SKZ declares war on the uncompressed flow front of thermosets
The Plastics Center SKZ is working together with RF Plast GmbH and Hiltel Formentechnik GmbH on the “Gas Counterpressure Thermoset Injection Molding” (GGD-DSG) research project to develop a process for eliminating uncompressed flow front areas that can occur during the filling process of the cavity in thermoset injection molding. The aim of the research project is to develop innovative tool technologies for sealing a thermoset injection molding tool. In addition, a robust special process is to be developed and its simulation-based design evaluated.
Defective molded part on the left component: Insufficient transmission of holding pressure in the area of the mounting bracket caused by irregularly varying uncompressed flow front areas, which lead to differences in filling. (Photo: Luca Hoffmannbeck, SKZ)
New process engineering for thermoset injection molding
Thermosets are highly resilient plastics that are in demand in the e-mobility and electronics industries in particular due to their excellent thermal, chemical and electrical insulating properties. However, material-specific flow phenomena occur during injection molding, which negatively affect component quality and process stability. The GGD-DSG project of the SKZ together with RF Plast GmbH and Hiltel Formentechnik GmbH aims to overcome these challenges and revolutionize the production of thermoset components.
Development of new injection molding tools
The main objective of the project is to develop a new process that keeps the flow front compressed when injecting thermosets and prevents uncompressed areas. To this end, new injection molding tools are being developed that enable the cavity to be evacuated and gas to be added in a controlled manner. The constant gas back pressure is intended to prevent the formation of uncompressed flow front areas, which leads to improved component quality (e.g. weld line strength) and process stability (e.g. reproducible filling process).
More precise prediction of component properties
Another focus of the project is on digital product and process development. The aim is to create virtual twins of the manufacturing processes to be developed and integrate them into established product development cycles. This enables a more precise prediction of component properties and a reduction of the Sim2Real gap, i.e. the deviation between simulation and real result. This will significantly increase the informative value of future simulations.
Increasing resource efficiency
The GGD-DSG project can thus make a significant contribution to solving technical and economic challenges in the plastics processing industry. Improving process stability and component quality increases resource efficiency and the sustainability of the process. This is particularly relevant for industries such as the automotive, electronics and aerospace industries, which depend on high-performance and reliable materials.
About the project:
The research project is being sponsored by the Bavarian state government as part of the Bavarian Joint Research Program (BayVFP) for a period of three years and associated support from industry is being provided by ENGEL Austria GmbH (injection molding machine in the project), Duresco GmbH (material supplier), Bakelite GmbH (material supplier), SimpaTec GmbH (simulation software) and WITTMANN BATTENFELD GmbH (GIT peripherals).
More about the research area of injection molding
