WITTMANN BATTENFELD with innovative injection molding

August 2012, Kottingbrunn/Austria
PRESS RELEASE
WITTMANN BATTENFELD at the Fakuma
WITTMANN BATTENFELD with innovative injection
molding technology and state-of-the-art process
technology at the Fakuma 2012
At this year’s Fakuma, held from 16 to 20 October in Friedrichshafen/Germany,
WITTMANN BATTENFELD is presenting latest injection molding technology
combined with high-tech processes in hall B1, booth 1204. The main focus at
this year’s event will be on CELLMOULD ® , the light-weight construction
technology developed by WITTMANN BATTENFELD.
Reliability paired with continuous innovation – this is how WITTMANN BATTENFELD
achieves sustainable customer benefit. Last year, the company succeeded in further
developing its proven PowerSeries and now offers its large machine model
MacroPower with clamping forces ranging from 400 to 1,100 t. But WITTMANN
BATTENFELD also shows its power by developing and implementing innovative
processes which open up new opportunities for excellence and high quality
standards in plastic parts and materials to be processed. CELLMOULD ® light-weight
construction technology and optimal surface quality through BFMOLD will be
demonstrated on 2 exhibits.
CELLMOULD ® application
NEW: MacroPower XL 550/5100 with CELLMOULD ® light-weight technology
In the area of injection molding machinery, the MacroPower XL 550 will be presented
for the first time at the Fakuma 2012. This is the 550 t machine model featuring extrawide
platens with a distance of1120 mm x 970 mm between tie-bars. The
MacroPower stands out by its minimal footprint, high speed, modularity, absolute
precision and cleanness. Its modular concept makes this new large machine suitable
for a great variety of applications. The linear guides supporting the moving platen
ensure a clean mold space as well as maximal, high-precision mold protection. The
MacroPower reaches its velocity with high movement speeds and extremely short
locking and pressure build-up times, which are achieved with the QuickLock locking
system developed by WITTMANN BATTENFELD.

Another feature of the MacroPower calling for special attention is its facility for easy
mold insertion from the rear of the machine.
At the Fakuma, the functionality of the MacroPower will be demonstrated by the
production of an ABS housing with a tandem mold supplied by Coko, Germany, using
the CELLMOULD ® light-weight construction process. CELLMOULD ® is a process for
manufacturing structured foam parts, in which nitrogen is added directly in the barrel
during plastification. The entire manufacturing equipment, such as the plastification
unit, injectors, gas flow regulator and nitrogen generator, has been developed and
built by WITTMANN BATTENFELD. This process enables the production of
extremely light and rigid components without sink marks. A W843 WITTMANN robot
will take care of removing the parts and depositing them on a conveyor belt. The
functions of the entire production line are fully integrated in the machine’s B6 control
system.
Highlight: CELLMOULD ® plus BFMOLD technology -
light weight combined with high-gloss surface
On a hydraulic HM 110/525 machine model, a combination of the BFMOLD TM and
CELLMOULD ® processes will be demonstrated by producing a desk telephone cover
within a cycle time of 34 seconds in a single-cavity mold supplied by KIMW. In the
BFMOLD process, the entire mold space underneath the cavity is utilized for
heating and cooling. This enables extremely even and, above all, fast heating and
cooling of the mold areas. With the help of BFMOLD technology, in particular, it is
possible to produce parts with premium surface quality without any visible flow lines
or sink marks. In this way, a perfect “piano black surface” can be achieved for
foamed parts manufactured by the CELLMOULD ® process. Moreover, this machine
has been designed as an insider solution, which means that the WITTMANN robot
for parts removal, the conveyor belt as well as the peripheral equipment for upstream
and downstream processing are all integrated in the machine frame. The finished
parts are removed and deposited on a conveyor belt by a W818 robot from
WITTMANN.
Multi-component technology: thermoplastic resin plus LSR
On an HM 180/350H/350V ServoPower, the LIM process will be demonstrated in a 2
C application by manufacturing a spectacle case in a mold supplied by Rico. This
spectacle case is a 2-component case made of a combination of thermoplastic
material (PBT 20% GF) and LSR. The dosing and mixing pumps for the LSR will be
supplied by 2 KM. TEMPRO plus D temperature controllers will be used to generate

