Machinery & Production

Machinery and equipment are not only at the heart of K, but also form a key part of K-Mag. Our articles offer fascinating insights into innovative production processes and the workings of pioneering machines that are taking efficiency and quality in the industry to new heights.

Nahaufnahme eines runden Metallgehäuses mit kupferfarbener, gezackter Innenstruktur vor unscharfem Zickzack-Hintergrund.

Results (51)

  • Ultrasonic welding of plastic: joining technology for adhesive-free applications

    At Herrmann Ultraschalltechnik GmbH & Co. KG, medical wearables are welded together instead of glued - for the benefit of the user Exclusively for K-Mag The automated ultrasonic welding system; Copyright: Herrmann Ultraschall 20.02.2025 Anyone who has ever had to wear a plaster for a long time knows that this can sometimes irritate the skin. This is often triggered by the adhesives that hold the individual layers of a plaster together. Medical wearables, such as CGM sensors for diabetics, are also often glued together. As these have to be worn permanently, skin irritation is more than just annoying for sensitive patients. One option is therefore to dispense with the adhesive altogether and join the plastic components using ultrasonic welding. We spoke to Michael Boerner, Head of Global Business Development Plastics at Herrmann Ultraschalltechnik , about this process for K-Mag. Avoiding skin irritation - the advantage of ultrasonic welding Michael Boerner, Head of Global Business Development Plastics at Herrmann Ultraschalltechnik. Copyright: Herrmann Ultraschalltechnik Mr. Boerner, chemicals such as isobornyl acrylate (IBOA) in adhesives can cause skin irritation in wearers of medical wearables. You therefore rely on ultrasonic welding. How can skin reactions be avoided? Michael Boerner: Ultrasonic welding makes it possible to join medical plastics without the use of chemical joining processes such as adhesives or solvents. Instead, mechanical vibrations are used to briefly heat the materials at the contact points and securely join them together. As no potentially irritating substances such as isobornyl acrylate are used, there is no risk of skin irritation or allergic reactions. This is a great advantage for patients, especially in the case of medical wearables such as CGM sensors, which are often worn directly on the skin for long periods of time. Can you explain the ultrasonic welding process in more detail and how mechanical vibrations are used to securely join plastics without adhesives? Boerner: During the ultrasonic welding process, electrical voltage is converted into mechanical vibrations via a converter. These vibrations are transferred to the two joining partners via the welding tool - the sonotrode. The friction between the two components generates heat at previously defined contact points, which melts the plastic in a targeted manner. This creates high-strength joints at a molecular level. In the laboratory, the parameters for each plastic and for each application are checked and the results analysed in detail. This means that customers can be sure of receiving an optimised product; Copyright: Herrmann Ultrachalltechnik Focus on efficiency: advantages of ultrasonic welding compared to traditional methods What specific advantages does ultrasonic welding offer compared to traditional bonding or welding methods, particularly in terms of process time and energy efficiency? Boerner: Depending on the application, ultrasound often only needs a few hundredths of a second to create tight connections. The components can also be processed immediately. This is particularly advantageous for the manufacture of medical products, which are produced automatically due to the high demand. In addition, ultrasonic joining requires very little energy and no other composite materials. Adhesives have to be cured or, in the case of thermal processes, the temperature on the tool has to be maintained permanently, which requires a lot of energy. Thermal joining processes are slower and generate stress on the component due to the direct external temperature effect, which can lead to deformation or damage, for example. Energy, and here we are talking about very low energy requirements, for the ultrasonic process is available worldwide. Chemical joining agents often have to be transported over long distances. This environmental factor is also eliminated by using ultrasound as a joining technology. Thermal joining processes require considerably more energy, as heat has to be constantly supplied. The targeted use of energy only in the joining zone, as with ultrasonic welding, is not possible. The individual components of a GCM sensor can be joined together without adhesives thanks to ultrasonic welding technology; Copyright; Herrmann Ultraschall Ultrasonic welding is suitable for sensitive components such as skin patches and sensors. How is it ensured that the thermal and mechanical stress on the component is kept to a minimum? Boerner: The decisive factor here is that the entire welding process is developed individually for the customer's application. We use our ultrasonic laboratories for this, where the application developers determine the correct welding parameters. The most important parameters include force, time and amplitude. Welding tests can be used to determine exactly how these parameters need to be set in order to create a safe and gentle joint. The values are stored in the welding system's control system and can be precisely reproduced in the customer's production process. Another crucial component is the energy direction generator - this is the name given to the points where the melt is created during the welding process. It is important that this energy direction generator is designed correctly so that the two plastics are only joined at this specific point. As a result, the surrounding areas of the component are only subjected to minimal thermal and mechanical stress. How does the choice of plastic material influence the effectiveness of ultrasonic welding? Boerner: In principle, all common thermoplastics can be joined with ultrasound. Which plastic is ultimately chosen has an immense influence on the welding process, as each plastic has unique properties. We have access to databases and many years of experience. As a trusted advisor, we also solve challenging applications. Data is summarised and constantly checked to ensure perfect results; Copyright: Herrmann Ultraschalltechnik Quality assurance through intelligent process control What measures do you use to ensure consistent welding quality and how are the optimum welding parameters determined for different applications? Boerner: The reproducible results are one of the biggest advantages of ultrasonic welding technology. This is made possible by intelligent process control . The ideal parameters for the process are stored there. It also monitors the entire joining process and collects up to 150 values per weld. These can be called up and evaluated at any time. This gives manufacturers the option of seamless, digital quality control. In order to determine the correct parameters, extensive series of tests are carried out in the ultrasonic laboratory for each application. Thanks to the experience of our application engineers, they often know which parameters are suitable for which plastics after just a few tests, which speeds up process development. To what extent is ultrasonic welding suitable for components with complex geometries, and what design considerations need to be taken into account? Boerner: Ultrasonics can also be used to reliably join components with complex geometries. However, there are some factors that need to be taken into account, such as the wall thickness of the material or the use of different materials within the same application. As already mentioned, the seam design also plays an important role in the welding process. This is why close cooperation between customer and ultrasonic partner is so important - especially when it comes to more complex components. K as a platform for innovations in the plastics industry You will also be exhibiting at K 2025. What can visitors look forward to when they visit your stand? Boerner: Ultrasound offers many advantages as a sustainable and fast joining technology, especially in the medical industry. We want to demonstrate this in particular at our stand at K 2025 . To this end, we have specially developed a new test specimen on which we can demonstrate the many different possible applications of ultrasound live. As most medical products are manufactured automatically, we will also be showing how our modules and components can be integrated into various production systems to save space - thanks to a retrofit of this kind, manufacturers with existing systems can also benefit from our technology. To what extent is K the perfect platform for you to present your company's innovations? Boerner: With its wide reach and international audience, K is always a highlight for us and an excellent stage for presenting new trends and topics. As we are also active in numerous other sectors besides medical, such as automotive , packaging and nonwovens , we also benefit from the wide range of visitors. We are therefore looking forward to an exciting trade fair and a lot of interest in our stand F28 in hall 11 . Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Simone Ernst (Editorial team K-Mag) More around Machinery & Production

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  • Material Tests for Space

