At K 2025, ENGEL will open its stand to a virtual twin of what it describes as the world's largest technical centre injection moulding machine. The interactive presentation focuses on a current trend in automotive construction, namely replacing large painted sheet metal parts with plastic solutions. Using a car roof as an example, the company will illustrate the process steps on a duo 5500 combi M with 55,000 kN clamping force, including the in-mould coating step based on polyurethane. Visitors will be able to examine the machine virtually, discuss options for large-surface components with ENGEL specialists and see how integrated processes can reduce complexity and cost in series production.
The duo 5500 combi M, available for customer trials at ENGEL’s technical centre in St. Valentin, is the largest technical centre machine in the company’s portfolio, with a clamping force of 55,000 kN. Its mould space features platens measuring 3.5 x 3.5 metres and a maximum platen distance of 6.6 metres, allowing the use of moulds weighing up to 150 tonnes. Shot weights of up to 42 kilograms are achievable via injection units with screw diameters up to 190 mm. Developed for the requirements of the automotive industry and technical injection moulding, the platform supports the substitution of painted metal body parts with large plastic components and provides a pathway from part and technology development through to mould and part sampling.
Experience the world's largest technical centre injection moulding machine virtually: detailed insights into injection moulding on a mega scale.
In-mould coating via clearmelt
The ENGEL clearmelt technology integrates the coating step into the injection moulding machine by overmoulding the produced part in the mould with polyurethane in a second step. ENGEL is further developing the process in close partnership with Cannon, a supplier of mixing and dosing technologies for reactive processes. The Cannon clearmelt system is integrated into the ENGEL portfolio as well as into the CC300 control, supporting process stability, straightforward operation and high levels of automation. The result is a shortened production chain and consistent surface quality for large exterior parts.
‘In-mould coating’ eliminates the need for expensive downstream painting lines: PUR flooding in the ENGELclearmelt process.
Competence centre and exhibition details
At the clearmelt Competence Centre in St. Valentin, ENGEL and Cannon combine decades of injection moulding experience with two decades of clearmelt know-how. ENGEL provides all services for PUR flooding from a single source, from process consulting and quotation preparation through production cell design to complete project handling with service for the entire cell. A team of 20 specialists supports customers from concept to series maturity. For development and trials, duo two-platen machines with clamping forces from 7,000 to 55,000 kN are available.
At the Expert Corner on the ENGEL stand, visitors can engage virtually and practically with the clearmelt process and the duo machine technology to seek a competitive advantage, "be the first". ENGEL will exhibit at K 2025 in Düsseldorf in Hall 15, stands B42 and C58.
