Improved cost efficiency in structural foam moulding

ENGEL e-foam XL multi powered by Trexel steigert deutlich die Wirtschaftlichkeit beim Schaumspritzgießen. (Bild: ENGEL) / ENGEL e-foam XL multi, powered by Trexel, is improving the cost effectiveness of structural foam moulding. (Picture: ENGEL)

ENGEL is improving the cost-effectiveness of structural foam moulding at the K show 2022 with new ENGEL e-foam XL multi central gas supply units. Another new feature: Sophisticated sample parts produced during the show do not require any additional overhead, but leave the injection moulding machine ready to fit with a structured class A surface.

Structural foam moulding is more popular than ever. It saves raw material, energy and weight, supporting the objective of producing and using plastic parts in a more sustainable way by doing so. At K 2022, ENGEL was presenting a new type of system technology for plastics processors who produce parts in parallel on several production cells using the structural foam moulding process. Where each injection moulding machine previously required its own gas supply, ENGEL now offers the e-foam XL multi, a central unit for supplying several injection moulding machines with highly compressed nitrogen for structural foam moulding. Only the plasticising and control technology is still decentralised on the individual machines. This new solution sees ENGEL significantly reduce the capital outlay for structural foam moulding and makes a major contribution to reducing unit costs.

The new modular ENGEL e-foam XL multi systems, based on Trexel's MuCell technology, are offered exclusively by ENGEL.

Premium surface without additional energy input

Together with Faurecia, a FORVIA Group company, ENGEL was demonstrating the huge potential of structural foam moulding technology at its trade fair stand. Sample parts with a sophisticated surface structure were being produced on an ENGEL duo 1000 injection moulding machine. The new MicroJect Advanced process developed by Faurecia's interior systems business unit, Faurecia Interiors, based in Hagenbach, Germany, and Eschmann Textures International (Gummersbach, Germany) was being used here. This makes it possible to produce lightweight visible components with a very high-quality class A surface using only structural foam moulding. Among other things, a new mould technology is responsible for this leap in development. Ceramic coatings in the cavities prevent the otherwise typical foam streaks, weld lines, tiger stripes or gloss differences appearing on the surface of the foam moulded part. Additionally, different surface structures can be created directly in the injection mould via the cavity coating.

In addition, the new materials developed by Faurecia Interiors for structural foam moulding contribute to the high surface quality. A talc-filled polypropylene with a recycled material content of 30 percent of the IniCycle type was being processed during the K show, for example. IniCycle is suitable for all physical and chemical foam moulding processes.

The combination of the new system technology by ENGEL and MicroJect Advanced leverages previously undreamed-of efficiency and sustainability potentials in structural foam moulding. Structural foam moulded parts no longer need to be painted, and there is no need for additional energy-intensive process technology, such as intermittent mould heating, for parts in customer-facing applications.

In general, structural foam moulding requires less energy and raw material, and uses lower clamping forces, than compact injection moulding. The dissolved blowing agent improves the flowability of the molten plastics. In addition, the foam moulding pressure, which is independent of the location, enables thicker ribs to be moulded. These effects can be used to reduce the wall thickness, which has a positive effect on the required cooling time and in turn on the cycle time.

Structural foam moulding conference in November

Another opportunity to experience the exhibit in action at first hand is the "foammelt – success with little pressure" symposium, which will be held at ENGEL's headquarters in Schwertberg, Austria, on 22 and 23 November 2022. The two-day event will provide compact details on the state of the art in structural and chemical foam moulding. It features prominent keynote speakers and is packed with practical content. The foammelt conference is held annually and is one of the best-attended events in ENGEL's event calendar.