    How the NextSpace TestRig secures the future of space travel Exclusively for K-Mag Being able to manufacture spare parts and tools directly in space would revolutionise space travel. Heavy materials would no longer have to be transported into space by rocket; Copyright: envato 18.06.2025 Materials for space must withstand extreme conditions in aerospace technology: Vacuum, strong temperature fluctuations and mechanical stresses act simultaneously on components and structures. Conventional test methods quickly reach their limits here. With the NextSpace TestRig from the University of Glasgow, a newly developed test method is now closing this gap. Funded by the British Space Agency, the test platform, which was developed by Dr Gilles Bailet and his team, enables realistic simulations for the qualification of materials and components for use in space - and also provides exciting impetus for applications on Earth. Dr Gilles Bailet; Copyright: Gilles Bailet / University of Glasgow Why conventional material tests are not sufficient for space travel Dr Bailet, what was the motivation behind the development of the NextSpace TestRig? Gilles Bailet: The space industry is rapidly adopting advanced materials and additive manufacturing , but we lack realistic testing methods to understand how these materials behave in the actual space environment. Traditional qualification methods often ignore the extreme conditions found in orbit or on the Moon—especially the combined effects of ultra-high vacuum and thermal cycling. The NextSpace TestRig, funded by the UK Space Agency , was developed to close this gap. Our goal was to create a ground-based platform capable of simulating space-like environments while applying mechanical loading, to better predict how materials perform in mission-critical scenarios. Which specific conditions can be simulated within the NextSpace TestRig – and why are they so crucial for material testing? Bailet: The TestRig, hosted within our NextSpace TestRig, can simultaneously simulate ultra-high vacuum (~10⁻⁶ mbar) and extreme thermal cycling (−100°C to +200°C) while performing real-time mechanical testing (up to 20,000 Newton force). This combination is crucial because many materials—especially polymers and composites—undergo significant changes in fracture strength, stiffness, or failure modes under such conditions. In one test, we observed a 43% reduction in fracture strain for a 3D-printed polymer (Nylon PA12) when tested in vacuum versus ambient conditions. These effects simply aren’t visible in traditional lab environments, yet they’re critical for designing safe and reliable components for space missions. Find out how high-performance plastics contribute to radiation protection in space in this interview! Dr Gilles Bailet during a microgravity parabolic flight to demonstrate the underpinning technology of his In-Space Manufacturing spin-out; Copyright: Gilles Bailet / University of Glasgow 3D-printed polymers and metallic materials at the centre of space tests What types of materials/plastics or components are typically tested – and what applications are they intended for? Bailet: We’ve tested a range of additively manufactured polymers, such as PA12, and are now expanding to metallic materials including Inconel and titanium alloys. These materials are commonly used in satellite structures, antenna supports, thermal control components, and lightweight mechanical parts. Many of the tests are focused on flight-ready geometries, helping space companies refine their qualification data and reduce overdesign. We are also working closely with international partners who are exploring ISRU (In-Situ Resource Utilisation) and 3D printing using regolith-derived materials for lunar infrastructure. What you should know! The NextSpace TestRig simulates ultra-high vacuum, extreme temperature fluctuations and mechanical loads - simultaneously . Polymers such as PA12, metals such as Inconel and titanium alloys are being tested - for satellites, antenna supports and thermal components for future applications on the moon. A test on 3D-printed nylon PA12 showed that the elongation at break was reduced by 43% in a vacuum compared to normal laboratory conditions. Additive manufacturing as a key technology for autonomous production in space What role does 3D printing play in the context of space materials, particularly with regard to autonomous production in space? Bailet: 3D printing—or additive manufacturing—is central to the vision of autonomous in-space manufacturing (ISAM). It allows us to produce components directly in orbit or on the Moon, reducing reliance on expensive and limited Earth-to-space logistics. But to make ISAM viable, we need confidence that printed materials will behave as expected under space conditions. Our TestRig helps provide that assurance. It also supports future plans for in-situ mechanical characterisation, where testing equipment itself could be miniaturised and deployed in orbit or on the lunar surface to validate structures in real time. How can insights from the TestRig be transferred to industrial applications on Earth – for example, in the field of high-performance materials? Bailet: There’s strong potential to transfer what we learn from space-grade material testing to high-performance Earth-based industries. For example, sectors like aerospace, nuclear, deep-sea, and energy often deal with similarly harsh conditions—extreme heat, vacuum, radiation, or aggressive chemicals. Our methods help characterise how materials degrade under coupled stresses, which is especially relevant for safety-critical components or new additive manufacturing techniques. We're already seeing interest from industrial partners exploring next-gen polymers and composites for lightweight, mission-critical applications on Earth. NextSpace Testrig team in front of the new facility (Dr Gilles Bailet, FRAeS; Matthew Deans; Charlie Patterson); Copyright: Gilles Bailet/Universtiy of Glasgow Next steps: miniaturised test systems for use in space What are the next steps? Are there already specific applications or planned tests involving new materials or components? Bailet: Building on the success of the NextSpace Testrig, we’re now planning to miniaturise the system for use in orbit and, eventually, on the Moon. At the same time, we’re eager to support other actors in the field to ensure that In-Space Manufacturing (ISM) becomes a safe and sustainable endeavour across the industry. Additionally, we’ve joined the Scottish Enterprise High Growth Spin-Out Programme to commercialise our own in-space manufacturing technologies, aimed at 3D printing functional structures like antennas and solar panels directly in orbit—a step that could significantly enhance spacecraft capabilities and mission flexibility. The K-Mag gives you an insight into current projects that visualise the potential of modern plastics. Experience how science and industry are working together on solutions. Discover 3D printing and Additive Manufacturing The portrait was generated by AI. Editor: Simone Ernst | K-Mag Simone Ernst has been writing for various industry magazines for eighteen years and has been part of the K-Mag editorial team since 2024. She is particularly interested in topics such as plastics recycling, sustainability in the plastics industry and career paths in the plastics and rubber industry. At a glance The NextSpace TestRig enables realistic material tests for use in space by combining vacuum, extreme temperatures and mechanical loads. For 3D-printed materials such as nylon PA12 in particular, it shows how much their properties can change in space. Polymers and metals that are to be used in satellite structures and future moon missions are among the materials being tested. Dr. Gilles Bailet The dedicated aerospace engineer (Power & Energy Systems) and lecturer in aerospace engineering, additive manufacturing at the University of Glasgow, develops 3D printing processes for extreme environments such as space. One current focus is on utilising local resources such as moon dust to manufacture materials in space. University of Glasgow - Dr. Gilles Bailet More around Machinery & Production

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  • “Surface quality in injection molding quality”: Why non-planar slicing software is a game changer for additive manufacturing

