Oerlikon HRSflow will use K 2025 to unveil several developments in hot runner technology aimed at higher process efficiency, surface quality and compact multi-cavity tooling. The company will introduce the patented Stargate HRS valve gate concept for precise melt control, the patent-pending Glow HRS solution for direct injection of aesthetic parts without halos, and a set of multi-cavity innovations under the Multiflow HRS line, including the Up Nozzle series for tight spaces and low shot weights. Live demonstrations across partner booths will cover applications from paint-free automotive components to thick-wall luxury cosmetic packaging and a conical blood filter. Oerlikon HRSflow’s K 2025 presence is organized in close cooperation with sister brand Oerlikon Balzers, reflecting an integrated approach to equipment, coating and process expertise. Additional partner exhibits will feature the Diamond Lux line on an automotive rear light concept and the Multi Valve Plate architecture for synchronized valve actuation in small-weight medical parts. Collectively, the exhibits target reduced cycle times, simplified maintenance and color changes, lower energy demand and pressure loss, as well as improved surface finishes directly from the mold, including when using recycled materials.
Stargate HRS: valve gate concept debuts on a bucket application
The newly developed Stargate HRS hot runner technology will be shown publicly for the first time at K 2025. The concept targets injection molding of PP, PE, PS and other amorphous thermoplastics. Compared to conventional designs, it eliminates production, assembly and maintenance needs for various components, shortens cycle time, facilitates color changes, and reduces power consumption and pressure loss. It also allows thinner back plates and enables short filling and packing times. The system will run at Bmb, where a 6-liter bucket with 1.1 mm wall thickness will be produced. The project involves Oerlikon HRSflow in cooperation with Dijkstra Plastics, R&D Plastics, Bmb, Oerlikon Balzers and Piovan.
Direct injection without halos for aesthetic parts
Also premiering is Glow HRS, a patent-pending solution for producing high-quality parts by direct injection while avoiding halos. With precise surface temperature control and a compact design, the system is adaptable to a wide range of applications, particularly in amorphous materials.
Paint-free automotive parts using Flexflow HRS
At Haitian International Germany, Oerlikon HRSflow will live-demonstrate the use of Flexflow HRS servo-driven needle valve technology to obtain premium automotive parts directly from the mold. The part is a car wheel arch developed with Dnp Group and Inevo. The showcase illustrates the potential to eliminate painting of large injection molded components and to minimize secondary operations, including when recycled materials are used. Additional benefits include fast color changes and reduced material waste.
Multiflow HRS for multi-cavity and thick-wall packaging
For compact tools and low shot weights, the new Up Nozzle series offers a gate-to-gate pitch down to 15 mm and a 12 mm nozzle cutout, enabling reliable access to hard-to-reach gate areas. Target sectors include beauty and personal care, packaging, beverages and technical applications. At its booth, Oerlikon HRSflow will also present crystal-clear, eco-friendly components produced with dedicated hot runner solutions for luxury cosmetic packaging. These parts combine optical clarity with wall thicknesses up to 12 mm and high process repeatability.
Advanced molding with partners at Engel and Boy
At Engel, a three-drop system from the Ga series of the Diamond Lux line will be demonstrated on a rear light concept. In this process, a decorative foil is back-injected with Plexiglas 8N from Röhm and then overflooded with PUR. The foil enhances the visual design of the final part. Partners on the project include Zechmayer as toolmaker, Leonhard Kurz for LED and surface design integration, Engel as injection molding machine supplier and Röhm as material supplier.
Precision for small-weight medical parts
At Boy, a conical blood filter will be molded using a Jestar medical demonstration tool on a Boy 35E injection molding machine. The setup employs Oerlikon HRSflow’s Multi Valve Plate technology with a 16-drop Multiflow HRS system from the SP series. The configuration enables synchronized valve actuation and reduced drop-to-drop spacing to increase precision in small weight applications.
Innovation highlights at the booth
- Stargate HRS: a valve gate concept designed to cut cycle time, simplify maintenance and color changes, and lower power consumption and pressure loss. The compact system will be shown in 6-liter bucket production in cooperation with Dijkstra Plastics at Bmb.
- Glow HRS: a patent-pending solution for premium parts that enables direct injection with flawless surfaces and no halos.
- Flexflow HRS for paint-free automotive parts: servo-driven valve gate technology demonstrated at Haitian with a car wheel arch, showing premium surfaces directly from the mold.
- Multiflow HRS multi-cavity line: new solutions include the Up Nozzle series for compact, tight-space applications with low shot weights, plus dedicated innovations for premium luxury and eco-friendly thick-wall parts in beauty and personal care.
- Diamond Nova HRS: a tailor-made hot runner solution for optic lenses, engineered for demanding polymers and processing conditions.
