>> Thinking differently from the outset often leads

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be the first. be the first.

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ENGEL VICTORY
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ENGEL COMBIMELT
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ENGEL APPLICATION TECHNOLOGY

Foammelt, Fluidmelt
Tecomelt, Fibermelt

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application technology
tel: +43 (0)50 620 0 fax: +43 (0)50 620 3009
e-mail: sales@engel.at www.engel.info

3000/e/08-2004/fr
ENGEL APPLICATION TECHNOLOGY.
Innovative Injection Moulding Technology for Special Products.
2 3
ENGEL TECOMELT.
W h e n e v e r t h e t o p i c o f t e xt i l e s o r f o i l for t he
surface area of components is of interest, the
p rod u c tio n so l u t i o n c a n n o t b e p ro v i de d by
s ta n d a rd i n j e c t i o n m o u l d i n g t e c h n o l o gy.
The reason is that the special texture properties
of fabrics and foils limit these from withstanding
t h e “ n or m a l ” p ro c e ss c o n d i t i o n s o f st a nda rd
injection moulding. The solution to the problem
is EN G EL T E COME LT – a n i n t e l l i g e n t proc e ss
technology for the low pressure processing of
plastic. Dependent on the size and complexity
of the component, a special injection moulding
t e c h n olog y o r a c o m b i n a t i o n o f i n j e ct ion
moulding or extrusion and presses is employed.
Th es e p ro c e sse s g u a r a n t e e t h e n e c essa r y
care fu l co n d i t i o n s f o r t h e d i re c t b o n ding of
fab r ic s or f o i l s wi t h p l a st i c c o m p o n e nt s. All
p roc e s s v a r i a t i o n s c a n b e c a r r i e d o ut w it h
au t om at io n . T h e o n e -st e p b o n d e d p a r t
p rod u c tio n i n c re a se s t h e p ro d u c t i v i t y a nd t he
leve l of q u a l i t y o f d e c o r a t i v e p a r t s.
F or d et a il s, se e p a g e 4
ENGEL FOAMMELT
Whe re v e r t he c ompone nt func t ion and
dimensional precision have priority over brilliant
sur fa c e qua lit y, t he ide a l c ondit ions for the
proc e ss t e c hnology E NG E L FO AMM ELT are
giv e n. Unde r t his produc t na me , e qui pm ent
pa c ka ge s a nd a pplic a t ion guide lines for the
production of parts with micro-foaming structure
a re de fine d.
Mic ro- foa m c ompone nt s a re light s tructures
w it h e xt re me minima l e v ide nc e of warpage.
This fe a t ure , a long w it h t he ma t e r ial s avi ngs ,
is t he ma in a dv a nt a ge for c omple x-functi on
pa r t s. The proc e ss is c a t e gor iz e d i n the l ow
pressure injection moulding process. As a result,
machine clamping force and size can be saved.
W it h t his c ha r a c t e r ist ic spe c t r um, ENGEL
FO AMME LT is ide a lly suit e d for c om bi nati on
w it h E NG E L TE CO ME LT.
For de t a ils, se e pa ge 18
ENGEL FIBERMELT.
The ENGEL FIBERM ELT technol ogy offers the
basis for series production of design innovations
i n autom obi l e s tructural parts . The product
nam e “ENGEL FIBERM ELT” encom pas s es the
equi pm ent and proces s s trategy for the
producti on of parts wi th i ntegrated l ong gl as s
fi bers . Com ponents rei nforced wi th l ong gl as s
fi bers are recom m ended i n l arge vol um e
producti on where hi gh s trength i s to be
com bi ned wi th addi ti onal properti es , l i ke
corros i on res i s tance, but wi th m etal s i m i l ar
s trength s i m ul taneous to wei ght reducti on.
Parts with this characteristic spectrum appear
above al l i n the l arge vol um e product
“automobile”. Fibermelt-injection moulded parts
addi ti onal l y offer the advantage that they can
be produced i n a one-s tep proces s .
W i th thorough uti l i zati on of the m ateri al
properties, more individual components can be
com bi ned i n one part i n m any appl i cati ons .
For detai l s , s ee page 28
ENGEL FLUIDMELT.
The overal l ex pres s i on “Fl u i d melt ” s t and s f o r
the i nj ecti on m oul di ng pro ces s i n whi ch f l ui d s
like nitrogen or water are applied in the injection
m oul di ng proces s under d ef i ned o v erp res s ure
to achi eve s peci al effects . To i t b el o ng t he
proces s vari ati ons ENGEL GASME LT and
ENGEL WATERM ELT. Both p ro ces s es are
ideal for moulded parts whose success can be
determ i ned by thei r aes thet i cs wi t h p reci s e
contour and adm i ri ng s urface. T he p o s s i b i l i t y
to precisely form and maintain the surface with
applied pressure of fluids or gases from within
enabl es the effi ci ent i m pl ement at i o n o f ev en
unus ual des i gn i deas . In a d d i t i o n, E N GE L
WATERM ELT, wi th the i nhe rent p ro p ert i es o f
the bas i s m edi um water, creat es a l arg e
i nnovati on potenti al i n the real i z at i o n o f p i p e-
form bodi es wi th com pl ex g eo met ri es , whi ch
woul d not be produced wit h o t her p ro ces s es .
For detai l s , s ee page 38
ENGEL TECOMELT.
Low-pressure injection moulding for in-mould decoration.

A-pillar

C-pillar

A-pillar

4 5

06
B-pillar

05

Door panel with TPO surface (BMW-Mini)

Interior trim at its trimmest.

An intelligent low-pressure adaptation of the normal
i n j e c t i o n m o u l d i n g p ro c e s s p e r m i t s t h e d i re c t
combination of textile fabrics with moulded parts in
01 Floor surround trim
o n e o p e r a t i o n . T h i s s i n g l e - s t a g e p ro c e s s n o t o n l y 02 A-, B-, C- and D-pillar trim
saves time but can also be automated. 03 Dashboard
And it also enhances the quality of functional plastic 04 Centre console
trim sections. 01 03 04 Door panel with TPO surface (BMW 6-Series) 05 Boot trim
T h i s n e w E n g e l t e c h n o l o g y i s c a l l e d Te c o m e lt . 06 Rear door trim
ENGEL TECOMELT.
The Engel process for combining fabrics and plastics.

Comparison of the cavity pressures of various plastics moulding processes

01 01
Standard injection moulding Low-pressure
High cavity pressures plastics processing
06 07 08 06 07 08 09 10
P re s s u re (bar) 400 350 300 250 200 150 100 50 0

Injection moulding

I n j e c t i o n - c o m p re s s i o n m o u l d i n g

Gasmelt 02
02
Structural foam
moulding 05
05
Te c o m e l t
6 p re s s
moulding
7
03 04 03 04

