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be the f i rst .

3000/us/07-2005/fr

Small and medium-sized machines

ENGEL VICTORY

ENGEL E-MOTION

Large-capacity machines

ENGEL DUO / CLASSIC

Special appl icat ions

ENGEL COMBIMELT

ENGEL INSERT

ENGEL ELAST / L IM

ENGEL macPET

Integrat ive technology

ENGEL ROBOTS

ENGEL PRECISION MOLDS

ENGEL CC 200

Applicat ion technology

ENGEL APPLICATION TECHNOLOGY

Foammelt , F lu idmelt

Tecomelt , F ibermelt

Services

ENGEL TRAINING

Summary

ENGEL SCOPE OF PRODUCTS

Language

german

engl ish

french

i ta l ian

spanish

pol ish

czech

russ ian

hungar ian

s lovenian

korean

mandar in

ENGEL NORTH AMERICA: www.engelmachinery.com

Mexico: Engel de Mexico S.A. de C.V.Mexico Ci ty, Mexico 11230te l : 52 555 399 8999fax: 52 555 399 2649e-mai l : [email protected]

USA: Engel Machinery Inc.York, PA, 17402te l : 717 764 6818fax: 717 764 0314e-mai l : [email protected]

Canada: Engel Canada Inc.Guelph, Ontar io, N1K 1C2te l : 519 836 0220fax: 519 836 3714e-mai l : sa [email protected]

be the f i rst .

scope of products

>> The future belongs to those who preparefor i t today. << Malcolm X (Amer ican c iv i l r ights leader )

Innovat ive in ject ion molding technology

Building machines is our passion –Your success is our goal.

Our business is focused on the in ject ion mold ing ofplast ics. Hardly any other mater ia l has made a greaterimpact on modern l ife than plastics. Featuring propertiesmid-way between minera l and organic mater ia ls , i tmakes futur ist ic v is ions of design and purpose apresent-day rea l i ty. I ts uses and design potent ia l arewidely var ied – just as such processes as paint ing,cast ing, extruding, thermoforming, b low molding andin ject ion mold ing are only a few of the many opt ionsavai lable to the p last ics processor.

I t is with in th is wide spectrum of possible opt ions thatEngel specia l izes in the process of in ject ion molding –and in every branch of th is technology, f rom machinesfor the mold ing of microprecis ion parts through toheavy-duty machines for large, heavy parts.Engel a lso manufactures the necessary molds andautomat ion equipment. In ject ion mold ing machinesgenerate and ut i l ize enormous forces.The bui ld ing of these machines – whether standard orcustomized – is our passion. The success of ourcustomers who use them is our goal .

Automation technologyLinear robots wi th servoor pneumat ic dr ives

Plastics injection molding – everything you need from just one s up

Kits for the do- i t-yoursel fassembly of robot gr ippers

- Automat ion per iphera ls- Conveyor systems- Safety guards

Inject ion moldsfor mult icomponent partsf rom Engel 's own mold making fac i l i ty

Standard machinesHydraul ic in ject ion mold ing machines witht iebarless clamping units for clamping forcesranging f rom 28 to 660 US tons

Inject ion molding machines with two-platen,tiebar-type clamping units for clamping forcesranging f rom 720 to 6000 US tons

In ject ion mold ing machines with vert ica lc lamping uni ts for c lamping forces rangingfrom 60 to 300 US tons

Hydraulic injection molding machines with toggleclamping units for clamping forces ranging from300 to 1000 US tons

Hor izonta l and vert ica l in ject ion mold ingmachines for rubber processing with c lampingforces ranging 28 to 1100 US tons

upplier.

Special machinesIn ject ion mold ing machinesfor mult i -component appl icat ions

Machines for the in ject ionmolding of l iqu id s i l icone rubber

Applicat ion technologyENGEL TECOMELT – an intel l igent processingtechnology for the low-pressure processingof p last ics

ENGEL FOAMMELTThis is the ideal process for use in applicationswhere component funct ion and dimensionalaccuracy take pr ior i ty over sur face f in ish

ENGEL FIBERMELT is the basic technology forthe mass product ion of structural components inthe automot ive industry

“F lu idmelt” is the genera l term for in ject ionmolding processes in which f lu ids – such asnitrogen gas or water – are subjected to a definedpressure for the purpose of obta in ing a specia leffect . Typica l processes are ENGEL GASMELTand ENGEL WATERMELT

Control systemCC 200 machine contro l system withdecentra l ized inte l l igence Windows-oriented display in conjunction with a 12"touchscreen color moni tor.Sett ings stored on CompactF lash.Author ized access with keycard.Ethernet interface. A comprehensive rangeof standard equipment plus requirement-oriented options ensure optimum operatorcomfort for a l l appl icat ions

ENGEL PLASTICS PROCESSING MACHINES.Engel know-how – global presence.

Over the past ha l f century, Engel hasdeveloped into a group consist ing of8 product ion p lants located on3 cont inents, wi th Sales and Serv icerepresentat ions in 90 countr ies.

Engel Canada Inc. Guelph, Ontario, Canada(Small/Medium-Sized Machines, Robots, Automation)

Engel Machinery Inc. York, Pennsylvania, USA(Large-Capacity Machines)

ENGEL AUTOMATISIERUNGSTECHNIKDEUTSCHLAND GMBH.Hagen, Germany (Automation Units)

ENGEL AUSTRIA GmbH.Plant Schwertberg, Austria(Small/Medium-Sized Machines)

ENGEL AUSTRIA GmbH.Plant St. Valentin, Austria(Large-Capacity Machines)

ENGEL AUSTRIA GmbH.Plant Dietach, Austria (Robots, Automation)

Engel Strojirenska spol s.r.o Kaplice,Czech Republic (Machine Components)

Engel Machinery Korea Ltd. Pyungtaek-City, Korea(Small/Medium-Sized Machines)

Sales and Serv ice Centers Product ion Faci l i t ies

8

THE COMPLETE ENGEL RANGE …. . . at a single glance.

ENGEL VICTORY (+VICTORY Electr ic)The standard machine – t iebar less, universal and modular

ENGEL VICTORY Combi / ENGEL DUO CombiStandard and large-capacity machines for mult i-componentin ject ion molding

ENGEL CLASSICMedium-sized machines featur ing classicaltoggle clamp technology

ENGEL ELASTComplete ser ies for rubber parts

ENGEL LIMMachines and technology for LSR parts

ENGEL COMBIMELTProcesses for mult i-color and mult i-componentin ject ion molding

ENGEL FOAMMELTMicrocel lu lar foam for l ightweight precis ion parts

ENGEL DUOLarge-capacity machines with two-platen clamping units,hydraul ic

ENGEL PRECISION MOLDSEngel in ject ion molds – with the focus on Combimelt technology

ENGEL GASMELT / WATERMELT (FLUIDMELT)Innovat ive solut ions using gas or water

ENGEL OPTIMELTNanostructured opt ical lenses

ENGEL FIBERMELTFor long glass f ibers in high-strength components

Technologies

> 10/11 > 12-15

> 20/21 > 22/23

> 28/29 > 30/31

> 36/37 > 38/39

> 44/45 > 46/47

> 52/53 > 54/55

+ +

9

ENGEL INSERTVert ical machines for metal and plast ic composites

ENGEL macPETToggle clamp machines, special ly for PET preforms

ENGEL E-MOTIONAl l-electr ic machines – modular, fast , h igh precis ion

ENGEL SPEEDNew toggle clamp ser ies – high performance for fast cycl ing

ENGEL ROBOTSLinear robots, special ly for in ject ion molding machines

ENGEL TECOMELTThe Engel process for combining fabr ics and plast ics

ENGEL TRAININGThe concept for customer employee qual i f icat ion

ENGEL AUTOMATION TOOLSPeripherals for automated parts removal and handl ing

ENGEL FOILMELTSurface design for plast ic components

ENGEL AT YOUR SERVICEProject engineer ing and management for complex appl icat ions

ENGEL X-MELTFor smal l shot weights and thin-sect ion parts

ENGEL GLAZEMELTCar windows in al l var iat ions

5 > 16/17 > 18/19

3 > 24/25 > 26/27

1 > 32/33 > 34/35

9 > 40/41 > 42/43

7 > 48/49 > 50/51

5 > 56/57 > 58/59

10 200 / … 310 / … 440 / … 740 / …

25/30

25/30

25/30

25/30

25/30

25/30

30/35

30/35

30/35

30/35

30/35

30/35

30/35

30/35

35/40

35/40

45/50

45/50

35/40/45

40/45/50 50/55/60

40/45/50

45/50/55

45/50/55

18/22/25

18/22/25

18/22/25

18/22/25

18/22/25

18/22/25

25/30/35

25/30/35

25/30/35

25/30/35

25/30/35

25/30/35

25/30/35

25/30/35

30/35/40

30/35/40

30/35/40

30/35/40

30/35/40

30/35/40

30/35/40

30/35/40

35/40/45

35/40/45

35/40/45

35/40/45

35/40/45 50/55/60

1050 / …750 / …650 / …500 / …330 / …200 / …80 / …

ENGEL V ICTORY.The standard machine – t iebarless, universal and modular.

Clamp units

Hydr. inject ion units*

VICTORY … / 28 US

VICTORY … / 40 US

VICTORY … / 50 US

VICTORY … / 65 US

VICTORY … / 75 US

VICTORY … / 85 US

VICTORY … / 100 US





Clamp units

Electromechanical inject ion units*

Avai lable screw diameter in mm per inject ion unit

VICTORY 65 US

VICTORY 75 US

VICTORY 85 US

VICTORY 100 US

VICTORY 120 US

VICTORY 130 US

VICTORY 145 US

VICTORY 165 US






VICTORY (1 … / 400 US




Clam units

Inject ion units *


ENGEL VICTORY 4550 / 660 USThe largest t iebar less machine

ENGEL VICTORY 80 / 28 USThe smal lest t iebar less machine

11

60/70/80

60/70/80

40/45/50

40/45/50

45/50/55

45/50/55

50/55/60

50/55/60

55/60/70

55/60/70

70/80/90

60/70/80

60/70/80

60/70/80

60/70/80

60/70/80

60/70/80

60/70/80

60/70/80

60/70/80

70/80/85

70/80/85

70/80/85

70/80/85

70/80/85

70/80/90

70/80/90

70/80/90

80/90/105

80/90/105

80/90/105

80/90/105

90/105/120

90/105/120

55/60/7045/50/55

45/50/55

50/55/60

50/55/60 55/60/70

55/60/70

55/60/70

60/70/80 70/80/85

60/70/8055/60/7040/45/50 45/50/55 50/55/60

650 / … 750 / … 1050 / … 1350 / … 1800 / … 2050 / … 2550 / … 3550 / … 4550 / … 5550 / … 7050 / …

US

US

US

US

US

0 US

0 US

0 US

0 US


* International type-size designation, calculated from: max. swept volume [cm3] x max. injection pressure in [bar] / 1000(1 Series conversion from the TL system to the Victory system is taking place continually

The systemThe system is based on the t iebar less in ject ionmolding machine concept which was introduced in1989. The t iebar less c lamping system is avai lab lein clamping forces ranging from 28 to 660 US tons,thus cover ing the ent i re range of appl icat ions forsmal l and medium-sized machines.

