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10-12-2016

From Cleanroom to Structural Foam

Wittmann Battenfeld

Preform injection molding, blow forming, and ejection – three stations up to a finished flacon (© Wittmann Battenfeld)

Wittmann Battenfeld GmbH from Kottingbrunn, Austria, will demonstrate production in a cleanroom at the trade fair. In a manufacturing cell built up around an injection molding machine type EcoPower Medical 110/350 with an 8-cavity mold, the central pump component of a Respimat inhaler from Boehringer Ingelheim microParts is produced from PEEK. The molded parts and sprues are removed by a handling robot (Wittmann W837) specially designed for use in cleanrooms. In order to comply with medical standards, the machine’s cleanroom version is fitted e. g. with a laminar flow box (Max Petek). Via an external tablet, the machine can also be operated from outside the cleanroom.

On a large MacroPower 1100/8800 machine, Wittmann Battenfeld will show the "Cellmould" structural foam process using an automotive application. The physical foaming procedure enables particularly light and distortion-free components with high stiffness to be produced. The finished components are removed by a handling robot, subjected to a quality inspection, and then placed on a conveyor belt. Also here, the main idea being followed is Industry 4.0, and on this machine a condition monitoring system (CMS) will be showcased for the first time under the name "Smart Services". For this, machine status data from the machine’s control system are evaluated. This permits flexible planning of maintenance intervals via a manufacturing execution system (MES).

The finished 150ml flacon (© Wittmann Battenfeld)

Included in the extended range of lightweight construction topics, a structural plastic/metal component is produced with a fully electric EcoPower 110/350 using a combined deep drawing and injection molding process. The technology was developed by the Institute for Plastic Processing (IKV) in Aachen, Germany. Hereby, a sheet-metal blank is placed in the injection mold, and is then deep drawn by a punch as the mold closes. Subsequently, the shaped sheet metal is back molded with polyamide and obtains its final geometry by means of the injection pressure. Finally, the finished hybrid component is removed and deposited.

In an application on a servohydraulic SmartPower 240/1330, PP preforms for a 150ml flacon are injection molded in a 2-cavity mold (J.P. Grosfilley), and then blow formed in the mold. The injection mold is fitted with a three-station indexing platen. In the first station, the preforms are injection molded, in the second station they are blow formed, and in the third station they are ejected by free fall. By integrating a fourth station, in which the preforms can be overmolded with an additional component, the production of packaging made of different plastics is also conceivable.

Hall 16, booth D22

Company profile

Wittmann Battenfeld GmbH

Wiener Neustädter Str. 81
AT 2542 KOTTINGBRUNN/N.Ö.
Tel.: +43 2252 404-0
Fax: +43 2252 404-1062

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