Carpet composite
The ENGEL TECOMELT moulding processes are low- t he st re ss on t he de c or a t iv e fa br ic , f or i t i s not
p re s s u re p ro c e sse s . T h e re a re t wo d i ffe re nt e xpose d t o t he high pre ssure s a nd t em peratures Fabric / foam composite 01 Pressure
processes, the choice of which depends on the size w hic h oc c ur dur ing a nor ma l inje c t ion m oul di ng 02 Melt flow
01 Pressure 03 Frozen-in outer layer
of p a r t an d/o r t h e mo u l d f i l l i n g p re ssu re : process. The woven or knitted structure of the fabric 02 Melt flow 04 Cavity surface
EN G EL TECOM E LT i n j e c t i o n mo u l d i n g a nd remains perfectly intact. The process is also suitable 03 Frozen-in outer layer 05 Plastic melt
EN G EL TECOM E LT p re ss mo u l d i n g . for a muc h w ide r v a r ie t y of fa br ic s. Com ponents 04 Cavity surface 06 Pile
de c or a t e d on bot h side s c a n a lso be produced by 05 Plastic melt 07 Carpet backing
ENGEL TECOMELT Injection moulding . me a ns of t he E NG E L TE CO ME LT pre s s m oul di ng 06 Top layer 08 Pile bond
Th e m a c h in e s u se d f o r t h e E NGE L T E CO ME LT process. Even the introduction of a fabric interlayer 07 Intermediate layer (foam) 09 Back coating
is a c onc e iv a ble me a ns of re inforc ing the m oul ded 08 Bottom layer (interliner) 10 Covering fabric
injection moulding process are of the conventional,
h or izon ta l t y p e , b u t f e a t u re c e r t a i n m o dific a t ions. part. The ENGEL TECOMELT press moulding process
The process differs from the conventional injection is pa r t ic ula r ly suit a ble for t he producti on of
moulding process in that the cavities are filled under la r ge - a re a pa r t s.
low p res s u re . T h i s c a n b e a c h i e v e d e i t he r t hrough
cascade-controlled, multiple pin gating (sequential Market trends.
op e n in g of t h e i n j e c t i o n p o i n t s ) o r b y c ombining I n t he a ut omot iv e indust r y, t he ma in m arket for
conventional injection moulding with a compression ENGEL TECOMELT parts, there is a growing demand
p roces s . E NGE L T E COME LT i n j e c t i o n moulding is for fa br ic - c ov e re d int e r ior t r im c omp onents whi ch
p a r t ic u la r ly s u i t a b l e f o r l o n g , n a r ro w pa r t s. are not only aesthetically appealing but also noise-
re duc ing a nd c ost - sa v ing. The a bov e-des cri bed
E N G E L T E COME LT Pres s mould ing. E NG E L TE CO ME LT proc e sse s a re parti cul arl y
A ve r t ic a l pre ss i s u se d f o r t h e E NGE L TE CO ME LT suit a ble for t he proc e ssing of c ont inuous s trand-
press moulding process. The melt is introduced into re inforc e d poly me r s w hic h a re dist ingui s hed both
t h e b ot tom h a l f o f t h e m o u l d b y m e a n s of a n by t he ir out st a nding me c ha nic a l properti es and by
extrusion coating system which follows the contours t he ir re duc e d splint e r ing t e nde nc y.
of th e m ou l d c a v i t y. T h e d e c o r a t i v e f a br ic is t he n More ov e r, t he E NG E L TE CO ME LT proces s can be
p laced ov e r t h e l a y e r o f m e l t a n d t h e tw o use d for c ombining fa br ic s a nd pla sti cs bel ongi ng U s i ng the ENGEL TECOM ELT p ro ces s , t he p l as t i cs
com p on e n ts a re p re sse d t o g e t h e r. T h i s e xt r usion t o t he sa me poly me r fa milie s, t hus reduci ng the processor can mould the composite part, including
coating process offers the advantage of being able numbe r of diffe re nt t y pe s of ma t e r ia l us ed i n car i ts fas teni ngs , i n one s i ngl e o p erat i o n. As no
t o p lace m o re me l t e x a c t l y wh e re m o re me lt is ma nufa c t ure a nd he nc e fa c ilit a t ing t he ul ti m ate adhesives are necessary for attaching the fabric to
required and, moreover, waives the need for costly re c y c ling proc e ss. All t old, t he E NG EL TECOM ELT the pl as ti c core, there are no heal t h haz ard s . T he
melt distribution systems (hot runners) in the mould. proc e sse s re duc e produc t ion c ost s by 15 to 30% fabri c m ates wi th the m el t mechani cal l y, ens uri ng
Th is p re s s u re l e ss mo u l d f i l l i n g o p e r a t i o n re duc e s c ompa re d w it h c onv e nt iona l la mina t i ng. an abs ol utel y i ns eparabl e bo nd .
ENGEL TECOMELT.
Horizontal machines for long, narrow parts.
8 9
Tw o p ro c e s s e s a re u s e d o n h o r i z o n t a l
E N G E L T E C O M E LT i n j e c t i o n m o u l d i n g m a c h i n e s :
Both processes are based on the use of a reduced
injection pressure (low pressure injection moulding).
L o w - pre s s u re in ject ion
m o u l d i n g pro ces s .
When the melt is injected into the closed mould. In
t h e cas e of t h e l o w-p re ssu re i n j e c t i o n moulding
p roc e s s , in j e c t i o n p re s su re re d u c t i o n i s a c hie v e d
b y re d u c in g t h e f l o w l e n g t h s . T h i s i s d o ne in most
cas e s b y equ i p p i n g t h e h o t r u n n e r s y st e m w it h
cas c a d e - co n t ro l l e d n e e d l e v a l v e n o z z l es.
Through the sequential opening of a defined number
of gates, the injection pressure is kept at a relatively
low leve l.
Horizontal injection moulding machine Type
ENGEL VICTORY 1350 / 350 Tecomelt
with ENGEL ERC 63/1-C linear robot
Low-p ressure injection-com pre ssion
m ould ing p rocess.
Whe n t he me lt is inje c t e d int o t he slightl y opened
mould. B y c ompa r ison, t he low - pre ssure i nj ecti on-
c ompre ssion proc e ss ge ne r a t e s a n e ven l ower
pre ssure in t he mould c a v it y.
As the mould cavity is not completely closed during
t he mould filling ope r a t ion, t he me lt has a m uch
broa de r flow c ha nne l a t it s disposa l, cons i derabl y
reducing the pressure and shear stress on the fabric.
Holding pressure can be kept low, or even waived,
in t he c a se of bot h proc e sse s.
01
a a
b b
c c
a Va l v e c l o s e d a Va l v e o p e n
b Va l v e c l o s e d b Va l v e c l o s e d
c Va l v e c l o s e d c Va l v e c l o s e d
Th e c a sc a de c on trol pr in c iple .
In order to reduce the i nj ecti on pres s ure i n
ENGEL TECOM ELT m oul ds to the requi red l ow-
pressure level while maintaining a uniform movement
of the m el t front, m ul ti pl e pi n gati ng m us t be us ed
in conjunction with a cascade control. The individual
needl e val ve nozzl es , whi ch are actuated ei ther
hydraul i cal l y or pneum ati cal l y, are opened
s equenti al l y i n dependence on ei ther the s crew
pos i ti on or the cavi ty pres s ure. The nozzl es open
only when the melt flow front has moved past them.
Thi s s equenti al openi ng of the nozzl es ens ures a
uniform movement and direction of the melt flow in
the cavi ty. The fabri c i s pres s ed agai ns t the cavi ty
s urface i n the di recti on of the m el t fl ow, thus
avoi di ng wri nkl es .
02
b
c
a Va l v e c l o s e d
b Va l v e o p e n
c Va l v e c l o s e d
01 Detailed view of the insert/removal situation in the
injection mold with double end of arm tooling. The
cut fabric is inserted in the moving side of the mold
and the finished molded part is removed form the
stationary mold half
02 The robot grips the end of the fabric web, pulls the
required length of fabric from the reel and cuts it off.
The fabric is then inserted into the mould with the
aid of a clamping frame and held there by the robot
until it is fixed in place by the closed mould. A new
piece of fabric is then cut in readiness for the next
cycle. After the cooling phase, the mould opens, the
part drops onto a conveyor belt and the next piece
of fabric can be inserted into the mould
ENGEL TECOMELT.
The injection-compression moulding process.
01
10
T h e C o n cept .
For the production of large area Tecomelt-composite
parts with long flow lengths, a solution with a hot
runner system with cascade control is either not
possible due to the given flow length/wall thickness
ratio or not economical due to extravagant design.
Alter natively, injection compression moulding is
applied. This is a process technology, in which the
plastic moulding compound is injected with low
injection pressure into a partially closed mould. After
filling the mould, the mould is closed by an additional
movement of the clamping unit and the moulding
compound is distributed in the cavity.
The core equipment of the Tecomelt-injection
compression moulding equipment are the ENGEL
DUO large machines, which are fined tuned to the
demands of the Tecomelt-process technology.
The design of the DUO 4-tie-bar clamping unit,
each tie-bar having an individual pressure pad,
together with the equipment for mold parallelism
measurement, offers the best conditions for a
sensitive injection compression process sequence.
02
Co m pres s io n
s tro ke
Schematic diagram of injection-compression
moulding process
A dva n ta ge s of I n je c tion
C om pre ssion M ou ldin g.
- Coi ni ng i s the i deal proces s for fl at, l es s
s tructural com ponents
- Fl ex i bl e uti l i zati on of the enti re bas i c s ys tem of
the ENGEL D U O m achi ne program
- P roces s s peci fi c advantages l i ke l ow cl am pi ng
force, l ow i nter nal s tres s i n the m ol ded part.
Th e P roc e ss S e qu e n c e .
P rerequi s i te for the appl i cati on of i nj ecti on
com pres s i on m oul di ng i s a m oul d wi th coi ni ng
adaptation. W ith it, the most essential characteristic
of the m oul d des i gn, nex t to the hol di ng devi ces
for the fabric texture, is the execution of the cavities
with so called vertical flash faces. Thus, the cavities
submerge into each other to a defined stroke (clamp
s troke and coi ni ng s troke, us ual l y 10-15 m m ).
D uri ng the m el t i nj ecti on wi th l ow i nj ecti on
pres s ure, the m oul d rem ai ns open to the s o-cal l ed
coining stroke. The vertical flash faces ensure that
the m el t does not es cape l ateral l y. The s hapi ng by
the coi ni ng s troke wi th the cl am pi ng uni t can be
carri ed out al ter nati vel y duri ng the m el t i nj ecti on
(s i m ul taneous coi ni ng) or di rectl y afterwards
(s eri es coi ni ng).
01 ENGEL DUO clamping unit with large mould mounting
platen area, also available in WP and WPX design
(for even larger platen dimensions at the same
clamping force)
02 P re s s u re p a d s w i t h c o i n i n g c a p a b i l i t y
11
Exact monitoring and evaluation of platen parallelism
ensures high reliability of operation and processing
Coining with Parallelism Control.
In combination with the ENGEL DUO large machines,
Engel offers the equipment package “mould
parallelism measurement ”. It offers the user new
possibilities to increase the process reliability and
mould protection. W ith this equipment, the software
recognizes deviations in the parallelism of both
mould halves, up to a value of 5 / 100 mm, in each
injection cycle. Fundamental to the process, the
exact position of all four tie-bars are measured under
clamping force and during injection. Through a
measurement comparison, any parallelism faults of
the injection mould can be detected.
High-resolution ultrasonic stroke transducers in the
4 pressure pads on the stationary machine platen
serve for the position measurement. Deviations from
the zero-position are shown to the machine operator
on the control screen. Conclusions to optimize the
injection moulding process can be drawn from the
measurement results.
In addition to the parallelism measurement, a
parallelism control is offered in combination with
the process technology “coining ”.
This is of decisive importance for the optimizing of
the process technology of injection compression
moulding. Through the parallelism control, parallel
closing is guaranteed even by eccentric loading. As
a result, the vertical flash faces in the mould are
protected and the jamming areas in the decorative
fabric are avoided.
ENGEL TECOMELT.
The press moulding process – for large-area parts.
Melt flow
12
01 Melt coating operation
Low cavity pressure
02 Pressing operation
03 Removal of moulded part
The low-pressure injection moulding of large-
area parts is possible only with the aid of
complex technology. Moreover, the relatively
high pressure near the gate can cause damage
to the fabric. The economical alter native is the
ENGEL TECOMELT press moulding process,
which is a combination of plastics extrusion
and compression moulding.
13
04 Slit die 05 C h a n g i n g t h e g e o m e t r y o f t h e m e l t s t r a n d
Th e variou s st ages of t h e p ro ces s :
01 M elt coating.
The plasticizing and injection unit, which is movable
in a ll dire c t ions, is e quippe d w it h a s l i t di e of the
kind used on an extruder. At the start of the cycle,
the injection unit moves forward and enters the open
mould, pla c ing a st r a nd of me lt in it s bottom hal f.
The strand is placed in such a way that its exposed
sur fa c e is a s sma ll a s possible a nd t he m el t fl ow
paths will be extremely short during the subsequent
pressing operation. A small surface and a fast melt
coating operation will prevent excessive cooling of
t he me lt .
02 Pressing op er ation.
As soon a s t he inje c t ion unit w it hdr aws from the
mould, t he mould c lose s. This ope r a ti on not onl y
sha pe s t he pa r t but a lso bonds t he previ ous l y
inse r t e d fa br ic w it h t he pla st ic me lt . The ex act
se que nt ia l c ont rol of spe e d a nd pre s s ure profi l es 04 Slit die. 05 Changing the geometry
dur ing t he pre ssing ope r a t ion is a n es s enti al The injection unit of the vertical ENGEL TECOMELT of the melt strand.
pre re quisit e for t he qua lit y of t he moul ded part. press moulding machine, which has been specially The eas i l y ex changeabl e draw p l at es p ermi t read y
d e v e l o p e d t o m e e t t h e p a r t i c u l a r re q u i re m e n t s o f adaptati on of the s trand pro f i l e t o t he act ual
03 Par ts rem oval. this process, is equipped with a slit die featuring a appl i cati on. W i thi n the l i m i ts s et b y t he max i mum
Aft e r t he c ooling pha se , t he mould opens and the rheologically optimized coathanger manifold which width and thickness of the extrusion die, any strand
in- mould de c or a t e d pa r t c a n be re mo ved. shapes the melt into a flat strand. geom etry m ay be chos en. Bes i d es rect ang ul ar
This process can, like the insertion of the fabric, be For universal application, i.e. for the production of profi l es , whi ch are the ones us ed i n mo s t cas es ,
carried out either manually or by means of a robot. s e v e r a l d i ff e re n t s h a p e s a n d s i z e s o f p a r t , t h e d i e s urface-m i ni m i zed s em i -ci rcul ar p ro f i l es o r t wi n
An a ut oma t e d sy st e m not only sa v e s l abour cos ts is also equipped with a set of exchangeable draw s trands are al s o pos s i bl e.
but a lso a ffords t he proc e ssor t he t im e-s avi ng plates which give the strand its final shape.
facility of inserting the fabric into the top half of the T h e s t r a n d i s c u t t o t h e re q u i re d l e n g t h b y m e a n s
mould w hile t he me lt is be ing e xt r uded i nto the of a pneumatically operated knife located under-
bot t om ha lf. neath the die orifice.
ENGEL TECOMELT.
The press moulding process – melt coating operation. The press moulding process – the machine.