In conjunct ion with the basic modules, theENGEL VICTORY machines can be adapted withaddit ional equipment modules for special appl icat ions.

The p lat formThe machine system uti l izes the t iebarless conceptas the basic technology – or p lat form – for amodular system for the design of complete,appl icat ion-or iented machines and extensionpackages.

ENGEL VICTORY Rubber :An a l ternat ive to the specia l machines of the ENGELELAST ser ies of rubber in ject ion mold ing machines.

ENGEL VICTORY Lim :For the processing of l iqu id s i l icone rubber, equippedwith ei ther a reciprocat ing screw or a plunger in ject ionuni t , depending on the appl icat ion.

ENGEL VICTORY HTV :P last ic iz ing uni t and process software forthe processing of so l id s i l icone.

ENGEL VICTORY PVC :For the processing f lex ib le or r ig id PVC.

ENGEL VICTORY Thermoset :Specia l p last ic iz ing assembly, processing softwareand mold heat ing systems for the in ject ion moldingof thermosets.

ENGEL VICTORY Electr ic / X-Melt :For the in ject ion mold ing of microprecis ion parts.

ENGEL VICTORY MuCel l®:For the manufacture of industr ia l parts inmicrocel lu lar foam.

ENGEL VICTORYTech

The economical machinefor 80% of al l standard appl icat ions.

ENGEL VICTORY Power

Performance tai lored to actualrequirements in f ive possible steps –meeting every demand for theutmost precision.

ENGEL VICTORYCombi

Two and more inject ion units –for mult i-color and mult i-componenttechnology.

ENGEL VICTORYElectr ic

Hydraul ic clamping unit combinedwith electromechanical precisioninject ion unit .

12

80

330 H / … L200 H / … L80 H / … L

30/35/4025/30/3518/22/25

8080

80/200

80/20080/200

80-330

80-33080-330

80/20080/200

80/200

80-33080-330

80-330

80-330

80-330

80

330 H / … V200 H / … V80 H / … V

30/35/4025/30/3518/22/25

8080

80/200

80/20080/200

80-330

80-33080-330

80/20080/200

80/200

80-33080-330

80-330

80-330

80-330

80

330 H / … W

30/35/40

8080

8080

80

80

80

ENGEL V ICTORY Combi.Standard machines for mult i-component inject ion molding.

In ject ion uni t combinat ionin “L” arrangement.The “L” arrangement of the in ject ion uni ts affordsunrestr icted access to the p last ic iz ing uni t .Injection units in “L” arrangement can be combinedwithin a wide range of sizes with all basic machines.

In ject ion uni ts in hor izonta land vert ica l arrangement.The vert ica l in ject ion uni t is mounted above thestat ionary p laten. When the mold has to bechanged, i t can be easi ly pushed back in thedirect ion of the hor izontal in ject ion unit . Center ingof the in ject ion nozz le over the gate is easy andaccurate.

In ject ion uni ts in “p iggyback”arrangement.The piggyback arrangement of the in ject ion uni ts( the second uni t is arranged at an angle above themain uni t ) const i tutes a space-sav ing solut ion foran automated Combimelt product ion machine witha handl ing robot mounted on the stat ionary platen.

Clamp units

Horizontal injection units*

Screw diameter

Clampunits


Screw diameter

Clamp units


Screw diameter

(1 Series conversion from TL systemto Victory system is taking place continually

* international type-size designation,calculated from:

max. swept volume [cm3] x max.injection pressure in [bar] / 1000

VICTORY … / 65 US Combi



VICTORY … / 100 US CombiVICTORY … / 120 US Combi






VICTORY … / 400 US CombiVICTORY … / 440 US CombiVICTORY … / 550 US Combi (1

VICTORY … / 660 US Combi (1






























13

1050 H / … L750 H / … L650 H / … L500 H / … L… L 1350 H / … L 1800 H / … L 2050 H / … L 2550 H / … L

50/55/6045/50/5540/45/5035/40/4540 55/60/70 60/70/80 60/70/80 70/80/85

30

3030

3030

30

30

30

80-50080-500

80-500

80-500

80-500

80-500

80-500

80-65080-650

80-650

80-500

80-500

80-65080-650

80-65080-1050

80-500

80-500

80-65080-650

80-65080-1050

80-65080-650

80-65080-1050

80-65080-650

80-65080-1050 80-1050 80-1050

80-1050 80-1050 80-1050 80-1050 80-1050 80-1050330/500330/500

330/500330/500

330/500330/500

500-750500-750

500-750500-750

1050 H / … V750 H / … V650 H / … V500 H / … V… V 1350 H / … V 1800 H / … V 2050 H / … V 2550 H / … V

50/55/6045/50/5540/45/5035/40/4540 55/60/70 60/70/80 60/70/80 70/80/85

30

3030

3030

30

30

30

80-50080-500

80-500

80-500

80-500

80-500

80-500

80-50080-500

80-500

80-500

80-500

80-50080-500

80-500

80-500

80-500

80-500

80-500

80-50080-500

80-500

80-500

80-500

80-50080-500

80-500

80-500

80-500

80-50080-500

80-500

80-500

80-500

80-500

80-500

80-500

80-500330/500

330/500

330/500

330/500

330/500

330/500500-750

500-750

500-750

500-750

1800 H / … W1350 H / … W1050 H / … W750 H / … W650 H / … W500 H / … W… W 2050 H / … W 2550 H / … W

60/70/8055/60/7050/55/6045/50/5540/45/5035/40/4540 60/70/80 70/80/85

80-330

80-330

80-330

80-330

80-330

80-33080-50080-500

80-500

8080

80

80

8080-50080-500

80-500

80-50080-500

80-500

80-50080-500

80-500

80-50080-500

80-500200-500

200-500

200-500

200-500

200-500

200-500

200-500

200-500

200-750

200-750

200-750

200-750330/500

330/500

330/500

330/500

330/500

330/500500-750

500-750

500-750

500-750

Avai lable combin at ions with “piggyback” inject ion units

Avai lable combinations with vert ical inject ion units in “V” arrangement

Available combinations with vertical injection units in “L” arrangement

14

2050 H / … W

60/70/80

DUO … / 3500 US Combi

330-750

2050 H / … M

60/70/80


1050-2050

02

01

ENGEL DUO Combi.Large-capacity machines for multi-component injection molding.

Clamp units

Horizontal injection units

Screw diameter

DUO … / 720, 770 US Combi

DUO … / 900, 1000 US Combi




DUO … / 2200, 2500 US Combi


ENGEL DUO 4550H / 330W / 1250 US Combi

ENGEL DUO 4550H / 2550M / 1000 US CombiClamp units

ENGEL DUO Combi HM

Screw diameter

DUO … / 720, 770 US Combi

DUO … / 900, 1000 US Combi




DUO … / 2200, 2500 US Combi


As an al ternat ive to the rotat ing center platen, the machines can be equipped witha central mold carr ier system to process with two molds simultaneously. There are twoinject ion units for maximum process and product ion f lexibi l i ty.

15

5550 H / … W4550 H / … W3550 H / … W2550 H / … W… W 7050 H / … W 11050 H / … W 16050 H / … W 23050 H / … W

80/90/10580/90/10570/80/9070/80/9080 90/105/120 105/120/135 120/135/150 135/150/160

650-2550 650-2550

650-2550 650-2550

330-1800 650-2550 650-2550

330-1800 330-1800 650-2550 650-2550

330-1800 330-1800 650-2550 650-2550

330-1050 330-1800 330-1800 650-2550

330-1050 330-1050 330-1800 330-1800

50 330-750 330-1050 330-1050 330-1050 330-1800

5550 H / … M4550 H / … M3550 H / … M2550 H / … M… M 7050 H / … M 11050 H / … M 16050 H / … M 23050 H / … M

80/90/10580/90/10570/80/9070/80/9080 90/105/120 105/120/135 120/135/150 135/150/160

1050-7050 1050-7050

1050-7050 1050-7050

1050-7050 1050-7050 1050-7050

1050-7050 1050-7050 1050-7050 1050-7050

1050-5550 1050-5550 1050-7050 1050-7050

1050-5550 1050-5550 1050-5550 1050-5550

1050-2550 1050-2550 1050-2550 1050-2550

50 1050-2550 1050-2550 1050-2550 1050-2550 1050-2550

Available injection unit combinations (other combinations are also available – please inquire)

01ENGEL DUO “piggyback” inject ion unit.The “piggyback” concept for ENGEL DUO machinesis ident ical to that of the ENGEL VICTORY ser ies ofsmall and medium-sized machines in respect of bothdesign and appl icat ion. As large-capacity machinesare genera l ly equipped with handl ing robots, th isconcept is the preferred one for ENGEL COMBIMELTappl icat ions.

Available injection unit combinations (second unit on moving platen)

02ENGEL DUO Combi HM – A machineconcept offer ing opt imum versat i l i ty.The machine concept of the ENGEL DUO Combi HM(H stands for “hor izontal” an M stand for “movable”)is based on the enormous appl icat ion potent ia la fforded by the two platen design of the ENGELDUO clamping uni t .A horizontal injection unit is mounted on each platen.The c lamping uni t may be equipped e i ther wi th arotary table or with a rotary module for the in ject ionmolds. Thus the machine is ideal for the product ionof large-area, two-component parts or for use withdouble-dayl ight or stack molds.

16

80 / … 200 / … 310 / … 440 / … 740 / … 940 / … 1340 / … 1640 / …

ENGEL E-MOTION.All-electr ic machines – modular, fast, high precision.

E-MOTION 60 US

E-MOTION 110 US

E-MOTION 165 US

E-MOTION 200 US

E-MOTION 200 T US

E-MOTION 250 T US

E-MOTION 310 T US

E-MOTION 385 T US**

Available screw diameter in mm per injection unit

Injection units *

Clamp units

ENGEL E-MOTION 80/60 US

* international type-size designation, calculated from: max. swept volume [cm3] x max. injection pressure in [bar] / 1000 ** In development

Toggle clamping unit with t iebars for high clamping force.

