
Technologies
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Engel Victory 120 tons injection molding machine is available for real MuCell tests.
A technology concerning physical foaming of the polymer by mixing it with nitrogen at its supercritical condition.The MuCell® process dedicated to technical products decreases the viscosity of thermoplastic resins by injecting into the melt small amounts of gas which, expanding in cavity, creates a microcellular structure of the moulded part.
The use of Mucell microcellular foaming gives several benefits such as:
- lightweight of moulded parts
- elimination of sink marks in all component surface
- maximum reduction or total elimination of moulding residual stresses
- reduction of moulding cycle time
- reduction of polymer viscosity
- reduction of the clamping force required by injection machine
Benefits
Moulds cavity
- expansion replaces the packing pressure
- lower clamping force
- less design limits
- reduction of cycle time
Injection unit and energy saving
- lower viscosity
- better filling
- dedicated design and gate positioning
- process temperature reduction and energy saving
Components
- reduced part weight
- high reduction of warpage
- less shrinkage
- strong reduction of sink marks
- high aesthetics
- accurate textures replication
- elimination of visible welding lines on the part’s surface
- possible decrease of injection pressures since the progressive cooling of melt during filling is less quick
Benefits
- excellent surface quality: glossy or matte, invisible welding lines
- improved brilliance of blacks and colors
- avoiding halos
- possible thickness reduction
- better propagation of packing pressure
- sink mark reduction
- reduction of aesthetic defects (gate marks, sink marks reduction
- reduction of aesthetic defects (gate marks, streaks …)
Benefits
Viscosity reduction during filling
- increase of flow length
- possibility to fill thin thicknesses
- reduction of injection pressure
- increased strength of welding lines
Better propagation of holding pressure
- better material packing
- reduction of sink marks
- improved dimensional stability
- reduction of warpage
Injecting the material in a very hot cavity
- excellent glossy surfaces (gloss, Piano Black effect…)
- chance to avoid painting
- improved quality of texturised and grained surfaces (matte, gloss reduction …)
- not visible welding lines
- elimination of flow marks, streaks … increase in crystallinity and mechanical properties
Technology that allows very rapid cooling of localized mould points which are difficult or impossible to reach with traditional conditioning. By exploiting CO2 expansion in specific mould areas of interest it can, quickly, remove a large amount of heat. Rapid cooling of difficult mould area contributes to reduce cycle time.
CO2 Cooling Spot Cooling allows, as well, the elimination of hot spots and the conditioning of very thin and deep cores obtaining a more efficient, uniform and faster mould cooling compared to conventional systems.
Benefit
- significant reduction of cooling time and, consequently, of cycle time
- elimination of hot spots
- uniform mould temperature
- conditioning of very thin cores
- no liquid refrigerants and hydraulic sealings are required
Benefits
- control of production processes
- part quality control
- possibility to set, during mould piloting, the ideal process conditions for both machine and mould
Benefits
- high mechanical performance of the component
- technology suitable for metal replacement
- easy industrial scalability
- reduced cycle-times, comparable to standard injection moulding
- no need to use chemicals and curing as for thermosetting
- better environmental sustainability
- no shelf life limitations as for thermosettings
Benefits
- homogeneity of melt temperature
- better control of cell distribution
- not inflammable
- applicable to all polymers
- eco-friendly: physical expansion without the use of foaming agents
Benefits
- surface quality improvements: Class “A” large surfaces, grained surfaces, aesthetical parts
- high process repeatability
- safe, clean and dry (no oil, no liquids)
- easy to use
- optimal flow balancing
- warpage reduction
- clamping force reduction up to 20%
Benefits
- high components customization
- low tooling cost
- possibility to use a wide materials range