ENGEL Boost Darmstadt University of Applied Sciences Education and Research

In the Bachelor’s programme in Plastics Technology, the new injection moulding machine will be used in practical training. Here, students will learn how to determine setting parameters, optimise the process for part quality, and use statistical experimental designs (DOE) to analyse the influencing factors on part characteristics. This practical application is crucial for translating theoretical knowledge into hands-on skills and preparing students for their future roles in the industry.

Prof. Dr.-Ing. Thomas Schröder, Head of the institute, commented on the significance of the new machine:

“The main advantage of the all-electric injection moulding machine is its complete readiness and equipment for digitalisation.”

“Engel can send over 32,000 parameters from the injection moulding machine via interfaces like OPCUA to a cloud, where they can be analysed using AI and correlated with the quality features of the produced products. Additionally, an all-electric injection moulding machine can demonstrate how energy-efficient these plastic parts can be manufactured.”

In the Master’s programme in Plastics Technology, the machine is supplemented by the ENGEL tool sim link. Sim link allows Cadmould simulations to be directly integrated into the injection moulding process, making the production start more efficient. Machine and tool parameters are analysed by students using artificial intelligence and linked to part characteristics. By using this technology, students and researchers can trace and optimise the entire process from simulation to production. Thus leading to a well-founded optimisation of the injection moulding process regarding production time, sustainability, and energy efficiency.

The new injection moulding machine from ENGEL will also offer numerous applications in research. Thanks to its comprehensive digital equipment, data on tool wear and predictive maintenance can be easily collected and analysed. This enables preventive measures and extends the lifespan of the tools, saving costs and increasing efficiency.

The ENGEL e-mac 100 is a compact, all-electric injection moulding machine known for its precision and energy efficiency. With a clamping force of 1000 kN, it provides the necessary performance for a wide range of applications. The machine is equipped with the ENGEL CC300 control unit, which allows intuitive operation and precise control of the injection moulding process. Additionally, the iQ assistance systems – iQ weight control for continuous compensation of fluctuations in plastic viscosity, and iQ clamp control for automatic optimisation of the clamping force – are integrated.

These systems enable real-time automatic adjustment of process parameters, resulting in consistent part quality, reduced scrap, and lower energy consumption. Furthermore, the machine features the iQ process observer, which monitors all four phases of the injection moulding process: plasticising, injecting, cooling, and demoulding. Finally, the ENGEL EDGE Device ensures secure connectivity for remote maintenance and other digital services from ENGEL.

With the delivery of the e-mac 100, ENGEL is making a significant contribution to education and research in the field of plastics technology at Darmstadt University of Applied Sciences. Students benefit from modern technology and practical teaching methods that optimally prepare them for their future roles in the industry. At the same time, the machine opens up new possibilities in research to develop innovative solutions and applications.