18 / 22 25 / 30

25 / 30 35 / 40

35 / 40

30 / 35

30 / 35

45 / 50 / 55

35 / 40 45 / 50 / 55

45 / 50 / 55

50 / 55 / 60

50 / 55 / 60

50 / 55 / 60 55 / 60 / 70

35 / 40 45 / 50 / 55 50 / 55 / 60

55 / 60 / 70 60/70/80

17

ENGEL E-MOTION 940/310 T US

A whole ser iesfor the h ighest demands.Engel injection molding machines featuring al l-electr icdr ive technology are now avai lable in a range ofc lamping forces f rom 60 to 310 US tons (up to385 US tons in the near future). In the lower clampingforce range, up to 200 US tons, four sizes of clampinguni t are offered, a l l of them featur ing automat ion-f r iendly t iebar less design, whi le a t iebar c lampingunit of new, innovat ive design is offered in the upperc lamping force range.

nsprüche.Common to a l l machines is the concept of thecompact in ject ion uni t wi th short-design doublespindle dr ive.

Options:Al l un i ts are a lso avai lable in a “High Speed”vers ion (h igher in ject ion speed).ENGEL X-MELT can be used in conjunct ion witha l l in ject ion uni ts up to s ize 440.

Tiebarless clamping unit in the lower clamping force range.

18

ENGEL INSERT.Vert ical machines for metal and plast ic composites.

80 H / … 200 H / … 330 H / … 500 H / … 600 H / … 700 H / … 1050 H1) / … 1300 H / …650 H1) / … 750 H1) / … 1350 H1) / …

Injection units / Horizontal * Rotary table

Available screw diameter in mm per injection unitClamp unit Diameter (inch)

INSERT … / 60 US

INSERT … / 80 US

INSERT … / 100 US

INSERT … / 120 US1)

INSERT … / 125 US (WP**)





INSERT … / 200 US1) (WP**)

INSERT … / 230 US1) (WP**)

INSERT … / 265 US1) (WP**)

INSERT … / 300 US

ENGEL INSERT 80H/60 US

Rotary table machine with hor izontal in ject ion unit

47.24

47.24

47.24

47.24

46.46 / 62.00

47.24

46.46 / 62.00

47.24

46.46 / 62.00

47.24 / 62.99

47.24 / 62.99

47.24 / 62.99

62.00

18/22/25

18/22/25

25/30/35

25/30/35

25/30/35

30/35/40

30/35/40

30/35/40

30/35/40 40/45/50

40/45/50

45/50/55

30/35/40

30/35/40

30/35/40 40/45/50

50/55/60

55/60/70

25/30/35

30/35/40 30/35/40

30/35/40 40/45/50 45/50/5530/35/40 50/55/6025/30/35

40/45/5030/35/40 30/35/40

30/35/40 40/45/50 45/50/5530/35/40 50/55/6025/30/35

45/50/55

30/35/40 40/45/50 45/50/5530/35/40 50/55/6025/30/35

55/60/7030/35/40 40/45/50 45/50/5530/35/40 50/55/6025/30/35

55/60/7030/35/40 40/45/50 45/50/5530/35/40 50/55/6025/30/35

55/60/7045/50/55

19

The basis of success.Through the use of standard structura lunits for the inject ion unit and the drive,ENGEL INSERT machines offer the samehigh degree of qual i ty as the standardrange of Engel in ject ion mold ingmachines. These basic combinations areonly the start ing point for a widespectrum of machine variants which canbe speci f ica l ly adapted to everyconceivable appl icat ion.

200 V / … 330 V / … 500 V / …Injection units / Vertical * Rotary table

Available screw diameter in mmper injection unit

)Clamp unit

INSERT … / 60 US


INSERT … / 90 US


INSERT … / 125 US

INSERT … / 150 US

Diameter (inch)

ENGEL INSERT 80V/60 US

Rotary table machine with vert ical in ject ion unit

38.38

46.46

38.38

46.46

62.00

62.00

25/30/35

25/30/35

25/30/35

25/30/35

25/30/35

30/35/40

30/35/40

30/35/40

35/40/45

30/35/40

30/35/40

30/35/40

35/40/45

35/40/45

35/40/45

25/30/35

* international type-size designation, calculated from: max. swept volume [cm3] x max. injection pressure in [bar] / 1000

** WP: Alternate table size available1) Future production of global design

20

70 / 80 / 90

80 / 90 / 105 80 / 90 / 105 90 / 105 / 120

80 / 90 / 105 90 / 105 / 120

90 / 105 / 120

90 / 105 / 120

80 / 90 / 105 80 / 90 / 105 90 / 105 / 12070 / 80 / 85

2550 3550 4550 5550 7050

ENGEL DUO.Large-capacity machines with two-platen clamping units, hydraul i

Clamp units

Injection units *

Avai lable screw di

DUO 720, 770 US

DUO 770 WP** US

DUO 770 WPX** US

DUO 900, 1000 US

DUO 1000 WP** US

DUO 1000 WPX** US

DUO 1250 US

DUO 1250 WP** US

DUO 1250 WPX** US

DUO 1650 US

* international type-size designation, calculated from: max. swept volume [cm3] x max. injection pressure in [bar] / 1000** WP / WPX: Additional size variants for platens (see technical data sheets)

ENGEL DUO – The universa llarge-capaci ty machine.Minimum space requirement, sturdy construct ion,easy automation and modular conf igurabi l i ty – thesewere the design pr inc ip les for th is ser ies of large-capacity Engel machines. Clamping units in a rangeof ten c lamping force categor ies f rom 720 to6000 US tons and eleven injection units are availablefor any desi red combinat ion.The funct ional nucleus of the ENGEL DUO clampinguni t is the carr iage-mounted moving platen.

This p laten is moved on i ts carr iage by means oftwo hydraul ic cy l inders. The four t iebars are r ig id lyconnected to the stationary platen, which is equippedwith four pressure pads, but not to the moving platenwhen the latter is being moved. Only when the moldcloses are the t iebars connected – by means of spl i tnuts – to the moving platen. The c lamping force isthen appl ied v ia the pressure pads.

ENGEL DUO 130000 / 6000 US

21

105 / 120 / 135

105 / 120 / 135 120 / 135 / 150

105 / 120 / 135 120 / 135 / 150 135 / 150 / 160

105 / 120 / 135 120 / 135 / 150 135 / 150 / 160

105 / 120 / 135 120 / 135 / 150 135 / 150 / 160 160 / 170 / 180

120 / 135 / 150 135 / 150 / 160 160 / 170 / 180 180 / 190 / 200

120 / 135 / 150 135 / 150 / 160 160 / 170 / 180 180 / 190 / 200

135 / 150 / 160 160 / 170 / 180 180 / 190 / 200

135 / 150 / 160 160 / 170 / 180 180 / 190 / 200 215 / 230 / 245

215 / 230 / 245

245 / 260

160 / 170 / 180

215 / 230 / 245

215 / 230 / 245

11050 16050 23050 35050 45050 75050 130000

ul ic.

w diameter in mm per inject ion unit

The advantages l ie in the basic concept:

> “ENGEL DUO Baseframe Technology” – the modular system to per fect ly customize your machine.

> Min imum space requirement thanks to compact two-platen design.

> Cycle t ime reduct ion is made possib le by two diagonal ly posi t ioned h igh-speed cy l inders featur ing fast lock ing spl i t nuts and rapid pressure bui ld-up t ime.

> High re l iab i l i ty in operat ion and h igh part qual i ty are insured by sturdy p laten guides which guarantee para l le l t rave l of the moving p laten.

> Easiest conceivable operator inter face thanks to contro l concept offer ing fu l l integrat ion potent ia l for machine, robot and per iphera l un i ts.

22

ENGEL CLASSIC.Medium-sized machines featur ing classical toggle clamp technol o

Clamp units

Injection units *


* international type-size designation, calculated from: max. swept volume [cm3] x max. injection pressure in [bar] / 1000

CLASSIC 610 US

CLASSIC 660 US

CLASSIC 720 US

CLASSIC 830 US

CLASSIC 880 US

CLASSIC 1000 US

Cont inu i ty is the key to success.For over 50 years, and despi te a l l the new andalternative systems that have been developed since,Engel has been putt ing i ts t rust in the advantagesof the fu l ly mechanica l f ive-point toggle system.This is not for the sake of t radi t ion, but because ofthe many benef i ts these systems offer to

processors work ing in many di fferent branches ofthe manufactur ing industry. This is why we havecont inued to develop the toggle c lamp machine –and wi l l cont inue to develop i t in future, as aninterest ing a l ternat ive to the many other systemsnow avai lable on the market.

ENGEL CLASSIC 7050 / 830 US

2550 3550 4550 5550 7050 11050

70/80/85 70/80/90 80/90/105 80/90/105

70/80/85 70/80/90 80/90/105 80/90/105

70/80/90 80/90/105 80/90/105 90/105/120

70/80/90 80/90/105 80/90/105 90/105/120

80/90/105 80/90/105 90/105/120 105/120/135

80/90/105 80/90/105 90/105/120 105/120/135

23

ol ogy.

This proven concept has undeniable advantages:

> Optimized force distr ibut ion and r ig idity of c lamping system due to f ive-point doubletoggle system and box-type design of moving p laten.

> Actual locking force is 10% greater than the rated locking force thanks to the typicalposi t ive locking mechanism of the toggle system, even at h igh rates of in ject ion.

> Extreme re l iab i l i ty thanks to ruggedly constructed machine components.

> Combinat ion with Engel 's compact-design in ject ion uni ts min imizes overa l l length of machine.

> Easiest conceivable operator inter face thanks to contro l concept offer ing fu l l integrat ion potent ia l for machine, robot and per iphera l un i ts.

1350 1800 2050 2550 3550

55/60 60/70 60/70 70/80/85

55/60 60/70 60/70 70/80/85

55/60 60/70 60/70 70/80/85

60/70 60/70 70/80/85 70/80/90

60/70 60/70 70/80/85 70/80/90

60/70 60/70 70/80/85 70/80/90

60/70 60/70 70/80/85 70/80/90

Clamping units

Inject ion units *


TOGGLE 300 US

TOGGLE 400 US

TOGGLE 450 US

TOGGLE 500 US

TOGGLE 500 WP** US

TOGGLE 550 US

TOGGLE 550 WP** US

** WP / WPX: Size variants for platens. (See also technical data sheets)

24

110 / 441

120 / 605

110 / 441

120 / 605

120 / 605 120 / 605

130 / 781 130 / 781

140 / 958 140 / 958

24 32 48 56 64 72 96 144

150 / 1008

ENGEL macPET.Innovative machine technology for PET preforms.

ENGEL macPET 320 / 130 / 96

PET preform machines and processing technologyfrom the market leader in in ject ion molding systems:

> Complete PET system ser ies: 5 s izes of machine for preform molds rangingfrom 24 to 144 cav i t ies.

