Lightweight technology by Injection molded composites

IMC-Machine-AutoD

Lightweight Technology by Injection Moulded Composites

The IMC - Injection Moulding composite - combines continuous compounding, Typical of extrusion systems, with injection moulding, which is a discontinuous process. This way long-fiber-reinforced thermoplastic components can be produced with better Properties and at a lower cost than using pellets.

The matrix polymer is first plasticized and mixed with additives in a corrugating twin-screw extruder.

The reinforcing fibers are fed into the extruder, wetted with the molten thermoplastic, which naturally shortens them, and transferred to an injection piston. During the brief injection and holding pressure phase, the compound, which is produced continuously, is collected in a melt buffer. The continuous melt process guarantees consistent material quality.

Lower production costs with better properties

Direct compounding/injection with the IMC saves energy and material costs (0.3 to 1.0 €/kg cheaper than processing LFT pellets). As a result, it has widely replaced LFT in manufacturing semi-structural components. The mechanical properties of finished parts are also better because the process is less destructive to the fibers. The fibers are only processed once (instead of twice if pellets are used) and they are fed into the melt in the direction of processing. Process steps such as pelletizing, cooling, and remelting are omitted.

Automated and flexible for series production

The IMC process can be highly automated. Together with other key benefits, this makes direct compounding the process of choice for producing big runs of fiber composite parts. The integrated control ensures that the formulation and the material quality are constant and that the process is fully documented. Changes to the formulation are simple, so that the process can be adapted flexibly to meet different part specifications. The IMC system is just one example of productive interdisciplinary collaboration successfully merges injection moulding know-how with expertise in Injection and extrusion.


IMC benefits

  • Material cost savings
  • Increased cost-effectiveness thanks to combination of processes
  • Most suitable for recyclates due to lower mass temperature needed
  • Highest part quality thanks to reproducible melting behaviour
  • Most suitable for recyclates, additivs, fibers etc. due to high mixing degree

Highlights

  • Ideal for long glass fiber processing
  • Increased cost-effectiveness thanks to combination of processes
  • Highest part quality thanks to reproducible melting behaviour
  • Highest part quality thanks to loss of one melting process
  • Reducing material costs by substitution of fiber-reinforced granulate

Your benefits:

  • Short cycle times enable fully automated production of higher quantities
  • Long fibers for better material properties and high stiffness
  • Lower material costs
Process IMC
Description The IMC - Injection Molding Composite - combines continuous compounding, typical of extrusion systems, with injection molding, which is a discontinuous process. This way long-fiber-reinforced thermoplastic components can be produced with better properties and at a lower cost than using pellets
Features
  • Highly automated process
  • Flexible adaptation to changing requirements
  • Compounding using low-cost standard raw materials
Typical applications Tailgate, Frontend carriers, transmission elements, front partitions, battery wells
Typical annual volumes 300,000 to 600,000 items


Comparison with Other moulding Processes



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