Trotz Krise Gerüstet Für Die Zukunft s2

Press release

Inject the future: ENGEL at K 2013

Schwertberg, Austria – June 2013. ENGEL is making global connections. The company, which has the stability of a family-run business, promises technological superiority, innovative machine concepts and expertise in systems designed for specific sectors. Once again, ENGEL will be demonstrating 'the perfect link' at K 2013, which takes place from 16th to 23rd October in Düsseldorf. With 25 exhibits – 12 of which will presented at the company's stands in hall 15 (B42 and C58) – the producer of injection moulding machines and automation specialist from the Austrian town of Schwertberg will open the door to new applications, set new efficiency records and provide answers to the big challenges of the future. The manufacturing cells on view will combine high levels of process integration and automation, strong performance, sustainability and process reliability. Also on show will be two new injection moulding machines (the ENGEL e-speed and ENGEL e-motion 30 TL), the first composite brake pedal produced in a one-shot process and the biggest vertical machine ever presented by ENGEL at a trade fair. Inject the future – with ENGEL at K 2013.

Automotive: Cost efficiency in high-volume lightweight construction

Composite brake pedal produced in one-shot process

ENGEL and its partner ZF-Friedrichshafen will reach a new milestone in automotive lightweight construction at K 2013 with a geometrically optimised and stress-resistant plastic brake pedal. The concept for manufacturing a hybrid, organic sheet brake pedal received the Composite Innovations Award in 2011; since then it has been consistently enhanced by ZF. ENGEL will be offering a first glimpse into the efficiency of the manufacturing process from its stand at the K event. Using a vertical ENGEL insert 1050H/200 injection moulding machine with an ENGEL easix multi-axis industrial robot and infrared oven, continuous fibre- reinforced thermoplastic semi-finished products (known as 'organic sheets') will be heated,

ENGEL AUSTRIA GmbH, A-4311 Schwertberg/Austria, Tel.: +43 50 620-0, Fax: +43 50 620-3009 E-mail: [email protected], http://www.engelglobal.com

1 Press release preformed in a mould and immediately overmoulded with polyamide. The system produces ready-to-fit components; no cutting is necessary.

Organic sheets offer high strength and rigidity. In designing the brake pedal, the ZF product developers also adapted the layer structure to the component load. This enabled the component weight to be reduced by around 30 percent compared to conventional steel brake pedals without impairing load-bearing capacity. Moreover, the lightweight construction method renders many manufacturing process steps superfluous, thereby raising productivity and cutting unit costs.

The control unit of the ENGEL easix multi-axis robot is fully incorporated into the control unit of the injection moulding machine. The robot is simple to operate and program, with the machine and robot movements precisely coordinated to one another. Since the robot can access the machine parameters, the gripper can enter the mould area during the opening movement, which in turn significantly reduces cycle times. Synchronous movements are important when it comes to handling pre-heated semi-finished products in particular; semi- finished products must not be allowed to cool too rapidly in advance of the forming process. Another factor that determines quality in this application is the high positional accuracy of the multi-axis robot.

The energy-saving ecodrive option also contributes to the high overall efficiency of the manufacturing cell. Thanks to servohydraulics, the ENGEL insert injection moulding machine achieves energy consumption values comparable to those of all-electric machines. Other advantages include lower coolant consumption, longer machine oil lifespan and significantly reduced heat and noise emissions.

ENGEL v-duo: trade fair premiere with RTM application

The ENGEL v-duo, which was unveiled last year, will make its trade show debut with another lightweight construction application. This will be the largest vertical machine ever presented by ENGEL at a trade event; despite this, the large-scale machines in the ENGEL v-duo

2 Press release series feature a compact design that reduces their height and weight. While the low machine height improves access to the handling and maintenance area, the relatively low weight of the machine cuts investment costs as existing halls can be used (and the cost of foundations is reduced where a new structure is built). Sidestepping the conventional hydraulic accumulator and opting for an energy-saving ecodrive as standard makes the machine even more cost-effective.

An ENGEL v-duo 700 will produce latch covers for the KTM X-Bow sports car at the K trade fair under the RTM procedure; automated manufacturing will be demonstrated. Meanwhile an ENGEL viper 20 linear robot will perform parts handling at the K event.