    Layer Performance software minimizes material consumption and post-processing Exclusively for K-Mag Production of a 1.8 m long mold for automotive body components. Optimized slicing strategies reduced production time and material usage by 70%. Copyright: Institute for Plastics Processing / Layer Performance 27.08.2025 How can 3D printing be made faster, more economical, and with injection molding quality? What role does slicing software play in this? K-Mag got answers to these questions in a chat with Lukas Pelzer from Layer Performance GmbH. Lukas Pelzer, Managing Director of Layer Performance GmbH; Copyright: Layer Performance Mr. Pelzer, what specific problem in additive manufacturing did you want to solve with your software? Lukas Pelzer: Additive manufacturing offers many advantages over conventional manufacturing processes, such as tool-free production of any complex geometry and a very high degree of agility: profitability is no longer linked to the number of identical parts, products can be customized, and on-demand manufacturing is possible. However, there are challenges that inhibit the transformation of the industry through additive manufacturing technologies: The layer-based approach often leads to poor component quality in terms of surface finish and mechanical properties. This is where our software comes in: The Layer Performance process preparation software takes over and optimizes the slicing step and creates application-specific machine code for any material-extruding additive manufacturing system. Compared to previous solutions, the 3D-optimized machine code enables up to ten times faster production with 90% less material and 96% less energy , with up to four times higher mechanical strength of the components and injection molding-quality surface finish. Did you know? Most 3D printers work in planar layers—like a lasagna casserole. Layer Performance does away with layer boundaries and thinks of slicing in three dimensions: this turns lasagna into something more like an ice cream cone with a spiral pattern. Thanks to non-planar slicing, Layer Performance can even be used to print on free-form surfaces—in theory, even a banana. In practice, this can be seen, for example, in the functionalization of individual medical devices. The slicing software incorporates not only mathematics but also artificial intelligence: the path planning adapts to loads – similar to fiber composite materials. Aviation hinge. Top: conventional slicer: cannot take real-world loads into account – the component fails prematurely. Bottom: Layer Performance Slicer: the layers are designed along the critical load paths, increasing component strength; Copyright: Layer Performance Scalable customization and 3D printing on free-form surfaces What are some typical challenges in everyday production? Pelzer: One typical challenge is the tension between mass production and customization : Increasing demands for modularity, upgradeability, and functionalization require us to rethink production, especially in high-wage countries. The Layer Performance Slicing software enables innovative approaches by making the combination of conventional and additive manufacturing processes simple and accessible: Thanks to the 3D-optimized, non-planar machine code, our customers are no longer limited to building components on flat construction platforms. Instead, strands, layers, and entire geometries can be applied directly to existing components with free-form surfaces. This allows individual products to be manufactured faster , more cost-effectively, and in a scalable manner. How does your software solution work in concrete terms, and what is special about your approach? Pelzer: In additive manufacturing, components are usually created in layers. This leads to several disadvantages, such as poor surface quality and low mechanical properties perpendicular to the layers. An example: The mechanical properties of 3D-printed components are currently highly directional. While the properties of the base material are achieved in the strand direction, the components exhibit significantly lower strength and stiffness in the build direction due to the layer composite. Fiber composites exhibit similar behavior, but this is not considered a disadvantage here—on the contrary, the anisotropy of the material is specifically exploited. And we make this possible for additive manufacturing with our slicing software: Strands can be aligned based on a load case. This can increase strength by a factor of four. How can your software be integrated into existing machine parks or production processes? Pelzer: In the additive manufacturing process chain, Layer Performance comes into play at the slicing stage. We do not introduce any new process steps, but replace conventional slicing programs with our optimized, browser-based software. The resulting machine code can be used for all material-extruding systems and all materials. 3D-printed shoe sole. Left: Poor surface quality and stepping due to the use of a conventional slicer. Right: Smooth surface and precise manufacturing due to the use of the Layer Performance Slicer. Copyright: Layer Performance 3D-optimized path planning for less support material and better surfaces How important is the topic of design for additive manufacturing—and what influence does your software have on it? Pelzer: It's an important topic. Thanks to 3D-optimized path planning, Layer Performance offers significantly greater geometric freedom in design and manufacturing. For example, for the first time, free-form surfaces are no longer just approximated, but precisely reproduced. Printing on free-form surfaces is also possible. Avoiding the typical staircase effect ensures excellent surfaces in injection molding quality without any post-processing. By avoiding support material, overhangs can be designed to be significantly steeper, which allows for greater freedom in design. For highly functional components, the targeted definition of mechanical properties analogous to the processing of fiber composites offers completely new possibilities. The targeted programming of local stiffnesses is advantageous for a wide range of industries, for example for ergonomic customization in the medical and healthcare sectors . The portrait was generated by AI. Editor: Simone Ernst | K-Mag Simone Ernst has been writing for various industry magazines for eighteen years and has been part of the K-Mag editorial team since 2024. She is particularly interested in topics such as plastics recycling, sustainability in the plastics industry and career paths in the plastics and rubber industry. At a glance Layer Performance's slicing software enables non-planar 3D printing with significantly better surface quality, higher strength, and less material usage. Co-founder Lukas Pelzer explains in an interview how free-form surfaces can be printed directly and components can be manufactured in injection molding quality without post-processing. Lukas Pelzer Lukas Pelzer is co-founder of the start-up Layer Performance Layer Performance , , which develops innovative software solutions for additive manufacturing and was awarded the 2024 Start-up Prize+ ( Gründungspreis+ des Bundeswirtschaftsministeriums ) by the German Federal Ministry for Economic Affairs and Energy. He is also a research assistant at the Institute for Plastics Processing (IKV) at RWTH Aachen University. Lukas Pelzer at LinkedIn More around Machinery & Production

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  • 6 World Premieres You Can Only Experience at K 2025

    From injection moulding to recycling – these machines set new standards in plastics processing Exclusively for K-Mag Technological world premieres are the hallmark of K. We are already showing you six innovations from K 2025 in the field of machines and systems. Copyright: ChatGPT More efficient, more intelligent, more sustainable – numerous machine solutions will celebrate their world premiere at K 2025. If you don't want to miss out on the plastics processing trends of tomorrow, you should make a note of these six highlights. The new generation of the tie-bar-less Victory Electric from ENGEL offers high precision on a small footprint. Copyright: ENGEL ENGEL: New Generation of the Victory Electric Tie-Bar-Less Injection Moulding Machine ENGEL is setting new standards in electric injection moulding with the latest generation of its victory series of tie-bar-less machines. The compact machine scores with a freely accessible mould space, automated seal assembly and energy-efficient production in a cycle time of just 23 seconds – perfect for technical moulded parts such as fittings. Hall 15 / B42 & C58 To the exhibitor profile of ENGEL The new vertical ALLROUNDER from ARBURG demonstrates film back-injection live at K 2025. Copyright: ARBURG ARBURG: Vertical ALLROUNDER for Film Back-injection ARBURG is exhibiting a vertical ALLROUNDER that demonstrates film back-injection live – in a minimal space, with a new control system and high energy efficiency. A clever solution for the mobility sector, where space-saving, automated production cells are increasingly in demand. Hall 13 / A13 To the exhibitor profile of ARBURG With the new Smartline, Bekum is showcasing a compact blow moulding machine for economical packaging solutions. Copyright: Bekum Bekum: Smartline Fully Electric Blow Moulding Machine The new fully electric Smartline from BEKUM offers excellent value for money with low total cost of ownership. The machine will be shown in action with consumer packaging – ideal for cost- and energy-optimised blow moulding processes in the consumer goods sector. Hall 14 / C03 To the exhibitor profile of Bekum After four years of development, Tederic's new Innova hybrid injection moulding machine is now celebrating its world premiere. Copyright: Tederic Tederic: Innova Electro-hydraulic Injection Moulding Machine Series Four years of development have gone into Tederic's new Innova hybrid series. For its world premiere, the company is presenting a high-speed cell for buckets – digital, efficient and fully automated. A forward-looking solution for the packaging sector. Hall 15 / D40 & C55 To the exhibitor profile of Tederic The new PX series from KraussMaffei scores with energy efficiency and intuitive control. Copyright: KraussMaffei KraussMaffei: Fully Electric PX Injection Moulding Machine with MC7 Control System KraussMaffei presents the new PX series – fully electric, energy-efficient and compact. The highlight is the new MC7 control system with an intuitive web interface. In combination with the LRXplus robot, this creates a fully digitalised production cell. Hall 15 / C24 To the exhibitor profile of KraussMaffei World first: Maximum material purity for sensitive applications. Copyright: Lindner Lindner: Revolutionary “purification process” in mechanical recycling At K 2025, Lindner will present an innovation in the field of mechanical recycling that achieves a degree of purity even with PCR plastics that meets the strict requirements of sensitive packaging applications. The technology and technology partners will be presented for the first time during the press conference on October 8 at 10:15 a.m. in Hall 10, Room 10.1A. Hall 9 / B17/19 and outdoor area CE-02 To the exhibitor profile of Lindner These six world premieres show where the journey in plastics processing is headed: more compact, more efficient and smarter. Anyone looking for future-proof production solutions should be at K 2025 in Düsseldorf from 8 to 15 October. Secure your ticket now and experience innovation live! The portrait was generated by AI. Author: Elena Blume | K-Mag Elena Blume has been writing for various industry magazines for eight years and joined the K-Mag editorial team in 2021. She is particularly interested in topics related to innovative plastics solutions that contribute to sustainability and address current challenges relevant to industry and society. At a glance Numerous technological innovations will celebrate their premiere at K 2025. We present six innovations that will be on display for the first time at the trade fair – compact, efficient and forward-looking for plastics processing. More around Machinery & Production

