At K 2022, Sumitomo (SHI) Demag showcased its in-mould decoration (IMD) processing expertise, manufacturing a complex electric vehicle (EV) application on an all-electric IntElect2 220/660-1100 injection moulding machine. Creating a 'smart' e-charging Wallbox column, weighing 110 grams, in a 60 second cycle time, this new demonstration centrered around sustainability. Despite its decor and complexity, the manufactured IMD part is especially durable due to its special material properties. Yet, the fully recyclable material used – a Makrolon RE polycarbonate supplied by Covestro – is also CO2-neutral.
Underpinning Sumitomo (SHI) Demag's Act! Sustainably commitment, the company continues to take decisive action, stating that all future innovations, machines and equipment are now totally manufactured with this ecological mission and the EU Digital Product Passport (DPP) in mind. Accordingly, complete integration of IMD within the injection moulding process on this application eliminates any additional manufacturing steps. This processing synergy significantly reduces CO2 emissions and is therefore widely regarded as being more sustainable.
A cooperation involving numerous partners and sustainability influencers, the K 2022 Wallbox project showcases the very best industry expertise and innovations reports Rustam Aliyev, Director Business Development Automotive & Electronic. Alongside Sumitomo (SHI) Demag and Covestro, KURZ presents its newest functionality and decorative manufacturing techniques. Frimo supplies the sprue separation system, Acsys provides the laser, and schöfer, a KURZ subsidiary, the tooling technology. The temperature control systems and material drying process are designed by Piovan.
Describing the extent of the technological advances accomplished by this Wallbox project, Rustam references the separation of component sprues after the injection process using a milling head equipped with clean room technology. "This single process ensures that particles are extracted in a controlled manner. Showcasing what can be achieved when likeminded industry innovators come together to resolve specific processing challenges."
Sustainability pioneer KURZ also shares its extensive decoration experience. The company's use of thin-film technology ensures recyclability of the components isn’t compromised. Additionally, by integrating the resource-saving IMD process into production means that extra drying energy is no longer required. This also eliminates wet paint contamination. Thus reducing component defects and consequently waste.