> Highest standards of product qual i ty achieved by means of an innovat ive in ject ionuni t des igned for the h igh-performance yet gent le processing of PET.The essent ia l system components of the p last ic iz ing uni t are the barr ier screw andthe melt accumulator wi th specia l hold ing pressure module.

> The t iebar-type, f ive-point double-toggle c lamping uni t features a generouslydimensioned guideway for the moving p laten on the baseframe, creat ing the bestpossib le prerequis i tes for fast and accurate movements and h igh work ing loads.

> Rel iable machine operat ion ensured by the Engel machine contro l system withintegrated robot and mold funct ions.

> Eff ic ient manufacture of complete product ion systems through c lose col laborat ionwith competent system partners.

> Serv ice and appl icat ion engineer ing supported by Engel 's g lobal networkof subsid iar ies and agencies.

PET system – Number of cavities

Machine models(Sizes shown in metric tonnage)

Available barrier screw diameter in mm / PET throughput (kg/hr)

macPET 250 / 110

macPET 250 / 120

macPET 320 / 120

macPET 320 / 130

macPET 500 / 140

macPET 500 / 150

25

The Engel in ject ion molding machine is the nucleus of a product ion cel l

Engel PET preform in ject ion mold ingmachines in serv ice wor ld-wide.After over 10 years of successfu l col laborat ion withSIG Corpoplast as a competent system partner, EngelPET in ject ion mold ing machines are today g iv ingre l iable serv ice in more than 20 countr ies wor ld-wide.

SIG Corpoplast's product l ine “PET Preform Systems”was complete ly taken over by Engel in 2003.

Al l the means of eff ic ient machine product ion in th isspecia l f ie ld of in ject ion mold ing are now complete lyat Engel ’s d isposal , guaranteeing cont inuous furtherdevelopment, technica l support in a l l mattersconcern ing appl icat ion as wel l as on-the-spot serv iceand ass istance through a wor ld-wide network ofsubsid iar ies and agencies.Engel PET in ject ion mold ing machines are at a l l t imesin tune with the t imes – a fact proven not least bycount less sat is f ied customers operat ing in th is verycompet i t ive branch of industry.

26

35* 45* 55* 2550** 4550**

30 / 35

40 / 45

50 / 55

70

80

ENGEL SPEED.High performance for packagings.

Clamp units (in metric tonnage)

Injection units *


* Size defined by screw diameter** International type size designation, calculated from: max. swept volume [cm3] x max. injection pressure in [bar] / 1000*** Gradual conversion to ENGEL SPEED machine system

SPEED 135

SPEED 175

SPEED 275

CLASSIC 350, 390 Speed US**

CLASSIC 500, 610 Speed US**

ENGEL SPEED 175 / 45

The new ser ies of fast cyc l ingEngel machines:The new ENGEL SPEED ser ies is the ideal bas is forthe fast cycl ing, cont inuous product ion of packagingconta iners. The key features of th is new ser ies ofh igh-performance machines are the innovat ive lyredesigned toggle c lamping uni t , the new “ in- l ine”injection unit and the hydraulic functions which operatein para l le l .

The two machines f rom the ENGEL CLASSIC-Speedseries offered in the higher upper clamping force rangeare equipped with e lectr ic screw dr ives and wi l lgradual ly be replaced by equiva lent models f rom theENGEL SPEED ser ies as they become avai lable.

27

ENGEL SPEED: the high-performance machine.

> Toggle c lamping uni t : fast – stabi l ized – sturdy.

> Toggle geometry designed for fast movements wi th gent leaccelerat ion and decelerat ion.

> The h ighly dynamic movements of the in ject ion uni t (up to 1000 mm / sec) and the clamping unit are actuated via a central hydraul ic accumulator working in conjunct ionwith h ighly dynamic va lves.

> Plast ic iz ing uni ts wi th barr ier screws for the h igh-performance yetgent le processing of PS, PP, HDPE.

> Fast cycle t imes thanks to h igh in ject ion speed and para l le l machine movements.

> Machine system rated for cont inuous, h igh-performance operat ion through sturdy base frame, modular construction, maintenance-free ultrasonic sensors and a service-proven, h igh-performance hydraul ic system.

> Complete system ser ies in 5 machine s izes.

28

ENGEL ELAST.Complete series for rubber parts.

Vertical rubber injection molding machines

ENGEL ELAST 4500 / 440 V USvert ica l rubber in ject ion mold ing machine

In addit ion to above machines from the ENGEL ELAST l ine with vert ical press design there are 3 addit ional machine models avai lable withvert ica l rotary table c lamp but hor izonta l in ject ion uni ts based on the ENGEL INSERT machine l ine –see a lso pages 18 / 19 (ENGEL INSERT Elast 85 H US, ENGEL INSERT Elast 200 H US, ENGEL INSERT Elast 300 H US,)For more deta i led informat ion p lease request our indiv idual data sheets.

US tons in3 standard in maximal in in

ELAST 110 V US

ELAST 175 V US

ELAST 275 V US

ELAST 440 V US

ELAST 660 V US

ELAST 880 V US

Schematic drawingof a vert ical t iebar-type clamp unit

FIFO (F i rst In-F i rst Out ) in ject ion uni tThe f i rst mater ia l p last ic ized is the f i rst in jected.By thermic consistancy of the p last i f ied mater ia land short f low paths, consistant product qual i tyis assured.

FIFOFirst In / F i rst Out- in ject ion unit

Clamp uni tOn al l vert ical machines and on horizontal machinesupwards of 440 US tons, convent ional 4-t iebarc lamping uni ts are used.

Machine type Clamp force Shot volume Heating platen dimensions Distance betweentiebars

110 17.08 – 61.02 14.17 x 19.69 17.32 x 21.65 17.7 x 10.0

175 26.24 – 122.05 19.69 x 21.65 21.65 x 25.6 23.2 x 11.6

275 45.75 – 219.68 21.65 x 25.6 25.6 x 29.52 26.0 x 12.6

440 91.5 – 366.14 27.95 x 36.22 31.89 x 40.15 32.3 x 19.7

660 164.48 – 640.75 31.5 x 43.3 35.43 x 47.24 37.0 x 23.2

880 164.48 – 1525.6 35.43 x 47.24 39.37 x 51.18 44.5 x 31.5

29

ELAST 110 VC US

ELAST 165 VC US

ELAST 200 VC US

ELAST 280 VC US

ELAST 440 H US**

Horizontal rubber injection molding machines

** Model wi th t iebar c lamping uni t

Machine type Clamping force Shot volume Heating platen dimensions Dry cycleaccording to

ENGEL ELAST 200 VC USHor izonta l rubber in ject ion mold ingmachine with brushing dev ices

Schematic drawing of a hor izontalt iebar less clamp unit

T iebar less ENGEL ELAST Clamp uni tThe layout of the t iebar less ELAST c lamp uni t isbased on the same design principles as the standard

machines for thermoplast ics and offers the bestcondi t ions for short mold change cycles andunrestr icted automat ion.

US tons in3 standard in max. in EUROMAP 6, in sec.

110-120 17.08 – 34.77 17,3 x 19.68 17,3 x 21,65 3,2

165-180 26,24 – 122,05 19.69 x 21.65 21,65 x 26,50 3,5

200-220 26.24 – 122.05 21.65 x 25.60 21,65 x 25,60 4,2

280-320 45,75 – 219,68 21.65 x 25.60 25,6 x 29,52 5,0

440-485 91,5 – 366 27.59 x 36.22 31.88 x 40.15 8,0

In addi t ion to above machines f rom the ENGEL ELAST l ine, speci f ica ly designed for processing rubber, there are 6 addi t ional machinemodels avai lable f rom the thermoplast machine l ine ENGEL VICTORY with an equipment package for rubber mold ing – see a lso pages10 / 11 (ENGEL VICTORY Rubber 28 TL US - ENGEL VICTORY Rubber 200 TL US) For more deta i led informat ion p lease request ourindiv idual data sheets.

30

2 x 57 2 x 57 2 x 57

2 x 70 2 x 70 2 x 70 2 x 70

2 x 100 2 x 100 2 x 100

30 30 30

40 40

45

40

15/18/22 15/18/22 15/18/22

25/30 25/30

30/35 30/35

35/40 35/40 35/40

45/50 45/50 45/50

50/55 50/55

ENGEL L IM.Machines and technology for LSR parts.

The ENGEL LIM-machine program is matched to thevar ious appl icat ions in the processing of l iquid si l iconerubber. This includes machines for the manufacture ofmicro products such as medical components,

large-volume products such as insulators and takesinto account the large var iat ions of commercia l ly avai-lable LSR types inc luding h ighly react ive and h ighlyf i l led LSR mater ia ls .

Selection cr i ter ia for the r ight combination:

Standard LSR-types

Highly reactive LSR-types

Highly f i l led LSR-types

High-viscosity LSR-types

Small injection volumes

Adding of color below 1%

Adding of additives

Screw injection unit Plunger injection unit Static mixer Dynamic mixer

ENGEL LIM-double plunger inject ion molding machines:

* Available plunger diameter in mm per injection unit

Injection unit*

LIM 1000 D /…

LIM 3000 D /…

LIM 6000 D /…

Clamp units

ENGEL LIM-screw inject ion molding machines:

Injection unit*

LIM 80 /…

LIM 200 /…

LIM 330 /…

LIM 500 /…

LIM 750 /…

LIM 1050 /…

International Size specification: max. shot volume [cm3] x max. injection pressure [bar] / 1000

Clamp units ... / 28 ... / 40-50 ... / 65-85 ... / 100-130 ... / 145-165 ... / 200-240 ... / 285-330

* Available screw diameter in mm per injection unit

ENGEL LIM-plunger inject ion molding machines:

* Available plunger diameter in mm per injection unit

Injection unit*

LIM 100 K /…

LIM 200 K /…

LIM 320 K /…

Clamp units ... / 40-50 ... / 65-85 ... / 100-130 ... / 145-165

... / 100 ... / 140 ... / 175 ... / 275 ... / 440 ... / 660

31

ENGEL LIMPlunger in ject ion mold ing machine, Type ENGEL VICTORY 100K / 50 US Lim

The ENGEL LIM-Machine range:

> The technology platform for al l ENGEL LIM-machines is the proven ENGEL VICTORY-machine l ines avai lable f rom 28 to 660 US tons c lamp force

> Suitable in ject ion uni ts avai lab le for a l l appl icat ions:- Screw uni t for h igh v iscosi ty LSR types- Plunger uni t for h igh react ive, h igh f i l led LSR types- Double p lunger uni t for large shot vo lumes

> LSR mater ia l feeding and meter mix system

> Support ava i lab le f rom Engel appl icat ion technology centerfor complete systems inc luding molds

32

ENGEL ROBOTS.Linear robots, special ly for inject ion molding machines.

