Foam tandem injection moulding process developed

Foam tandem injection moulding process gives more freedom in design, and saves time and money - resulting in an overall reduction of the cycle time of more than 50%.

In collaboration with Trexel of Wiehl, the Erwin Quarder Group of Espelkamp (Germany) introduced an innovative technology combination.

The MuCell injection moulding method by developer and patent holder Trexel gives more freedom in design, and saves time and money in combination with Quarder's tandem technology.

Quarder presented this unique combination to their customers and other interested parties during their open days in March 2007.

The MuCell process involves the controlled use of gas in its supercritical state to create a foamed part.

The major advantages of the MuCell process include more design freedom through the elimination of sink marks and viscosity reduction, significant reductions in cycle time and reduced use of materials, which can save up to 15% in weight, depending on the application.

The avoidance of internal stress in the injection mould produces improved shrinkage freedom and dimensional stability, resulting in less optimisation looping as well as faster production cycle times.

This in turn results in a reduction of the secondary costs.

The combination of the MuCell method with the tandem method results in an overall reduction of the cycle time of more than 50% compared with the traditional injection moulding process.

A tandem mould works like a stacking tool.

The difference is in the locking faces that open in alternating sequence rather than simultaneously.

The tandem mould is used in alternating sequence for the cooling time in the injection process.

While the cooling time runs in parting line 1, parting line 2 is already injected.

The fusion of both methods has been developed within one year.

The Erwin Quarder Group and the Trexel Company jointly support the design and the pilot production.

"The process results are inspected using a custom-designed prototype," said Stephan Fischer, manager at Erwin Quarder Werkzeugtechnik.

"Based on these results, we have made a 4 + 4 tandem MuCell tool for the production of lock closures parts for automotive customers in the USA.

The lock closures parts are manufactured using a 420tonf (4200kN) Krauss-Maffei machine.

The machine will be built in Germany and subsequently transported to Quarder in the USA.".

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