world of innovation world of innovation

MacroPower Combimould

400 – 2000 t

The flexible large-molding machine

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MacroPower Combimould

Extra functionality and more freedom for design

Based on the MacroPower model with 2-platen technology, the MacroPower Combimould series comes

with a wide range of options and an extensive choice of different combinations, thus offering the right

package for every multi-component technology. In this way the machine, mold and automation technologies can be optimally adapted to each individual product.

Combimould stands for WITTMANN BATTENFELD’s multi-component injection molding technology. In

this process, a basic part is produced in the first injection molding station, then plastic components

in different colors or made of different materials are added in one or several more injection molding

stations, all in one cyclical sequence. In this way, various material attributes are combined with each

other to create a composite part of better quality in terms of visual attractiveness and functionality.

This material combination technology can be used to produce individual parts as well as integrated

components joined together by assembly injection molding. Depending on the parts geometry in each

case, this requires different process variants.

The WITTMANN BATTENFELD know-how covers all process variants, such as multi-color, 2-component,

assembly, multi-component and sandwich injection molding.

For technical details of standard MacroPower machines see the MacroPower brochure.

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MacroPower Combimould

Applications » Hard-soft combinations and overmolded sealing

components

The use of thermoplastic elastomers allows direct

overmolding of sealing components. Moreover, the

surface touch can be improved by adding a soft

component. The bonding strength can be increased by

mechanical anchoring. Multi-component technology

is also frequently used in LIM processes (liquid silicon

processing).

» Multi-color injection molding

Several parts made of the same material but in

different colors are combined into one component.

Classic examples are multi-colored bottle cases with

soft-handles and the frames for flat screens (LED TV

sets, computers, laptops etc.) with piano finish effect.

Multi-color injection molding improves the appearance

of parts with guaranteed colorfastness.

» In-Mold Assembling

Parts consisting of two halves can be joined together

directly in the mold. For example, to make this twocomponent oil closure, its two halves are injected in

separate stations with the help of cube molds, then,

following rotation, brought together in the 3rd station

by closing the mold. But jointed connections can also

be injected in one production step. Non-adhesive mate

-

rials are chosen for this purpose. Ball joints and hings

can easily be formed in this way.

» Sandwich injection molding – co-injection technology

This process serves to produce parts with a three-layer

structure, consisting of two continuous outer surface

layers and a core layer. This is achieved by consecutive

injection of two materials through the same nozzle

into a conventional mold. A foamed or reinforced core

component improves the part’s mechanical attributes.

Costs can be reduced by using regrind and Cellmould

foam technology. The surface layers consisting of

high-grade materials provide the desired high-quality

surface attributes. In the packaging industry, barrier

layers can be incorporated in the parts. Reproducible,

attractive marbling effects can be achieved by swit

-

ching several times between two materials of different

colors. Depending on the area of application and the

requirements to be met by the production equipment,

a sandwich adapter plate, a sandwich and interval

nozzle or a “monosandwich” process is used.

Photo: Haidlmair GmbH

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Combimould PROCESS TECHNOLOGY

Optimally coordinated solution

» Rotary unit process

The standard process

Rotary unit technology is the most frequently used

Combimould variant. It is used both for overmolding

and back molding. Here, the ejector half of an X +

X-cavity mold is mounted on a rotary unit. The rotary

unit can be designed for alternating rotation movements of +/- 180 degrees (2 stations), 120 degrees (3

stations) or 90 degrees (4 stations).

Following the injection molding process in station

1, the base part produced there is transferred to the

overmolding station by opening and rotating the mold

half on the ejector side. Parallel to molding the additional components in the subsequent stations, the next

base part is produced in station 1. The finished part is

removed from the last station.

» Index plate process

For complex part design

In index plate technology, the rotation and transfer

mechanism is an integral part of the mold. This

process must be applied if the second component is

to be added on both sides of the part. To this end, the

preform must be transferred to a station to receive a

modified shape on both sides. This is carried out with

the help of an intermediate plate inside the mold, also

known as index plate, by which the parts are lifted out

of station 1, turned and then re-inserted into station 2.

The drive system for the index plate is either integrated

in the mold or may be connected to the machine with

a servo-electric drive. Rotations of +/- 180 degrees (2

stations), 120 degrees (3 stations) or 90 degrees (4

stations) are possible. The index plate system offers

the maximum possible flexibility for molded parts

engineering.

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» Transfer process

For special cases and small series projects

This process is used as an alternative to the index plate

process where the molded part No. 1, due to its geometry, has an insufficient contact area on the index plate

for being transported by the index plate between the

injection molding stations. Other types of applications

are combinations of bulky inserts (such as screwdrivers

or knife blades) with plastic components, or a low-cost

production alternative for small series.

» Valve gate retraction process

To add flat components without parts transfer

In valve gate technology, the second component is

added without prior mold opening and rotation. The

different geometry required inside the cavity is produced by a hydraulic valve gate which, when retracted,

provides the space for adding the second component.