System layout of theENGEL ERC ser ies of robots

ERC 33 - 53 F, FA, FH 63 - 83 F, FH 94 - 144 F13 - 23 F

For injection molding machines:(clamping force in US tons)

Demolding stroke

Vertical axis

Horizontal axis

Max. handling weight(parts + gripper)

Max. speed (Y-axis)Asynchronous servo drive

Servo drive

High-speed drive

Repeatability

X

Y

Z

FA

F

FH

mm

mm

mm

Ibs

m/s

m/s

m/s

mm

ENGEL ERC 13 - 23 FFast and compactSpecia l compact design for use onsmal l machines.

ENGEL ERC 33 - 53 F (a l ternat iveopt ions FA and FH) – Fast and f lex ib leRated for in ject ion molding machines with clampingforces of between 40 and 750 US tons.- Avai lable wi th a choice of three d i fferent dr ive

var iants:> Asynchronous servo dr ive (FA)

for long and medium cycle t imes> Servo dr ive (F)

for fast tota l cyc le t imes (h ighly dynamic)> High-speed digi ta l servo dr ive (FH)

for extremely fast parts removal (demolding t imes as fast as 0.5 sec where

the tota l cyc le t ime is only 5 sec) .

ENGEL ERC 63 - 83 F, FHThe Power ClassRated for in ject ion mold ing machineswith c lamping forces of between250 and 2000 US tons.- Servo dr ive (version F)- L inear speeds of up to 3 m/s when

handl ing a work ing load of 66 lbs.- High speed version (FH) wi th d ig i ta l

servo dr ive capable of l inear speedsof 4 m/s when handl ing a work ingload of 44 lbs.

ENGEL ERC 94 - 144 FThe power package for largein ject ion mold ing machinesRated for use on large-capaci ty machineswith c lamping forces upwards of 1500 UStons.

US-tons 40 - 750 250 - 2000 1500 - 6000

± 0.1

700 - 1300

1000 - 2200

1880 - 8120

± 0.05

1300 - 3000

1800 - 3000

2360 - 9920

300 - 700

± 0.05

600 - 1600

1400 - 5720

40 – 450

300 / 600

± 0.1

600 / 1200

950 - 3000

44 - 66

3

4

66 - 176

2,5 - 3

6.6 - 22

2

3

5

6.6 – 13.2

3,5 / 4

33

Basic automation:ER-USP sprue removal robots.

ER – USP 5, ER – USP 7Sprue removal and separat ion are centra l to the automat ionprocess. Under the product designat ion USP (Universal SpeedPicker) , Engel offers a high-speed universal robot for in ject ionmolding machines with c lamping forces ranging f rom 28 to250 US tons. This robot is ava i lab le in two s izes:- ER - USP 5 with 500 mm Y stroke- ER - USP 7 with 700 mm Y stroke.The ER – USP is d ist inguished by i ts part icu lar ly fastoperat ion ( the min imum sprue removal t ime is between0.8 and 1.2 seconds) .

HLi Robot: fu l ly benef i t ing from thet iebar less machine concept.

Integrated handl ing robots for t iebar lessin ject ion mold ing machines: ER-HLiFor standard “pick and place” appl icat ions on Engel t iebar lessmachines with in the 28 to 660 US tons range, theENGEL ER-HLi robots represent a low-cost meansof automat ion.

Highest speedsfor the thinnest l ightweights.

High-speed parts-removal robots:ERS (Speedy) .Current product development general ly reveals a marked trendtowards increasingly thinner and l ighter parts – and increasinglyfaster product ion t imes.The answer to th is t rend – in terms of automat ion – is theERS (Speedy) . This h igh-speed parts-removal robot hasbeen designed for the handl ing of th in-wal l or th in-sect ionparts and for use in conjunct ion with fast-cycl ing in ject ionmolding machines.

34

ENGEL AUTOMATION TOOLS.Peripherals for automated parts removal and handl ing.

Engel Gr ip Tools-Ki t .The D. I .Y. construct ion k i t for robot gr ippers.

Your advantage:- The Gr ip Tool Ki t permits gr ipper construct ion

without any need for design engineer ing, thus sav ing considerable t ime at the pro jectp lanning stage

- You get exact ly what you need- Opt imum assortment of components based on

20 years of exper ience- Optimized price/performance ratio of al l components- Fast and easy assembly thanks to c lear

arrangement of components- Global purchasing concept ensures fast

supply of component parts

Engel Gr ip Tools-Assistant.The Engel Gr ip Tool Ass istant is an importantt ime-saving aid, for i t enables the automation engineerto bui ld the robot gr ipper pr ior to complet ion of therespect ive in ject ion mold.

Just one prototype part is suff ic ient for the purpose ofbui lding the robot gripper and carrying out performancetests. S imi lar ly, the Engel Gr ip Tool Ass istant is animportant a id to the maintenance engineer.

I t is equipped with a l l the funct ional means of- per forming f ina l adjustment

of the gr ipper sett ings- carry ing out demolding t r ia ls- test ing the work ing of the

vacuum / e lectronic components- test ing the work ing of the e lectr ica l

gr ipper s ignals.

35

Engel Conveying Systems.Conveying systems are the ideal complement tomachine automation systems. They are an indispensablepart of downstream collecting zones or cooling sectionsafter removal of the parts f rom the mold, or for l ink ingthe in ject ion mold ing machine – as the centra lproduction unit – with the production faci l i ty’s logist icsor mater ia l handl ing systems. In i ts own specia lcompetence center for automat ion per iphera ls, Engeldevelops and manufactures a wide range of conveyorbelt systems. Special-purpose and integrated systemsare a lso avai lable.Remember: a complete product ion l ine is only as goodas the sum of i ts indiv idual component uni ts.

For fur ther deta i ls p lease request Engel ’s productcata logue “Automat ion Tools” or v is i t Engel ’son- l ine shop at www.engel . in fo

Engel Safety Components.Part icu lar care and attent ion must be paid to thesafeguarding of automated product ion processes –without adversely affect ing the user- f r iendl iness andeasy maintenance of the indiv idual component units ofthe product ion system.This is where inte l l igent solut ions are ca l led for.Engel has developed a system component concept forretrof i t table safety dev ices (see product cata logue“Automation Tools”). Special pr iv i leged access systemswith inter faces for machine monitor ing are part andparcel of th is safety system.

Specia l so lut ions and adaptat ions to specia lrequi rements necessi tated by in-house or nat ionalstandards are avai lable. P lease inqui re.

36

ENGEL PRECISION MOLDS.Engel injection molds – with the focus on Combimelt technology.

From the in i t ia l idea to thef in ished product.Precis ion molds are part and parcel of thecomprehensive inject ion molding package offeredby Engel for the product ion of innovat ive lydesigned parts. They enjoy appl icat ion whereverunique combinat ions of funct ional and mater ia lpropert ies are needed for the creat ion ofcompletely new kinds of parts for completely newuses. Ful l ut i l izat ion of the potent ia l of ENGELCOMBIMELT technology is Engel 's corporatestrategy and corporate object ive ro l led into one.

Picture by Schneegans, Emmer ich/D

37

Engel molds – mult icomponent molds for a mult i tude of appl icat ions:

> Col laborat ion between Engel 's mold making and appl icat ion technology departments is centra l to the development and manufacture of molds for the product ion of mult icomponent parts for every conceivable appl icat ion – f rom automot ive engineer ing through to medical technology.

> Specia l izat ion in ENGEL COMBIMELT mult icomponent in ject ion mold ing technology g ives Engel the edge on i ts compet i tors in terms ofknow-how and, by the same token, the advantage of increased product iv i ty.

> A fu l ly integrated CAD/CAM product ion system ensures the h ighest standard of precis ion. Moreover, Engel 's mult icomponent technology is based on the standardrange of machines and equipment – an obvious advantage when i t comes to meetingcustomers' requi rements quick ly and eff ic ient ly.

38

ENGEL COMBIMELT.Processes for mult i-colour and mult i-component inject ion moldin g

The rotary table is a standard opt ion which is avai lablewith every Engel in ject ion molding machine. A specialrotary coupl ing permits the unrestr icted supply of media(heat ing-cool ing medium, electr ical wir ing, hydraul ic oi l )to the in ject ion mold

Rotary table system – withvert ica l rotary module.The rotary table system is the one most frequentlyused with the Combimelt process. I t is used bothfor the overmold ing and for the add-on mold ingprocess. The moving platen of the machine isequipped with a rotary module. The stat ionarymold hal f has two di fferent mold cav i t ies, whi lethe moving mold hal f has two ident ica l cav i t ies.

After the f irst molding cycle in station 1, the rotarytable turns through an angle of 180 degrees andtransfers the substrate to the second, larger cavityin the stat ionary mold hal f . The empty spacebetween the preform and the cav i ty wal l is nowf i l led with the second mater ia l .

The rotary table is designed for alternating rotationthrough an angle of ±180 degrees. A special rotarycoupl ing permits the unrestr icted supply of mediato the in ject ion mold. As the rotary table is anintegra l part of the in ject ion mold ing machine, i tcan be used for severa l molds. Rotary tables areavai lable wi th up to 4 indexing posi t ions.

The “ index plate” is normal ly an integral part of the mold. After each injection operation, the index plate movesout of the “parent” mold, rotates together with the partand then moves back into the mold in readiness for thenext injection operation. The system is l imited in terms ofsize by the maximum part weight that can be handled bythe index plate

Index p late system – forunl imi ted possib i l i t ies.With the index p late system, the rotat ing andtransfer funct ions are integrated in the mold.This system must be used in cases where thesecond component mater ia l is to be molded ontoboth sides of the substrate (moving mold hal f andf ixed mold hal f ) .

To th is end, the substrate, af ter being molded instat ion 1, must be t ransferred, v ia rotat ion, tostat ion 2, and then overmolded on both s ides ofthe substrate. This is done by means of a so-cal led index p late in the in ject ion mold whichremoves the part ia l ly molded part f rom the cavity,rotates i t and replaces i t .

The dr ive of the index plate is integrated into thein ject ion mold and adapted to the actual moldingrequirement. The index p late system enables thegreatest possib le design f reedom for combin ingtwo or more mater ia ls in a molded part .

39

n g.

Transfer system – for smal l batchesand specia l so lut ions.This process is used pr imar i ly in cases ofappl icat ion where composi te in ject ion mold ingshave to be combined with awkwardly s ized orshaped inserts or where the use of a rotary tableor index p late system would necessi tate the useof a d isproport ionate ly large c lamping uni t .

The t ransfer system is a lso used instead of theindex p late system when the preform cannot beheld by an index p late because of i ts geometry.A handing robot is used for transferr ing the partsf rom cavi ty 1 to cav i ty 2. The t ransfer operat ionmay take p lace e i ther in the same mold, wi thoutany need for rotat ion, or between two adjacentin ject ion mold ing machines. Vert ica l rotary-tableindexing machines with workpiece holding f ixturesare a lso used in specia l cases.