01 02 01 02

14 15
03 03

Tw o i n j e ct io n u n it s an d on e m achine.
Th e v e r t ic a l E NGE L T E COM E LT p re ss moulding
machine equipped with two extrusion/injection units
is ava ila b le i n a c h o i c e o f t wo v e r s i o n s.
Ver s ion 1 fe a t u re s t wo i n j e c t i o n u n i t s w hic h mov e
Vertical ENGEL TECOMELT press moulding machines
in d ep en d ent l y o f e a c h o t h e r i n t h e x-, y - a nd z -
have been s peci al l y des i gned for the m oul di ng of
axes, permitting the simultaneous production of two
fabri c/ pl as ti c com pos i tes :
parts having different geometries but requiring similar
p las tic iz in g, c o o l i n g a n d h a n d l i n g t i m es. I t is a lso
p os s ib le to p ro c e ss d i ff e re n t ma t e r i a l s in t he t w o S pe c ia l f e a tu re s:
injection units, extruding either into separate moulds - l ow worki ng hei ght
or, c on s ecut i v e l y, i n t o t h e s a m e mo u l d. - eas y acces s i bi l i ty
01 Overall view of a twin injection unit arrangement with 01 Type ENGEL TECOMELT 2500 / 2500 / 800 VR
Ver s ion 2 c o m p r i se s t wo i n j e c t i o n u n i t s w hic h extrusion die heads, each unit mounted on a carriage - low construction permitting floor-level operation press moulding machine
perform parallel movements in the longitudinal and capable of independent movement in 3 axes - readi l y autom ated thanks to s am e control
ve r t ic a l d ire c t i o n , b u t m o v e i n d e p e n d ent ly of e a c h concept for both m achi ne and robot 02 Press moulding machine in practical application /
02 Version with just one injection unit for one mould
- general purpos e operati on optimum ergonomics for the operating personnel
ot h e r in t h e t r a n sv e r s e d i re c t i o n . T h i s sy st e m is
p ar tic u la r ly su i t a b l e f o r t h e si mu l t a n e o us 03 Version featuring simultaneous operation of two wi th ei ther s i ngl e-cavi ty or two-cavi ty m oul d 03 Press moulding machine with automation peripherals
manufacture of two identical or mirror-inverted parts. injection units for two forms - accum ul ator for rapi d cl am pi ng force bui l d-up for fabric handling and parts removal
ENGEL TECOMELT.
Production cells for manufacturing textile compound mouldings.

Production cell based on Production plant with six ENGEL VICTORY 2550 / 600 Tecomelt.
ENGEL DUO 7050 / 1700 Tecomelt Large volume production plant for Tecomelt-mouldings for manufacturing
For the automatic manufacturing of large trim panels of A,B,C-Column trim panels for automobiles.
with deco function in automobiles.

Articulated arm robot for

textile- and finished parts
manipulation, mounted on
fixed machine platen

T iebar pulling unit for

easy mounting / removal
of large moulds
16 17

Accumulator unit
for fast injection

Periphery station with

logistics function for textile
cuts (feeding via pallet)
and finished parts

Preheating station
for textile cuts
Photo: Intier Eybl,
Straubing / Germany

Automobile interior door panel C-Column panel

Door panels or large area covers with low deep
draw ratios are moulded directly with the injection
moulding process. As a specific feature with a
large number of applications a foamed plastic
structure is combined with the textile fabric
The automatic production of A-, B-, C-column
panels requires due to the specific shaping a
high level of automation around the injection
moulding process – from textile cutting to
postprocessing. The Engel center for automation
and project planning offers their services as know
how partners for plant projects
ENGEL FOAMMELT.
Light parts for heavy duty.

Lightness is trumps –
and savings win the game.
Light-duty machines for lightweight mouldings with
properties that make them the ideal cost-saving parts
for heavy-duty applications. Maximum saving with not
even a minimum loss of inherent values - that's the
philosophy behind ENGEL FOAMMELT. Parts injection
moulded by the ENGEL FOAMMELT process enjoy
application wherever the visual appeal of the exterior
belies the strength of the interior, wherever character
comes before appearance. Their lightweight foam
structures give strength to decorative surfaces, perform
insulating functions, increase the precision of complex
mouldings and, last but by no means least, utilize less
material, consume less machine energy and can be
18 processed on machines that take up far less space. 19
ENGEL FOAMMELT.
Structural foam moulding: the processes and the alter natives. Characteristic features of the structural foaming process.

Decision matrix Chemically blown foam Mechanically blown foam 01 02

Cell structure + ++ Density (g/m 2 ) 30 40 50 60 70 80 90 100 %
Standard polymers + +
Engineering polymers + / – ++ Solid
Processing latitude + +++ Supercritical
Blowing agent costs – +++ fluid
Liquid gas

Pre ssure (P c )
Possible weight reduction + ++

Cross-se c tion
Shape fidelity ++ ++

Wall thicknesses under 5 mm
Residues from foaming process
Gas pressure during foaming
Clamping force reduction
Capital investment
20
de nsity
Me a n
– +++
– +++
+ +++
+ +
+++ – Gas
General-purpose, thick-walled parts Thin-walled industrial parts produced in
produced in small to medium sized batches, large quantities, e.g. automotive parts,
e.g.: toys, household appliances, furniture
parts, leisure and sports equipment
electrical parts, office equipment
components
Temperature (Tc ) 21
03 04
600
2 cavity pressure graphs 500

Peak cavity pressure (bar)

500 related to foaming degree

400

Cavity pressure (bar)

400

300
300
Basically, structural foam parts can be injection
moulded by means of two alter native processes. 200
Common to both processes is the formation of a 200
cellular structure inside the moulded part through
the dispersion of gas bubbles within the basic 100
100
polymer material.
0
Chemically blown foam. Mechanically blown foam. 1,00 0,95 0,90 0,85 0,80 0,75 0,70 1 2 3 4
W ith this process, the gas is generated by the Mechanically blown foam is produced by introducing Degree of foaming (–) Time (s)
chemical decomposition of the blowing agent - pressurized nitrogen or carbon dioxide directly into
consisting of chemical substances based on the melt during the plasticizing process. The high
PA PP PPM PPT PPL Conventional
bicarbonate and citric acid - when exposed to the pressure in the plasticizing cylinder causes the gas
heat of the melt during the plasticizing process. to dissolve in the melt completely, thus ensuring its PAG PPH PP1M PPG Foamed with N2
uniform dispersion. Following injection of the gas-
The powdered blowing agent is mixed into the laden melt into the unpressurized mould, the gas
moulding compound together with an adhesive oil. and the melt separate, whereby the gas expands to
The exact formulations for the mixture depend on produce a microcellular foam.
the actual application. As the pressure of the gas
in the melt is extremely low, only very low injection W ith this process, the pressure of the gas in the
pressure may be used for the mould filling process. melt is considerably higher than that generated by
This means that there are limits both to the precision the chemical foaming process, thus permitting a 01 Diagram showing the different states of nitrogen as 03 Reduction of cavity pressure through increased
with which a part can be moulded and to the extent wider processing latitude and greater moulding the pressure and temperature increase. Within a degree of foaming
to which shrinkage can be compensated. precision. The process is ideal for the moulding of defined pressure and temperature range, nitrogen
becomes a „supercritical fluid” which dissolves in 04 Potential saving achievable with structural foam
lightweight precision parts from engineering the melt completely during the plasticizing process. injection moulding: Comparison of cavity pressures
Despite its negligible demands on machine polymers with wall and section thicknesses of less The melt and the gas separate again following for the same part produced by conventional injection
technology, structural foam moulding with chemical than 5 mm. The necessary higher capital investment injection of the melt into the mould cavity moulding and by structur al foam moulding
blowing agents is restricted largely to the production is balanced by the economic advantages of more
02 Cross-section of structural foam moulded part.
of thick-walled parts in PE and PP which do not profitable applications and faster cycle times. Clearly visible is the sandwich structure formed by
have to meet high quality standards. the solid outer skin and the foamed core
ENGEL FOAMMELT – MuCell ® -TECHNOLOGY.
Machine equipment and function. The cycle sequence.

01 04 02 03 01 02

05

22 23
01 Needle valve nozzle 03 MuCell ® -plasticizing screw
02 Gas injector (L/D ratio: 24:1) 03 04
04 Homogenizing section for gas/melt mixture
05 Plastics granules without blowing agent

MuC e l l ® p l a sti c i zi ng uni t

04 03 02 01

Process sequence

M ic roc e llu la r f oa m str u c tu re s th rou gh
u n if or m ly dispe r se d n itroge n .
The m echani cal foam i ng proces s neces s i tates the
use of a specially adapted plasticizing cylinder, into
which nitrogen or carbon dioxide is injected during
the plasticizing process and finely dispersed by the
hom ogeni zi ng acti on of the s crew.
01 Process stage 1: The plasticizing process takes place
after injection of the previous shot and during the
mould cooling phase. With the needle valve nozzle
closed, the melt builds up in the space in front of
the screw. Gas injectors introduce nitrogen in its
“supercritical fluid state ” into the metering zone
during the plasticizing process.
Under the heat and pressure generated by the
plasticizing screw, the gas is completely dissolved
and dispersed in the melt

The high pressure in the plasticizing cylinder causes 02 Process stage 2: The mould opens and the part is
the gas to dissolve in the melt completely. Not until demoulded. The melt for the next shot is kept under
pressure so as to ensure a uniform melt temperature.
the m el t i s i nj ected i nto the m oul d does the gas This is a prerequisite for the optimally uniform foam
expand to form foam. The advantage of the extremely structure of the moulded part
even di s tri buti on of gas i n the m el t l i es i n the
cons i s tentl y hi gh qual i ty and di m ens i onal s tabi l i ty 03 Process stage 3: The mould closes. The needle valve
nozzle opens and the melt is injected. During
of the m oul ded part. S hri nkage and warpage are injection, the finely dispersed gas in the melt
m i ni m i zed. Wei ght s avi ngs of between 25 and 30 nucleates and expands to produce a microcellular
percent and cycl e ti m e reducti ons of up to 50 foam. The foamed melt flows easily, necessitating a
percent are pos s i bl e. relatively low mould locking force
01 Plasticizing of plastics 03 Mixing and dissolving of the fluid.
02 Injecting of supercritical fluid Homogenizing of the miscellany 04 Process stage 4: The melt expands to fill the mould,
into plastic melt 04 During injection process starting of nucleation forming a solid outer skin and a microcellular foam
and creating of microcellular foam structure core of extremely uniform structure
ENGEL FOAMMELT .
The system components – and the machines. The Equipment Control.

