Injection and compression molding

The injection and compression molding group specializes in the development of large-series processing technologies for flowable material systems. In addition to standard injection molding and compression molding processes, work is focused on single-stage resource- and energy-efficient direct processes, tailored local continuous-fiber reinforcement, and spraying processes.

Thermoplastic foam injection molding charges the polymer melt with a blowing agent that leads to the foaming of the molding compound in the cavity after injection. Together with our partners we develop material compositions and processes for foamed components using both chemical and physical (Mucell® / Direct-Foam) blowing agents.

When compounding technology and injection molding are combined into a single process, plastic processors gain new, innovative options to improve the mechanical properties of injection molded components while saving energy and material costs. The gentle integration of fibers and resin via the compounding extruder also allows much higher fiber lengths to be achieved than in conventional injection molding. In compression molding, these materials can be processed with a productive and flexible direct process (two-machine technology). This technology offers particular flexibility in terms of the possible combinations of matrix materials and the reinforcing fibers used, as well as shorter cycle times during manufacture. In addition, the back-molding of metallic inserts or continuous-fiber-reinforced thermoplastic semi-finished products offers significant potential for further developing this material class towards its application in structural components.

In comparison to thermoplastics, thermosetting (cross-linking) polymers have advantages in terms of media and temperature stability which make them attractive for high-performance applications under demanding conditions. For example, it is possible to substitute aluminum die casting with free-flowing, thermosetting molding compounds based on phenolic and epoxy resins, leading to weight and cost reduction.

SMC components are finding increasing application in the automobile and utility vehicle sectors. They are associated with various advantages such as low density, high thermal and chemical stability, dimensional stability and an achievable class-A quality surface appearance. SMC enables lightweight construction solutions in application areas that are characterized by stringent requirements regarding mechanical, chemical and thermal stress.
We are active in the field of material and process development for the compounding and extrusion compression molding of SMC. This includes for example formulation development, the implementation of novel resin systems and reinforcing fibers, the development of new production units for semi-finished products and improved process control in component manufacture. The main focus is class A surfaces, lightweight SMC, locally reinforced SMC components, and the processing of nanoparticles and natural and carbon fibers.