Dorn Demag Corp.’s Ergotech Extra machines are designed for flexible, general purpose molding. The machines, which were first launched in Europe, were introduced to the North American market at this year’s NPE. The series includes eight models ranging between 28 and 220 tons. Tech machines from 28 to 120 tons have a hydraulic clamping unit, while the machines with 140 to 220 tons of clamping force are equipped with a toggle clamp. The machines feature programmable back pressure, parallel ejector movement and automatic start-up/shut-down programming.

The start-up program enables oil pre-heating, barrel heating, mold temperature control and the plug connector combination to be started without operator intervention.

Stephen Sales Group 905-940-5577

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Structural web process molds 75-lb. parts

A new standard for large part molding has been set with the help of Uniloy Milacron’s first 2000-ton Structural Web, low-pressure, gas-assist injection molding machine. Stormtech, a manufacturer of thermoplastic stormwater detention systems, is using the machine to produce one of the largest injection molded parts ever made — 5 ft. wide by 3 ft. tall by 7 ft. long polypropylene storm water chamber sections. Each overlapping section weighs 75 lb.

Stormtech (Old Saybrook, CT) spent four years and $7.5 million to design and develop the stormwater handling system. The company worked closely with Uniloy to develop a machine capable of molding the parts. Using a traditional, high-pressure injection molding machine, the parts would have required a machine with 12,000 tons of clamping force. This machine would have three times the cost of the 2000-ton Uniloy and resulted in twice the mold cost, reports Roy Moore, vice president of manufacturing at Infiltrator Systems, the parent company of Stormtech.

Each water chamber section is molded with internal voids, which provide material savings, enhance structural strength and improve cycle time. The chambers are made from virgin polypropylene. Polypropylene, rather than polyethylene, was chosen for its lighter weight, higher transition temperature and resistance to environmental stress cracking. Yellow coloring in the PP reflects the sun’s energy, keeping the surface temperature as much as 70 F cooler than comparable black products.

One unique feature of the system is an auxiliary 8 in. extruder. The extruder provides up to 6000 lb. output and can accommodate an additional extruder. The Structural Web machine has 120 in. of mold daylight and a 90 in. stroke to accept the large molds required for the chamber sections and end caps. Individual control of 16 injection nozzles balances flow and pressure for efficient and complete fill. Multiple nozzles also lower internal stresses in the finished part.

“Just making a standard machine does not fit what we do,” says Moore. “Like other molders, we have problems to solve and need plastics machinery manufacturers to design problem-solving machines.”

Uniloy Milacron 800-666-8852