Equipment Integration.
01 The function of the MuCell ® gas supply equipment
is integrated into the cycle sequence of the injection
moulding machine with an interface and own process
software and is adjustable from the machine
control screen. The adjustable parameters and the
internal functions are clearly displayed on the control
screen page of the ENGEL CC 200 machine control.

24 25
02 03

Graphical Display.
The proper application of the gas control is of
significant importance for the cycle sequence.
The actual values of the injector function time are
graphically displayed for better orientation for the
machine operator. Additionally, the metered
volume of gas is indicated.

The MuCell ® equ ipmen t package Savings Calculator.

comprising:
- M u C ell ® p l a s t i c i z i n g u n i t wi t h L /D r at io of 24:1,
incl. MuCell ® sc re w, g a s i n j e c t o r s
- Needle valve nozzle for plasticizing cylinder
- Melt pressure transducer, arranged
under gas injector 1
- Servo valve control with small accumulator
for MPP control
- M u C ell ® s o f t wa re f o r p e r m a n e n t p re ssur iz a t ion
of the melt and feedback control of screw position
a n d n eedl e v a l v e n o z z l e
In order to obtain a direct overview of the material
savings from the foam structure, the compact
injection moulded part can be compared to the
MuCell ® -foam injected moulded part with an
integrated savings calculator. The resulting savings
of material, clamp force, and cycle time are also
given, as well as the used gas volume.
01 Production cell consisting of standard injection
moulding machine with equipment package for the
MuCell ® microcellular foam moulding process and
ENGEL ER-Hli demoulding robot

additional equipment: 02 Close-up view of MuCell ® plasticizing cylinder

equipped with two gas injectors
Gas supply units for the metered injection of nitrogen
and carbon dioxide 03 Close-up view of gas pressure control unit
ENGEL FOAMMELT – MuCell ® -TECHNOLOGY.
Complete production cells for microcellular foam moulded parts.

MuCell ® -2-K-Production Cell Based on an MuCell ® -Production Cell Based on ENGEL DUO 16050 / 1700.
ENGEL VICTORY 1350H / 330W / 300 Combi. Large area structural parts in automobiles require generous space conditions in the
clamping unit, for the mounting of the injection mold as well as for removal of the molded
MuCell ®- 2C-Production Cell Based on an ENGEL VICTORY Mid-Size Machine
part. The ENGEL DUO machine concept offers this advantage.
Production cell for 2-component molded parts based on an ENGEL VICTORY
mid-size machine with tie-bar-less clamping unit with combination injection
unit of a horizontal MuCell ® main- injection unit and a compact injection unit
in W (piggyback) arrangement.
Part removal robot
Part removal robot ENGEL ERC 103 / 1-E
ENGEL ERC 53 / 1-E in standard design
in standard design

26 Compact injection unit

ES 330 in W (piggyback)
27
arrangement for second
material components Injection unit ES 16050 in
MuCell ® -design with melt
barrel having L/D ration 24:1
Injection unit ES 1350 in
MuCell ® -design with
90 mm melt barrel having
L / D ration 24:1 MuCell ® -Mucell gas supply
and control equipment

MuCell ® -gas supply and

control equipment Accu-equipment
for fast injection

Photo:
Loadhog, Sheffield / UK

Car door trim Pallet lid (Loadhog Lid)

Decorative fabric surfaces can be ideally
combined with low pressure structural foam
moulded parts – a typical MuCell ® application.
®
Detail view of MuCell -injection unit with
gas injectors and gas regulation unit in combination
with second injection in W-configuration
W ith large mouldings e.g. for logistic systems, with
higher priority on function than on brilliant surface
quality, the MuCell ® technology is first choise. Detail view of MuCell ® -large-machine-injection-unit
Lightweight mouldings are the result. with gas injectors and gas regulation unit

Photo:
Loadhog, Sheffield / UK
ENGEL FIBERMELT.
Plastic with Long Glass Fibers for “Strength” Parts in Automob iles.

01 02 03

Stossfängerträger

Instrumentaltafel-Träger

28 29

Safety and lightness in the moder n car.

Innovative solutions are always needed whenever high
s tren gth h as t o b e c omb i ne d w i t h ot he r p ro pe rti e s.
In th e con text of t he a ut omot i v e i nd ust ry, m a ss-
pro du ced comp one nt p a rt s a nd a sse mb li e s m ust no t
o n ly f eatu re a w hol e sp e c t rum of ma t e ri al pro pe rti e s
bu t als o me e t d e ma nd i ng p rod uc t i on re q ui re m e nts. Autotür-Funktionsmodul
First and foremost, they must be resistant to corrosion,
manufacturable by a single-stage process without any
need for subsequent finishing, exceedingly strong and
light in weight. Parts injection moulded from long glass
fibre-reinforced thermoplastics have enormous potential
f o r s u ch in nov a t i v e sol ut i ons. ENG EL FIB ER M ELT i s 01 Sound shield for engine compartment
the technology on which the production of such high- 02 Underbody assembly
s tren gth part s i s b a se d . 03 Lift-up tailgate module
Automobil-Frontmodul
ENGEL FIBERMELT.
The material.
30
Electron micrograph of plastic / fibre matrix
Definitions.
Long glass fibre-reinforced thermoplastics generally
have an initial fibre length of up to 50 mm. This
length of fibre lies approximately halfway between
the fibre length normally used for chopped-fibre
reinforced thermoplastics (0.3 mm) and the fibre
length used for glass mat reinforced composites.
The degree of reinforcement may in most cases be
a n y th in g b e t we e n 1 5 a n d 6 0 % w/w. T he most
c om m on ly use d f i b re s h a v e d i a me t e r s of be t w e e n
10 an d 15 µ m. T h e re a re a l s o o t h e r me t hods of
rein forc e m e n t u s i n g c a r b o n o r a r a m i d fibre s a nd –
to an e v e r i n c re a s i n g e x t e n t – n a t u r a l f ibre s suc h
a s h e m p or s i sa l .
Polypropylene and polyamide are the thermoplastics
m os t com mo n l y u se d f o r t h e i n j e c t i o n moulding of
fib re rein forc e d p a r t s .
01
02
03
04
Types of pellet used for the injection moulding of
long fibre-reinforced parts:
01 Compounded material with an
initial fibre length of 2.5 mm
02 Pultruded, rod-shaped pellets
with 10 mm fibre length
03 Pultruded, rod-shaped pellets
with 25 mm fibre length
04 Material loosely mixed from long
glass fibres and unreinforced pellets
Pultruded, rod-shaped pellets are the most common,
and most important, commercial form of long fibre-
reinforced thermoplastic compounds. These pellets
a re produc e d by a c ont inuous e xt r usi on proces s
similar to that used for the sheathing of cables. The
continuous glass fibres are sheathed in thermoplastic
and then cut into specific pellet lengths (mostly 10
or 25 mm) depending on their intended application.
The pe lle t s a re t he n imme dia t e ly proces s ed
dow nst re a m on t he inje c t ion moulding m achi ne.
B e side s t he se re a dy - t o- use pe lle t s, there are al s o
c ont inuous gla ss fibre c onc e nt r a t e s whi ch can be
mixe d w it h unfille d t he r mopla st ic pe l l ets i n rati os
c or re sponding t o t he de sire d de gre e of
re inforc e me nt . This me t hod ma ke s for i ncreas ed
proc e ssing fle xibilit y.
Long fibre-reinforced thermoplastics: the advantages.
E ff e c t i v e g l a s s f i b re l e n g t h ( m m ) i n m o u l d e d p a r t
0 0,5 1,5 2,5 3,5 4,5 5,5 6,5 7,5 8,5 9,5 10,5
Modulus of
elasticity
F i b re l e n g t h d i s t r i b u t i o n *
Rigidity
F ibermelt p l a s t i c i z i n g p ro c e s s
St
and
ard
p la s t
i c iz in g I m p a c t re s i s t a n c e
p ro c e s
s
Injection-compression Deposit compression
Injection moulding moulding moulding 31
*Length definitions: Chopped glass fibres: < 0.3 mm, long glass fibres: > 0.3 mm
In moulded parts reinforced with long glass fibres there is a direct relationship between fib re length distribution
and the mechanical properties of the part. The chopped (short) fibre content contributes to the rigidity and modulus
of elasticity of the moulded part, the medium-length fibre content gives the part its strengt h, and the long) fibre
content has a decisively positive influence on impact resistance. By virtue of its gentle processing action, the
ENGEL FIBERMELT plasticizing system increases the content of long fibres in the moulded part.
Improvement of physical properties. Increased component strength, even at
high temperatures.
- Increased impact resistance: The longer the fibres are, the greater will be the
Depending on their length, a more or less dense force which the moulded part is capable of
three-dimensional network of fibres forms in the transmitting. However, this strength improvement is
moulded part, considerably increasing the limited to a certain maximum length of fibre, which
latter's stability and impact resistance. The is defined as the critical fibre length. The critical
degree to which stability and impact resistance fibre length is determined by various factors such
is increased is best explained by the enormous as, for example, the specific combination of polymer
amount of energy which would be required to and fibre, the coupling agent, the ratio of fibre length
debond the matrix, i.e. to separate the fibres to fibre diameter and the temperature range within
from the plastic. which the polymer/fibre composite is to be used.
- Negligible thermal expansion: Easy to manufacture.
The addition of glass fibres can reduce the high One of the principle advantages of this process over
coefficient of thermal expansion of the plastic the glass mat reinforcement of thermoplastics – a
material to that of aluminium. This is particularly process which is mainly suitable for the production
advantageous in cases of application where of two-dimensional parts – is the fact that it can be
structural units are assembled from components readily integrated in the production system and
made of different materials, e.g. carbodies permits production in one single operation. Glass
mat reinforced parts, on the other hand, must be
- Improved fracture behaviour: provided with a reduced glass content in certain
The cohesiveness of the three-dimensional areas where their function would otherwise be
network of glass fibres reduces splintering adversely affected, e.g. screw domes.
tendency in cases of fracture.
ENGEL FIBERMELT.
The fundamentals of its technology. The ENGEL FIBERMELT equipment package.