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  • K 2025: ENGEL focuses on digitalisation, automation and sustainability

    Stefan Engleder, CEO, ENGEL AUSTRIA GmbH gives an insight into the tradefair ENGEL will once again be represented with its injection moulding machines at K 2025. They can be found in Hall 15/B42...C58; Copyright: ENGEL AUSTRIA GmbH Be connected with the future of injection moulding – is ENGEL's motto for the K 2025 Mr Engleder, what does your company stand for - and what particularly characterises your product or service portfolio? Stefan Engleder : ENGEL stands for technologically leading injection moulding solutions that combine maximum efficiency with customised customer orientation. Our product portfolio ranges from standardised WINTEC solutions to highly integrated, digitalised ENGEL production cells with a focus on sustainability and automation. With this two-brand strategy - ENGEL for tailor-made innovations and WINTEC for accessible, near-standard solutions - we offer investment-proof technologies for every injection moulding company. What topic or innovation are you bringing to K 2025 - and why is it relevant for the industry? Engleder: ENGEL is presenting three main focal points at this K: Focus on digitalisation and AI . Digital assistants and the possibilities of AI systems in particular offer enormous potential in injection moulding. Process deviations can be recognised more quickly, thus increasing quality and productivity. ENGEL will be demonstrating its solution expertise in various industries. Whether highly decorative large-surface components in the exterior of vehicles that are flooded with polyurethane, solutions for the energy transition using fuel cell seals on vertical machines, packaging solutions with recycled material or shortened validation processes in the medical sector using digital assistants. ENGEL has a suitable customer solution in its portfolio for every challenge. We present a mechanical engineering innovation. A combination of flexibility, efficiency and precision. Unfortunately, we can't reveal any more here at the moment, but you can look forward to it - it's well worth it! "The plastics and rubber industry of the future is networked, responsible and ready to actively shape social change with technical excellence." Stefan Engleder, CEO ENGEL AUSTRIA GmbH ENGEL focusses on exchange, customer solutions and new partnerships at K 2025 What would you like to talk to visitors about at K 2025 - what is particularly important to you? Engleder: Open dialogue about practical, customised solutions is a key concern for us. We want to consider together how technological innovation can improve our customers' everyday lives - simply, efficiently and future-proof. Did you know? During injection moulding, plastic is injected into a mould under high pressure. This allows components to be produced quickly in large quantities. From toothbrush handles to coffee machines and car interiors - injection moulding technologies can be found in countless everyday objects. What do you expect from your participation in K 2025 - and what are you personally looking forward to the most? Engleder: We expect to deepen existing customer relationships, initiate new partnerships and develop concrete project ideas. Personally, I'm looking forward to the direct dialogue - direct feedback from the market is key to our further development. Here you will find the ENGEL stand during K 2025 The portrait was generated by AI. Editor: Simone Ernst | K-Mag Simone Ernst has been writing for various industry magazines for eighteen years and has been part of the K-Mag editorial team since 2024. She is particularly interested in topics such as plastics recycling, sustainability in the plastics industry and career paths in the plastics and rubber industry. At a glance ENGEL will be presenting digital assistance systems, automation solutions and sustainable injection moulding technologies at K 2025. The focus will be on practical, customised solutions and direct exchange with existing and new business partners. More around Machinery & Production

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  • Wilson Sporting Goods using 3D printing to accelerate the injection molding process

    Using soluble molds enables company to fail faster, explore thousands of options cost-effectively Exclusively for K-MAG Copyright: Nexa3D 03.11.2023 Baseball bats. These are not the products that one would typically associate with accelerated product development for injection molding. Unless, of course, your name is Glen Mason and you are the director of advanced manufacturing for Chicago-based Wilson Sporting Goods Co. Mason, who sold his injection molding company CF Plastics in Hillsboro, Ore., to Wilson in 2019, joked in a recent interview that "Advanced manufacturing means something we don't know how to do. So I'm the director of things we don’t know how to do." But he is learning fast, and he and his colleagues are leveraging the latest 3D printing technology to accomplish things in injection molding that were never possible before. The Wilson subsidiary called DeMarini Sports Inc., headquartered near Mason's former firm in Hillsboro, has been developing and manufacturing youth baseball bats for more than three decades. These include aluminum bats, polymer composite bats with carbon fiber-reinforced barrels and bats made primarily with thermoplastics. Specific components such as knobs, end caps and the interface between the handle and the barrel tend to be injection molded from engineering resins. DeMarini's customers include everyone below the Major League level – from Little League and college teams to the minor leagues. Mason said he has known these neighbors of his since the late 1990s, just years before Wilson bought DeMarini in 2000. "I started working with Wilson as a customer," he recalled, "and we developed a lot of great technology together." Size matters: The large build volumes of Nexa3D printers support the printing of large molds and mold inserts. Copyright: Nexa3D A one-day design / print / mold cycle: 6 mold sets printed in one batch. Copyright: Nexa3D The Nexa3D LSPc membrane allows massive parts to be printed with ease. Copyright: Nexa3D Low-volume injection molding Mason says "Most people don't think of injection molding as low volume – why would I want to do that? But that's really the world that we're in. We make a lot of parts in a relatively low-volume model, on time. Our average lead time is 24 hours, between when we know we need something and when we deliver it to our team." Wilson employs a range of engineering plastics and no commodity resins, but he declined to specify which materials they use. Mason had been dabbling in 3D printing since 2008 but three years ago, in the midst of the Covid pandemic, he met some officials from Copenhagen-based Addifab ApS, the developer of Freedom Injection Molding (FIM) technology, which has proven to be a game-changer. Their FIM process creates tool parts from computer-aided design files to a molded component in a single day using soluble, single-use 3D printed molds. This process previously often would take months. The FIM technology also eliminates demolding and ejection obstacles, such as drafts, split lines, sliders and collapsible cores. "We benchmarked the process," Mason recalled in a phone interview. "We brought in their original system, a very small printer. It was very easy to use, but just too small for us." Entry of Nexa3D Then, in April 2023, Ventura, Calif.-based 3D printer maker Nexa3D Inc. closed on its deal to acquire Addifab. At roughly the same time Nexa3D also introduced its latest model, the Xip Pro, its largest industrial resin printer yet with what Nexa calls the largest build volume and fastest print speed in its class. With a 19.5-liter build volume, XiP Pro is said to deliver the daily throughput equal to more than four other industrial resin-based printers. Nexa3D leverages its Lubricant Sublayer Photo-curing (LSPc) photopolymerization technology to achieve its high speeds. "That's what sets the Nexa3D printers apart," says Lasse Staal, the firm's business development director. A new design is born: 3D-printed mold inserts allow customization in mass manufacturing. Copyright: Nexa3D. The end result: An art-to-part journey shaving 40% off the mold design cycle. Copyright: Nexa3D Mason was fascinated by the possibilities. "Once the Nexa3D relationship started, we thought this was fantastic. Their print speed was much faster – not just in the Z print direction but also the actual X-Y capacity they have, the overall build volume. We were probably 10x faster on the X-Y plane and probably 20x faster on the overall build volume. For us, this opened up many more opportunities." "We started working together – Nexa3D as the printer supplier, Addifab as the resin supplier, and us as the black-box R&D for Wilson. We saw the opportunity for Wilson to help both Nexa3D and Addifab to integrate this technology for their customers." Mason rightly proclaims that "Nobody wants molds. People want the parts that come out of the molds. So I helped to integrate the solution version of this – not the technology version, the solution version – of how do we get to that finished part." Collaborating for the common good Via this novel arrangement, Nexa3D reaches out to Mason and his team when a customer wants to test a specific product concept, and Mason then works with the customer to develop prototypes and find solutions based on FIM. "It's a good partnership because Wilson learns a lot as we get exposed to challenges, ideas and processes that we probably wouldn’t have looked at. And it helps Nexa3D to better support customer application development. So it's a great collaboration, a win-win for all, including for the OEMs." He notes how the parties can have a conference call with an OEM seeking a solution. They discuss the options, and then, like magic, five days later the customer receives some injection molded prototype parts made in their material. "Now they say, 'OK, this is real!'. For me, as an internal R&D person at Wilson, the best solution is lots of people using this technology. I'm not worried about keeping this a secret. I want it to survive, I want it to thrive." Glen Mason sold his injection molding company to Wilson Sporting Goods and joined them to head their advanced manufacturing efforts. Copyright: Wilson Sporting Goods Mason says that he that he believes the team at Nexa3D, "has fundamentally changed what injection molding is. They've opened up access to injection molding for so many new ideas. The cost of participation is so low. Cap-ex is relatively low. The operating costs of the machine are almost insignificant. Material cost, if you’re doing elegant design work, is not that high." "Now I can get there faster, cheaper and continue to iterate within our model. We can try all the ideas and see which ones develop more organically." Mason notes that Wilson has been using the Xip Pro to print prototypes. Prototypes are great, he says, but as with molds, a prototype is not really what you want. "What you want is a prototype process that can scale to deliver. Right now, Nexa3D has that process." Nexa3D has its xMOLD resin, a high-performance dissolvable resin developed for the Freeform Injection Molding process. Mason sees this technology as a tool "that basically unlocks all of the injection molding options." To date, he says he has yet to find a process that is faster and less expensive than injection molding. "So my focus is how do I use 3D printing to accelerate injection molding. We're already very good at low-volume injection molding, what I call digital injection molding, basically making one part. This enabling us to do that on a much, much larger scale and at a way lower cost." "Because we can iterate so much quicker, print tools faster than we can machine, and eliminate a couple of the steps in the process, our R&D team can afford to be wrong," Mason said. "This helps us to greatly improve our time-to-market, allowing us to be quick and nimble with our design decision-making process." Robert Grace More around Additive Manufacturing

