Arburg Set to Exhibit at Fakuma 2024

Arburg’s complex processes such as LSR and multi-component injection moulding and automation, will be demonstrated at Fakuma 2024 with a fascinating two-component application. At Arburg’s stand 3101 in Hall A3, an Allrounder More 2000 processes thermoplastic (PBT) and liquid silicone rubber (LSR) to produce ready-to-use, food-safe spatulas. The cycle time and energy consumption are optimised by intelligent assistance functions in the Gestica control system. Handling is performed by a Yaskawa six-axis robot.

As a pioneer in multi-component injection moulding, Arburg offers a special machine series: the Allrounder More is designed for the efficient production of high-quality plastic parts, in this case, in a hard-soft combination.

Allrounder More: More Space, Modularity, and Comfort

The Allrounder More series machines provide more space for larger tools, rotary units, media connections, and increased ejector stroke. Thanks to the modular structure and various optimised features for enhanced operator comfort and easy maintenance, they can be very flexibly adapted to meet customer and market needs. With the Allrounder More, different processing methods can be combined with ease, allowing for the realisation of all common multi-component applications. The machines are equipped as standard with a high-dynamic, electrically operated toggle clamp unit, energy-efficient liquid-cooled servomotors, two electric injection units, and a choice of either 1,600 or 2,000 kN clamping force.

Two-Component Spatula from Thermoplastic and Silicone

At Fakuma 2024, a fully electric Allrounder More 2000 with 2,000 kN clamping force in the “Ultimate” performance variant will be in use. This two-component machine processes thermoplastic (PBT) and liquid silicone rubber (LSR) into food-safe spatulas, such as those used in the kitchen for baking. The machine is equipped with two electric injection units, sizes 170 and 400. The smaller vertical injection unit produces the handle from food-grade PBT (supplied by BASF).

The pre-moulded part is rotated by a servo-electric index unit with a motor from Arburg’s sister company AMKmotion, in a 1+1-cavity tool from Polar-Form, from the upper to the lower final station. There, the soft spatula component is moulded from an unheated LSR (supplied by Wacker) using a horizontal injection unit.

The two components are moulded directly and without waste. A hot runner system is used for the PBT handle, while the LSR overmoulding is carried out via a servo-electric cold runner with a needle valve system from Ewikon. In the subsequent cooling station, the spatulas are precisely cooled. They are then passed to a laser station from Rea, where surface textures are applied accurately and in the correct position. Finally, the spatulas are placed on a conveyor belt by the Yaskawa six-axis robot. The careful selection of materials and automation ensures that the end product is ready for use, with a cycle time of around 60 seconds. The hard-soft spatulas are food-safe.

Gestica Control System for Optimal Processes

The Yaskawa six-axis robot, “powered by Arburg,” is fully integrated into the Gestica control system and can be directly programmed, much like a linear Multilift robot system. Additional peripheral devices, such as temperature control units, can also be integrated. This includes the LSR dosing system from Elmet, which communicates with the Gestica via the Euromap 82.3 interface.

Assistance functions in the control system optimise the injection moulding process in terms of cycle time and energy consumption. The “aXw Control CycleAssist” feature provides a graphical comparison between the actual times of each cycle step and the previously defined reference values. By clicking, unproductive time segments can be identified and optimised. This results in short cycle times and high productivity. Additionally, the “aXw Control EnergyAssist” bundles all key functions of the plastification cylinder and tool, optimising the heating and cooling of all zones. This significantly reduces energy consumption during the heating phase and enables energy-efficient production.

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