The transfer system makes pract ical use of the possibi l i t ies afforded by handl ing technology, e.g. for the insert ion of metal parts or for t ransferr ing the molded part f rom one posit ion to another within the same mold or f rom one mold to another when working with two adjacent machines. By combining two machines each equipped with two in ject ion units i t is possible to produce four-component moldings relat ively easi ly. The transfer system may also be used in conjunct ion with ENGEL INSERT rotary-table machines (see the ENGEL INSERT brochure for more detai led information)

Core back system –with hor izonta l rotary module.An ideal solut ion for the product ion of large – andespecia l ly for long – parts is the use of the large-capacity ENGEL DUO (two platen) injection moldingmachine. The machine is used in conjunct ion witha rotary module mounted on a s l id ing carr iageins ide the c lamping uni t and two in ject ion uni tsmounted on the p latens.For such appl icat ions, the combinat ion of thehor izonta l rotary module and the cube-shapedcentral part of the injection mold makes better useof the avai lable space between the t ie-bars thanis possib le wi th a rotary table system.What is part icu lar ly advantageous about th issystem is that the two inject ion units are mountedon the two opposite platens. This permits a simpledesign of the centra l , moving stack of the moldand waives the need for a compl icated hot runnersystem. This system is part icu lar ly su i table forlarge-area parts wi th integra l ly molded seals orgaskets (e.g. car window panes) .

The hor izontal rotary module carr ies the center stack of a double-dayl ight (stack) mold. The combination of thehorizontal rotary module and the cube-shaped central partof the in ject ion mold permits opt imum ut i l izat ion of theavai lable space between the t iebars. As the central partof the mold can revolve in steps of 90 degrees, i t affordsopt imum access for insert-placing and parts-removal robots. As in the case of any standard double-dayl ight(stack) mold, the center stack of the mold is kept in acentral posit ion, in re lat ion to the platens, dur ing theopening and closing movements of the clamping unit bymeans of a posit ively actuated hydraul ic control

40

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04

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06

ENGEL TECOMELT.The Engel process for combining fabrics and plast ics.

The ENGEL TECOMELT molding processes are low-pressure processes. There are two different processes,the choice of which depends on the size of part and/orthe mold f i l l ing pressure: ENGEL TECOMELT in ject ionmolding and ENGEL TECOMELT compression molding.

ENGEL TECOMELT INJECTION MOLDINGThe machines used for the ENGEL TECOMELT injectionmolding process are of the convent ional , hor izonta ltype, but feature certa in modi f icat ions. The processdiffers from the conventional in ject ion molding processin that the cav i t ies are f i l led under low pressure. Thiscan be achieved e i ther through cascade-contro l led,multiple valve gating (sequential opening of the injectionpoints) or by combining convent ional in ject ion moldingwith a compression process.ENGEL TECOMELT in ject ion mold ing is part icu lar lysu i table for long, narrow parts.

01 Dashboard02 A-, B-, C- and

D-pi l lar t r im03 Rear door tr im04 Floor surround tr im05 Center console06 Door tr im07 Trunk tr im

02

01

ENGEL TECOMELT PRESSESA vert ica l press is used for the ENGEL TECOMELTcompression mold ing process. The melt is int roducedinto the bottom hal f of the mold by means of anextrus ion coat ing system which fo l lows the contoursof the mold cavity. The decorat ive fabric is then placedover the layer of mel t and the two components arepressed together. This extrusion coating process offersthe advantage of being able to place more melt exact lywhere more melt is required and, moreover, waives theneed for cost ly melt d istr ibut ion systems (hot runners)in the mold.

01 Frozen-in outer layer02 Plast ic melt

03 Top layer04 Bottom layer (interliner)

07 Back coat ing08 Cover ing fabr ic

05 Pi le with Pi le bond06 Carpet backing

Fabric / foam composite

Pressure

03 04

01

02

Carpet composite

Pressure

06 05 07 08

02

01

Intermediate layer ( foam)

Cavity surface Cavity surface

Melt f lowMelt f low

41The robot grips the end of the fabric web, pulls the requiredlength of fabr ic f rom the reel and cuts i t off . The fabr ic isthen inserted into the mold with the aid of a clamping frameand held there by the robot unt i l i t is f ixed in place by theclosed mold

Detai l v iew of c lamp unit with two press moldsand view of extrusion dies

Horizontal in ject ion molding machine Type ENGEL VICTORY1350 / 385 US Tecomelt with ENGEL ERC 63/1-C l inear robot

Melt coat ing operat ion Pressing operat ion Removal of molded part

Melt f low

Low cavity pressure

Type ENGEL TECOMELT 2500 / 2500 / 800 VRcompression molding machine

The compression molding process – for large-area parts.

Horizontal machines for long, narrow parts.

4201 02 03

ENGEL FOILMELT.Surface design for plast ic components.

Ind iv idual i ty means qual i ty of l i fe .Indiv idual ly sty led, h igh-qual i ty products are a part ofour environment. Surface design is an important aspectin this regard. With the aid of decorative f i lms and foi ls,sur face f in ishes and effects can be readi ly combinedwith the base mater ia l to meet indiv idual needs. Thisprocess takes place in the in ject ion molding machine.In-mold sur face decorat ion with composi te f i lms orfoi ls can be used for a great many different applications:

- High-qual i ty three-dimensional sur faces- Specia l sur face effects (meta l l ic lacquer, a lumin ium

f in ish, chameleon effect , holograms)- Change of sur face design possib le f rom one

part to the next- No downstream f in ish ing of molded

part necessary

01 Imitat ion wood or a luminium f in ish for car inter iors

02 Ice cream container in ject ion molded with decorat ive label ( foi l ) as an example of the cost-reducing potentialof in-mold label l ing on fast-cycl ing machines for packaging containers

03 Surface decorat ion for garden furni ture

43

01Process stage 1: 3D – foi l shaping inthermoform- or high pressure formpress(necessary only with complex 3D shapes –not required for f lat parts or for low deepdraw rat ios. In these cases the foi l shapingis done dur ing the in ject ion process)

02Process stage 2: Cutt ing of the foi ls bystamping, mi l l ing or cutt ing with highpressure water or laser beam

01 Foi l preforming 02 Foi l cutt ing

03 Insert ing of fo i ls 04 In ject ion molding process

03Process stage 3: Insert ing of fo i ls intoinject ion mold. For secur ing the exactposit ion in the mold a handl ing device isut i l ized. In the per ipheral handl ing stat ion,the foi ls are provided in stacks and aftertreatment with ionized air for dust removalcentered for take over

04Process stage 4: Plast ic in ject ionmolding process with “foi l adequate”process control

Stamping Unit

In ject ion Mold

Vacuum

The Process.

Product ion cel l for th inwal lOff ice Desk-Organiser.In ject ion molding machine ENGEL VICTORY 200 / 130Power US with High speed l inear robot ENGEL ERSand robot per iphery consist ing of t rayserver andaddit ional ENGEL ROBOT ERC 23 / 0-E for fo i ldestacking and manipulat ion.

In order to synchronize the robot per iphery wi th theshort cycle t ime of the injection mold ( less than 8 sec.),2 robots are ut i l ized for fo i l and f in ished partsmanipulat ion. The ENGEL ERS robot is used exclu-s ively for the fast cycl ing loading and unloading of thein ject ion mold; the ENGEL ERC robot for the fo i l andf in ished parts manipulat ion outs ide f rom the mold.

44

ENGEL GASMELT / WATERMELT (FLUIDMELT).Innovative solut ions using gas or water.

Technology below the sur faceis the beauty of i t .The Gasmelt and Watermelt processes offeredby Engel a l low the mold ing of parts wi th th ickerwal ls and sect ions than normal ly permit ted bythe mater ia l used.With both processes, a separate medium is in-jected into the mold dur ing the mold ing cycle.This medium generates pressure ins ide the partso as to ensure that the shrinkage of the material,which normal ly occurs dur ing the cool ing phase,cannot pul l the sur faces of the parts away f romthe walls of the mold cavity and cause sink marksand other sur face b lemishes.

Close-up of gas pressure control unit

Production unit comprising of Engel injection molding machine with CompactWATERMELT Unit. The latter is connected to the machine by the media hosesand interface cable.

Overview of the appl icat ion scope of Gasmelt / Watermelt processes

WATERMELTGASMELT

Industrial parts with large cavities (not visible when in use)

Industrial parts with large cavities (visible when in use)

Handles with small to medium-sized cavities (up to approx. 20 cm3)

Handles with large cavities

Structural components with relatively small, partial cavities

Structural components with large cavities

Large-area, ribbed parts, e.g. fronts of TV sets

45

>

>

01 Example of local gas in ject ion with control led cavity volume. The cavit ies are located in f ive separate parts of this ergonomical ly designed handle in order to ensureopt imum smoothness

02 Armrest/handle for car door: example of GASMELT blow-out appl icat ion (necessary on account of the extremely high qual i ty of surface f in ish required). In th is part icularappl icat ion, the melt is forced back into the space in f ront of the screw

03 Housing for a te levis ion set with local cavit ies for compensat ing contract ion through shr inkage (surface improvement, avoidance of s ink marks) at the points of the housing where fastening elements are incorporated. The cavit ies are produced by means of the GASMELT blow-out process

01 Example of car engine water manifold, in ject ion molded by a combinat ion of WATERMELT with the overf low process (using auxi l iary cavit ies) and the f lushing process. The sprues ( f rom the auxi l iary cavit ies) are reclaimed and fed back into the in ject ion molding process

02 Finished water manifold after sprue removal

03 Cross-sect ional v iew of water manifold. The advantageof the WATERMELT process l ies in i ts abi l i ty to produceparts of uni form wal l th ickness over re lat ively long melt f low-paths

01 01

02

0303

02

ENGEL GASMELT.For optimum surface qual i ty.

ENGEL WATERMELT.For long f low paths.

Hol low core in ject ion mold

Gas in ject ionpoints

Auxi l iary sprue

Auxi l iary cavit ies

Molded part : RSL-Kendrion

>

>

46

ENGEL FOAMMELT.Microcel lular foam for l ightweight precision parts.

Decision matrix Chemically blown foam Mechanically blown foam

General-purpose, thick-walled parts produced insmall to medium sized batches, e.g.: toys,household appliances, furniture parts, leisure andsports equipment

Thin-walled industrial parts produced in largequantities, e.g. automotive parts, electrical parts,office equipment components

Cel l st ructure + ++Standard polymers + +Engineer ing polymers + / – ++Processing lat i tude + +++Blowing agent costs – +++Possib le weight reduct ion + ++True shape reproduct ion ++ ++Wal l th icknesses under 5 mm – +++Residues f rom foaming process – +++Gas pressure dur ing foaming + +++Clamping force reduct ion + +Capita l investment +++ –

Basical ly, structural foam parts can be injection moldedby means of two a l ternat ive processes. Common toboth processes is the format ion of a cel lu lar structureins ide the molded part through the d ispers ion of gasbubbles wi th in the basic polymer mater ia l .