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  • In-house Recycling: Economical Plastics Recycling for the Injection Molding Industry

    How WITTMANN is driving the circular economy through digitalisation Exclusively for K-Mag WITTMANN relies on in-house recycling to make injection molding production more sustainable. Copyright: WITTMANN 04.12.2024 Rising raw material prices, sustainability pressure and the development of a circular economy are presenting the injection molding industry with new challenges. With in-house recycling, which integrates waste directly back into production, WITTMANN offers a solution that not only reduces costs but also protects the environment. In an interview with K-Mag, Michael Wittmann talks about solutions for a more sustainable plastics industry, the S-Max 2 granulators from WITTMANN and the role of digitalisation for a functioning circular economy. Challenges and solutions Michael Wittmann, Managing Director, WITTMANN Technology GmbH. Copyright: WITTMANN Mr Wittmann, what challenges is the injection molding industry currently facing? Michael Wittmann: The challenges are manifold, first and foremost the development of a circular economy for plastics. It is our goal and our responsibility as a plastics industry to ensure that no more plastic materials end up in the environment – worldwide. To achieve this, we need to provide information and education, establish and expand structures – such as collection systems and recycling capacities - and develop new technologies for even more efficient and higher-quality recycling. Efficient, because sustainability must always pay off so that everyone can participate. High-quality, because we still downcycle too much. But that is precisely a dead end. To really keep materials in the cycle, we need to ensure that products made from recycled material fulfil the same requirements and have the same properties as the products from which the recycled material was obtained. What technical challenges arise when integrating recycled materials into the injection molding process, and how do the S-Max 2 granulators from WITTMANN help to overcome them? Wittmann: There are various recycling processes. With our granulators, we are active in the field of mechanical recycling. The granulators are used directly in the plastics processing plant and make it possible for production waste, such as sprues and rejects, to be ground on site and fed back into the injection molding machine. The advantages are waste-free production and easy access to unmixed recyclate. This in-house recycling enables processors to fulfil prescribed recyclate usage quotas very cost-effectively. The cost of purchasing raw materials is reduced and the cost of disposing of production waste is also saved. As far as the technical challenges are concerned, it is all about constant processes, which we achieve through digital assistance. There are no further technical challenges for the injection moulding machine. It makes no difference to the machine whether it processes virgin material or recycled material. Four S-Max 2 granulators from WITTMANN are used for in-house recycling in the new recycling centre of a well-known manufacturer of electronic components. Copyright: WITTMANN Efficiency and cost-effectiveness through in-house recycling Processing plastics with a high glass fibre content often places special demands on the grinder. What properties of your S-Max 2 granulators enable efficient processing of materials with a high glass fibre content? Wittmann: When choosing a granulator, it is always important to consider the material, just as when selecting injection moulding machines and peripherals. Classic granulators are sufficient for most materials. We have developed special surfaces for particularly abrasive materials, such as glass fibre-reinforced plastics. The grinding principle of the S-Max 2 also reduces wear. The S-Max 2 works with toothed rollers and low speeds, which means a high torque with a reduced mechanical load. This means that the S-Max 2 grinders achieve long service lives even when grinding abrasive materials. The plant uses 15 injection molding machines that produce a wide range of plugs and connectors. The latest systems include two energy-efficient SmartPower machines from WITTMANN, which impressed the decision-makers. Copyright: WITTMANN The S-Max 2 grinders amortise after just six months. What factors contribute to this rapid amortisation? Wittmann: The amortisation time always depends on the application. It is often even less than six months. The rule is: the more expensive the raw materials and the higher the proportion of recycled material, the faster the investment in a granulator for in-house recycling pays for itself. How does this affect the competitiveness of your customers? Wittmann: A customer from the electronics industry recently told us that he can only achieve competitive unit costs by using recycled material. He has therefore set up a recycling centre with four S-Max 2 granulators in the injection moulding production facility. Since the start of the in-house recycling project, the consumption of virgin material has fallen continuously, which is directly reflected in the unit costs and thus strengthens competitiveness. He can add up to 25% recyclate to his products. Digitalisation for consistent quality in the recycling process A material bin with regrind is transported to the central material supply system on the upper floor using a forklift truck and a sophisticated safety mechanism. Copyright: WITTMANN What role do digitalisation and automation play in the recycling process? Wittmann: Both topics play a very important role, with different effects being achieved independently of each other. Automation is a must in plastics processing companies, especially in high-wage countries. And this doesn't just refer to automated parts handling through the integration of robots into the injection moulding machines. Our granulators also achieve a high degree of automation. For example, the automatic self-tensioning system in our granulators eliminates the need for constant retensioning of the drive belt, meaning that the granulators can be operated maintenance-free. There is a level sensor in the grinder's grist container for automatic emptying of the grist container. We use digital assistance in the injection moulding machine to achieve a constant process. The quality of recycled materials – especially PCR from municipal collections - is subject to greater fluctuations than the quality of virgin material. This is precisely where HiQ Flow comes in. The software determines the viscosity of the plastic melt during the injection phase. If the viscosity deviates from the reference value, it adjusts the processing parameters to the current conditions in order to keep the component weight constant. This happens in fractions of a second and this is precisely where the great opportunity of digitalisation lies. The production of rejects can thus be proactively prevented. Gravimetric dosing devices of the Gravimax type feed the regrind into the material supply system precisely to the gram. Copyright: WITTMANN What challenges do you see for your customers in the coming years, and how will WITTMANN support them in mastering them? Wittmann: Many of the current challenges result from legal requirements. The EU wants to be climate-neutral by 2050. This also obliges manufacturing companies to gradually reduce their CO2 emissions, which brings the product carbon footprint (PCF) into focus. Information about the carbon footprint of individual products is a prerequisite for implementing effective measures to reduce greenhouse gas emissions. So it's all about transparency. This is because emissions from the entire life cycle of a product – from raw material extraction to recycling – are included in the PCF. The calculation can be correspondingly laborious. We are simplifying this process for our customers with new software. In future, the software will be available as a new functionality of TEMI+, the WITTMANN Group's MES. We have also developed our own software to determine the energy consumption of the production cell required for the calculation. iMAGOxt makes the energy consumption of each individual consumer within the production cell transparent cycle by cycle. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Elena Blume (Editorial team K-Mag) More around Machinery & Production

