world of innovation

EcoPower Combimould

55 – 300 t

All-electric multi-component technology

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EcoPower COMBIMOULD

Highly versatile multi-component injection molding

EcoPower stands for the WITTMANN BATTENFELD injection molding machines with small to medium

clamping force sizes (55 to 550 t), featuring a highly efficient servo-electric drive system combined with

a compact servo-electric clamping unit and lean injection units in the international standard sizes of 70

to 5000.

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 (for details see page 4).

EcoPower Combimould from 55 to 300 t stands for the combination of EcoPower machines with one or

several additional plasticizing/injection aggregates in various configurations.

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

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© PLAYMOBIL®

EcoPower Combimould

Applications

» Back molding

Simple back molding of two or three plastic layers

on a base part or certain areas thereof is the most

frequent application. Examples are decorations or

anti-wear protection layers.

» Assembly injection molding

By targeted use of the differences in attributes of the

plastic materials combined with each other, assemblies can be produced with individual movable or

detachable parts. Examples are flexible toy figures,

chain links, switch rockers or spout closures with

resealing caps.

» Hard-soft composites

An important field of application for assembly injection molding is seal installation. In this process, sealing

lips made of silicone or thermoplastic elastomers can

be molded directly onto housing bodies or technical

parts in a second injection molding step.

» Overmolding

“Overmolding” is a special form of hard-soft combination, where soft, skid-resistant surfaces are created

on housing parts or appliance handles with elastomer

layers.

» 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. In terms of process technology,

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 switching 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

or a sandwich and interval nozzle is used.

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COMBIMOULD PROCESS TECHNOLOGY

Optimally coordinated solution

» 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.

» 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.

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[5]

[1]

[4] [3]

[6]

[2]

CLAMPING UNIT

Servo-electric speed and dynamism

» Ample space for complex molds

– Generously dimensioned mold platens [1] and a clean toggle lever

clamping system offer the optimal environment for all molds

including all media connections.

– The ejector area and the environment of the platens offer easy

access for machine setup and adjustment work. [2]

» Sensitive and precise

In the EcoPower clamping system, the tie-bars are exclusively used for

force transmission between the outer platens. The moving platen travels virtually free of friction across the linear bearings without coming

into contact with the tie-bars. [3]

» Servo-electric dynamism

– The moving platen is moved quickly and with high precision by a

self-locking 5-point toggle lever. [4]

– The toggle lever is driven by a highly dynamic servo motor via a rackand-pinion drive system. [5]

– The synchronized mold height adjustment via 4 bronze bar nuts

and a sun gear system is driven by a servo motor. In this way, an

extremely accurate clamping force regulation can be achieved. [6]

» Servo-hydraulic ancillary strokes

To drive the ancillary strokes (ejector, nozzle strokes and core pulls), a

hydraulic aggregate powered by a servo-electric motor is mounted on

the inside of the machine frame. Being specially designed for high efficiency, it requires no cooling water connection. The maintenance-friendly access is from the rear, behind the clamping unit. Servo-mechanical

drives for the ancillary strokes are available as options.

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[7]

[9] [10] [8]

INJECTION UNIT

Precision from beginning to end

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» Everything to ensure series consistency

– All screws > 25 mm come with a 22:1 L/D ratio.

– All injection units offer a wide injection pressure range.

– Plasticizing parallel to clamping unit movements and start of the

injection process during clamping force build-up are possible as

standard.

– EcoPower injection units with a higher injection performance can be

supplied as an option.

– Moment-free nozzle contact thanks to axial configuration of traveling cylinders [7]

– Plasticizing units can be mounted to different injection aggregates

with identical screw diameters.

– In combination with WITTMANN BATTENFELD HiQ software packages sensitive adjustment facilities are available in the form of

(optional) software modules to compensate environmental factors

such as temperature and moisture, regrind or masterbatch content.

» Optimal operational excellence

– The complete range of all-electric injection units is designed for

quick barrel exchange from above.

– Easy access for changeover work thanks to compact design and sliding guard [8]

» More productivity and efficiency

– High-resolution absolute value encoder for precise control [9]

– Low-noise injection spindle with modern ball screw drive and

“spacer” technology and low grease consumption [10]

Anti-wear options

In addition to the premiumquality standard equipment,

an extensive range of options

is available to provide extra

anti-wear and/or anti-corrosion

protection. Predefined option

packages and a selection matrix

facilitate the selection of the

right plasticizing unit.

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INJECTION UNIT

The right combination for every application

In addition to the (horizontal) aggregate included in series production, EcoPower Combimould machines

can be fitted in V (vertical) and L (horizontal at the rear of the machine) configurations. Simultaneous,

parallel operation of all servo-electric injection units is possible as standard. All process variants can be set

individually.