In spite of a longer cycle time due to serial production steps, the valve gate process may be of interest

economically in mold technology for small numbers

of units because of the lower cost of mold technology.

In some cases, the compact mold design even allows

the use of smaller machines. However, a possible use

strongly depends on the design of the molded part and

on flat geometries of the additions.

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CLAMPING UNIT

High functionality with ample mold space

» Large and flexible

The extensive MacroPower system construction kit offers a wide

range of combination options from numerous clamping force

variants with matching distances between tie-bars, in both

standard and XL versions.

» Sensitive and precise

In the MacroPower clamping system, the tie-bars are only used

for the force transmission between the mold platens. The moving

platen is mounted on a carriage, which travels on high-precision

linear bearings along the machine frame. The minimal rolling

friction in the linear bearings is the prerequisite for highly sensitive mold protection and high cleanless.

» Fast and synchronized

The Quicklock locking system between the tie-bars and the

moving platen consists of four synchronized tooth segment

nuts, which are integrated in the moving platen to minimize the

machine’s footprint.

» Compact design for minimal footprint

The integrated tie-bar nuts and short tie-bars offer two advantages: short footprint and simultaneously free space for lateral

mold insertion.

» Symmetrical and powerful

The moving platen is driven by two diagonally positioned traveling cylinders designed for high speed. The traveling drive in

combination with a hydraulic differential gear system provides

the basic conditions for high speed, precision in movements and

power.

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CLAMPING UNIT

Fast rotation units

The optional, adaptive rotary table comes with a servo-electric drive

and is laid out for a rotation angle of 360° or +/-180°.

In addition, it is characterized by extremely low installation height,

high dynamics, flexibility, safety and gentle treatment of the mold.

» Highly dynamic servo motor

– Minimal rotation times

– Parallel movements

– Shorter cycle times

» Short changeover times

– Very low installation height

– Easy and flexible installation and removal

– Unit can be deactivated via control-system

» Safety and mold protection

– Dampened end position control

– Indexing device

» Extension of the standard version by various options

– 3-station (120°) or 4-station (90°) processes

– Additional media circuits

– Individual ejector positions

– Magnetic clamping plate

Best access

for rotation devices

Rotation devices for the required media, for temperature control,

hydraulics and pneumatics can be supplied with up to 12 circuits.

The 2-platen technology design of the MacroPower machines

ensures optimal access to its media supply connections.

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INJECTION UNIT

Configurations

Injection unit

Configuration

The MacroPower Combimould offers a choice of V, S and L

configurations as standard. Special configurations, such as

the Y, B or H-H configuration, are available upon request.

» V configuration

Injection from above, also into the mold parting line

– Generous adjustment range

– Sliding unit with linear guides

– Easy horizontal adjustment

– Complete V aggregate can be moved back to provide an absolutely free mold space

» S configuration

Slanted above horizontal injection unit

– Compact machine design

– Small footprint

– S and H aggregates can be moved independently

– Independent, adjustable, torque-free nozzle contact

pressure

– Excellent access to the nozzle

» L configuration

Injection from the non-operator side, also into the

mold parting line

– Sliding unit freely mounted on the back of the fixed

platen

– Injection unit supported by linear guides

– Long adjustment path

– Access to the nozzle and to the mold from the rear

via large operator safety gate

– Fixed platen kept free for standard linear robot

» B configuration

Injection unit on the moving platen

– For cube technology

– Injection into the moving mold half

» H-H configuration

2 parallel horizontal aggregates

– Both aggregates can be moved independently

– For sandwich technology

– Excellent thermal insulation of each aggregate

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DRIVE TECHNOLOGY

Energy efficient and modular

Fast-responding, precise, thrifty

“Drive-on-Demand” is the innovative combination of a fast-responding, speed-controlled, air-cooled servo

motor with a fixed displacement pump. This drive unit is only activated when required by movements

and pressure build-up. During cooling times or cycle pauses for parts handling, the servo drive remains

switched off and thus consumes no energy. In operation, “Drive-on-Demand” is the basis for highly

dynamic, controlled machine movements and short cycle times. Monitored shut-off valves are installed in

the suction pipes to ensure operational safety.

The “Drive-on-Demand” system is standard in the MacroPower machine series.

Hydraulic system extension levels for parallel functions

» S1: twin pump system

for parallel movements of ejector and core pull

» S2: twin pump system with increased drive performance (optional) for parallel

movements of ejector and core pull plus faster injection

» S4: twin pump system with increased drive performance (optional)

for parallel movements of ejector and core pull and high-speed injection with an

accumulator for short cycle times

A brake on operating costs

» The “Drive-on-Demand” system is standard equipment.

» “Drive-on-Demand” lowers energy consumption by up to 40 per

cent compared to modern variable displacement pump systems.

