The machines delivered in 2023 also come already equipped with the new B8X control system and the HiQ Flow assistance system. The B8X control system includes several control components developed in-house. These allow a higher internal clock frequency with shorter response times to sensor signals and consequently a higher standard of parts reproducibility, with user-friendliness and familiar visualisation remaining unchanged.

The RotaricE² concept integrates several production steps — including assembly — in a small space. The technology will be demonstrated by Arburg (Hall 13, Booth A13-1-B13) on an Allrounder More machine, which will produce a Luer pharmaceutical cap measuring 10 mm in diameter and 11 mm in length.

“The Insider cells based on the servo-hydraulic SmartPower and WITTMANN linear robots meet our requirements in every respect”, Maximilian Högn confirms. “The equipment is space-saving, highly energy-efficient, easily accessible and easy to operate.”

All SmartPower machines except one are designed as Insider cells, which means that they come with a WITTMANN robot and a conveyor belt integrated in the production cell. This variant offers a number of advantages, ranging from an enormous amount of space saved compared to systems with conventional automation solutions, all the way to cost advantages from the fact that all hazardous areas are already secured and certified ex works. Moreover, the robot cycle time can be minimised due to shorter travel distances and direct parts depositing on the conveyor belt.

To make all these parts, a number of injection moulding machines ranging from 450 to 5,200 kN in clamping force are in operation, 17 of which have come from WITTMANN BATTENFELD. Moreover, FUSO is also a long-standing customer of the WITTMANN Group for automation equipment, using more than 40 handling devices with load capacities from 5 to 30 kg, including No. 7 robots as well as latest No. 9 series models with R9 control systems.

Notably, the multi-component Braunform side-gate injection mold will combine capping and unscrewing functions. The 4+4 cavity mold serves as a basis for a compact series mold in a modular design with up to 64+64 cavities. Six functions are combined in the ejector side — core-back, two sliders per cavity, lifting of the lid, translational capping of the closures, unscrewing, and final ejection. Modules are individually centered and easily accessible, and the overall design is cleanroom compatible thanks to electric drives, corrosion-resistant steel, low-fat lubrication, and rolling element centering systems. Diffusion-welded inserts facilitate die insert cooling on the nozzle side.

Ultimately, Braunform claims 45% overall production savings with RotaricE² technology by eliminating the need for two injection molds and machines, as well as an assembly line.

Kistler developed the two indirect pressure sensors used in each injection mold cavity to detect defective parts, which are sorted out by the handling system.

Last, but not least, the quality of the after-sales service including the possibility of using an online service also play an important part in the purchasing decision according to Klaus Großtesner. In the acquisition of robots, easy programmability is a top priority in addition to all other criteria which are also applicable to the machines.

By integrating servo-electric rotary drives in the mold and redirecting rotary movement into translational movement, Braunform achieves compact radial arrangement of injection mold cavities with slides or masking devices around a sprue or, preferably, a side-gate system, the company said.

The family-owned company managed by its CEO Maximilian Högn and its CSO Klaus Großtesner makes highly sophisticated plastic parts from a great variety of materials, including high-temperature plastics, for many different sectors of industry, with about 80 workers on a production floor of just under 3,000 m².

The RotaricE² injection mold system reportedly achieves 45% overall production savings by integrating several production steps.

With the rising demands from customers on the parts and assemblies produced, FUSO’s own demands on the injection moulding equipment used are also increasing. The company’s machinery is state-of-the-art, with a high level of automation on its production floor. All systems are fitted with matching robots to ensure careful parts handling.

The items produced range from micro parts weighing just 0.03 g right up to large parts weighing 2 kg. In addition to manufacturing complex plastic parts by 1- or 2-component injection moulding, the company offers insert moulding for functional parts, mounting of complete assemblies, as well as gluing and welding, plus decoration by 4-colour pad printing and laser printing, and 3D scanning for reverse engineering.

In addition to a good price-performance ratio, FUSO requires from injection moulding machines above all stability, as well as easy access for servicing and cleaning, a smooth, easy-to-clean surface, user-friendliness in operation and a high standard of repeatability. Other factors gaining increasingly in significance are the machines’ energy efficiency, their networkability with robots and auxiliaries and availability of assistance systems.

Requirements from the customer base concerning quality standards and attributes of the parts in terms of tolerances, outward appearance and materials used are constantly becoming more and more stringent. FUSO scores with purchasers by its extensive technical know-how and many years of experience in making high-quality parts and assemblies. This wealth of expertise enables the company to offer top-quality solutions which are both sustainable and cost-efficient. FUSO also stands out on the market by its high supply availability and reliability towards its customers.

A Smart Control system by hot-runner specialist Ewikon ensures real-time data mining on the hot side. The hot-runner system is especially important for the Luer cap, as the shot weight of the TPE-based second component is only 0.05 g.

From the left: Martin Stammhammer, Int. sales manager Robots, WITTMANN Technology, Maximilian Högn, CEO of FUSO, Klaus Großtesner, CSO of FUSO, Andreas Högn, majority shareholder and advisor, FUSO, Roland Pechtl, area sales manager WITTMANN BATTENFELD

The cooperation between FUSO and WITTMANN BATTENFELD has already been in existence for four decades. The machines most recently supplied by WITTMANN BATTENFELD are exclusively models from the SmartPower series. The machines from the SmartPower series are hydraulic machines equipped with fast-responding servo motors and powerful constant displacement pumps. This technology, combined with the KERS (Kinetic Energy Recovery System) to recover the deceleration energy within the machine, which is included as standard, provides the SmartPower’s high level of energy efficiency. Further characteristics of the SmartPower are its small footprint and its pivotable injection unit, which ensures easy access to the barrel for quick and comfortable barrel change.

German injection mold supplier Braunform will showcase its RotaricE² technology, which achieves time and cost savings by emphasizing process control over quality control, at K 2022 on Oct. 19 to 26 in Düsseldorf, Germany.

The HiQ Flow assistance system is an injection regulation function by which viscosity fluctuations in the material used can be compensated. This function enables automatic process automation and compensates even minimal fluctuations in the material quality. FUSO is so completely satisfied with this system that all of the company’s other machines have been retrofitted with it, too, wherever technically feasible and economically advisable.

Geoff Giordano is a tech journalist with more than 30 years’ experience in all facets of publishing. He has reported extensively on the gamut of plastics manufacturing technologies and issues, including 3D printing materials and methods; injection, blow, micro and rotomolding; additives, colorants and nanomodifiers; blown and cast films; packaging; thermoforming; tooling; ancillary equipment; and the circular economy. Contact him at [email protected].

Joh. Fuchs & Sohn – FUSO – was established in 1947 in Waidhofen on the river Ybbs in Lower Austria. In 1964, it started off into plastic injection moulding by producing the orange-coloured lids for Ovomaltine cans.

3D prints for rapid prototyping are also possible. Injection moulding tools and automation systems are planned, designed and manufactured in-house at the company’s own mould-making shop. For ecological purposes, the company has made a special point of installing tool-friendly cooling water systems. Further evidence of FUSO’s commitment to protecting the environment are waste heat utilisation and a photovoltaic system.

The company makes a point of supplying technical plastic parts and assemblies to a solid, mixed industrial customer base. The various sectors served by FUSO include the automotive and railway industries, as well as consumer goods, electronics, medical technology, building construction, telecommunication, mechanical engineering and renewable energy generation.