Multi component Technology

how to optimize processes

cut production costs with overmoulding

distribution of melt with sandwich moulding

Over molding
standard and TandemMould
9 Overmoulding
for production of multi material specimen
(color, rigidity, mechanical aspects, )
two step process
(make preform, overmould preform)
high repeatability with overmoulding productionunit
high investment
(machine: + 60 %, mould: special mould maker)
9 Cut cost
increase output
use simple technology

Product cost

1,6
product cost

1,4
1,2

Labour
Mould
Machine
Resin

0,8
0,6
0,4
0,2
0
cycle time

TandemMould

TandemMould vs stack mould

TandemMould technique

TandemMould

on Arburg machine

Cost Calculation

Cycle time for TandemMould-slow-run

Cycle time for TandemMould-fast-run

Preform Transfer with

rotational transport

9
9
9
9
9

turn of strip plate

turn with index plate and additional ejector
turn of insert plate
turn of movable mold half
turn of middle plate

Tooth brush mold

Cycle 3

Stack-Turning Technology:
Cube System

Injection Unit 2

Cycle 2
Assembly

Cycle 1
Injection Unit 1

Cycle 4
Part removal

TandemMould-2K

TandemMould-2K

Preform Transfer with handling

9
9
9
9

manual transport
transport via handling robot
transport with vertical transport axis
transport with transfer plate

TandemMould-Overmoulding
transport with handling

9 size of mould get smaller

9 faster process
handling needs no additional
movement inside mould
two processes alternate
9 high repeatability
preform always with similar
temperature, const. process

TandemMould-Overmoulding
transport with handling

Standard

Standard

TandemMould

process
stability

--

handling

--

mould size

++

machine size

investment

with two machines with one machines

1)

1) with handling two machines must run exactly synchronized

Sandwich-Specimen with optimized

Distribution of Core Material
9 Save production cost with regrind core material
9 Vary Product properties
foamed core material
fibre reinforced material
.
9 Simulations with 2,5 und 3-D software
9 Proof results with modified production mould
9 alternative solution, new mould concept

project: G. Kessler

Sandwichmoulding examples

Gear box handle

over molding and
Monosandwich

Standard
Process

Sandwich molding Machine

Nozzle types for Sandwich Machines

Sandwich Molding with hot runner

(Ferromatik and Incoe)

Sandwichmoulding with
overmoulding machine

Principle Monosandwich

Principle Monosandwich

Monosandwich
9 skin (whit) is intruded into
the black core material
9 The ejection switches the
configuration
9 The plastification of the
black core material is the
start configuration

Repeatability of
Monosandwich process

Shot by shot
the same
picture

Different cavities have

different filling pattern

Example housing for loud speaker

Old version
thermoplastic foam
bad surface
High cost for finishing

Box for loud speaker with Sandwich

structure

Inside foamed
material

Outside compact
virgin material

Distribution of
core material

Optimization of
core material distribution

Result of Calculation
Skin Thickness

First Proof of Optimization Strategy

Theory an Practise with

2D-Model Geometry

Modification of Production Mould

(add additional plate)

Result after Mould Modification

Distribution of Core Material inside

Front area

Alternative Solution with

Monosandwich Process

Calculated Result of
Alternative Solution

Realization with
56,000 KN machine