At K 2025 in Düsseldorf, October 8–15, Sigma Engineering GmbH will present the latest developments of Sigmasoft at booth A80 in hall 13 and discuss insights derived from running injection molding production cells on the show floor. The company will detail applications hosted at partner booths and enable visitors to compare optimized simulation results directly with the reality observed on working cells. In process simulation, result reliability is central as users increasingly rely on digital representations of the process. Costly correction loops and time losses are no longer acceptable in a competitive environment, so the ability to validate predictions against production is a key focus of the presentation.
At the Sigma booth, visitors will be able to review the simulation setup and outputs for selected parts, gaining a deeper understanding of what occurs inside the tool during the cycle. The simulations are used to visualize heat flow, filling, curing and related effects in a way that makes the tool steel effectively transparent, supporting interpretation of the inner workings of the mold. Sigma notes that this approach facilitates direct comparison between simulated and measured behavior in the cells operating at partner stands, closing the loop between virtual analysis and production reality.
Applications highlighted with partners
Sigmasoft data and results support several production cells operated by partner companies at the show. These applications span thermoplastic and elastomer processing and feature automation and integrated robotics.
- Momentive, hall 6: production of a hard-soft combination part, a frisbee.
- Maplan, hall 16: molding of a folding cup with lid using a four-cavity mold.
- Engel, hall 15: complex manufacturing of a very large fuel cell seal.
- Nexus, hall 12: production of needle-free connectors at the company’s new booth.
All listed cells are fully automated with integrated robotics and are expected to attract strong interest. For attendees who cannot access detailed views at the partner stands, Sigma will present the corresponding simulations, providing additional transparency into tool behavior and process conditions.
Continuous validation and development
Sigmasoft Virtual Molding has been developed and refined for more than 25 years with the objective of representing production reality with increasing fidelity. Continuous validation in practice is a core element of this work, linking model assumptions and numerical results with measured outcomes on the machine. The K show setting enables side-by-side comparison that is not always possible in day-to-day engineering environments.
“Normally, we can only demonstrate the comprehensive possibilities and advantages of Sigmasoft on screen,” says Timo Gebauer, CTO of Sigma. “The K show gives us the opportunity, together with our partners, to showcase how our results compare with reality. This allows professionals to clearly grasp the benefits and significance of process simulation for their own future applications.”
By consolidating real production data with virtual analyses, Sigma aims to support informed decision-making in tool and process optimization. Booth A80 in hall 13 will serve as the hub for these comparisons and for technical discussions based on the showcased applications.