D e c i s i o n m a t r i x f o r p ro c e s s c h o i c e
01 02
T h e bas ic a i m of ENG EL FIBERMELT t e c hno l o g y
Extreme moulded-part Gentle treatment of fibres
is th e economi c a l l y e ffi c i e nt – i .e . a ut o m a te d – complexity (component strength)
manufacture of moulded parts within the optimum
spectrum of fibre lengths. Basically, there are three
pro ces s e s for t he ma nufa c t ure of c ont i nuo us
f ibre- rein forc e d p a rt s:

- In ject i on moul d i ng
- In ject i on-c omp re ssi on moul d i ng
- Deposi t c omp re ssi on moul d i ng

32 Injection moulding Injection compression

moulding
Deposit compression
moulding
33
The decision in favour of a particular process will depend
on the geometry of the moulded part and the demands
which it is expected to meet. What all three processes
have in common is the need to modify the plasticizing units
and the processing technology in order to achieve as gentle
a treatment of the fibres as possible.

G e n tl e fibre t reat men t by red ucing Depending on application, the injection moulder can
m e c h a n i cal s h ear. s el ect hi s s tarti ng m ateri al from a wi de range of
com m erci al l y avai l abl e pol ym ers .
- Opt imiz e d p ro c e s s p a ra m e t e rs
In a ll t h re e p ro c e sse s , p l a st i c i z i n g t a ke s pla c e 01 L on g gla ss f ibre -re in f orc e d
in s cre w p l a s t i c i z i n g u n i t s . I n o rd e r t o minimiz e pu ltr u de d pe lle ts. Dire c t a ddition of gla s s f i b re s .
mechanical influences it is necessary to strike a These compounds consist of pultruded, rod-shaped Ins tead of bei ng i ncorporated i n t he p el l et s , t he
h ap p y m e d i u m b e t we e n g e n t l e f i b re t re a t me nt pellets (10 – 25 mm long) with a type-specific glass gl as s fi bres can be fed di rec t l y i nt o t he p l as t i ci z ed
an d e ffe c t i v e h o m o g e n i z a t i o n o f t h e me lt . This fi bre content (20, 30, 40, 50% w/ w). One of thei r polymer. This method minimizes mechanical damage
com p rom i se i s a c h i e v e d b y re d u c i ng t he sc re w m ai n advantages i s thei r ready avai l abi l i ty. to the fibres and the moulding operation takes place
s p e e d a n d si mu l t a n e o u s l y i n c re a si ng t he dw e ll The responsibility for these compounds lies with the i m m edi atel y after thei r addi t i o n. E x t rud ers – e. g .
time. The energy required for plasticizing is now raw m ateri al m anufacturer. twi n s crew ex truders – are u s ed f o r t hi s p ro ces s ,
gen er a te d l e s s b y f r i c t i o n a n d m o re by t he m ai nl y i n conj uncti on wi th met eri ng uni t s , s uch as
increased number of heating zones of the cylinder s crew or ram accum ul ators . T he mai n ap p l i cat i o n
02 L on g gla ss f ibre c on c e n tr a te s. for thi s proces s i s the pres surel es s d ep o s i t i ng o f
in c on ju n c t i o n wi t h a l o n g e r p l a st i c iz ing ( dw e ll) For flexible adaptation of the glass fibre content to
t im e a n d l o we r sc re w sp e e d . m el t i n com pres s i on m oul ds (d ep o s i t co mp res s i o n
s peci fi c requi rem ents , raw m ateri al m anufacturers m oul di ng).
now offer, as a com pl etel y new devel opm ent,
- Opt imiz e d g e o m e t ri e s continuous glass fibre-reinforced pellets with a glass
En gel h a s d e v e l o p e d sp e c i a l sc re w ge ome t r ie s The disadvantages counterbalancing the advantages
fi bre content of over 50%. U s i ng s peci al of l ower raw m ateri al cos ts and i mp ro v ed p ro d uct
for t h e g e n t l e t re a t me n t o f c o n t i n u ous fibre - m anufacturi ng proces s es , i t i s pos s i bl e to achi eve
reinforced thermoplastics. Nozzles, too, feature qual i ty are qui te cons i derable: hi g her cap i t al
a rel i abl e pre-i m pregnati on of the fi l am ents even investment, reduced utilization of available capacity,
wide flow paths and smooth transitions so as to wi th a gl as s fi bre content of up to 75%.
reduce mechanical shear to a minimum. The same the added responsibility as regards the quality and
The advantage l i es i n the greater proces s i ng rel i abi l i ty of the m ateri al , and t he rel at i v e l ack o f
d es ign a p p ro a c h i s a d o p t e d f o r t h e r unne r fl ex i bi l i ty, as there i s no need to s tore m ateri al s
system, too. Thus generous dimensions, „flowing i nfl uence over fi bre i m pregnat i o n and d i s t ri b ut i o n.
havi ng di fferent gl as s fi bre contents . Further
lines” and rheologically optimized melt flow-ways advantages are the l ower pri ce and the i m proved
are th e s o l u t i o n a l l a l o n g t h e l i n e – from t he On account of these disadvantages, Engel does not
feed perform ance duri ng proces s i ng. The requi red recom m end proces s i ng techno l o g i es b as ed o n t he
s c rew t h ro u g h t h e n o z z l e t o t h e g a t ing sy st e m mixing ratio is maintained by means of a combined
in th e m o u l d . di rect addi ti on of gl as s fi bres .
m eteri ng, m i x i ng and wei ghi ng s tati on.
ENGEL FIBERMELT.
The injection moulding process.
Engel offers its Fibermelt processing technology in
conjunction with its ENGEL DUO range of large-
capacity injection moulding machines.
These machines are offered with a number of standard
and special options. The nucleus of the Fibermelt
injection moulding system is the specially developed
ENGEL FIBERMELT plasticizing unit.
Advantages:
- Particularly suitable for geometrically complex
parts with many apertures.
- Engel processing know-how minimizes
damage tothe fibres
- Typical Fibermelt injection-moulded parts are:
> dashboard supports
34 > front end modules
E N GE L DU O-i nj e c ti on
mou l d in g m a c h i ne s
01 02
The ENGEL FIBERMELT
equipment package.
Basis: ENGEL DUO series of injection moulding
machines with two-platen clamping system
Technology module:
ENGEL FIBERMELT injection unit
- Fibermelt screw featuring optimized geometry
(available in diameters from 90 mm upwards)
- Plasticizing cylinder with L/D ratio of 26:1 for
gentle plasticizing action
- Electric screw drive for parallel metering (optional)
- Weigh feeding unit for glass fibre concentrates
(optional)
- Screws and non-retur n valves from the Engel
Marathon product range
(see special product leaflets)
Close-up of injection unit with weigh feeding unit
03 01 Coupling segments for tiebar
coupling with platen
02 ENGEL DUO two-platen clamping unit
03 Pressure pad
Software options.
Available for use with Fibermelt is Engel's entire
range of application and quality control software
(see brochures „ENGEL DUO” and „ENGEL CC 200”)
Of particular advantage when processing continuous
fibre-reinforced thermoplastics is the operational
software package „AUTOPROTECT INJECTION
MONITORING”. This software monitors the injection
and holding pressure profiles. Comparison of refe-
rence and actual values gives early recognition of
critical deviations, thus permitting timely adjustment
and, in tur n, effectively preventing possible damage
to the injection unit and the mould.
The injection-compression moulding process.
The ENGEL FIBERM ELT i nj ecti on-com pres s i on Schematic
diagram of
m oul di ng proces s com bi nes the s i m pl e m el t injection-
del i very s ys tem of the conventi onal i nj ecti on compression
m oul di ng proces s wi th the fi bre-fri endl y moulding
m oul di ng acti on of the com pres s i on m oul di ng process
proces s . Engel offers a s peci al l y devel oped
proces s s oftware for the us e of the i nj ecti on-
compression moulding process on ENGEL DUO C om pre s s ion s t rok e
i nj ecti on m oul di ng m achi nes .
35
I nj e c t i on- c om p re s s i on m oul d i ng w i t h 01 ENGEL FIBERMELT plasticizing unit
02 Weigh feeding unit
t he E N G E L D U O i nj e c t i on m oul d i ng
03 Pressure pad with compression facility
m a c hi ne
03
02
01
Th e proc e ss. A s the hol di ng pres s ure i s a p p l i ed no t b y t he
A prerequi s i te for the us e of the i nj ecti on- injection unit but by the clamping unit, the pressure
com pres s i on m oul di ng proces s i s a m oul d whi ch i s di s tri buted m uch m ore evenl y and a l o wer
can be equi pped wi th a com pres s i on m oul di ng cl am pi ng force i s requi red.
adapter. D uri ng the fi bre-fri endl y, l ow-pres s ure
i nj ecti on of the m el t i nto the m oul d, the l atter A dva n ta ge s of th is m o u l d i n g p ro c e s s .
remains open by a distance of 10-20 mm – the so- - Inj ecti on com pres s i on m o ul d i ng i s t he i d eal
called compression stroke – and vertical flash faces proces s for the producti o n o f l arg e- area,
prevent the melt from escaping via the gap between rel ati vel y uncom pl i cated p art s d es i g ned f o r
the m oul d hal ves . applications which make heavy demands on their
The m achi ne perform s the m oul di ng operati on by fi bre s tructures , e. g. car und erb o d i es , eng i ne
cl os i ng the m oul d, ei ther duri ng the m oul d fi l l i ng com partm ents or car doo r mo d ul es
operation (simultaneous injection and compression) - Fl ex i bl e uti l i zati on of ENG E L D U O machi nes
or i m m edi atel y after (cons ecuti ve i nj ecti on and - P roces s i ng advantages such as neg l i g i b l e f i b re
com pres s i on). dam age, reduced cl am pi ng f o rce req ui rement ,
negl i gi bl e i nter nal s tres s es i n t he mo ul d ed p art
ENGEL FIBERMELT.
Potential for the future: material combinations point the way f orward.
01 S u b s equ en t rein forcement
w i th m et al part s .
A con ceiv a b l e f u t u re d e v e l o p m e n t i s t he
p rod u c tio n o f l a r g e -a re a l o n g g l a ss fibre
re in forced p a r t s wh i c h a re s u b s e q u e nt ly
s tren gt h e n e d i n c r i t i c a l a re a s wi t h w e lde d- in
s h e e t m e t a l p a r t s. D i st o r t i o n a n d i n t e r na l
s tres s es wo u l d b e e a s i e r t o c o n t ro l tha n in t he
cas e of h y b r i d c o m p o si t e s, e .g . m e t a l pa r t s
s u b s eq u e n t l y st re n g t h e n e d wi t h i n j e c t ion
m ou ld e d r i b s. I n t h i s wa y i t wo u l d b e possible
t o avoid o v e r s i z i n g p l a st i c p a r t s me re ly for t he
p u r p os e o f g i v i n g t h e m a d d e d st re n g t h.
A vast saving of material and weight would result.
36
01
03
a b
d
e
a fabric reinforcement
b foam st ructure
c inlay with reinforcing rib
d long glass fibre reinforcement
e glass fibre tapes
03
S a n dw i c h co mbin at io n s of
m a te r i a l propert ies .
Sandwich constructions for noise reduction and heat
in s u la tion , e .g . c o mb i n a t i o n s o f l o n g gla ss fibre -
re in forced t h e r mo p l a st i c s a n d f o a m m at e r ia ls, a nd
als o s im ilar sa n d wi c h c o n s t r u c t i o n s f o r e ne r gy
absorption, are currently at the experimental stage.
01 02 02 F ibe r m e lt a n d su r f a c e re f i n e me n t .
As with all other processes in this and other areas
of plastics processing, FIBERMELT's potential for
i nnovati on l i es i n i ts abi l i ty t o co mb i ne read i l y
wi th other proces s es , e. g. wi t h PFM (Pai nt l es s
Fi l m M oul di ng). A s the s urf ace t ex t ures o f l o ng
gl as s fi bre-rei nforced parts are g eneral l y
unacceptabl e i n aes theti c t erms , t he rang e o f
appl i cati on of s uch parts can b e co ns i d erab l y
widened through combination with suitable surface
enhancem ent and decorati o n p ro ces s es .
Com pl etel y new appl i cati on s are co ncei v ab l e –
e.g. carbody components and car door modules
– where aes theti c appeal i s j us t as i mp o rt ant as
m ateri al s trength. 37
03
A ddition a l loc a l re in f o rc e me n t .
A f u r t h er co n cei vab l e w ay o f exte n d in g th e sp e c tru m
of possible applications for long glass fibre-reinforced
p ar t s w o u l d b e t o p ro vi d e t h ose a re a s of a mou ld e d
p ar t w h i ch are s u b j ect ed t o p a rtic u la rly h igh le ve ls of
s t res s w i t h ad d i t i o n al l o cal rein f orc e me n t in th e f orm
o f g l as s f i b re m at s an d t ap es .
Processing solutions for such reinforcement techniques
h ave al read y b een d evel o p ed .
Re c yc la ble a lte r n a tive t o S MC.
A further potential application is the production of long
glass fibre-reinforced parts as SMC substitutes. Sheet
m o u l d i n g co m p o u n d s are d i ff i c u lt to re c yc le a n d th e
car manufacturing industry's requirement for a recycling
q u o t a o f 8 5 % can b e m et o n l y a t c on sid e ra b le c ost.
02
Moreover, compared with SMC parts, long glass fibre-
reinforced parts require little or no subsequent finishing.
ENGEL GASMELT / WATERMELT.
The alter native solution for thick-section parts and good surfa ce finishes.

