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Forschung - Entwicklung - Weiterbildung

Process

Injection molding

Since the foundation of SKZ, companies have been supported in the optimization and quality assurance of injection molding processes. Our knowledge, built up over several decades, is continuously expanded and is passed on to companies within the framework of research and industry projects, as well as advanced and further training.

State-of-the-art injection molding machines between 800 & 5,000 kN and peripheral equipment are available in our certified technical center to handle your inquiries. Our strength is to process your individual questions competently and at short notice.

Bernhard Hennrich

Group Manager | Research Injection Molding

Würzburg

+49 931 4104-243

b.hennrich@skz.de

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Our industrial services

Injection molding machines and technologies

Overview test specimen

Overview injection molding parts

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Impression

State-of-the-art equipment for best results and products

A look inside our technical center. On more than 1,000 square meters, we offer you service at the highest level. Challenge us. Together we will find a solution for your problem.

Technical equipment

Thermoplastic foam injection molding is becoming increasingly important in industry. In particular, markets such as packaging, furniture and automotive will be market drivers here in the coming years. To generate an optimum foam structure and to make the best possible use of the many advantages of the process, a profound understanding is required with regard to material selection, mold design and processing parameters. At SKZ, we have been working on thermoplastic foam injection molding (chemical & physical foaming) for several years and can provide you with competent advice and support for your questions.

Wittmann-Battenfeld Smart Power 240

fully hydraulic
2.400 kN clamping force
suitable for physical & chemical foaming
exchange unit for standard injection molding
screw diameter 45 & 50 mm
handling unit
comprehensive equipment with interfaces
Wittmann 4.0 with integrated peripherals

Contact:
Anika Fuhrmann | +49 931 4104-244 | a.fuhrmann@skz.de

Fiber-reinforced polymers have very high thermal and mechanical properties. In addition to the type and proportion of fibers, the fiber length(s) present in the component and their orientation are decisive for the subsequent service properties. The process developed jointly with ARBURG for the direct incorporation of fibers is based on a standard injection molding machine with a special unit. With this set-up, it is possible to add fibers directly to an already melted polymer and to adjust the fiber content easily during operation.

We support you in the processing of long fiber pellets and direct injection molding (FDC) at your site or in the SKZ pilot plant. Appropriate analytical methods are available for all questions:

Determination of fiber content
Analysis of fiber length distributions
Micrographs
CT examinations for visualization and quantification of fiber orientation,
determination of weld line strength
...

ARBURG Allrounder 920S

hybrid
5,000 kN clamping force
Direct injection moulding FDC
Exchange unit for standard injection moulding
Screw diameter 60 mm
position controlled screw
PVC & mixing screws
Handling unit
comprehensive equipment with interfaces

Contact:
Christian Deubel | +49 931 4104-242 | c.deubel@skz.de

Together with partners from industry and research, we are establishing a competence center for digitization at SKZ for the application area of injection molding. In addition to machine data, which is continuously generated during production, necessary data from peripheral devices and component quality will also be automatically recorded, processed and evaluated using inline measuring systems. The SKZ wants to offer companies a platform to make their company Industrie 4.0 -ready.

KraussMaffei KM160 750 PX

fully electric
1,600 kN clamping force
two injection molding units
Screw diameter 35 & 50 mm
handling unit
comprehensive equipment with interfaces
APC
Data-Explorer
I4.0 interfaces
via OPC-UA integrated temperature control units & drying/dosing ...

Contact:
Christian Deubel | +49 931 4104-242 | c.deubel@skz.de
Jakob Schüder | +49 931 4104-304 | j.schueder@skz.de

Analytics in the field of injection molding

Inline-capable measuring systems enable 100% inspection of the manufactured components.

Thermography

Thermography makes it possible to analyze, optimize and monitor manufacturing processes in a simple and economical way.

Application examples:

Detection of over and under spraying
Reject diverters with good/bad part detection
Control of process constancy and mold temperature control
Optimization of cycle time

With a suitable system, thermography can also be retrofitted easily and cost-effectively into existing production lines. A ready-made solution for integrating thermography into the production process, consisting of hardware and software, is available at the SKZ technical center for on-site customer trials. The measuring system can be flexibly adapted to different injection molding machines and consists of the following components:

Thermal camera (Micro-Epsilon) in resolutions up to 640x480 pixels, normal, wide angle or macro lenses.
Software (SKZ TDI) for inline acquisition of thermographic images and their immediate visualization with user-specific evaluation options (target value specification, tolerances, ...)
I/O module for communication with the injection molding machine or handling device for triggered recordings, good/bad diverters, mold temperature control ...

The measuring system developed at SKZ and used in a variety of industrial applications is available for customer trials and on-site consulting. For a permanent installation in your production, the system can be purchased.

Weight measurement

For many components, the component weight reflects the process consistency and thus the component quality. Together with a partner, a system for inline weight measurement was developed at SKZ, which can be integrated directly between the gripper and the handling system. In the injection molding of complex components and/or difficult materials, the process consistency can be assessed by documenting the component or shot weight, and problems in the injection molding process can be detected immediately (over/under injection, missing inserts, process temperatures change/are incorrect ...).

Possible applications:

general process constancy/tolerances depending on the mold and/or processed thermoplastics
influence of processing parameters on part/shot weight
evaluation/optimization/monitoring of chemically/physically foamed components
...

Color measurement

An innovative inline color measurement system developed by ColorLite GmbH in cooperation with SKZ enables non-contact measurement of the demolding temperature. Using previously determined cooling curves stored in the software, these color values are converted to a reference temperature (24°C). With the inline color measurement, changes in the Lab values can be detected directly after demolding of the components, so that measures can be taken immediately.

Possible application scenarios are:

Evaluation of the consistency of the coloring over a longer period of time
Duration of color change processes
Comparisons between different coloring methods and/or colorants
Influence of process parameters and/or mixing elements
...

Depending on your question, use in customer trials or sampling is possible.

Streak detection

Inhomogeneities on the component surface usually indicate insufficient homogenization of the supplied ink, excessive processing moisture of the material, segregation of fillers/additives, malfunctions of peripheral equipment or problems during plasticizing. The reliable detection of these structures so that measures can be taken is part of our current R&D activities.

Possible applications are:

Assessment of homogeneity in coloring over a longer period of time
Duration of color change processes (streaks)
Comparison of homogenization between different coloring methods and/or colorants
Influence of process parameters and/or mixing elements on homogenization
Quantification of the surface quality of foamed, fiber-reinforced or highly filled components
...

The newly developed measuring system is available for customer trials and sampling in the SKZ pilot plant.

Contact:
Christian Deubel | +49 931 4104-242 | c.deubel@skz.de
Christoph Mussauer | +49 931 4104-190 | c.mussauer@skz.de

Training courses in spotlight

18.05. - 21.05.2026

Injection Molding – Basics and defects

This compact training course with the practical training on the machine provides participants with a general…

1.225,00 EUR

Injection molding

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Injection molding

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Service

State-of-the-art equipment for best results and products

Technical equipment