» Additional energy cost cuts through reduction of idle power

» Lower total expense for cooling, since oil cooling is normally not

required

» Lower maintenance expense through longer preservation of the

oil quality due to less thermal load

» Lower sound emission levels, consequently less investment in

sound protection required

» Second servo drive package is standard, third servo drive package for parallel movements for the mold shut-off nozzle system

as an option

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COMBINATION OPTIONS

MacroPower Combimould

H horizontal

V vertical

S slanted from above

L horizontal from rear

B horizontal on clamping unit

HH horizontal parallel

Further combinations and B or H-H configuration available upon request.

Further combinations and B or H-H configuration available upon request.

MacroPower Combimould 400 / 450

Injection unit H 130 210 350 525 750

1330 V − L V − L − S V − L − S V − L − S V − L − S

2250 V − L V − L − S V − L − S V − L − S V − L − S

3400 V − L V − L − S V − L − S V − L − S V − L − S

MacroPower Combimould XL 450 / 500 / 550

Injection unit H 130 210 350 525 750

1330 V − L V − L − S V − L − S V − L − S V − L − S

2250 V − L V − L − S V − L − S V − L − S V − L − S

3400 V − L V − L − S V − L − S V − L − S V − L − S

MacroPower Combimould XL 550 / 650 / 700

Injection unit H 210 350 525 750

2250 V − L − S V − L − S V − L − S V − L − S

3400 V − L − S V − L − S V − L − S V − L − S

5100 V − L − S V − L − S V − L − S V − L − S

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TPE based on

polyamide

TPE-polyesterelastomers

TPE based on

polyolefin

TPE based on

styrene

TPE thermoplastic plyurethane

TPE types with

modified adhesive properties

ABS ■ ■ ■ ■ ▲ ▲

ASA ▲ ▲

CA ▲

PA 6 ▲ ■ ■ ▲ ▲

PA 6.6 ▲ ■ ▲ ▲

PA-Blend ▲ ■ ■ ▲

PBTP ■ ■ ▲ ■ ▲

PC ■ ■ ■ ■ ▲ ▲

PC/ABS ■ ■ ■ ■ ▲ ▲

PC/PBT ■ ■ ■ ■ ▲ ▲

PC/PET ■ ■ ■ ■ ▲ ▲

PE ■ ■ ■ ▲

PETP ■ ▲

PMMA ■ ■ ▲

POM ■ ▲ ▲

PP ■ ■ ▲ ▲

PPO ■ ▲

PS ■ ■ ■ ▲

PAN ■ ▲ ▲ ABS ASA CA PA 6 PA 6.6 PA-Blend PBTP PC PC/ABS PC/PBT PC/PET PE PETP PMMA POMPP PPOPS SAN

TPE/TPU

ABS ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ■ ▲ ▲ ■ ■ ■ ■

ASA ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ■ ▲ ▲ ■ ■ ■ ■ ▲ ■

CA ▲ ▲ ▲ ▲ ■ ■ ■ ■

PA 6 ▲ ▲ ▲ ▲ ▲ ■ ▲ ▲ ▲ ■ ■ ■ ■ ■ ■

PA 6.6 ▲ ▲ ▲ ▲ ▲ ■ ▲ ▲ ▲ ■ ■ ■ ■ ■ ■

PA-Blend ▲ ▲ ▲ ■ ■ ■ ■

PBTP ▲ ▲ ▲ ▲ ■ ▲ ▲ ▲ ▲ ▲ ■ ▲ ■ ■ ■ ■ ▲ ■

PC ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ■ ▲ ■ ■ ■ ▲ ■

PC/ABS ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ■ ■ ■ ■ ■

PC/PBT ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ■ ▲ ▲ ■ ■ ■ ■

PC/PET ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ ■ ▲ ▲ ■ ■ ■ ■

PE ■ ■ ■ ■ ■ ■ ▲ ▲ ■ ▲

PETP ▲ ▲ ▲ ▲ ▲ ▲ ■ ▲ ■

PMMA ▲ ▲ ■ ▲ ▲ ■ ▲ ■ ■ ■ ▲ ■

POM ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ▲ ■

PP ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ▲ ■

PPO ■ ■ ■ ■ ■ ■ ■ ■ ▲ ■

PS ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ▲ ▲ ■

SAN ■ ▲ ▲ ▲ ▲ ■ ■ ■ ■ ▲ ■ ■ ▲ ▲

TPE/TPU ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ▲ ■ ■ ■ ▲ ■ ■ ▲ ▲

■ limited bonding

■ no bonding

▲ good bonding

▲ excellent bonding

Bonding of hard-soft material combinations

Bonding of thermoplastic materials in multi-component injection molding

Due to the great variety

of TPE types, the bonding

strength must be checked

in each individual case.

The bonding strength

also depends on the

part geometry, process

conditions and processes

involved.

In some cases, particularly where modified

materials are involved,

tests must be carried out

to check the bonding

strength.

WITTMANN BATTENFELD GmbH

Wiener Neustädter Strasse 81

2542 Kottingbrunn | Austria

Tel.: +43 2252 404-0

info@wittmann-group.com

www.wittmann-group.com

MacroPower Combimould | Article number: BPK0000009 (English) | 2022/08| Printed in Austria | Subject to change.