» V configuration

Injection from above, also into the mold parting line

– Generously dimensioned adjustment range

– Slide device with linear guides

– Simple horizontal adjustment

– V aggregate completely retractable to the rear to

provide an absolutely free mold space

– Nozzle position stroke measurement incl. display

in the control system

» L configuration

Injection from the non-operator side, even into

the mold parting line

– Slide device free on the rear of the fixed platen

– Injection unit supported on linear guides

– Large adjustment range

– Access to the nozzles and to the mold from the

rear via large operator safety gate

– Fixed platen free for standard linear robot

– Nozzle position stroke measurement incl. display in control system

9

DRIVE TECHNOLOGY

Efficient through servo motors

Fast-responding, precise, cost-efficient

The use of servo-electric drive technology for all main movements affecting the cycle offers a large number of advantages compared to conventional hydraulic injection molding machines:

» Energy efficiency through direct drive without energy conversion into hydro energy

» Energy efficiency through the servo drives’ high efficiency rates

» Digital control for maximum repeatability

» Use of recovered braking energy via KERS system for powering of heater bands

» Cycle flexibility thanks to possibilities with parallel movements

» Low sound emission (< 65 dBA)

The combination of servo motors and drive units (rack-and-pinion drive for the toggle lever and spindle

drive for the injection stroke) can be supplied at different performance levels for different speeds.

Basically, the EcoPower drive concept offers the advantage of modularity for demand-oriented adjustment of drive performance to the intended use in each case.

Servo-hydraulic drive for ancillary strokes

» Integrated in the machine frame without additional space requirements

» Drive unit for hydraulic core pulls

» Energy-efficient, maintenance-free nozzle contact with high pressure

» No cooling required for standard applications

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UNILOG B8

Complex matters simplified

Unilog B8

Highlights

» Operating logic

with a high degree of self-explanation, similar to

modern communication devices

» 2 major operating principles

– Operating/movement functions via tactile keys

– Process functions on touch screen (access via RFID,

key card or key ring)

» Process visualization

via 21.5\" touch screen display (full HD),

pivoting laterally

» New screen functions

– Uniform layout for all WITTMANN appliances

– Recognition of gestures (wiping and zooming by

finger movements)

– Container function – split screen for sub-functions

and programs

» Status visualization

uniform signaling system across the entire

WITTMANN Group

– Headline on the screen with colored status bars and

pop-up menus

– ambiLED display on machine

» Operator assistance

– QuickSetup: process parameter setting assistant

using an integrated material database and a simple

query system to retrieve molded part data with

machine settings pre-selection

– Extensive help library integrated

The Unilog B8 machine control system is the WITTMANN BATTENFELD solution to

facilitate the operation of complex processes for human operators. For this purpose,

the integrated industrial PC has been equipped with an enlarged intuitive touch screen

operator terminal. The visualization screen is the interface to the new Windows® 10

loT operating system, which offers extensive process control functions. Next to the pivotable monitor screen, a connected panel/handset is mounted on the machine’s central

console.

For more information see the Unilog B8 brochure.

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COMBINATION OPTIONS

EcoPower Combimould

V vertical L horizontal from rear

For more information see the Unilog B8 brochure.

EcoPower Combimould 55

Injection unit 70H 130H 350H

70 V – L V – L V – L

130 V – L V – L V – L

EcoPower Combimould 90 / 110

Injection unit 130H 350H 750H

70 V – L V – L V – L

130 V – L V – L V – L

350 V – L V – L V – L

EcoPower Combimould 160 / 180

Injection unit 350H 750H 1330H

70 V – L V – L V – L

130 V – L V – L V – L

350 V – L V – L V – L

EcoPower Combimould 240

Injection unit 350H 750H 1330H

70 V – L V – L V – L

130 V – L V – L V – L

350 V – L V – L V – L

EcoPower Combimould 300

Injection unit 750H 1330H 2100H

70 V – L V – L V – L

130 V – L V – L V – L

350 V – L V – L V – L

H horizontal

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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

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.

Bonding of hard-soft material combinations

Bonding of thermoplastic materials in multi-component injection molding

WITTMANN BATTENFELD GmbH

Wiener Neustädter Strasse 81

2542 Kottingbrunn | Austria

Tel.: +43 2252 404-0

info@wittmann-group.com

www.wittmann-group.com

EcoPower Combimould | Article number: BPK0000062 | (English) | 2022/08 | Subject to change | Printed in Austria.