A number of partners have collaborated to realise this manufacturing cell. Wethje (of Hengersberg in Germany) is the producer of the components and preforms, while the mould is contributed by Langer (of Illmensee in Germany). Hennecke (of St. Augustin in Germany) is responsible for the HP-RTM system, and the PUR-RTM system is provided by BASF Polyurethanes (of Lemförde in Germany). Finally, KTM Technologies (based in the Austrian city of Salzburg) is responsible for the component design and the composite- specific construction, including the simulation of the manufacturing process (RTM filling simulation).

A new quality of soft touch

The third exhibit to be presented in the automotive area combines three production processes in an ENGEL duo 3550/650 pico combi M injection moulding machine and redefines the manufacturing process for soft touch components. In a single process step, the Varysoft process devised by Georg Kaufmann Formenbau (of Busslingen in Switzerland) will be used to produce dashboards for the Hyundai Kia Automotive Group from a thermoplastic substrate, a decorative overlay and a layer of polyurethane foam. The dashboards have an outstanding look and feel.

3 Press release

The TPE-foils are preheated in an integrated infrared oven. The PUR system for this application will be provided by BASF Polyurethanes, based in the German town of Lemförde, while the polyurethane processing system is supplied by Hennecke of St. Augustin in Germany.

Compared to other processes for manufacturing soft touch surfaces, Varysoft offers even greater softness while allowing undercuts in the mould design. The integrated production process showcased at the ENGEL stand – automated with an ENGEL viper 40 double robot and an ENGEL easix multi-axis robot (for trimming the overlapping foil with an ultrasonic cutting head) – meets the needs of automobile manufacturers in terms of combining top product quality and high cost efficiency. To reduce component weight at the same time, MuCell technology pioneered by Trexel of Wilmington, Massachusetts in the USA is used for the injection moulding of the thermoplastic substrate structure.

Medical: Process integration and top performance for security

Tri-component drip chamber with filter in a single step

Visitors to the trade fair can also look forward to a world premiere in the medical section of the show. Drip chambers for blood transfusions, with an integrated filter, will be produced using an ENGEL e-victory 310H/80W/50V 160 combi tri-component injection moulding machine with ecodrive and a clean room design. Each chamber comprises an ABS and a TPE component injection moulded in a single work step; the filter is mounted and joined by means of overmoulding with polypropylene. This unprecedented level of integration significantly improves efficiency in the manufacturing of multi-component hollow bodies with inlays and will revolutionise not only manufacturing practices in the medical engineering sector but also, for example, the production of fuel filters. Conventionally, the two hollow body components are individually injection moulded; the inlay is then fitted and bonded in subsequent process steps.

4 Press release

One key prerequisite in realising the integrated process is servoelectric drive technology for all movements of the index plate mould; this facilitates the synchronous control of mutually independent movements. For this application, the mould production partner is Hack Formenbau of Kirchheim in Germany. The precision platen parallelism setting on the tie-bar- less injection moulding machine ensures a high level of mould protection. As clamping force builds up, the platen parallelism is automatically adapted to the mould parallelism. Platen parallelism is guaranteed, even where moulds are heavy, thanks to prestressing by the patented FlexLink system and the support of the solid C-frame.

An ENGEL easix multi-axis robot is also integrated in the manufacturing cell along with a system for total quality control. The drip chambers are inspected for seal tightness directly after injection moulding.

High performance with maximum security

Larger moulds, higher throughput ... the productivity demands on manufacturing processes are rising all the time. The medical engineering sector in particular has no room for compromise when it comes to process stability and the quality of parts. For this reason, ENGEL has consistently developed its all-electric series of ENGEL e-motion injection moulding machines for high performance applications even in the high clamping force ranges. Working with the automation specialist HEKUMA (of Eching in Germany) and mould manufacturer Braunform (of Bahlingen, also in Germany), ENGEL will feature a highly automated manufacturing cell for making needle holders for insulin pens at K 2013 – and thereby demonstrate process reliability that is hard to beat. The cores of the 96-cavity mould have a diameter of just 0.3mm. To counter deformation of cores effectively, the premium version of the electric injection unit is equipped with a direct drive. Highly dynamic injection movements and injection speeds of up to 500mm/s are thereby attained. A camera-based monitoring system instantly identifies any problems with parts. Thanks to cavity specific handling, reject parts are automatically separated and the injection mould can carry on

5 Press release producing without deactivating the cavity. The all-electric ENGEL e-motion 440/220 T achieves cycle times of around five seconds despite the delicate mould cores.

