Superior surface replication, longer flow length, and lower pressure drop can be achieved with a combination of Roctool and Elix’s ABS/PC grade.

Elix Ultra HH4115HI ABS/PC, which was introduced just over a year ago, has several advantages over a PC/ABS (which contains less ABS and more polycarbonate). For example, it is around 5% less dense, it has lower emissions and odor, a higher flow rate, and higher impact strength. It is suitable for crash-relevant parts such as interior trim and parts that may be subject to knee or head impacts, as well as for exterior applications such as pillar covers and other painted side moldings.

Stefan Wolf, Euroform's managing partner said: "We play a pivotal role in automotive supply chains and our work begins in the early development phase of a new vehicle. Technical competence is crucial for exploiting the potential of innovative manufacturing solutions and CADCAM systems."

Wolf concluded: "Automated manufacturing and digital processes are essential, given the current challenges in the global marketplace.

The final HD Plastics characterizations are based on the study of the flow using the Spiral mold for thicknesses of 1 and 1.5 mm. This study shows substantial improvement using Roctool technology versus conventional technology in terms of pressure drop reduction, which is up to 60%, and flow length, which rises by up to 100%.

Based in the Hungarian capital Budapest, Euroform was established in 1993 to provide a tool and mould making service from design to production and trialling. Approximately 70 employees fulfil innovative solutions for a range of different injection moulding processes, mainly for customers in the automotive industry.

“HD Plastics characterization highlighted the improvement made by using Roctool technology with surface quality improved by the level of gloss and the black intensity. Indeed, Roctool’s technology allowed a reduction of the color lightness and we obtained a ‘piano black’ part with a perfect surface finish.” says Abad. In addition, replication of the textured surface was improved by over 50%, and there were significant improvements for each type of surface structure, especially with low roughness.

By heating the mold temperature above the glass transition temperature, an excellent cavity surface replication is achieved–even for surfaces that have the finest laser-etched grain structures – as well as the elimination of weld lines and sink marks. It therefore reduces or even eliminates the need for painting or in-mold decoration. Furthermore, shear stress in the melt is reduced which can have an important effect on the mechanical properties of the part and thinner walls.

“We are operating in a highly competitive market, so it is important for us to go the extra mile to demonstrate to our customers how they can get the most out of our materials,” says José Pedro Abad, business Development Manager Automotive at Elix. “We wanted to quantify the possible improvements – in terms of part aesthetics and also processing performance – using Heat and Cool technology. We chose to use Roctool induction heating technology to characterize our innovative ABS/PC blend Elix Ultra HH4115HI, a leading Heat and Cool technology (H&C), in order to expand the already wide range of applications.” continues Abad.

Euroform has been using machine tools from DMG MORI since 1995, latterly in a modern factory that it moved into in 2011 and expanded in 2016. Managing Director responsible for day-to-day business at Euroform, Krisztina Zwick, mentioned the supplier's broad machine portfolio and good service: "DMG MORI was one of the first machine tool manufacturers to open a subsidiary in Hungary, which meant that response times were always quick when service was required. Our latest investment in automation was necessary to utilise the machine during unattended shifts, giving us a competitive edge.”

"The recent Corona pandemic, the war in Ukraine and high inflation have clearly shown us that we need to develop constantly in order to remain competitive.

The material characterization is part of Roctool’s ongoing effort to further develop its High Definition Plastics material database which is designed to help OEM’s achieve exceptional part quality and increased performance” comments Mathieu Boulanger, Roctool CEO. “Roctool’s H&C can have significant effects on surface quality; it also helps to eliminate evidence of weld lines and flow marks. Mold cavity surface is heated very quickly up to temperatures that can exceed 200°C just before injection. The surface is then cooled quickly, to achieve the necessary demolding temperature to minimize any increase in total cycle time.” continues Mathieu Boulanger.

To characterize the innovative ABS/PC blend Elix Ultra HH4115HI under H&C conditions and according to the HD Plastics process, Roctool determined the surface replication for the following three surface structures: Chemical grain; electric discharge machining (EDM) grain; and laser grain as well as improvements in gloss and color. Besides surface replication, flow length studies were also carried out.

Five-axis simultaneous machining of workpieces up to 1,100 mm in diameter by 1,600 mm and weighing 2,200 kg had already been carried out on a DMU 100 P duoBLOCK in the factory. Euroform's experience with the machining centre was consistently good, leading to the purchase in 2022 of a latest-generation model with a 1,000 × 1,250 × 1,000 mm working envelope.

The firm currently uses eight machining centres from DMG MORI for tool production, including DMU monoBLOCKs, an HSC 75 linear and, most recently, a DMU 100 P duoBLOCK with PH Cell 2000 automation system for pallet handling to allow unattended production at night and during the weekends.

When Euroform ordered the new DMU 100 P duoBLOCK, DMG MORI already had a large pallet handling system in development, based on the smaller, proven, modular PH Cell 300. The bigger capacity automation system handles pallets measuring up to 1,100 mm in diameter, so is able to deploy Euroform's 1,000 × 800 mm pallets. The PH Cell 2000 has twelve pallet positions on two levels and can accept workpieces up to 1,350 mm tall. (Other variants are available with three or four racks housing up to 17 or 21 pallets respectively.)

Stephen has been with PlasticsToday and its preceding publications Modern Plastics and Injection Molding since 1992, throughout this time based in the Asia Pacific region, including stints in Japan, Australia, and his current location Singapore. His current beat focuses on automotive. Stephen is an avid folding bicycle rider, often taking his bike on overseas business trips, and is a proud dachshund owner.

Acrylonitrile-butadiene-styrene (ABS) polymer and blends supplier Elix Polymers reports that significant surface finish improvements are being achieved by using Roctool’s Heat and Cool technology to mold its Elix Ultra HH4115HI ABS/polycarbonate (PC) blend. The company recently completed a series of tests using this technology, carried out in line with its strategy of providing tailor-made solutions and service to companies processing its specialist materials.

Another focus that accompanies business development at Euroform is digitalisation. The company has had a paperless working environment for many years, from design through to quality control. The mould maker is an enthusiastic adopter of the digital 'my DMG MORI' app when it comes to online service requests, which Zwick said significantly accelerates the process of calling in a service technician.

"With targeted investment in technology and the training and further education of junior staff, we will continue to successfully meet these challenges.”

The DMU 100 P duoBLOCK 5-axis machining centre with PH Cell 2000 pallet storage and handling system on the shop floor at Euroform, Budapest.

“Elix Ultra HH4115HI ABS/PC is now included in the HD Plastics material database based on the excellent results demonstrated by the characterization. The outstanding properties of this material will help us select Elix Ultra HH4115HI ABS/PC as an excellent candidate for upcoming projects with OEM’s.” explains Jose Feigenblum, Roctool’s CTO.

As Euroform almost exclusively manufactures one-offs, pallet handling such as the PH Cell 2000 is the optimal solution. Operators set up jobs offline on several pallets using a zero-point clamping system while machining is in progress on another mould, so production downtime is minimal, even at night.