Oerlikon HRSflow at Fakuma 2026: Hot-runner solutions for all industries

Oerlikon HRSflow will present its cross-industry hot-runner injection molding expertise at Fakuma 2026, held from October 12 to 16 in Friedrichshafen. The company will exhibit in Hall A1, Stand A1-1211. Its presentation will cover developments related to the needle-less STARgate HRS system, new applications for the Xp nozzle series in thick-walled containers and the use of GLOW HRS to reduce post-processing steps for automotive visible parts. The company will also show several hot-runner applications in live production at partner booths, including systems for technical parts, automotive lighting components and medical-related molded parts.

STARgate HRS for a wider polymer range

Following its official launch at K 2025, the STARgate HRS hot-runner nozzle concept will be presented for PP and r-PP applications intended to comply with the new PPWR regulations. Oerlikon HRSflow will also show the system for processing resins such as PMMA and ABS, extending its application range across market segments.

The concept uses a diaphragm-like mechanical system. Compared with conventional solutions, this design enables fast color change and optimal cooling performance, resulting in a significant reduction in cycle time and increased productivity.

Matteo Badella, Global Sales Director Pac-Med, Consumer Goods, and Logistics at Oerlikon HRSflow, said: "Less than a year after the official market launch of STARgate HRS, we’ve already received many positive reports from customers who have achieved reduced part wall thicknesses, lower component weight and a significant reduction in cycle time compared with conventional production."

Xp nozzles for thick-walled cosmetic parts

Following the presentation at Luxe Pack 2026 in New York, Oerlikon HRSflow will show the new Xp series of valve gate nozzles at Fakuma. The nozzles are engineered for a wide range of applications and adapted to the requirements of the cosmetics industry. Accurate thermal control of the nozzle, combined with a new gate seal solution, is designed to ensure injection quality for thick, transparent parts with shot weights up to 70 g.

The Xp nozzle series is intended for thick-walled injection molded parts made from r-PET, PET and recyclable copolyesters such as PETG, PCTA and PCTG, with additional materials to be tested.

At the exhibition, the company will present multiple cosmetic jars with different demanding shapes. The jars are made from Eastman PET Cristal One Renew IM812 and have a crystal-clear appearance and a flawless surface. According to the source material, the use of this material supports a high level of sustainability because its recycled content, determined by mass balance, can be as high as 100%. The r-PET also enables injection molding of parts with wall thicknesses of up to 12 mm.

These projects were developed in cooperation with Cromes, a mold maker for the cosmetics industry, and Technicaps, a converter integrating the innovation into high-end, refillable packaging solutions.

STARgate HRS will be presented not only for PP and r-PP applications but also for the processing of resins such as PMMA and ABS. This widens its range of applications across market segments

Precision components for medical technology

Oerlikon HRSflow will also present the use of r-PET in medical applications. One example is a precision, direct-gated Luer-lock component manufactured using LNP ELCRIN W1000JiQ. This next-generation medical-grade PBT from SABIC is derived from chemically recycled PET and supplied by GUZTEC POLYMERS. The part will also be produced using PEEK technopolymer for demanding applications.

The related multi-cavity mold is equipped with an Oerlikon HRSflow TECHflow HRS valve gate line. According to the company, its external nozzle end rings provide increased wear resistance when processing abrasive, reinforced thermoplastics, including materials with flame-retardant additives, which combine a narrow processing window with high processing temperatures. A uniform temperature profile is intended to ensure a wider processing window, high dimensional stability and easy machine restart in the production of Luer-lock connectors.

The mold is manufactured by C.P. Stampi and equipped with a MOULDING DEVUP automatic unscrewing system for precise demolding of the internal threads of the Luer-lock connectors.

Automotive visible parts with reduced post-processing

For the automotive sector, Oerlikon HRSflow will present GLOW HRS, a compact solution for direct injection molding of high-quality parts. The system is designed to prevent halos and enable high surface aesthetics, while reducing post-processing steps and improving process efficiency.

The company will also present a scratch-resistant bumper that combines polyurethane coating and decorative film technology in a single process. According to the source material, this reduces production time and investment costs compared with a two-stage process. The solution is supported by the configuration of the Oerlikon HRSflow system, developed for the integration of both technologies and equipped with nine conical needle-valve nozzles. Project partners include Borealis, Cannon, DNP, ENGEL, INEVO and the Inabata Group.

Live demonstrations at partner booths

Oerlikon HRSflow hot-runner systems will be demonstrated live at several partner booths during Fakuma 2026.

• Fanuc, Hall A7, Stand A7-7304: A Fanuc injection molding machine will produce 1.2 g cable clipper parts made of PA6.6-GF30 as an example of small technical parts. The mold features a 16-cavity hot-runner system with TECHflow HRS valve gate technology and Sa series nozzles. Oerlikon HRSflow developed this system for processing glass-fiber-reinforced plastics. The machine’s real-time monitoring system tracks cavity filling behavior and automatically adjusts process parameters to ensure uniform filling of all cavities. Cavity Eye, a specialist in cavity pressure measurement in injection molding tools, is also involved.
• Haitian, Hall B1, Stand B1-1205: A Haitian injection molding machine will operate live, producing a lighting trunk bar as an example of a high-quality automotive application. The servo-driven flexibility of FLEXflow HRS valve gate technology enables direct injection of transparent materials and optimizes warpage control.
• Wittman, Hall B1, Stand B1-1204: Production of a PP pen cap for self-drug delivery will be presented as another medical application of Oerlikon HRSflow MULTIflow HRS technology. The displayed solution is an eight-cavity mold equipped with V-Series nozzles with a torpedo tip, intended to ensure a stable and reliable process.