Packaging: Precise high performance, unbeatable efficiency

The new ENGEL e-speed: Fast and powerful

The new ENGEL e-speed 650 injection moulding machine brings together the best of both worlds: ENGEL's new speedster harnesses the proven technology of the all-electric high performance machines in the ENGEL e-motion and e-cap series as well as the benefits of the ENGEL speed range to combine maximum injection speeds with unbeatable energy efficiency. Even with bigger screw diameters from 60 mm onwards injection speeds of up to 800 mm/s are reached. With its new drive system and energy storage system, the ENGEL e- speed 650 is setting new standards in high performance applications with a large clamping force requirement. The hybrid machine with the electric clamping unit and hydraulic injection unit has a very big opening stroke that enables even large stack moulds to be mounted easily. At the K fair, an ENGEL e-speed 650/90 will produce thin-wall containers in an 8+8- cavity stack mould by StackTeck of Ontario in Canada with a total cycle time of under four seconds. The containers will be removed by a high-speed robot from Campetella, a company based in the Italian town of Montecassiano.

Space-saving large-scale machine with unprecedented energy efficiency

The latest addition to the ENGEL duo double-platen machine series, which has performed successfully over many years, is the ENGEL e-duo. With its electric injection unit, the machine combines the high precision and repeatability of electric machines with the space- saving double-platen technology of ENGEL's large-scale machines to create an extremely efficient hybrid machine. At the K event, an ENGEL e-duo 5440/700 with a mould by Haidlmair of Nussbach in Austria will demonstrate how the integration of gas injection technology (ENGEL gasmelt) and in-mould labelling allows highly decorated, high volume

6 Press release packaging parts such as beverage crates and containers to be manufactured with minimal resources, costs and energy. The use of ENGEL gasmelt also reduces part weight; an ENGEL viper 60 linear robot is used for the in-mould labelling. IML films will be provided by Viappiani (of Milan in Italy) while the cooperation partner for the gas injection technology is Bauer Kompressoren of Aix-Les-Bains in France.

Teletronics: Efficiency and precision for electronics and lifestyle

The new ENGEL e-motion 30 TL: All-electric, highly accurate and tie-bar-less

The highlight of the Teletronics area of the exhibition will be the new all-electric and tie-bar- less ENGEL e-motion 30 TL injection moulding machine, which will be presented to an international audience for the first time at K 2013. Combining the benefits of ENGEL tie-bar- less technology and all-electric drive technology, ENGEL is responding to the needs of the electronics industry in the low clamping force area. Outstanding precision, extremely low energy consumption levels and maximum flexibility are all essential in this field. Using a 16- cavity mould, 60-pin board-to-board connectors will be produced at K. This requires very high precision on the part of the injection moulding machine as the distance between the pins is just 0.5mm.

In this application, the new small and tie-bar-less variant in the ENGEL e-motion series will work with an injection pressure of 3,200 bar and an unprecedented injection speed of 800mm/s, which has been enabled by an acceleration of more than 40 m/s². The high number of cavities also raises productivity; moulds with 4 to 8 cavities are generally used in the production of FFC/FPC connectors.

From punched part to 4-pin connector with a rotary table machine

All-electric machines are not always required for maximum precision, as will be proven by a vertical ENGEL insert 80V/60 rotary rotary table machine used to manufacture complex, three-dimensional connectors. Pre-assembled punched parts will be inserted into the 4-

7 Press release cavity mould provided by Conttek of Pforzheim in Germany before being overmoulded with thermoplastic. Given their complex shape, punched and prefabricated parts require extreme precision in terms of both parts handling and the injection moulding process. In this case, an ENGEL viper 20 will fully exploit the strengths of the latest generation of ENGEL linear robots. Thanks to software packages for vibration control, mass identification and efficiency control, ENGEL viper robots of all sizes combine sensitivity with maximum dynamism. In this application, the ENGEL viper 20 robot will be supported on base plates to guarantee unrestricted access to the mould room, thereby speeding up the conversion process.