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  • Particle foam, shapely and flexible: BEAD.MACHINE sets new standards in processing

    Interview with Stefan Hofmann, Managing Director, Siegfried Hofmann GmbH Exclusively for K-Mag The BEAD.MACHINE from Siegfried Hofmann GmbH enables the efficient production of complex moulded parts from particle foam – setting new standards. Copyright: Hofmann 31.01.2024 Lightweight with great significance: particle foam offers a wide range of applications – from automotive to packaging and lifestyle. The BEAD.MACHINE from Siegfried Hofmann GmbH marks a significant advance in the processing of this versatile class of materials: it enables the efficient production of complex moulded particle foam parts, setting new standards in terms of product quality and environmental friendliness. Stefan Hofmann. Copyright: Hofmann In an interview with K-Mag, Managing Director Stefan Hofmann talks about the BEAD.MACHINE and its innovation and contribution to sustainability, as well as the extent to which Siegfried Hofmann GmbH is helping to shape the plastics industry of the future. Mr Hofmann, which particle foam materials can be processed with your BEAD.MACHINE? Stefan Hofmann: Our moulding machine gets the best out of a wide range of materials: from EPP, EPA, E-TPU, EPS, EPE to m-PPE, lightweight end products with good shock absorption, insulating properties, energy absorption or high impact resistance can be produced as required. As an option, PP inlays can be encapsulated directly in the mould so that 2K products can be easily implemented. This opens up a wide range of possibilities for the sports and lifestyle, packaging or automotive sectors - with just one machine. The BEAD.MACHINE can process a wide range of materials, including EPP, EPA, E-TPU, EPS, EPE and m-PPE. Copyright: Hofmann Which technological innovations are decisive for the high product quality? Hofmann: The basis for premium quality is our additively manufactured moulds, which are produced using 3D metal printing: Thanks to the invisible integration of the nozzle outlets into the mould, smooth surfaces suitable for visible areas are no problem. This means that previously unthinkable shapes and parts can be realised. A similar effect can only be achieved with conventional aluminium tools using expensive graining processes or laser ablation. In addition, the secret of maximum dimensional accuracy lies in the technology of the BEAD.MACHINE: thanks to its electric spindle drive, it is probably the most accurately controllable particle foam moulding machine: High parallelism of the clamping plates and precise plate positioning of ± 0.01 mm ensure high-quality results. Adjustable travel dynamics, supplemented by any travel and embossing profiles, enable maximum customisation options with the best, consistent finish. With the patented surface technology, fine details and detailed structures can be realised without visible nozzle outlets. Copyright: Hofmann What new product possibilities and designs does the BEAD.MACHINE enable that were previously unrealisable in particle foam processing? Hofmann: Thanks to the surface technology we have developed and patented, fine details and detailed structures can be realised without visible nozzle outlets. This enables our customers to realise high-quality products with interesting designs that were previously unthinkable. This innovation can be used to produce new creations and inspire end customers, particularly in the lifestyle sector. In this way, our technology can potentially give our customers a competitive edge. This is particularly interesting in combination with plastic inlays: with the BEAD.MACHINE, these are easily encased in particle foam and firmly bonded to form a product. Our spiral ball demonstrator - developed jointly with WSVK Oederan GmbH – shows how dimensionally stable and flexible the result can be. The spiral ball demonstrator was developed together with WSVK Oederan GmbH and shows how dimensionally stable and flexible the result can be. Copyright: Hofmann How exactly does the machine contribute to environmentally friendly production? Hofmann: Sustainability was particularly important to us when developing the BEAD.MACHINE: the machine is characterised by its low consumption of water, energy and compressed air. The 3D-printed moulds are up to 95% lighter than conventional alternatives and can therefore be heated and cooled much faster. The resulting reduced cycle time saves corresponding resources. In addition, the high dimensional accuracy and reproducibility, combined with very stable cycles, tend to result in fewer rejects, which is reflected in lower material consumption – another plus point for the environment. The machine is also sustainable in terms of transport: thanks to its compact footprint of approx. 5.8 m², the particle foam moulding machine fits on a normal truck. This not only simplifies logistics, but also saves CO2. A positive side effect is, of course, that it fits into small production halls and existing structures can therefore be optimally utilised. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category What customisation options does the BEAD.MACHINE offer? Hofmann: The BEAD.MACHINE is available as part of a flexible system: The basis is always the moulding machine in combination with a specially developed filling container. Conveyor belts and customised automation solutions are available as options. Depending on their requirements, our customers can choose from various technologies such as handling systems, grippers or quality inspection technology, so that fully automated processes can be easily mapped. We have enough space to assemble and perfect turnkey solutions in-house according to our customers' process specifications and deliver them ready to use to the desired location worldwide. Of course, we also support our customers in mapping their processes with digital twins or simulations. The BEAD.MACHINE is available as part of a flexible system: the basis is the moulding machine with a filling container. Customers can then choose from different technologies depending on their requirements. Copyright: Hofmann What feedback have you received from your first customers? Hofmann: As the BEAD.MACHINE is our first in-house product, we were naturally particularly excited about the feedback from our customers – we were all the more pleased to receive positive feedback. Our customers were particularly impressed by the flexibility of the machine and the quality of the end products. In fact, we have already received further enquiries and orders for BEAD.MACHINEs, which proves that we have hit a nerve in the market. One particular highlight was the positive feedback from Oechsler, which was published on their LinkedIn profile. How do you see your role in the plastics industry of the future? Hofmann: Basically, Siegfried Hofmann GmbH stands for innovative all-inclusive premium solutions in mould making and mechanical engineering with the best service, even after delivery. We don't leave our customers to fend for themselves, and this also applies to the ever-increasing demands in terms of sustainability. For example, we have been dealing with the issue of carbon footprint for a long time and are already listed on monitoring platforms such as Ecovadis and Integrity-Next to make it easier for our customers to fulfil legal or internal sustainability requirements. Sustainability combined with innovation and top quality – that is our goal. Elena Blume (Editorial team K-Mag) More around Machinery & Plants

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  • 3D Printing Redefined: Manufacturing Plastic Components Faster and More Precisely

