Super-Thin Wall Molding Now Possible

Engel’s X-Melt process is a new technology for high-speed injection molding of parts and sections with the thinnest possible walls over extremely long flow lengths. The process, which is being introduced at the K Show, can mold parts with wall and section thicknesses ranging from 0.8 mm down to 0.1 mm, with flow length-to-wall thicknesses ratios as high as 400:1. The energy required for rapid injection is stored in the melt itself, which is precompressed in the space in front of the screw, or in the hot runner system. This eliminates the need for a separate hydraulic accumulator normally required for high-speed injection. The mold cavity is filled in seconds by the rapid expansion of the compressed melt when the needle valve nozzle of the hot runner is opened. For multi-cavity molding, Engel worked with Mold-Masters Inc. to optimize the design of a hot runner system in which all the needle valve nozzles open at exactly the same time, providing a consistent shot size. The technology is used in conjunction with an Engel all-electric E-Motion machine for production of microprecision parts made of engineering plastics. X-Melt will be used at K 2004 to produce a battery case with a wall thickness of only 0.15 mm in a cycle time of 5 sec. in a four cavity mold.

Engel Canada Inc. 519-836-0220