Technology below the surface

is the beauty of it.
Shapes that lie comfortably in your hand, absolute dimen-
sional precision, surface finishes that leave absolutely nothing
to be desired – these are the qualities that decisively influ-
ence the success of a new product. Being able to combine
design and function without having to pay heed to the limits
imposed by the material has a twofold advantage: new
materials can be utilized and, by the same token, new
products can be developed – for the ultimate benefit of the
user. Technologies for achieving optimum surface quality of
the moulded part by applying, with either a gas or a fluid,
a constant internal pressure during the critical holding and
cooling phases considerably broaden the scope of possible
applications for plastic parts. The technologies developed
38 by Engel to this end are called Gasmelt and Watermelt. 39
ENGEL GASMELT / WATERMELT.
The processes – an overview of possible applications. Partial filling and inflation – the standard process.

Overview of application scope of Gasmelt / Watermelt processes 01 02

GASMELT WATERMELT

Industrial parts with large cavities (visible when in use)

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

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

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

Handles with large cavities

Structural components with relatively small, partial cavities

40 Structural components with large cavities 41

03 04

Th e G a s m e l t a n d Wa t e r me l t p ro c e sse s offe re d by
Engel permit the moulding of parts with thicker walls
and sections than normally permitted by the material
u s ed . W it h b o t h p ro c e sse s , a s e p a r a t e me dium is
in je c te d in t o t h e mo u l d d u r i n g t h e mo uld filling
op e r at ion . T h i s me d i u m g e n e r a t e s p re s sure inside The standard Gasmelt
th e p ar t s o a s t o e n su re t h a t t h e s h r i n ka ge of t he or Watermelt process.
m at e r ial w hi c h n o r ma l l y o c c u r s d u r i n g t he c ooling The mould cavity is first partially filled with a defined
p h a s e c a n n o t p u l l t h e s u r f a c e s o f t h e pa r t s a w a y quanti ty of m el t, fol l owed by gas or water i nj ected
from t h e w a l l s o f t h e mo u l d c a v i t y a n d c a use sink at a pressure of between 30 and 400 bar or 20 and 01 Process stage 1: Injection unit with shut-off nozzle
m ar k s a n d o t h e r su r f a c e b l e m i s h e s . T he pre ssure closed. Melt accumulates in the space in front of
200 bar res pecti vel y. The pres s ure m edi um forces the screw in readiness fo r injection
m ed iu m u s e d i s e i t h e r n i t ro g e n o r wa t er. Nit roge n the m el t agai ns t the wal l s of the m oul d cavi ty i n
is used in cases where chemical inertness is a prime order to m oul d the part. Inj ecti on of the pres s ure 02 Process stage 2: Shut-off nozzle opens. Melt is
c on s id er a tio n ; wa t e r i s u se d i n c a se s w he re c y c le m edi um i s effected ei ther vi a the m achi ne nozzl e injected (partial filling). Shut-off nozzle closes
tim e, h eat t r a n s f e r a n d l o n g m e l t f l o w- pa t he s t a ke (only if gas is used) or via a nozzle located near the
03 Process stage 3: Gas is injected via gas needle
p r ior ity. Th e s e p re ssu re me d i a d o n o t just se r v e t o gate or via a nozzle leading directly into the mould into mould cavity. The nitrogen expands inside the
c om p en s a te sh r i n k a g e b u t a l so , a n d e qua lly im- (gas and water). The medium cannot enter the mould melt and forces the latter against the walls of the
p or t a n tly, to re d u c e wa l l t h i c k n e s s b y produc ing unti l i ts pres s ure ex ceeds that of the m el t. mould cavity (the optimum quantity of melt is
determined beforehand b y successive
hollow areas inside the parts. Reducing wall thick- After performing its moulding function, the pressure approximation)
ness also reduces the amount of material used, and m edi um takes over the hol di ng pres s ure functi on
th is in t u r n me a n s a re d u c t i o n i n c o o l i ng t ime . The normally performed by the injection unit. Upon com- 04 Process stage 4: Gas pressure is maintained during
bottom line: improved surface quality and dimensio- pletion of the defined holding pressure phase, most the cooling phase (the gas pressure performs the
holding pressure function). Gas pressure is then
n a l p re c is io n o n t h e o n e h a n d , f a s t e r c y c le t ime s of the pressure medium – water or gas – is reclaimed reduced and the gas is reclaimed.
on t h e ot h e r. for us e duri ng the nex t m oul di ng cycl e. The part is then demoulded
ENGEL GASMELT / WATERMELT.
The blow-out process – for optimum surface quality.
01
42
03
When thick walls and sinkfree surfaces
is an absolute must.
Th e b low - o u t p ro c e s s d i ff e r s f ro m t h e st a nda rd
partial filling and inflation process inasmuch as the
m ou ld c a v it y i s f i r st c o mp l e t e l y f i l l e d w it h me lt .
G as or w a te r i s t h e n i n j e c t e d i n t o t h e me lt from a
p os it ion at t h e e n d o f t h e me l t f l o w-way, w he re by
the core of the melt is forced out of the cavity, either
back into the space in front of the screw or into an
a u x iliar y ca v i t y.
W ith t h is p ro c e ss i t i s p o s si b l e t o p re v e nt t he oc -
c u r re n c e of s u r f a c e d e f e c t s wh i c h mi g ht ot he r w ise
b e cau s e d wh e n s wi t c h i n g o v e r f ro m m e lt t o ga s
injection, especially in the case of critical materials
( e. g. h igh ly c r y s t a l l i n e p l a s t i c s) o r p i g me nt a t ions,
or when using highly polished or specially textured
m ou ld in s er t s.
02
04
01 Process stage 1: A prerequisite for this process is
an injection mould equipped both with a gas needle
in its cavity and with an auxiliary cavity which is
separated from the mould cavity by a sliding split.
Melt accumulates in the space in front of the screw
in readiness for injection
02 Process stage 2: The melt is injected into the mould
cavity, filling it completely.
The sliding split is closed
03
Process stage 3: The sliding split opens, exposing
the auxiliary cavity. At the same time, the gas is
injected into the melt, forcing the core of the melt
into the auxiliary cavity until the latter is
completely filled
04 Process stage 4: Gas pressure is maintained during
the cooling phase. Gas pressure is then reduced
and the gas is reclaimed.
The part is then demoulded
ENGEL GASMELT.
Local gas injection for parts featuring several
different cross-sections.
01
03
Local gas injection
(possible only with Gasmelt).
When moulding parts which are thick in some places
a n d t h i n i n o t h e r s , i t i s n e c e s s a r y t o c o r re l a t e t h e
volume of injected gas with the respective volumes
of melt in the thin-walled and thick-walled parts of
the mould cavity. This is not possible using standard
g a s i n j e c t i o n t e c h n o l o g y, e s p e c i a l l y i n t h e c a s e o f
re l a t i v e l y c o m p l e x p a r t s , n o t e v e n w i t h t h e a i d o f
f l o w a n a l y s i s s o f t w a re .
If the melt is gated into the thick-walled part of the
mould cavity such that the cavity is partially filled
(as with the standard Gasmelt process), the injected
gas will in most cases not be able to force the melt
into the thin-walled parts of the cavity on account
of the high flow length/wall thickness ratio, not even
at a pressure of 400 bar. Moreover, the gas pressure
acting on the melt in the thick-walled part of the
c a v i t y w i l l n o t s u ff i c e a s h o l d i n g p re s s u re f o r t h e
thin-walled parts.
02
43
04
In such cases, the mould must be equipped with
sliding splits which permit controlled adaptation to
the cavity dimensions. These splits are moved either
a u t o m a t i c a l l y o r t h ro u g h t h e p re s s u re o f t h e g a s ,
permitting the production of uniformly moulded parts
w i t h c a v i t i e s e x a c t l y w h e re t h e y a re re q u i re d .
01 Process stage 1: For parts having several different
cross sections, the mould must be equipped with
one or more sliding splits permitting localized wall
thickness control using two or more gas injection