Stable CFK lightweight construction for the highest design requirements

In a third application for the teletronics industry, ENGEL will combine innovative CFK lightweight construction with outdoor robustness, minimal wall thicknesses and a high gloss finish, thereby meeting all the needs of the consumer electronics industry at a stroke with just one highly integrated manufacturing cell. At the heart of the demonstration will be an ENGEL e-mac 170/100 injection moulding machine from ENGEL's new all-electric range fitted with an ENGEL viper 12 linear robot. To produce casings for mobile electronic devices such as Tablet PC, Smartphone or e-book reader, pre-formed organic sheets (pressed in advance using variothermal technology) will be inserted into the mould and overmoulded with PC/ABS, again using variothermal technology. This method allows extremely even surfaces and minimal wall thicknesses to be achieved despite the differing contraction levels of CFK and the cladding material. The housing components, which are produced in high gloss piano black, are also provided with a partial PVD coating. Metallisation of the plastic surface serves as electromagnetic shielding. The PVD coating of plastic surfaces is traditionally performed in a separate intermittent process, but at the K fair ENGEL will show how a high vacuum process can be incorporated inline within the injection moulding cell. ENGEL will work with Impact Coatings of Linköping in Sweden for

8 Press release the PVD technology, while the partner for the variothermal mould in the exhibit will be Roctool of Le Bourget du Lac in France.

Technical moulding: Intelligent solutions with perspective

Multi-layer technology for high quality optical moulded products

More and more high quality optical components for cars and lighting in buildings are being produced using synthetic materials. Two factors are driving this trend. Firstly, glass is being replaced by lighter polymers that can be processed more cost effectively; and secondly, plastics offer greater scope in terms of product design. The challenge is to strike the right balance between superior optical quality and high cost effectiveness – and at the K event, ENGEL will demonstrate how to achieve this balancing act by means of overmoulding. To do this, an ENGEL e-motion 200/110 T with integrated ENGEL viper 12 robot will firstly produce a pre-moulded part in a mould supplied by the firm Krallmann of Hiddenhausen in Germany. This part will then be recoated with further layers of the same material in a subsequent step. The approach is an improvement on the single-layer process because recoating removes sink marks, thereby achieving very high optical quality with much shorter cooling times (and therefore cycle times). The process demonstrated by ENGEL at the K trade fair requires just one injection unit instead of two, thus raising cost efficiency.

LIM processing: fully automated, reworking-free, waste-free and low in burrs

The main demands as regards the processing of liquid silicone are that it must be fully automatic, waste-free, low in burrs and require no reworking. An ENGEL e-victory 200H/80W/120 combi injection moulding machine – automated with an ENGEL viper 20 linear robot – will impressively show that ENGEL system solutions not only meet these requirements fully, but also handle LIM multi-component processes securely and efficiently. A mould provided by ACH solution of Fischlham in Austria will be used to produce sensor housings for flow measurement with integrated seals. Using servo-powered injection units

9 Press release guarantees maximum precision, which would normally call for special solutions in the LSR field where very small injection unit volumes are involved but which in this case is provided by a standard unit. For the first time, iQ weight control software patented by ENGEL is applied in the system for LSR processing; this recognises and automatically compensates for fluctuations in melt quantity during the injection process.

The tie-bar-less technology of the ENGEL victory and e-victory injection moulding machines also offers benefits in terms of multi-component processes using silicone. On the one hand, large multi-component moulds can be installed in relatively small injection moulding machines; on the other, the outstanding platen rigidity of tie-bar-less machines provides better support to moulds, which reduces burr formation and thus raises product quality. Free access to the mould room facilitates the most effective possible automation concepts.

Automation: From a single source

Largest ENGEL viper 120 makes trade fair debut

At K 2013, ENGEL will be devoting a special exhibition area to automation. For some considerable time, ENGEL viper linear robots have not only been combined with ENGEL injection moulding machines, but also used to replace old equipment and work with machines from other manufacturers. In a world premiere, the new ENGEL viper 120 will be seen in action at a trade fair for the first time. A nominal load-bearing capacity of 120kg makes this the largest linear robot in its competitive class; its demoulding stroke of 3,000mm and range of 3,550mm have opened up brand new dimensions in linear handling.

Maximum stability, dynamism, ease of use and lightweight construction are qualities common to ENGEL viper robots of all sizes. An innovative design that utilises laser-welded steel sections has kept the dead weight of the robots low, enabling the load-bearing capacity to be raised. Smart software packages reduce the structure-borne vibration of the robots – even with longer axis dimensions – and optimise their movement and dynamic values, resulting in enhanced efficiency. The viper robots therefore make a crucial

10 Press release contribution towards the reduction of cycle times and the increase of productivity for a range of applications, whilst also demonstrating their high level of energy efficiency. Since ENGEL supplies both injection moulding machines and robots from a single source, full integration of the two control environments is guaranteed.

