K 2025, the triennial global trade fair for plastics and rubber, will be held in Düsseldorf from October 8 to 15, gathering stakeholders across manufacturing, processing, machinery, automotive, electronics, medical, packaging, construction and related sectors. FCS Group will exhibit in hall 12, stand B80, under the theme "Smart Manufacturing × Sustainable Action". The company plans a full lineup of all-electric molding machines combined with recycled materials processing, microcellular foaming and smart manufacturing systems. The presentations target single and multi-component applications with an emphasis on precision, energy efficiency and production stability, aligning with industry requirements for high efficiency, low carbon and intelligent manufacturing.
Core exhibits will include two-component overmolding on the CT-230R using PP and TPE to produce a dual-color household product, and a compact CT-120e cell molding eyewear frames from PA6 with glass fiber regenerated from ocean-recovered fishing nets. The latter is presented as part of a Circular Eyewear Molding System that combines design considerations with material reuse. Across the exhibits, FCS will connect machines to its in-house iMF 4.0 Intelligent Manufactory System for real-time production and energy data, predictive maintenance and remote diagnostics.
Lightweighting will be addressed through two microcellular foaming technologies. MuCell, developed with Trexel, applies supercritical fluid injection to reduce part weight, material consumption and injection pressure, while supporting dimensional stability in sectors such as footwear, 3C packaging and automotive. The Gentrex foaming platform, co-developed with Tien Kang Group, focuses on thermoplastic elastomer systems including TPU, TPEE, PEBA, EVA-POE and SEBS for applications requiring elasticity and cushioning such as midsoles, bicycle parts and scooter components.
Complementing the hardware and process demonstrations, iMF 4.0 will aggregate key parameters across the injection cycle. The platform provides real-time monitoring of injection pressure, cycle time, energy use and material consumption, predictive maintenance alerts to mitigate unplanned downtime, multi-machine cloud dashboards for remote and cross-shift management and reporting to support energy savings and ESG transparency. The combined approach aims to facilitate data-driven, lower-carbon operations.
Two-component molding on CT-230R
The CT-230R is an all-electric two-component injection molding machine equipped with a high-precision rotary table and dual independent injection units. It targets high-end multi-material or multi-color applications in fields such as automotive interiors, power tools and medical devices. At the fair, the machine will overmold a dual-color household product in PP and TPE.
- Rotary table positioning accuracy of ±0.005°
- Servo-driven rotation speed increased by 30 to 50 percent, reducing cycle times
- Linear-guide injection unit enabling precise back pressure control and reduced material overflow
- High repeatability and production stability for complex, high-value components
The CT-230R cell is integrated with the in-house iMF 4.0 system for real-time production monitoring, energy tracking, predictive maintenance and remote diagnostics, supporting both equipment efficiency and product quality.
Compact all-electric CT-120e for circular eyewear
The CT-120e is a compact all-electric injection molding machine designed for clean, high-speed and stable production in optical, medical and environmentally oriented applications. During K 2025, it will mold eyewear frames using PA6 with glass fiber regenerated from ocean-recovered fishing nets as part of the Circular Eyewear Molding System.
- Injection speed up to 300 mm/s for rapid filling
- Tie-bar-free clamping design to minimize contamination, suitable for cleanroom use
- Full-servo closed-loop control for high-precision molding
- Advanced injection profile control for stable processing of recycled materials
Lightweighting with microcellular foaming
FCS will present two foaming options that support material and carbon reduction strategies:
- MuCell foaming technology, developed with Trexel in the United States, uses supercritical fluid injection to decrease part weight, material usage and injection pressure, while improving dimensional stability. It is suitable for footwear, 3C packaging and automotive components.
- Gentrex foaming system, co-developed with Tien Kang Group in Taiwan, specializes in foaming thermoplastic elastomers including TPU, TPEE, PEBA, EVA-POE and SEBS. It targets midsoles, bicycle parts and scooter components where cushioning and comfort are required.
iMF 4.0, from monitoring to ESG implementation
The iMF 4.0 Intelligent Manufactory System is FCS’s proprietary platform for smart factory operations. It consolidates production and energy parameters across the injection cycle and delivers:
- Real-time monitoring of injection pressure, cycle time, energy usage and material consumption
- Predictive maintenance alerts to prevent unplanned downtime
- Multi-machine cloud dashboards for remote and cross-shift management
- Carbon footprint and energy-saving reports to support ESG transparency
By combining iMF 4.0 with microcellular foaming, manufacturers can lower material consumption and energy use without compromising product strength or design. The active use of recycled plastics aligns with ESG objectives and encourages collaboration with material suppliers and brand owners in support of a circular economy and a lower-carbon production model.