nozzles. At the commencement of the cycle, the
sliding split(s) is/are in the front position
02 Process stage 2: the cavity is filled completely;
the shut-off nozzle of the injection unit is closed
03 Process stage 3: The sliding split in the mould
moves into its rear position. The gas is injected.
Gas pressure is maintained during the cooling
phase. Gas pressure is then reduced and the gas
is reclaimed
04 Even complex, relatively large parts can be moulded
by means of this process
ENGEL GASMELT / WATERMELT.
Multipoint injection – for large parts.
01
44
M u l ti p o i n t in ject io n
( G a sm e l t an d Wat ermelt ) .
I n o rd e r t o e n s u re t h a t a m o u l d e d p a r t c a n m e e t
the highest possible demands, it is often necessary
to inject water or gas at several points in the mould
c a v i t y s i m u l t a n e o u s l y. I n t h i s w a y, c a v i t i e s c a n b e
f o r m e d w h e re t h e y a re a c t u a l l y re q u i re d . T h e a d -
vantage is that the part no longer has to be moulded
w i t h r i b s w h i c h h i t h e r t o s e r v e d p u re l y a s a m e a n s
o f t r a n s p o r t i n g t h e g a s o r w a t e r a n d w e re n o t n e -
c e s s a r y f o r t h e s t r u c t u r a l re i n f o rc e m e n t o r t h e
function of the part. In the case of extremely large
mouldings, e.g. car bumpers, it is possible, using
several gas pressure control units, to obtain different
g a s p re s s u re p ro f i l e s f o r t h e i n d i v i d u a l i n j e c t i o n
p o i n t s w h i c h c a n b e c o n t ro l l e d i n d e p e n d e n t l y o f
one another, either simultaneously or sequentially.
This principle may also be utilized for multicavity
moulds. Multipoint injection can, in principle, be
combined with all basic Gasmelt processes (inflati-
on, blow-out, local gas injection).
02
03
01 Multipoint gas injection in a mould for a beverage
crate – one injection point for each of the four grip
openings
02 Multipoint gas injection in a mould for a shopping
trolley. The chassis is equipped with two injection
points for the frame parts and the basket with two
injection points for the transition zone between
the handle and the receptacle
03 Multi-position injection on a collapsible crate for
vegetables – 4 gas locations in order to be able to
develop the hinge border exactly
ENGEL WATERMELT.
The circulation process – for short cycle times.
01 02
45
03 04
Un if or m wa ll th ic k n e sse s by
u sin g wa te r pre ssu re .
T h i s p ro c e s s h a s b e e n s p e c i a l l y d e v e l o p e d f o r t h e This in tur n makes for faster demoulding and hence
use of water as a pressure and heat transfer medium. a s h o r t e r c y c l e t i m e . T h e p ro c e s s c a n b e u s e d t o
Wa t e r i s n o t o n l y a v i r t u a l l y i n c o m p re s s i b l e a n d particular advantage when moulding long, tubular
h e n c e e x c e l l e n t p re s s u re t r a n s f e r m e d i u m f o r l o n g parts or large-volume parts.
melt flow-ways but also a highly conductive and
hence excellent heat transfer medium. The term 01 Process Step 1: Injection mould with 2 injectors in
" f l u s h i n g p ro c e s s " re f e r s t o t h e c o n t ro l l e d f l u s h i n g the mould cavity. Melt accumulates in the space in
of the hollow moulded part with water as a particu- front of the screw in read iness for injection
larly effective means of dissipating heat. The flushing
02 Process Step 2: Plastic is injected
p ro c e s s c a n b e u s e d i n c o n j u n c t i o n w i t h b o t h t h e
Wa t e r m e l t p a r t i a l f i l l i n g / i n f l a t i o n p ro c e s s a n d w i t h 03 Process Step 3: The water injection occurs with
t h e Wa t e r m e l t b l o w - o u t p ro c e s s . the injector nearest the sprue, so long until the
desired cavity and overflow cavity have
been produced
T h e f l u s h i n g p ro c e s s u t i l i z e s 2 w a t e r i n j e c t o r s f o r
each mould cavity. After the mould filling operation, 04 Process Step 4: After the water bubble has reached
the injectors alter nately inject and extract the water, the second injector, a circulation purging takes
generating a water circuit with alter nating directions place for inner cooling of the injection moulded
part. Subsequently, the water is blown back
o f f l o w. T h e re s u l t a n t t u r b u l e n c e f u r t h e r s h e a t d i s - into the system with air and the sprue system
sipation and hence accelerates the cooling process. is separated
ENGEL GASMELT. ENGEL WATERMELT.
Typical examples of application for surface improvement. Practical example of application: long melt flow-ways.

01 02 01 02

> >

> >
Gas injection
points

Hollow core
injection mould
Moulded part:
46 Moulded part: RSL-Kendrion Uteschen y, Zaisenhausen/D 47
03 04 03 04
>
>
>

>
>

>

Moulded part:
Thermoplast, Idstein, Dana

01 Example of local gas injection with controlled cavity
volume. The cavities are located in five separate
parts of this ergonomically designed h andle in order
to ensure optimum smoothness
02 Armrest/handle for car door: example of Gasmelt
blow-out application (necessary on account of the
extremely high quality of surface finish required). In
this particular application, the melt is forced back
into the space in front of the screw
03 Car door handle, manufactured by the Gasmelt
process (blowing out into auxiliary cavity)
04 Housing for television set with local cavities for
compensating contraction through shrinkage
(surface improvement, avoidance of sink marks) at
the points of the housing where fas tening elements
are incorporated. The cavities are produced by
means of the Gasmelt blow-out process
01 Example of the process combination of Combimelt
with Watermelt: Door handle for Engel injection
moulding machines base body of PA 6.6/GF 30 and
grip component of TPE – Blowing out into overflow
cavity with recirculation process
02 Auto-Clutch pedal of PA 6.6 + GF 30, produced
with the process variation “blow back into the melt
space in front of the screw ”
03 Product Example: Side panel of a fruit box of PP
with integrated reinforcement elements, produced
with the blow out process (blow out into an overflow
cavity and subsequent cooling with water
recirculation)
04 Auto Motor / Suction Pipe for Auto Oil Pan,
manufactured according to the Watermelt-blow out
process. Display of the moulded part including
overflow cavity and sprue manifold
ENGEL GASMELT.
The equipment for the Gasmelt process.

EGM HD 230/330 EGM HD 300/330 EGM HD 500/400 EGM HDZ 1200/400 EGM HDZ 3000/400
Compact Gasmelt Units Central Gasmelt Units
COMPACT COMPACT COMPACT CENTRAL CENTRAL
Gas volume* 230 cm3 300 cm3 500 cm3 Gas volume* 1200 cm3 3000 cm3
Max. gas pressure 300 bar 330 bar 400 bar Max. gas pressure 400 bar 400 bar
Max. preload pressure 200 bar Max. preload pressure 200 bar 200 bar
Cycle time for recharging 60 sek. 60 sek. 60 sek. Cycle time for recharging 50 sek. 60 sek.
Max. N2 recuperation 85 % 85 % 85 % Max. N2 recuperation 90 % 90 %
Pressure booster 0,8 lt Pressure booster 2,4 lt 6 lt
Ram accumulator 1,5 lt 2,5 lt 5 lt Ram accumulator 10 lt 20 lt
Pressure accumulator 2,5 lt 2,5 lt 5 lt Pressure accumulator 20 lt 50 lt
Gas recovery tank 10 lt 10 lt 24 lt Gas recovery tank 24 lt 50 lt
Necessary N2 input pressure 30 bar 30 bar 25 bar Necessary N2 input pressure 22-25 bar 22-25 bar
Drive rating 2,2 kW 5,5 kW 7,5 kW Drive rating 18,5 kW 37 kW
Oil requirement 30 lt 40 lt 100 lt Oil requirement 160 lt 400 lt
Cooling water requirement 0,6 m3/h 0,6 m3/h 0,8 m3/h Cooling water requirement 1,5 cm3/h 1,3 cm3/h
Max. cooling water temperature 20 °C 20 °C 20 °C Max. cooling water temperature 20 °C 20 °C

48 Weight**
Length x width x height (mm)
250 kg
800 x 600 x 1700
500 kg (550 kg)***
1550 x 1000 x 1700
950 kg (1000 kg)****
1000 x 1700 x 1750
Weight**
Length x width x height (mm)
1200 kg
1850 x 950 x 1750
2800 kg
2000 x 1500 x 2400
49
Abbreviations: Abbreviations:
EGM HD = Engel Gasmelt High Pressure EGM HD = Engel Gasmelt High Pressure
* -------- at maximum gas pressure Z = Zentralanlage (Central Unit)
** ------- without oil * -----at maximum gas pressure
*** ------ data applicable for compact units with gas recuperation system ** ----without oil
**** ----- weight with second integrated gas control unit