    Electrophotographic 3D printing from TH Köln and mz Toner Technologies offers potential for applications in aerospace and electronics Exclusively for K-Mag The new 3D printing process is suitable for manufacturing precise plastic parts under zero gravity conditions. Copyright: Oulailux - stock.adobe.com 06.11.2024 Just a few years ago, 3D printing was still a niche product. Today, it has long been relevant to the market. The market volume for 2024 is estimated at 27.52 billion US dollars, with an annual growth rate of 23.6% forecast until 2032. However, despite the rapid increase, there are limits, for example in terms of production speed or printing accuracy. The electrophotographic 3D printing process at TH Köln could overcome these limitations. In an interview with K-Mag, Prof. Dr. Danka Katrakova-Krüger explains the advantages of this process and which industries could benefit from it. From idea to implementation: the path to an innovative printing process Prof. Dr. Danka Katrakova-Krüger, Laboratory for Materials at the Institute for General Mechanical Engineering, Cologne University of Applied Sciences. Copyright: TH Köln How did the idea for the research project come about and what were the most important goals of the project? Prof. Dr. Danka Katrakova-Krüger: Our company partner mz Toner already had experience in "flat" printing in the field of ceramic decoration. However, in order to obtain three-dimensional objects from this, an additional step was required in which the previously printed (multiple) layers are stacked and bonded together. Toners made of suitable polymer materials had to be developed for this purpose. The process has great potential for application, for example for spare parts in space where there is no or low gravity, as no loose powder is used, but the particle sizes are such that good mechanical properties can be achieved. Can you explain the printing process used in your method in more detail? Katrakova-Krüger: The new electrophotographic 3D printing process works as follows: First, an electrical charge image is selectively generated on a charged photo drum, in a similar way to laser printing. The toner mixture accumulates at the points of the charge image, creating a layer of the image. The polymer particles of this layer are then transferred from the photo drum to the transfer medium and pre-fixed. In a separate machine, the individual layers of the transfer medium are superimposed and fixed to create the finished three-dimensional component. Figure 1: Electrical charge image is generated. Copyright: mz Toner Technologies Figure 2: Layers are transferred and fixed by the transfer medium. Copyright: mz Toner Technologies Challenges and solutions in the development process hat particular challenges had to be overcome in the development of this new 3D printing process? Katrakova-Krüger: There were essentially three hurdles that had to be overcome: toner, transfer medium and stamping machine. During development, particular focus was placed on the toners, which are a complex mixture of material to be printed, in our case polymer, carrier material and many other additives in the right quantity and morphology. Setting the triboelectric charge is also a demanding task. The next challenge was to find a suitable transfer medium. On the one hand, this must ensure good adhesion of the printed layers and, at the same time, enable good release during the stamping process. There were various aspects to consider during stamping, in particular positioning accuracy, pressure distribution and temperature in the installation space. The optimum process windows for the different polymers then had to be determined. Comparable material properties and competitive advantages Printed tensile samples on transfer medium. Copyright: mz Toner Technologies What material properties and mechanical characteristics do the printed components have, and how do they compare with components from other manufacturing processes such as the fused layer process or injection molding? Katrakova-Krüger: An electrophotographically printed tension rod made of ABS has a tensile strength of around 1900 MPa, a modulus of elasticity of around 40 MPa and an elongation at break of just over 2 percent. This means that our tensile strength is 25 percent higher than that of FDM (1627 MPa) and 20 percent lower than that of injection molding (2300 MPa). The modulus of elasticity of our sample is 43% higher than that of FDM (22 MPa) and only 12% lower than that of injection molding (44 MPa) for the same material. The elongation at break is similar to FDM at around 3%, but significantly lower than the values achieved in injection molding (12%). However, we are continuously working on further improving the mechanical properties. What advantages does this process offer, for example for industrial applications, compared to other 3D printing processes? Katrakova-Krüger: Thanks to the high printing speed of electrophotography and the two-step process, high production rates can be achieved. The use of small polymer particles enables a high print resolution. It is also possible to process different materials in one component and produce several parts at the same time. As the process is not dependent on gravity, an application in space would also be possible. What is the current throughput of the developed 3D printing prototype and what factors influence the number of workpieces that can be produced? Katrakova-Krüger: The maximum build-up rate depends on the 2D printer size and the number of stamping machines. In the 2D area, printing speeds of up to 5 m² per minute are currently possible. It is possible to print several layers of a component or to print different components at the same time. Up to 8 different toner materials per layer can be printed simultaneously. The overall production speed increases the more transfer units work in parallel. In principle, the process is able to compete with injection molding in terms of quantities. Industrial applications and potential for the future Finished tension rod (here ABS). Copyright: TH Köln What role could this technology play in the future of additive manufacturing and which industries could benefit in particular? Katrakova-Krüger: Electrophotographic 3D printing is a serious competitor to injection molding. In contrast to classic injection molding, this process does not require any specially manufactured, expensive tools. Therefore, different components can be produced with the same machine setup without any retooling. This leads to savings in storage, manufacturing and retooling costs and enables full automation of the process in line with Industry 4.0. In addition, the process is currently being extended to other materials, meaning that electrophotographic 3D printing should also be available for metallic and ceramic materials in the long term. Many areas of application are conceivable: in aerospace, which triggered the development, but also in electronics, for solar cells, batteries, and why not also for consumer goods such as household electrical appliances – there would be no limits to material and color combinations. Elena Blume (Editorial team K-Mag) More around Machinery & Production

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  • traceless materials secures €36.6 Million Series A to build first industry plant for bio-circular alternative to plastic

    Copyright: traceless 01.12.2023 Bioeconomy startup traceless, which produces a natural biomaterial as an alternative to plastic, announces the completion of a €36.6 million funding round. The Series A funding round is led by private equity fund UB Forest Industry Green Growth Fund ("UB FIGG") , which invests in sustainable and resource-efficient forest and bio-based industries, and complemented by SWEN CP's Blue Ocean fund , which invests in innovations that help address the three existential threats to ocean health: overfishing, pollution, and climate change. A local banking syndicate consisting of GLS Bank, Hamburg , and Hamburger Sparkasse also participated in the financing round, as well as the company's three existing investors, green-tech investor Planet A Ventures, seed investor High-Tech Gründerfonds (HTGF) , and deep tech investor b.value . Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Transforming to a circular economy Plastics not only leave behind the visible traces of global plastic pollution, but also contribute significantly to the climate crisis through their resource-intensive production from fossil raw materials. As part of a sustainable circular economy, the bioeconomy offers a solution: traceless materials has developed a holistically sustainable material to tackle the plastic crises. The natural biomaterial traceless® is certified completely bio-based, home-compostable, and plastic-free. By using agricultural residues, valuable biomass resources are conserved. The patent-pending technology is based on natural polymers, contains no potentially harmful chemicals, and has a minimal ecological footprint: compared to plastic, 91% of CO2 emissions and 89% of fossil energy requirements are savedduring production and disposal. Anne Lamp, Co-Founder & CEO says: "Through scaling our innovative technology, we prove that a climate-friendly, circular, resilient and regenerative industry is possible. With our novel biomaterial, we can make a significant contribution to solving plastic pollution. We are convinced that UB FIGG and SWEN's Blue Ocean fund are a great addition to our shareholders as they have relevant knowledge in our industry. The fact that both our investors and the banks fully support our mission was a decisive criterion for us." In order to implement the innovative technology on an industrial scale for the first time, traceless is building a demonstration plant in Hamburg. With this production plant, the company will replace several thousand tons of conventional plastic annually and at the same time save a significant amount of CO2 emissions, fossil resources, water, and agricultural land. Sakari Saarela, Partner at UB FIGG: "traceless' approach to use widely available agricultural side streams to replace fossil-based plastic and the financial opportunity their solution proposes convinced us both economically and ecologically. The traceless team has achieved extremely strong results in terms of material performance, development times and commercialization of the new material. We are looking forward to accompanying Anne, Johanna and the team in the scale up of this innovative technology." The Series A financing round is now the second part of the company's financing strategy to expand its production capacities. As announced earlier this year, the Federal Ministry for the Environment, Nature Conservation, Nuclear Safety and Consumer Protection is funding this project with an amount of EUR 5,128,401 from the Environmental Innovation Programme. Johanna Baare, Co-Founder & COO explains: "Financing capital-intensive start-ups is still unfamiliar to many investors and banks. This makes it a special challenge for industrial manufacturing start-ups like us that are developing the innovativetechnologies of tomorrow. We are very pleased that with UB FIGG, SWEN CP, Planet A, HTGF, b.value our local bank consortium we have found partners who share our vision and have recognized and understood the challenges of financing our hardware scale-up. With their support, we are going to reach our ambitious goals to make our contribution to solve global plastic pollution!" The company produces traceless® materials in the form of a granulate that can be further processed using standard technologies in the plastics and packaging industry. Thus, the material can be used in awide range of end products - from rigid molded parts and flexible films to paper coatings or adhesives. The traceless team is celebrating the closing of their Series A funding round. Source: traceless Olivier Raybaud, Managing Director of SWEN Capital Partners says: "The Blue Ocean fund seeks to invest in startups bringing innovative solutions to address the 3 main threats to our ocean: overfishing, ocean pollution and climate change. As plastic pollution is one of the main pollutants threatening our ocean, we were seduced by traceless, a bio-based and biodegradable material that can replace plastics in products that easily end up in the environment, and hence in our ocean, such as single-use packaging as well as hidden plastics in adhesives and paper coatings. traceless is a compelling alternative to applications where reusable solutions are not sustainable and technical recycling is not feasible." Founded in 2020, the traceless team of 40 employees is aiming to replace plastics in large quantities by demonstrating for the first time that the innovative process can be implemented on an industrial scale. In parallel with the technology scale-up, the continuously growing is developing pilot products made from traceless® materials with its customers and partners. traceless' mission: to address global plastic pollution, as well as challenges related to climate change, resource scarcity, and the loss of biodiversity. With its innovative material solution, traceless aims to be a change-enabler for driving the green transformation of the industry. Source traceless materials GmbH More around Machinery & Plants

