ENGEL will present the inject AI framework at K 2025, positioned as the next step in its digitalisation roadmap following inject 4.0. The company states that nearly 20,000 ENGEL machines are equipped with intelligent assistance systems and around 15,000 are networked, and that the new framework brings expanded use of artificial intelligence to tackle quality, efficiency and staffing challenges. "Artificial intelligence has long been a lived reality at Engel," said Gerhard Dimmler, CTO of ENGEL Austria GmbH.
The exhibition highlight will be a fully self-regulating injection moulding cell demonstrated on an industrial scale. "We are showcasing the world’s first industrial solution for an autonomous, self-regulating injection moulding cell at K 2025. The machine autonomously produces high-quality parts with AI support," said Stefan Engleder, CEO of the ENGEL Group. Instead of tuning abstract machine parameters, operators will be able to input product-specific quality targets, after which the machine will automatically control all process settings. With AI-supported initialisation, the system is designed to infer quality characteristics directly, removing the need for manual optimisation loops and trial series.
Quality control with reduced material and energy consumption: ENGEL’s compact autonomous injection moulding cell featuring an all-electric e-mac 80 injection moulding machine, ENGEL compact cell automation and inline quality monitoring at its core.
According to ENGEL, the autonomous control approach can cut material usage by up to 5 percent by reliably running close to lower tolerance limits. For annual outputs of around one million parts, this can translate into savings of several thousand euros. Setup times are also expected to drop from hours to minutes. The extended digital assistance system iQ weight control plus now adds a second operating mode, requiring only two input values, and can cut scrap by up to 50 percent. It compensates for material fluctuations on every shot and is intended to keep production stable even when running 100 percent recycled feedstock.
Maximum precision without manual optimisation loops: The component produced with Engel's inject AI demonstrates how AI ensures quality.
AI-based assistance and service tools
The inject AI framework includes several software-driven functions intended to deliver immediate operational value. The iQ process observer with AI functions automatically analyses more than 1,000 parameters in real time, detects deviations and issues concrete recommendations for action. The tool is designed to reduce misadjustments, support optimisation and transfer ENGEL’s process expertise directly to the machine level.
ENGEL will also premiere the ENGEL Virtual Assistant (EVA) at the show. This AI-based 24-hour assistant answers technical questions drawn from the machine’s documentation within seconds and can automatically generate checklists and instructions tailored to an individual production cell in any language, enabling users to interact with the documentation for their specific equipment.
For maintenance and service, part finder enables AI-driven spare parts identification from a photo. Operators can photograph a component on the machine to identify and request the corresponding spare part.
Skills, deployment and outlook
ENGEL positions inject AI as a response to the ongoing shortage of skilled personnel in plastics processing. By translating complex process data into clear, actionable instructions, the systems aim to increase transparency and productivity without requiring extensive manual data analysis. The company describes inject AI as a comprehensive and expanding framework that combines in-depth injection moulding know-how with current AI technology.
Visitors to K 2025 will be able to experience inject AI solutions on the stand and discuss implementation in the Expert Corners. ENGEL plans to demonstrate how AI-supported production can target maximum productivity, consistent quality and lower costs. The company will exhibit in Hall 15, Stand B42 and C58.
