Wittmann Battenfeld is set to present a comprehensive portfolio of injection molding solutions at K 2025 in Düsseldorf, under the theme “Smart Choices – Smart Savings.” Visitors to booth B22 in hall 15 will encounter a range of innovations designed to optimize resource use, enhance process efficiency, and address current sustainability demands in plastics processing. For the first time, the entire Wittmann Group will present its offerings together on a common booth, reflecting the company’s integrated approach to machinery, automation, and digitalization.
New MacroPower with one-piece machine body
The highlight of Wittmann Battenfeld’s exhibition will be the new MacroPower 500/3400, distinguished by its compact, one-piece machine body. This design innovation reduces installation time and space requirements, while the pivotable injection unit simplifies screw changes and maintenance. The MacroPower is equipped with the Unilog B8X control system, featuring in-house developed components that enable faster response times and improved part reproducibility. The new MacroPower series, available in clamping forces from 400 to 600 t, will be demonstrated by producing a “HAIBOX” from polypropylene (PP) supplied by Borealis, using a single-cavity mold from Haidlmair. The process integrates in-mold labeling (IML) with labels from Viapiani and employs thermal imaging for quality control, with SKZ’s TD14.0 software ensuring only parts within temperature tolerances proceed to packaging.
MacroPower 500/3400 with one-piece machine body
HAIBOX (Picture: Haidlmair)
Multi-component and energy-efficient injection molding
Wittmann Battenfeld will also display a MacroPower 650/2250H/1330H Combimould with a 1500 mm rotary table, demonstrating multi-component molding with two horizontal injection units. This setup produces a foldable laundry basket from PP and TPE using a 1+1-cavity mold from ATA Kalip ve Plastik, with a Primus 148T robot handling part removal and placement.
Foldable laundry basket made of PP and TPE – produced by a multi-component process (Picture: ATA Kalip ve Plastik)
The new EcoPrimus, an all-electric model from the EcoPower series, will be introduced as a standardized, energy-efficient solution for applications with limited customization needs. On the EcoPrimus 100/525, closing caps for medical applications are produced using a 24-cavity mold from HTW, with a W918 robot and packaging integration by Ravizza Packaging.
Closing caps for small eye drop bottles – produced on the new EcoPower Primus
For liquid silicone rubber (LSR) processing, an EcoPower 110/350 will manufacture pump housings using a 2-cavity mold from Elmet and the TOP 5100 dosing pump, highlighting process stability and cost efficiency. A W918 robot manages part removal.
Compact, integrated, and micro injection molding solutions
The SmartPower 160/1000 Insider cell integrates a servo-hydraulic machine, W918 robot, conveyor, and auxiliary equipment into a single compact unit. The all-electric injection unit combines the flexibility of SmartPower with the dynamic regulation of EcoPower, demonstrated by producing aerosol spray caps from PP with an 8-cavity mold from HTW.
Aerosol spray caps – produced on a space-saving SmartPower 160 Insider cell
Micro injection molding is addressed with the all-electric MicroPower 15/10, designed for precision and minimal material use. At the booth, a lab-on-a-chip will be produced from transparent PP using 3D-printed mold inserts from NanoVoxel, integrated in a tool box from Ernst Wittner. The process achieves high repeatability and nearly waste-free production of micro parts, with the W9VS2 robot managing part handling.
MicroPower 15/10
Vertical molding and natural fiber composites
The VPower series will be represented by a vertical machine featuring a 2-tie-bar rotary table for optimal accessibility and high-speed operation. At the show, a decorated structural component will be produced from NFPP (natural fiber polypropylene) in a joint project with Leonhard Kurz, Frimo Innovative Technologies, Polyvlies, and Wittmann Battenfeld. The process involves over-molding a natural fiber mat with decorative foil, followed by automated handling, printing, and quality inspection.
VPower 160
All machines at the Wittmann booth are supplied and regulated by a central materials handling and control system. In addition, visitors can explore the TEMI+ MES and iMAGOxt energy management software, designed to improve energy efficiency and cost control in plastics processing operations.
Digitalization and AI in service
Wittmann will demonstrate AIM4Help, an AI-driven expert system for technical support and troubleshooting, available via a web portal. This system provides first-level assistance for setup, operation, and error analysis of Wittmann equipment, supporting efficient maintenance and reduced downtime.
Power of Plastics Forum: sustainable and innovative applications
At the VDMA Power of Plastics Forum (outdoor area E06), Wittmann Battenfeld will present two machines that embody the event’s “Green – Smart – Responsible” theme. The SmartPower 350/1670 will demonstrate the production of edible, compostable ice cream cones from a plant-based material developed by Wafflerie, UAE. The process, using a 4-cavity mold from Precupa and a Primus 128 robot, yields cones with consistent quality and mechanical strength, offering a sustainable alternative to traditional packaging.
The EcoPower 180/750+ DC Insider cell, operating independently from the exhibition power grid via a salt battery storage system from Inesco, will produce a “wild pot” container from 100% post-consumer recycled (PCR) material supplied by Wildplastic. The process utilizes Cellmould foam injection molding to reduce material and energy use, while TagTec technology provides traceability through embedded markers and QR codes.
Partner collaboration: LIM technology at Momentive booth
At the Momentive booth (hall 6, B15), a SmartPower 120/350 in LIM configuration will produce Frisbee disks by over-molding Ultramid B3S preforms from BASF with Siloprene LSR 2740 from Momentive. The process uses a single-cavity mold with electric nozzle regulation from ACH Solution, demonstrating precise liquid silicone molding for consumer products.
Frisbee disk – produced on a SmartPower 120/350 LIM at the booth of Momentive (Picture: Momentive)