Chemical ly b lown foam.With this process, the gas is generated by the chemicaldecomposi t ion of the b lowing agent - consist ing ofchemical substances based on bicarbonate and c i t r icacid - when exposed to the heat of the melt dur ing theplast ic iz ing process. As the pressure of the gas in themelt is extremely low, only very low in ject ion pressuremay be used for the mold f i l l ing stage. This means thatthere are l imits both to the precis ion with which a partcan be molded and to the extent to which shr inkagecan be compensated.Despite i ts negl igible demands on machine technology,structura l foam molding with chemical b lowing agentsis restr icted largely to the product ion of th ick-wal ledparts in PE and PP which do not have to meet h ighqual i ty standards.

Phys ica l ly b lown foam.Physica l ly b lown foam is produced by introducingpressurized nitrogen or carbon dioxide direct ly into themelt dur ing the plast ic iz ing process. The high pressurein the p last ic iz ing cy l inder causes the gas to d issolvein the melt complete ly, thus ensur ing i ts uni formdispers ion. Fol lowing in ject ion of the gas- laden meltinto the unpressur ized mold, the gas and the meltseparate, whereby the gas expands to produce amicrocel lu lar foam. W ith th is process, the pressureof the gas in the melt is considerably h igher thanthat generated by the chemical foaming process,thus permit t ing a wider process window and greatermold ing precis ion.

4702 03

01

The MuCel l® equipment packagecompr is ing of :- MuCel l® p last ic iz ing uni t wi th L/D rat io of 24:1, inc l . MuCel l® screw, gas in jectors- Shut-off nozz le for barre l- Mel t pressure t ransducer, arranged under gas in jector 1- Servo va lve contro l wi th smal l accumulator for MPP contro l- MuCel l® software for permanent pressur izat ion

of the melt and feedback contro l of screw posi t ionand shut-off nozz le

addi t ional equipment:Gas supply uni ts for the metered in ject ion of n i t rogenand carbon diox ide

01 Product ion cel l consist ing of standard in ject ion molding machine with equipment package for the MuCel l® microcel lu lar foam molding process and ENGEL ER-Hl i robot

02 Close-up view of MuCel l® plast ic iz ing cyl inder equipped with two gas in jectors

03 Close-up view of gas pressure control unit

48 1 cm

ENGEL X-MELT.For smal l shot weights and thin-section parts.

The X-MELT concept.ENGEL X-MELT is an unconvent ional process for thehigh-speed in ject ion mold ing of smal l and/or th in-sect ion parts. Convent ional h igh-speed in ject ion isbased on a machine technology which ut i l izes a h ighdrive output for the inject ion of the melt, involv ing highaccelerat ion and decelerat ion of the screw as i tper forms i ts forward movement. X-MELT, on the otherhand, ut i l izes the energy stored in the h ighlycompressed melt in the space in f ront of the screw.Inject ion is effected simply by opening the needle valvegate, a l lowing the melt to expand and f i l l the moldcavi ty. No addi t ional means of generat ing in ject ionpressure are necessary.

The appl icat ion of ENGEL X-MELT begins whereconvent ional in ject ion molding has already reached i tsl imi ts. Typica l shot weights range f rom 20 g down to0.1 g, whi le typica l wal l or sect ion th icknesses rangefrom 1 mm down to 0.1 mm. A system prerequis i te isa p last ic iz ing screw which is accurate ly posi t ionable,as featured on the ENGEL E-MOTION system.ENGEL X-MELT is avai lab le as an equipment opt iononly in conjunct ion with an ENGEL E-MOTION andENGEL VICTORY Electr ic in ject ion mold ing machineequipped with an in ject ion uni t wi th in the s ize rangefrom EM 80 / . . . to EM 440 / . . . , thus t ransforming astandard machine into a specia l machine formicro in ject ion mold ing.

The process – the overv iew.The rea l h ighl ight of the ENGEL X-MELT techno-logy is the outstanding repeatabil ity of the processcycle. That resul ts f rom the exact to posi t ion,e lectromechanic screw dr ive. Var iat ions of thelocking behavior of the non return are e l iminatedby an adapt ive software.The residual pressure after melt pressure relaxationworks l ike the hold pressure as with the conven-t ional mold ing process.

Screw PositionMelt Pressure

Compression Pressure: 2200 barHolding Pressure: 350 barPlasticizing Stroke: 100 mm

2000

1500

1000

500

2500

80

60

40

20

100

Time (s)

1 2 3 4 5

0,08 Sec.

Expansion

Compression

Plasticizing

Scr

ew P

ositi

on (m

m)

Mel

t P

ress

ure

(bar

)ENGEL X-MELT Process

49

Process stage 1: Plast ic iz ingThe plast ic iz ing uni t of the machine or, preferably, thehot runner system of the inject ion mold (see i l lustrat ionabove) is equipped with a needle shut-off nozz le.The nozz le is c losed when in i ts start ing posi t ion.The plast iciz ing screw rotates and plast icizes a def inedamount of mater ia l .

Process stage 2: Compression of the meltUpon complet ion of the plast ic iz ing process, and withthe shut-off nozzle st i l l in i ts closed posit ion, the screwthen serves as a p lunger to compress the melt .Depending both on the appl icat ion and on the material,the compression pressure ranges f rom 2,000 to 2,500bar. At th is pressure, the metered volume of mel t isreduced by approximate ly 10 %. The state ofcompression is mainta ined for a short t ime in order toensure a uni form temperature throughout the melt .

Process stage 3: Fi l l ing the moldThe shut-off nozzle is now opened. The melt “explodes”abrupt ly and f i l ls the mold cav i t ies in only f ract ions ofa second. The res idual pressure acts as hold ingpressure to compensate shr inkage.Dur ing the mold f i l l ing operat ion, the screw is kept inexact ly the same posi t ion, thus ensur ing per fectrepeatabi l i ty of the process.

50

01

02

04

03

ENGEL GLAZEMELT.Car windows in al l var iat ions.

Mode of operat ion.For large parts, and especia l ly for long ENGEL DUO-Combimelt parts, Engel offers an ENGEL DUO(large-capacity, two-platen) machine conf igurat ion witha rotat ing module mounted on a carr iage with in theclamping uni t and two in ject ion uni ts work ing inconjunct ion with the two platens.

The hor izonta l p lane of rotat ion and the cube-shapedcentra l b lock of the in ject ion mold permit betterut i l izat ion of the avai lable space between the t iebarsthan is possib le wi th a rotary table system.

A part icular advantage l ies in the diametrical ly opposedarrangement of the in ject ion uni ts on the two platens.This permits a re lat ive ly s imple design of the centerstack, as there is no need to equip i t wi th a complexhot runner manifold. The system is part icular ly suitablefor the in ject ion mold ing of large-area parts wi thintegra l ly molded seals (e.g. car window panes) .

01 The rotary module, which rotates in a hor izontal plane,supports the center stack of a stack mold. Rotat ion ofthe cube-shaped center stack permits opt imum ut i l izat ion of the platen area between the t iebars. Rotat ing in steps of 90° , the center stack affords readyaccess to al low insert-placing or parts-removal robots.Like the central platen of a conventional stack mold, thecarr iage-mounted center stack is kept in a central posit ion dur ing the opening and closing of the mold bymeans of an automatic hydraul ic control

02 Second in ject ion unit mounted on the moving platen

03 ENGEL DUO clamping unit ( for detai ls see brochure“ENGEL LARGE-CAPACITY MACHINES”)

04 Rotat ing in a hor izontal plane, the rotary module is equipped with an integrated media supply system for the center stack (cube-shaped block) of the in ject ion mold. The rotary module is mounted on a carriage whichis kept in a central posit ion in re lat ion to the platens dur ing the opening and closing of the mold

51

Product ion of car sunroof modules

Engel innovat ions for the in ject ion molding of car windows:

> Greater scope for creat ive, weight-sav ing design in the automot ive industry.

> ENGEL GLAZEMELT based on ENGEL DUO machine technology.

> Integrat ion of severa l components in one part us ing mult i -componentin ject ion mold ing technology.

> Large parts – low c lamp force.

> ENGEL GLAZEMELT in ject ion-compression mold ing, wi th or wi thout p latenpara l le l ism contro l , is the basis for the product ion of h igh-qual i ty partswith negl ig ib le internal st ress.

Product ion of car headl ight lenses

52

01 02

1µ

ENGEL OPTIMELT.Inject ion-compression molding for optics of the highest qual i ty.

Innovat ive product potent ia l .Opt imelt is an innovat ive Engel technology for thein ject ion-compression mold ing (coin ing) of opt ica lcomponents. Even th ick-sect ion lenses designed forthe most demanding opt ica l appl icat ions can bere l iab ly and economical ly manufactured withOpt imelt technology.

Inspi red by nature.High-qual i ty opt ica l components can nowadays berendered non-ref lect ive in severa l ways, not leastthrough the use of microstructured sur faces. As is sooften the case, i t was nature which inspi red th isdevelopment: the non-ref lect ing, facetted structure ofthe cornea of a moth's eye serves as an excel lentcamouf lage. Using the new in ject ion-compressionmodule, such microscopic surface structures (< 1 µm)can a lso be molded with excel lent reproducib i l i ty.Scratch-res istant sur faces can be obta ined throughcombinat ions with PC f i lms.

01 Non-ref lect ing, facetted structureof the cornea of a moth's eye

02 Non-ref lect ing surface obtained by the direct molding of a nanostructure on the surface of the lens

53

05

0304

01

02

06

07

08

08

06

01 In ject ion compression unit (coining box) as anequipment module for the in ject ion molding machine

02 Hydraul ic pressure pad

03 Compression r ing

04 Stroke measur ing system

05 Pressure sensor

06 Compression core in the in ject ion mold

07 Thermal insulat ion between the mold inserts andthe standard mold unit . The heat ing-cool ing system thus acts on only a smal l mass. This minimizes the react ion t ime

08 Core temperature control system

The operat ing principle.

The process.In most cases, complete volumetr ic f i l l ing of the cavityis chosen for the in ject ion-compression mold ing ofsmal l and thick-wal led opt ical components. In order toavoid jett ing, which has a very negative effect on opticalqual i ty, a very low f i l l ing speed is necessary, but th isin turn can result in excessive cool ing of the melt whi lei t is st i l l be ing in jected.