the high mold temperature required for vulcanizing the LSR. The machine comes
with a silicone processing equipment package (special injection unit, vacuum
package, etc.). The servo-driven rotary unit is integrated in the machine. The parts
are manufactured in a 1+ 1-cavity mold within a cycle time of about 50 seconds.
The machine’s ServoPower drive technology also enables extremely energy-efficient
operation.
High-precision micro injection molding
WITTMANN BATTENFELD’s expertise in micro injection molding will be
demonstrated with an interesting application from the field of optoelectronics. A
MicroPower 15/10 will be shown manufacturing a POM barrel holder with a mold
supplied by Wittner/Austria. This part is a focusing instrument for lenses used in
cameras, to focus the lenses and hold them in place.
The special feature of this part is a thread with an unscrewing core, which means
that, following the injection molding process, a threaded core is screwed back directly
in the mold, before a WITTMANN W8VS2 robot specially designed for this machine
removes the part, then presents it for inspection to a camera integrated in the
machine’s control system and finally deposits it on a conveyor belt, sorted according
to cavities.
EcoPower with IML process
For the first time at a trade fair, an EcoPower with an IML application will be on
display. The EcoPower is the extremely energy-efficient, all-electric machine from
WITTMANN BATTENFELD’s PowerSeries. The EcoPower’s high energy efficiency is
achieved by completely utilizing the deceleration energy from its drives within the
machine (which would normally be returned to the power supply network by an
elaborate process) to provide the necessary voltage for the control system, and for
barrel heating. At the Fakuma, bank cards will be produced from a bioplastic material
(PLA) on an EcoPower 180/750 with a 4-cavity mold, using the IML process. A
WITTMANN W837 high-speed robot operating from the side will insert printed labels
and blank labels prepared for individual printing into the cavities and remove the
finished parts from the mold. The cards will subsequently be presented to a camera
for inspection, to check the position of the labels.

WebService round the clock
The exhibition program of WITTMANN BATTENFELD is rounded off by a
presentation of its WebService 24/7. WebService 24/7 stands for the online service
from WITTMANN BATTENFELD, which is available round the clock on 7 days a
week. Visitors to the Fakuma will have an opportunity to experience the operation of
WebService 24/7 first-hand via a live connection at the service center specially
installed for this purpose. This service center provides information to visitors about
the other services offered by WITTMANN BATTENFELD as well, such as customer
support, application technology, training, or the Battenfeld K4 production data
acquisition system.
Fig. 1: A housing component in CELLMOULD ® light-weight technology is produced on a MacroPower
XL 550.
Fig. 2: MicroPower 15/10

Fig. 3: EcoPower 180 for manufacturing bank cards in an IML process
Fig. 4: Desk telephone cover, manufactured on an HM 110/525 with CELLMOULD ® and BFMOLD
Fig. 5: 2C spectacle case produced in a LIM process on an HM 180/350H/350V

WITTMANN BATTENFELD
WITTMANN BATTENFELD, a company of the WITTMANN group based in
Kottingbrunn, Austria is a leading manufacturer of injection molding machines for the
plastics industry. With its own sales and service companies as well as
representations in about 60 countries, WITTMANN BATTENFELD provides optimal
support to its customers in all matters concerning injection molding technology. Its
innovative strength, highest precision and strong focus on maximum customer
benefit make WITTMANN BATTENFELD a valuable partner for its customers.
Contact:
WITTMANN BATTENFELD GmbH & Co.KG
Werner-Battenfeld-Strasse 1
D-58540 Meinerzhagen / Germany
Tel.: +49 2354 72-0
Fax: +49 2354 72-485
info@wittmann-group.com
www.wittmann-group.com
WITTMANN BATTENFELD GmbH
Wiener Neustädter Strasse 81
A-2542 Kottingbrunn / Austria
Tel.: +43 2252 404-1400
Fax: +43 2252 404-991400
gabriele.hopf@wittmann-group.com
www.wittmann-group.com