Compact Gasmelt Units.
In order to meet the many different demands of the
m a r k e t , E n g e l o ff e r s a r a n g e o f c o m p a c t G a s m e l t
units covering every conceivable application. These
compact units have been developed for optimum
flexibility and are available in a choice of three sizes:
Size I f o r re l a t i v e l y s m a l l c a v i t i e s , s u i t a b l e f o r
l a b o r a t o r y a n d / o r m o u l d p ro v i n g
applications;
Size II for medium-sized cavities and/or when
m a s s p ro d u c t i o n t a k e s p r i o r i t y.
S i z e I I I f o r re l a t i v e l y l a r g e c a v i t i e s , a n d a l s o f o r
optional parallel operation of max. two
injection moulding machines.
All three sizes of unit are supplied with two control
systems as standard. Using the compact control for
t h e i n t e g r a t e d g a s p re s s u re c o n t ro l u n i t ( g a s p re s -
sure control valve), the Gasmelt unit can be operated
in „inter nal mode” completely independently of the
injection moulding machine, which means that it
can be used with any make of machine in this mode.
T h e s e c o n d c o n t ro l s y s t e m s e r v e s t o o p e r a t e t h e
compressor, but may also be switched to „exter nal
mode” for operation of the Gasmelt unit by means
of the gas pressure control module incorporated in
the control software of the Engel injection moulding
machine. This universality of the Gasmelt unit affords
t h e u s e r t h e g re a t e s t p o s s i b l e f l e x i b i l i t y.
Engel Central Gasmelt Units.
The Central Gasmelt Units essentially comprise a u p t o 4 0 0 b a r. A s o p e r a t i o n a t t h e s e p re s s u re s
hydraulically driven piston compressor with a nitro- necessitates an enormous consumption of nitrogen,
gen accumulator and a nitrogen recuperation tank, Engel also offers a complete range of nitrogen pro-
a l l c o n t a i n e d i n a f re e - s t a n d i n g h o u s i n g f o r t h e duction units for every requirement. These nitrogen
s u p p l y o f n i t ro g e n t o s e v e r a l i n j e c t i o n m o u l d i n g production units can be readily combined with, and
machines, the latter being additionally equipped adapted to, any size of Gasmelt unit.
with one or several gas pressure control units. The
re q u i re d r i s e a n d f a l l o f t h e g a s p re s s u re p ro f i l e s ,
including pressure ramps and time sequences, can
b e i n p u t t e d d i re c t l y a t t h e V D U o f t h e re s p e c t i v e
machine control system. Depending on actual requi-
rements, the Engel Central Gasmelt Units are availa-
b l e i n t w o s i z e s , b o t h r a t e d f o r p re s s u re s o f
ENGEL GASMELT.
Well thought-out, self-contained systems. The control system.

ENGEL GASMELT system components Compact Units EGM HD... Central Units EGM HDZ... Nitrogen
production
Integration into machine
... 230 / 330 ... 300 / 330 ... 500 / 400 ... 1200 / 400 ... 3000 / 400 units control system.
ENGEL GASMELT UNIT
The operating functions of the Gasmelt and
Machine shoes S S S
Castors for Gasmelt unit S S S X X Watermelt units can be integrated into the cycle
Special painted finish X X X X X X control system of the injection moulding machine
Automatic cylinder switch-over X X S S via interfaces and special process software.
Acoustic signal for cylinder change X X Dedicated operating pages can be selected by
Integration of N2 recuperation system X S S S S
OPTIONS

Integration of a 2nd gas pressure control unit X X means of softkeys. The VDU clearly visualizes all
Gas ingress recognition (on gas pressure control unit) X X inter nal functions of the Gasmelt or Watermelt unit
Flat colour VDU screen X X and also its operating status at any time during the
Low-setting control for gas pressure control units S S S X X moulding cycle.
Electrical contamination indicator X
INJECTION MOULDING MACHINE
Interface for gas pressure control unit (GOS)* X X X X X
Interface for GOS double panel X X X X
50 Gas ingress recognition
Gate closing program** X X X
X
X
X
X
51
Abbreviations:
X ... Optionally available
A lth ou gh EN GE L GA S ME L T u n i t s h a v e be e n S ... Standard
* ... The interface package includes the software for the Gasmelt units and
d es ign e d as a n c i l l a r y u n i t s wh i c h a re re a dy t o also the special programs for „blow-out into auxiliary cavity” and „press
con n ect u p t o t h e ma c h i n e , t h e y c a n also be back into injection cylinder” Graphical Display.
in d ivid u a lly e x t e n d e d a n d a d a p t e d a s re quire d. ** ... only in conjunction with a Gasmelt machine nozzle The user-friendly gas pressure control is of decisive
importance for the moulding cycle. All the settings
for the gas control valves, such as pressure, starting
time for gas injection, gas holding pressure, gas
Nitrogen production units EGM N 12 EGM N 18 EGM N 24
recuperation time, are clearly indicated on dedicated
display pages.
Output rate* 12 Nrn3/h 18 Nrn3/h 24 Nrn3/h The same is valid for the process Watermelt.
Max. output pressure 30 bar 30 bar 30 bar

Purity of nitrogen 98 % 98 % 98 %

Volume of working tank 50 It 50 It 100 It

Required air input pressure 6 - 7 bar 6 - 7 bar 6 - 7 bar

Required air input rate 44 Nm3/h 64 Nm3/h 84 Nm3/h

Drive rating 2,2 kW 2,2 kW 5,5 kW

Weight 700 kg 750 kg 800 kg

Length x width x height (mm) 1900 x 900 x 2000 1900 x 900 x 2000 1900 x 900 x 2000

Abbreviations:
EGM N = ENGEL GASMELT/Nitrogen
* Output rate at max. output pressure

Optimum Wall Thickness Distribution.

In order to optimize cavity shape and/or wall
G a s su pply. thickness distribution, the gas pressures can be set
Th e n itroge n re q u i re d f o r t h e o p e r a t i o n of t he E nge l offe r s t he se nit roge n produc t io n uni ts i n a individually via the injection cycle. Gas pressure
Gasmelt units may be supplied either from standard, c hoic e of t hre e siz e s, e a c h one a v a ilabl e as an profiles can be adjusted via the machine's VDU. All
commercially available gas cylinders or, alternatively, inde pe nde nt module for c onne c t ion to the data can be stored together with the settings for
from a n it ro g e n p ro d u c t i o n u n i t wh i c h e xt r a c t s t he G a sme lt unit . the injection mould and are thus reproducible for
n it rogen d ire c t l y f ro m t h e a mb i e n t a i r. every new production start-up.
ENGEL WATERMELT.
Watermelt-Equipment for Water-Injection.

01 02

52 53
WATERMELT UNIT 30 / 200 30 / 300 WATERMELT – SYSTEM COMPONENTS 30 / 200 … / 300 04 03
Min./Max. Water Pressure 0 - 200 bar 0 - 300 bar 30 29,9
WATERMELT UNIT
Min./Max. Flow Rate 5 - 30 lt/min 5 - 30 lt/min 25
Intervals 5 5 Special Paint Color X 20,5
20

Pressure (bar)
Min./Max. Pressure Water Temp. 20 - 60 °C 20 - 60 °C Spare Parts Package X
OPTIONS

15,2
Water Inlet Pressure 2 bar 2 bar Diagnostic-equipment 15
- for recording of actual values X
Cooling Water Requirement 10 It / min 10 It / min of water pressure and flow rate
10
8,5 9,0
Max. Cooling Water Temperature 20 °C 20 °C
INJECTION MOULDING MACHINE 5
Drive Rating 23 kW 32 kW 0,7 2,3 2,0 4,8
1,6 3,5
0,6
Weight* 800 kg 850 kg Watermelt-Interface*
With program for diagnostic X
Length x Width x Height (mm) 1800 x 1100 x 1650 recording and process monitoring 0 5 10 15 20 25 30 Delivery
(l/min)

* without water filling * The accompanying software for the Watermelt unit Standard injector with lateral drilling
is included in the interface package
Annular gap injector
ENGEL WATERMELT G3-Injector

The Solution for Long Hollow Parts.

Especially for moulded parts with large volume
h o l l o w c h a n n e l s , E n g e l o ff e r s t h e w a t e r i n j e c t i o n
unit series as a supplement and alternative to the
G a s m e l t - p ro c e s s t e c h n o l o g y. I n c o m p a r i s o n t o t h e
p ro c e s s t e c h n o l o g y w i t h t h e c o m p re s s i b l e m e d i u m
“gas”, the media water allows better defined hollow
a re a s . A d d i t i o n a l l y, t h e m e d i a w a t e r o ff e r s t h e a d -
vantage of inner-cooling of injection moulded parts
due to the high thermal conductivity. Where allowed
by the moulded part geometry, drastic shorter cycle
t i m e s a re t h e re s u l t .
B o t h c o n t ro l o f t h e w a t e r f l o w r a t e a n d re a l i z a t i o n
o f a w a t e r p re s s u re p ro f i l e c a n b e a c c o m p l i s h e d 01 Door handle for Engel injection moulding machines
with the Watermelt unit. The water flows in a closed base body of PA 6.6/GF 30 and grip component
c i rc u i t i n o rd e r t o m i n i m i z e t h e a m o u n t o f w a t e r of TPE – Blowing out into overflow cavity with
recirculation process
l o s s . D u r i n g t h e w a t e r re c o v e r y i n t h e s p e c i f i c a l l y
f o re s e e n t a n k , a c o n t i n u o u s f i l t e r i n g a n d n e w 02 Situation of injectors built into the injection mould
t re a t m e n t o f t h e m e d i a o c c u r s .
As a result, the equipment and mold can be protec- 03 Injectors with adjustable stroke
for the water flow control
ted from micro organisms and abrasive constituents
without the addition of chemicals. 04 Engel offers injectors with determined performance
characteristics for every application
ENGEL GASMELT.
Technology modules for the production of innovative injection mouldings.

COMPLETE PRODUCTION SYSTEM E N G E L V I C TO RY 1350 / 250 w i t h E N G E L E R H Li 71 l i ne a r ro b o t

Complete production system comprising several Engel injection moulding Production cell with clean-air cabin for the production of car headlight reflectors using
machines working in conjunction with a Central Gasmelt Unit. local gas injection in order to compensate distortion and contraction caused by shrinkage
– thus obtaining absolutely correct reflector geometry.

Engel injection moulding

machine with tiebarless
clamping unit and clean-
room equipment package
Gas pressure control
unit on every injection
54 moulding machine,
each one connected to the
55
Linear robot
Central Gasmelt Unit ENGEL ER-HLi 71 for
tiebarless clamping unit

Gas pressure control unit

with connection to
Central Gasmelt Unit

Clean-air cabin above

clamping unit and
conveyor belt for onward
transport of parts for
downstream processing

Power saw handle Car headlight reflector

Power saw handle as a typical example of Car headlight reflector as a typical example of
the kind of ergonomically designed parts industrial parts with surface geometries which
which are possible using the Gasmelt system. demand the utmost precision.

Close-up of gas pressure control unit Engel Central Gasmelt Unit