freeformer | ALLROUNDER

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Fakuma 2014Product range overview14 to 18 October, Friedrichshafen

Experience the next step in production efficiency. In addition to a holistic approach, we will examine the cost-effective production of plastic parts, from one-off parts to mass-produced items.

Exhibits at our exhibition stand in Hall A3 include:

• The entire spectrum from additive manufacturing to injection moulding covered by ARBURG – the only manufacturer to do so

• The freeformer, which additively manufactures fully functional parts directly from CAD data using stand-ard granulate, without the need for a mould

Visit us at the Fakuma 2014

• Hydraulic, hybrid and electric ALLROUNDER injection moulding machines

• Innovations such as the micro-injection unit

• Automation solutions for all requirements

• Future topics like Industry 4.0, functional integration and lightweight construction with practical examples

• Applications for important industries and sophisti-cated processes

• Our entire service range

Our main focus at this year’s trade fair will be on production efficiency – from one-off parts to mass-produced items. The spectrum ranges from the additive manufacture of one-off parts with the freeformer to the production of mass-produced items with ALLROUNDER machines.

Additive manufacturing with the freeformer • Two freeformers with a three-axis component carrier

and two discharge units will produce plastic parts from two different materials.

• One of the main areas of focus in the manufacture of two-component parts are products with supporting structures that can be subsequently removed in a water bath.

• A freeformer is integrated in the “Industry 4.0” project to personalise the moulded parts by applying lettering in an additive process.

Production efficiency – from one-off parts to mass-produced items

Mass production with an electric ALLROUNDER • We will present the electric ALLROUNDER 820 A

with a clamping force of 4,000 kN and size 2100 electric injection unit as an example of our high-speed machines.

• The exhibit will use a 24+24-cavity mould from Fratelli Bianchi to produce 24 knives and forks in around 5.5 seconds, including demoulding, set-down and immediate packaging. This corresponds to an output of around 31,500 ready-to-ship parts per hour.

ALLROUNDERs for all applications• Other hydraulic, hybrid and electric ALLROUNDER

injection moulding machines will also demonstrate a wide range of capabilities, from individual plastic parts to mass-produced articles.

Industry 4.0 is a future project involving the vision of a smart factory. This requires the networking of machines, order information and process data. We will show you that this vision can already be a practical reality, while also explaining the numer-ous advantages on offer.

Individuality • Four different types of scissors – for right or

left-handed users and with pointed or rounded tips – will be produced in a one-piece-flow process on an ALLROUNDER 370 E.

• Each pair of scissors will be customised with a DMC code applied by laser. In addition,

lettering can be added to each unique scissors in an additive process using the freeformer.

Industry 4.0

Flexibility• The data is transferred to the SELOGICA machine

control system on an individual basis via chip cards.• Variants can be changed over quickly thanks to

interactive operation involving cooperation between human and robot.

Traceability• The central ARBURG host computer system (ALS)

networks machines, order information and process data, transmits the data to a web server and ensures processes are transparent.

• The relevant process data is available on a part- specific web page. The data is accessed by means of the unique DMC code lasered onto the part. This means that all information is available in real time using mobile end devices.

Weight savings and the integration of func-tionality helps further increase production efficiency. We will present two innovative processes for this purpose.

Particle-foam Composite Injection Moulding (PCIM)• The PCIM process was developed in conjunction with

partners Ruch Novaplast and Krallmann to enable plastic components to be injected onto particle foam.

• The next stage in the development of this process is to integrate a foaming system in the production cell.

• The foamed preliminary products are inserted in an ALLROUNDER 470 S by means of a six-axis robotic system, which forms a centred standard thread with a positive material bond.

• In a further step, these functional parts can be integrated in a foamed housing, for example.

Functional inte-gration and light-weight construction

• The system is an example of functional integration, the focus of the Blue Competence campaign “There's more to plastic” of the Plastics and Rubber Machinery Association (KuG) within the German Machinery and Plant Manufacturers Association (VDMA).

Long-fibre direct injection moulding• In long-fibre direct injection moulding, fibres with a

length of up to 50 mm are fed via a side feeder on the injection unit directly into the liquid melt, where they are evenly distributed. The fibre length, fibre content and material combination can be set individually.

• An energy-optimised ALLROUNDER 820 S with servo-hydraulic system produces lightweight pedals for the automotive industry.

• The process with integrated inline quality control through flexural testing is fully automated.

Automation is an important topic for increasing production efficiency. The focus here is on high process stability, availability, output and part quality. Experience the full spectrum of our auto-mation solutions at the Fakuma.

• Our range extends from the electric INTEGRALPICKER and the linear MULTILIFT robotic systems, through to mobile six-axis robots with addi-tional linear axis.

• A flexible solution will be presented in the form of an interactive process involving human/robot coop-eration in the context of the “Industry 4.0” project. The inserts are manually transferred to the robotic system. This ensures flexibility and disposes with the need for complex feeder peripherals.

Automation

• High flexibility and complexity are offered by the mobile robotic cell with a small six-axis robotic system from Kuka, which also moves along an additional lin-ear axis. The advantages of this solution, implement-ed with cooperative partners fpt Robotik, are short cycle times, an enlarged working area and the option of using the cell on different ALLROUNDER machines.

Production efficiency is achieved with solutions designed for specific products and industries. We can offer you a full range of options with our modular product range.

New micro-injection unit • The new micro-injection unit in Euromap size 5

combines two screws and is integrated in a systemsolution consisting of an electric ALLROUNDER 270 Awith clean air module and a specially designedMULTILIFT H 3+1 horizontal robotic system.

High-speed packaging application• A Packaging version of the hybrid ALLROUNDER

520 H demonstrates the high-speed production ofIML thin-walled products. SKET cups with peel-offlabels - a new development from Uniplast - will beproduced in a process that minimises time and ma-terial waste. Wall thicknesses of less than

0.3 millimetres are combined with a thick sealing edge, giving greater stability. The cycle time for a cup is 3.7 seconds.

Efficient production solutions • All exhibits will focus on production efficiency.• Key industries, such as automotive and packaging,

will be represented• The range of sophisticated processes includes

ARBURG Plastic Freeforming (AKF), three-componentinjection moulding, long-fibre direct injection mould-ing, micro-injection moulding, Particle-foam Com-posite Injection Moulding (PCIM) and liquid siliconeprocessing (LSR).

Processes and industries