In keeping with the motto 'Inject the future', ENGEL will demonstrate at K 2013 how intelligent system solutions for specific sectors can create global competitive advantages. The planning and supply of injection moulding machines, process technology and automation from a single source can maximise efficiency potential and open the door to new applications – with one eye on minimising unit costs from the outset.

ENGEL at K 2013: Hall 15, stands B42 and C58

11 Press release

ENGEL automotive

As its trade show debut, an ENGEL v-duo 700 will produce latch covers for the KTM X-Bow sports car. (Pictures: KTM)

ENGEL medical

Process integration at its best: At its trade fair stand ENGEL is producing tri-component drip chambers with filter in a single step. (Picture: ENGEL)

12 Press release

High performance for medical applications: Producing needle holders for insulin pens, the all-electric ENGEL e-motion 440/220 T achieves cycle times of around five seconds despite the delicate mould cores. (Pictures: ENGEL)

ENGEL packaging

The new ENGEL e-speed injection moulding machine combines maximum injection speeds with unbeatable energy efficiency. An ENGEL e-speed 650/90 will produce thin-wall containers in an 8+8- cavity stack mould. (Pictures: ENGEL)

13 Press release

Unprecedented energy efficiency: The ENGEL e-duo machine combines the high precision and repeatability of electric machines with the space-saving double-platen technology of ENGEL's large- scale machines. (Picture: ENGEL)

ENGEL teletronics

With its new all-electric ENGEL e-motion 30 TL series ENGEL is responding to the needs of the electronics industry in the low clamping force area. 60-pin board-to-board connectors will be produced at K. (Pictures: ENGEL)

14 Press release

Pre-assembled punched parts will be inserted into the 4-cavity mould of an vertical ENGEL insert 80V/60 rotary injection moulding machine before being overmoulded with thermoplastic. (Pictures: ENGEL)

Thanks to their remarkably compact design, the ENGEL e-mac machines will save customers production floor space and lower their operating costs. (Picture: ENGEL)

15 Press release

Stable lightweight construction: To produce casings for mobile electronic devices, pre-formed organic sheets are inserted into the mould and overmoulded with PC/ABS, using variothermal technology. (Picture: ENGEL)

ENGEL technical moulding

Shortest cooling and cycle times: Multi-layer technology is taping new efficiency potentials in the production of high quality optical moulded products. (Picture: ENGEL)

16 Press release

An ENGEL e-victory 200H/80W/120 combi injection moulding machine will impressively show that ENGEL system solutions handle LIM multi-component processes securely and efficiently. Sensor housings for flow measurement with integrated seals are produced at K 2013. (Picture: ENGEL)

ENGEL Automation

With the new ENGEL viper 120 ENGEL reaches new heights in linear robotics. (Picture: ENGEL)

17 Press release

ENGEL AUSTRIA GmbH ENGEL is one of the global leaders in the manufacture of plastics processing machines. Today, the ENGEL Group offers a full range of technology modules for plastics processing as a single source supplier: Injection moulding machines for thermoplastics and elastomers, and automation, with the assurance that individual components are also competitive and successful in the world markets. With eight production plants in Europe, North America and Asia (China, Korea), subsidiaries and representatives in over 85 countries, ENGEL offers its customers the optimal global support they need to compete and succeed with new technologies and leading-edge production systems. Contact for journalists: Gerd Liebig, Group Marketing Director, ENGEL AUSTRIA GmbH, Ludwig-Engel-Strasse 1, A-4311 Schwertberg, Austria, Tel.: +43 (0)50 620 3800, fax: -3009, email: [email protected] Susanne Zinckgraf, Manager Public Relations, ENGEL AUSTRIA GmbH, Ludwig-Engel-Strasse 1, A-4311 Schwertberg, Austria PR Office: Theodor-Heuss-Strasse 85, D-67435 Neustadt, Germany, Tel.: +49 (0)6327 97699-02, fax: -03, email: [email protected] Contact for readers: ENGEL AUSTRIA GmbH, Ludwig-Engel-Strasse 1, A-4311 Schwertberg, Austria, Tel.: +43 (0)50 6200, fax: -3009, email: [email protected], www.engelglobal.com