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  • Challenges and Perspectives in the Plastics and Rubber Industry

    VDMA Calls for Courage and Innovation in Difficult Times Despite a 22% decline in incoming orders in 2023, the German plastics and rubber machinery industry achieved a price-adjusted sales increase of 13%. 27.06.2024 The associations of the plastics and rubber machinery industry are facing significant challenges. Geopolitical changes, high energy costs, and declining order intakes require new strategies and bold decisions. Impact of Geopolitical Changes on the Machinery Industry At the annual conference of the associations for plastics and rubber machinery, waste and recycling technology, EMINT, and the working group for hybrid lightweight technologies on June 5, 2024, Ulrich Ackermann, Head of VDMA Foreign Trade, discussed the impact of geopolitical changes: "The globalization of the world economy is increasingly under pressure. China is pursuing autonomy with corresponding consequences for European mechanical engineering, and in the USA, the Biden administration has continued the 'national approach' to trade policy of the Trump administration in recent years. As a result, the world is heading towards a new bipolar world order." For European mechanical engineering, this means the necessity of establishing their own production facilities in major target markets and offering market-specific products. Many plastics and rubber machinery manufacturers have already adapted to these challenges. Decline in Order Intakes Despite Revenue Growth Although order intakes dropped by 22% in 2023, the German plastics and rubber machinery industry managed to conclude the year with a price-adjusted revenue increase of 13%. This growth is gratifying and shows that companies were able to acquire many orders in recent years, which are now being successively fulfilled. Ulrich Reifenhäuser, Chairman VDMA Plastics and Rubber Machinery Association However, global conditions have changed, and many companies are currently dealing with underutilization. Causes of the Challenges The industry is facing several factors: Economic Uncertainties: Global economic turbulence is affecting the business environment. Raw Material Shortages: Bottlenecks in essential raw materials are hampering production. Sustainability Requirements: Stricter environmental regulations demand new production processes. Outlook and Strategies to Overcome the Crisis On the revenue side, the current year remains challenging due to the lack of new orders. If market uncertainties gradually diminish by summer and interest rates stabilize, investments in new machinery could pick up again. Depending on how quickly new orders are received, revenue development this year could either remain flat or slightly decline. Mechanical engineering is a cyclical business. The current economic downturn in the plastics and rubber machinery industry is more than just a cyclical dip. "We cannot and must not downplay the economic weakness resulting from the current situation. But what we can do is focus on our strengths, use our innovative power, and solve current market issues with new, precise solutions," Reifenhäuser is convinced. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Outlook on K 2025 European machinery manufacturers deliver the technologies and digital solutions necessary to tackle today's major challenges: more circular economy and recycling, climate protection through reduced CO2 emissions, and machines and systems tailored to the needs of customers worldwide. The VDMA fully supports the motto of K 2025 "The Power of Plastics! Green – Smart – Responsible" and its Hot Topics "Shaping the Circular Economy", "Embracing Digitalization" and "Caring about People". At the general meeting, the new board of the Plastics and Rubber Machinery Association for 2024 to 2027 was elected. Ulrich Reifenhäuser remains the chairman of the committee. Source VDMA More around Machinery & Plants

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  • Laboratory extruder relaunched: ZE 28 BluePower

    Copyright: KraussMaffei Group GmbH 22.12.2023 KraussMaffei Extrusion GmbH introduced the newly designed ZE 28 BluePower laboratory extruder. In addition to fast availability and a highly attractive price, this extruder is characterized by improved ease of operation and enhanced performance. The new high-performance laboratory-scale extruder convinces by a perfect combination of free volume (OD/ID =1.65) and high torque density of 13.6 Nm/cm³. Depending on the specific process requirements, the processing section can be configured within a length range of 32 to 64 D and equipped with up to three side feeders. Just like the other extruders in this series, the ZE 28 BluePower is available in three material variants, in order to offer the wear resistance and corrosion protection required for customer-specific applications. New paths for laboratory extruder customers: The design study shows the new low-cost standard version of the ZE 28 BluePower extruder. Exhibitors & products around machinery & equipment Machinery and plant for processing Post processing machines & downstream equipment Machinery & plant for finishing, decorating, printing and marking Welding machines Process automation To all exhibitors in this category Solution for any application with optimized ease of operation The laboratory extruder is designed to implement bespoke process solutions thanks to a wide variety of configuration options. These include processing section elements in high-temperature design with a thermal resistance of up to 420°C. In addition, the automatic screw removal towards the drive – or "UltraGlide" feature for short – further expands the range of applications for this machine. Since October 2022, the standard version of the ZE BluePower extruder has been equipped with the newly developed "pioneer processControl" (ppC) featuring wizards (assistants) for enhanced production reliability. These wizards provide the operator with step-by-step instructions for certain procedures such as starting the production line or shutting it down. As a matter of course, common up- and downstream systems can be integrated into the new control system. Focus on higher efficiency, shorter delivery times and increased cost effectiveness "After intensive discussions with our customers, we have responded to current market requirements and improved our twin-screw extruder accordingly", says the Michael Tieben, Product Manager for the ZE BluePower series. "In the future, we will offer our extruder with a cost advantage as compared to our competitors and an attractive delivery time." High energy efficiency, excellent temperature control within the processing section, improved surface cleaning, enhanced power electronics protection and an optimized strand extrusion die are the key features of the relaunched ZE 28 BluePower design. The processing sections including the screw configurations are still customized and all process-engineering results can be scaled up without any problems to the entire BluePower extruder range from size ZE 42 up to the ZE 186. Source KraussMaffei Group GmbH More around Machinery & Plants

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Plastics in Practice

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