At K 2025, stand 13A13, Arburg will present a broad set of digital and AI enhancements for injection moulding. The line-up spans the premiere of Gestica lite, a control variant for standard machines with an extended user interface, new assistants and pilots that stabilise processes, and upgrades to the arburgXworld customer portal and the ALS host computer system. Highlights include direct machine to mould communication via the Euromap 82.5 interface using the "aXw Control MoldlifeAssist", recyclate-oriented optimisation with the "aXw Control RecyclatePilot", and a virtual twin of an exhibit that allows simulation and program optimisation on a PC. The "Ask Arburg" app gains machine-specific knowledge and deeper integration into ALS and the control system, while tools such as "Energy Calculator", "Shift Planner" and "Workflow" support planning, analysis and notifications across devices. Demonstrations will run on several Allrounder exhibits, reflecting a modular approach to setup guidance, condition monitoring, predictive maintenance and shot-to-shot compensation.
Gestica lite focuses on ease of use
Gestica lite debuts as a new control variant for standard machines. It uses a robust industrial panel and shares the software basis with Gestica, with full inter-compatibility of data records. The extended interface is designed for intuitive operation by non-specialists while maintaining flexibility for experienced operators. A new "Dashboard" homepage displays key functions for daily work, including job and process information and direct access to the most important parameters and KPIs. Operators can use touch navigation to jump directly to detailed pages for the clamping and injection units, temperature settings and the robotic system. The new "Status Center" provides access to pending alarms, and the "Help Center" links to online support. The "Tasks" area covers maintenance, material supply and parts disposal, and a digital "Pinboard" supports collaborative notes at the machine. Navigation and search are simplified and enhanced with AI, and assisted workflows with visual solution trees support troubleshooting. Optional assistants and pilots such as "aXw EnergyAssist" and "aXw Control RecyclatePilot" can be added. At the fair, the electric Allrounder Trend and the vertical Allrounder 475 V are among four exhibits equipped with this control variant, with a demonstrator monitor available for feature explanations.
New control variant Gestica lite: easy to operate with a new, clear dashboard.
MoldlifeAssist connects machine and mould
The "aXw Control MoldlifeAssist" integrates the "Moldlife Sense" system from partner Hack Digital Solutions into Gestica, targeting complex moulds and high-duty applications. Communication between the machine or production cell and the mould is enabled via Euromap 82.5. The hardware comprises a connector on the fixed mould plate and a box on the rear of the machine, allowing one system to be used across multiple moulds. The function supports setup, monitoring and maintenance to improve availability and operator safety. A "Set-Up Assistant" with a digital alignment aid guides the operator step by step through the setup process. During operation, the tool is monitored over its life cycle for temperature, acoustics, breathing and alignment using integrated sensors. Measured values are visualised in the Gestica control, individual events such as warnings, alarms and errors can be displayed, and tool data is logged and documented. Predictive maintenance enables condition-based intervals and provides guidance during service, with a maintenance logbook accessible via Gestica. At K 2025, MoldlifeAssist will be demonstrated within a digitally networked production cell based on an electric Allrounder 570 A producing caps for injector pens.
New pilot functions for recyclate processing
Once activated, pilots independently optimise the process. The "aXw Control RecyclatePilot" improves part quality by compensating material fluctuations using existing machine sensors to maintain constant shot weight. This is relevant for recyclate processing as well as batch changes or inhomogeneous virgin material. A new capability is adjustment of the holding pressure level according to material viscosity. Within a cycle, the injection volume is regulated via the switchover point on a shot-to-shot basis. Across cycles, the metering volume can be corrected to compensate for long-term volume fluctuations.
Virtual twin in the arburgXworld portal
The arburgXworld customer portal expands with a virtual twin of Gestica lite, available in the "Virtual Control" premium app from 2026. Users will be able to optimise programs on a PC and run an automatic cycle to further refine the process and cycle time. Based on the data set of an injection moulding application, the complete cycle, including injection and holding pressure, can be simulated with associated graphics and curve diagrams. The integration of automation or the interval until the granulate container needs refilling can also be simulated. At K 2025, the virtual twin of the Allrounder 1000 e Trend, which produces connectors at the stand, will be shown live on a monitor.
New feature of the customer portal app “Virtual Control”: With the help of a virtual twin in the Gestica lite, the process and cycle time can be further optimised directly on the PC based on a data set.
Customer portal and "Ask Arburg" enhancements
The premium app "Ask Arburg" illustrates the use of AI within a secure, self-contained environment. It works like "ChatGTP" and can answer specific questions about Arburg products and injection moulding processes. Answers are now more specific by incorporating machine-specific knowledge via an interface to master data. In apps such as "DataDecoder" and "Programs", the tool provides contextual support using an AI agent that can execute tasks without human intervention. The app can also be accessed within the ALS system and directly on the Gestica control. Access is possible offline via QR code or, with the latest software version, online via smartphone. A new app in the free basic version of the portal is the "Energy Calculator", which enables energy calculations in accordance with Euromap 60.2 for subsidy applications or certifications. E-mail notifications support daily use, and "Notifications" can deliver push messages to smartwatches or smartphones when the status of tickets or machines changes.
Updates to the ALS host computer system
For complex production environments and high-precision components, Arburg's MES can improve transparency, process reliability and efficiency, particularly when coupled with the customer portal. Newly presented is the digital "Shift Planner" for detailed planning and optimisation within shifts, providing transparency on responsibilities and allowing manual assignment of employees based on ALS data. The new "Workflow" module supports further digitalisation of processes in the production environment. Event-driven push notifications can be delivered directly to smartphones, PCs and other end devices via "Notification", and, if required, also via the arburgXworld app. In future, users will be able to have reports analysed via AI, for example to compare shift reports.
