"Enjoy Innovation": Wittmann Battenfeld at K 2019

Medical application on MicroPower 15/10 production cell

Another medical technology application will be demonstrated on a machine from the MicroPower series from Wittmann Battenfeld designed for the production of micro parts in the clean-room version. Using a MicroPower 15/10 with 150 kN clamping force, a micro retaining ring for medical miniature tubes will be produced from PC with an 8-cavity mold supplied by Wittner, Austria. This product has a part weight of only 2 mg.

The machine comes with a rotary unit, an integrated Wittmann W8VS2 robot and a camera for complete parts inspection. Following removal and camera inspection, the parts are transferred to transport containers, separated according to individual cavities.

A novelty in the MicroPower is a further improved, 2-step screw-and-plunger injection unit now able to process shot volumes of up to 6 cm3.

Lightweight technology for the automotive industry

With an example from the automotive industry, Wittmann Battenfeld will demonstrate at the K 2019 its competence in Cellmould structured foam technology, which enables the production of extremely light-weight parts as are required primarily in the automotive industry to reduce fuel consumption and/or increase the battery range. On a MacroPower 1100/12800 with an energy-efficient servo drive, a seat bench support for a German sports car will be manufactured from PP with a single-cavity mold supplied by Frimo, Germany. The machine is equipped with the SEDE combined nitrogen and pressure generator unit developed and manufactured by Wittmann Battenfeld. The nitrogen required for this technology is taken from the ambient air and compressed to the working pressure of up to 330 bar. The material processed will be a type of PP suitable for automotive applications supplied by Borealis. It is the type ME225SY, which contains 25 % post-consumer recycling material and 25 % talcum. With the use of recycling material in passenger car interiors, Wittmann Battenfeld makes a significant contribution to promoting the recycling economy in the automotive industry. The parts will be removed and deposited by a WX152 robot from Wittmann.

On this machine, the CMS condition monitoring system from Wittmann Battenfeld has been installed, too, which ensures continuous condition monitoring of the most important machine parameters. The current condition of the MacroPower 1100 can be read out from a CMS info and control station placed directly next to the machine. Beside this machine, there is also an Airrmould/Cellmoul info stand, where visitors can get detailed information about the processes being demonstrated.

MacroPower 1100 Cellmould
Cellmould module on a MacroPower 1100

High-tech sheet for the automotive industry

A second application for the automotive industry will be presented on a machine from the SmartPower series in XL configuration. With a SmartPower 240 XL, a module for a car headliner with a functional surface will be produced with a single-cavity mold supplied by Georg Kaufmann, Switzerland. The module consists of an operating section mounted at the center and lighting sections on each side. For the production of this module, the IMD Varioform process developed by Leonhard Kurz (hall 5, booth A19 - E09) is used. In this process, a partially translucent decoration sheet is combined with a functional sheet with a printed-on sensor structure on the inside of the molded part. The poly TC sensor demonstrates the touch operation of light on/off and dimming functions as well as setting of the color of the LED light source behind it. 

The machine is equipped with an automation system from Wittmann Battenfeld Deutschland in Nuremberg. It consists of a WX142 robot from Wittmann with a C axis and an infrared radiation heater on the Y-axis to heat the continuous sheet used for this application. The WX142 inserts the functional sheet with sensor structure into the mold. The next step is to pull the IMD Varioform sheet through, heat it and then thermoform it using a vacuum. During the same production step, both sheets are overmolded. In this application, the sensor sheet can be optionally selected via a touch button. In this way, it is possible to injection-mold parts either with or without sensor sheet.

SmartPower 240 XL with automation from Wittmann Battenfeld Deutschland, Nuremberg to produce sensor sheet

LSR application on EcoPower 160

One of Wittmann Battenfeld's main application technology themes at the K 2019 will be silicone injection molding. Wittmann Battenfeld will demonstrate its expertise in this area at its booth in hall 15 by producing a valve for medical technology from an LSR formulation on a machine of its all-electric EcoPower series, an EcoPower 160/350, with a 16-cavity mold supplied by Nexus, Austria (hall 12, booth E49-01). The injection unit in open design enables easy integration of the LSR metering unit. The Nexus Highline metering unit comes with a new servomix metering system with OPC-UA integration. In the mold, latest cold runner technology is used including Timeshot needle shut-off control. Parts removal and depositing will be handled by a WX142 robot from Wittmann.
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