This can be remedied by the so-cal led var iothermalmold cool ing system, a temporal ly dynamic heat ing-cool ing system which rapid ly heats the mold cav i tydur ing in ject ion of the melt and then cools i tintensive ly. The resul t is a uni form melt temperatureand min imized internal st resses. Cool ing t imes canl ikewise be kept short .

54 03

02

05

04 0706

01

04

0 0,5 1,5 2,5 3,5 4,5 5,5 6,5 7,5 8,5 9,5 10,5

ENGEL F IBERMELT.For long glass f ibers in high-strength components.

01 Car door module02 Dashboard support03 Front end module04 Bumper support05 Underbody assembly06 Sound shield for

engine compartment07 Lif t-up tai lgate module

ENGEL FIBERMELT is the basic application technology for themanufacture of composite parts from thermoplastics and longglass f ibers. Fibermelt composites are distinguished by theirhigh strength, even at high temperatures. The main aim ofENGEL FIBERMELT technology is the cost-effective, automated,reproducible mass production of components with an optimizedfiber length distribution. Basically, three processes are availablefor the molding of such high-strength components:> Injection molding> Injection-compression molding

(special injection molding process)> Deposit compression molding

(similar to ENGEL TECOMELT process)The decision in favour of one process or the other wi l l depend mainlyon the geometry of the part to be molded and on the demands whichit is expected to meet. What al l three processes have in common aretheir plast ic iz ing units which are opt imized for the gent lest possibletreatment of the f ibers ( f iber length) .

Decision matr ix for process choice

Highly complexmolded part

Gent le treatment off ibers (component strength)

Inject ion molding Deposit compressionmolding

Inject ion compressionmolding

Long f iber-reinforced thermoplast ics: the advantages.

In molded parts reinforced with long glass fibers there is a direct relationship between fiber length distribution and the mechanical propertiesof the part. The chopped (short) fiber content contributes to the rigidity and E-module of the molded part, the medium-length fiber contentgives the part its strength, and the long fiber content has a decisively positive influence on impact resistance. By virtue of its gentleprocessing action, the ENGEL FIBERMELT plasticizing system increases the content of long fibers in the molded part.

Inject ion molding Inject ion-compressionmolding

Deposit compressionmolding

Effect ive glass f iber length (mm) in molded part

Fib

er

len

gth

dis

trib

uti

on

Leng

th d

efin

ition

s:C

hop

ped

Gla

ss F

iber

s: <

0.3

mm

,Lo

ng G

lass

Fib

ers:

> 0

.3 m

m.

Standard plasticizing process

E-Module

Rigidi ty

Impact resistance

Fibermelt plast iciz ing process

55

i s part icu lar ly su i table for geometr ica l ly complex partswith many apertures. In ject ion molds and runner/gatesystems are designed for the gentlest possible processingof the melt in order to min imize damage to the f ibers.Engel offers i ts F IBERMELT processing technology inconjunction with i ts ENGEL DUO range of large-capacitymachines. The heart of the processing system is thespecial ly developed ENGEL FIBERMELT plast iciz ing unit.

Equipment package.- Plast ic iz ing cy l inder wi th an L/D rat io of 26:1

(avai lable in d iameters f rom 90 mm upwards)- ENGEL FIBERMELT plast ic iz ing screw with an L/D

rat io of 26:1, featur ing optimized geometry for gent leplast ic iz ing act ion and wear-res istant sur face f in ish( inc luding non-return va lve)

- E lectr ic screw dr ive for para l le l recovery (opt ional )- Weigh feeding uni t for g lass f iber concentrates

(opt ional )

Software opt ions.Avai lable for use with FIBERMELT is Engel's ent ire rangeof application and quality control software (see brochures“ENGEL DUO” and “ENGEL CC 200”) .

Close-up of in ject ion unit with weigh feeding unit

Of part icu lar advantage when processingthermoplast ics f i l led with long f ibers is theoperat ional sof tware package “AutoprotectInject ion Monitor ing”. This software monitors thein ject ion and hold ing pressure prof i les.

is ideal for the product ion of large-area, re lat ive lyuncompl icated parts designed for appl icat ions whichmake heavy demands on the i r st rength propert ies, e.g.car underbodies, car door modules etc. The in ject ion-compression molding process combines the simple meltdel ivery system of the convent ional in ject ion mold ingprocess with the f iber- f r iendly mold ing act ion of thecompression mold ing process. The process can bereadily used on ENGEL DUO two-platen machines withoutany need for specia l equipment. A specia l processsoftware contro ls the processing sequence.

The process.A prerequis i te for the use of the in ject ion-compressionmolding process is a mold which can be equipped witha compression molding adapter. During the f iber-fr iendly,low-pressure in ject ion of the melt into the mold, thelat ter remains open by a d istance of preferably 10-20mm – the so-cal led compression stroke – and vert ica ldiv ing edges prevent the melt from escaping via the gapbetween the mold halves.

The machine performs the molding operation by closingthe mold, e i ther dur ing the mold f i l l ing operat ion(s imul taneous in ject ion and compression) orimmediate ly af ter (consecut ive in ject ion andcompression) . As the hold ing pressure is appl ied notby the in ject ion uni t but by the c lamping uni t , thepressure is d ist r ibuted absolute ly evenly and a lowerc lamping force is requi red.

Compression

stroke

Schematicdiagram ofin ject ion-compressionmoldingprocess

The inject ion molding process

The inject ion-compression molding process

56

ENGEL TRAINING.The concept for customer employee qual i f icat ion.

e-Learning.As a supplement to our regular t ra in ing modules weoffer mult imedia training. Our latest and most advancedteaching mater ia l is the ENGEL e-TRAlNER CD ROM,offer ing a fu l ly funct ional s imulat ion of an in ject ionmolding machine. This is presented in combination witha learn ing program, integrat ing basic theoret ica lin format ion and exerc ises.

* Avai lable in 2006

Consult ing.We can ass ist you in developing indiv idual t ra in ingprograms in l ine wi th your personnel ’s requi rements.Together we can def ine the target groups, check theirleve l of knowledge and ta i lor a t ra in ing program tothei r speci f ic needs.

Small groups.We ensure that our t ra iners can respond to the needsof every part ic ipant. To these ends, we choose to l imitthe number of part ic ipants. Registrat ions are taken ona “ f i rst come, f i rst served” basis.

Modular i ty.“Brev i ty is the soul of wi t ! ” (Shakespeare – Hamlet ) .That is to say, intel l igent communicat ion should aim atus ing few words. This guarantees that the knowledgecan be easi ly grasped and digested by the part icipants.Our courses are designed to be precise and concise.The courses offered are designed to su i t yourknowledge and exper ience, from beginners to experts.

For detai led information on ENGEL TRAINING please vis i t :www.engelmachinery.com

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Practice is paramount.Pract ica l exerc ises on in ject ion mold ing machines,v i r tua l as wel l as rea l machines, are essent ia l to ourt ra in ing program. Here the theoret ica l knowledge canbe appl ied immediate ly and reta ined for later use.Our latest in ject ion mold ing machines are at yourdisposal. Your newly acqired ski l ls in in ject ion moldingtechnology can be “test f lown” on our ENGEL e-TRAINER s imulator for the CC 200 contro l ler, just l ikewith a f l ight s imulator.

Customized seminars.Upon request, we can put together a customizedtra in ing seminar ta i lored to your indiv idual needs.Depending upon your requirements, the seminars cantake place at your faci l i ty. This wi l l save you the travelt ime and related costs. You decide the t ime, the placeand course content. These seminars are also avai lablefor o lder or specia l machines.

i -Coaching.For opt imum transfer to knowledge into dai ly pract isewe offer fo l low-up support v ia te lephone or emai l .Our trainers are avai lable to answer any quest ions thatyou may have, fo l lowing your t ra in ing seminar, onceyou have returned to your respect ive fac i l i t ies.

International.Engel ’s t ra in ing concept is internat ional . I t is ourcommitment to provide training services with consistentqual i ty and content. Work ing with in the wor ldwideEngel network of subsid iar ies and representat ives,every Engel t ra in ing center is at your d isposal .

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ENGEL AT YOUR SERVICE.Project engineering and management for complex appl icat ions.

Everyth ing f rom one suppl ier.Engel offers not only the machines and the technologyfor the in ject ion mold ing of p last ics but a lso, whenrequired, the necessary engineer ing serv ices for theplanning and insta l lat ion of cost-eff ic ient massproduct ion systems.

Pro ject engineer ing.Scope of possib le serv ices:> Design of in ject ion-molded parts based on

speci f ied requirements> Select ion of su i table product ion technology> Speci f icat ion of product ion and

infrastructure equipment> Calculat ion of capaci ty requi rements and avai lable

machine capaci t ies> Determin ing space requirements> Draf t ing of product ion bui ld ing and

insta l lat ion layouts> Draf t ing of mater ia l f low charts, i f requi red> Calculat ion of media requirements

Pro ject management.Scope of possib le serv ices:> Co-ordinat ion of internal and

external pro ject partners> Draf t ing and monitor ing of pro ject schedules> Co-ordinat ion and monitor ing of del iver ies and

insta l lat ion operat ions> Organizat ion of per formance tests and pre-

product ion t r ia ls> Co-ordinat ion of t ra in ing schedules> Assistance with product ion start-up, i f requi red

The services offered comprise of the necessary projectengineer ing (des ign) and the necessary pro jectmanagement (organizat ion) .

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03 ENGEL PROCESS TECHNOLOGY CONSULTING.This service helps customers to explore the capabil i t iesof their Engel machines to the ful lest , result ing in maximum economic eff iciency and productivity. Anothermain focus is the technology transfer of basic developments and new molding technologies to mass product ion solut ions

04 ENGEL MATERIALS CONSULTING.Engel 's mater ia ls research and development work is focused not just on plast ics but a lso on those areas ofprocessing where the metal components of the machinecan interact with the plast ics being processed – in theplast ic iz ing unit , for example. The special ized know-how obtained in this area of expert ise may also serve as the base for expert analysis of processing problems,wear or component damage issues

Special ized know-how for special tasks.

01 ENGEL AFTER-SALES SERVICE.No matter whether your machine is 2 months or 20 yearsold, Engel offers you al l the help and/or replacement parts you may need. Engel 's after-sales service organizat ion is based on a decentral ized network of subsidiar ies, branches and agencies, thus reducing response t imes and travel l ing or transport distances toa very minimum

02 ENGEL COMPONENTS.Through the overhaul, maintenance and repair of complexstructural units, Engel offers you the economical optionof prolonging the useful working l i fe of your in ject ion molding machine. A central warehouse at the parent factory, with a storage capacity of 3,800 pal let places and 10,000 bin places, is l inked on-l ine with the local store faci l i t ies at Engel 's branches and subsidiar ies, thus ensur ing complete avai labi l i ty of component parts

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