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Also on Engel’s stand will be a v-duo, which was unveiled last year, becoming the largest vertical machine ever presented by Engel at a show. A v-duo 700 will produce latch covers for the KTM X-Bow sports using resin transfer molding. An Engel viper 20 linear robot will handle parts. The company partnered with Wethje, which supplied the components and preforms; Langer, which built the tool; Hennecke, which provided the HP-RTM system; and BASF, which brought the PUR-RTM system. KTM provided component design and the composite-specific construction, including the simulation of the manufacturing process.

The third automotive exhibit combines three production processes in an Engel duo 3550/650 pico combi M injection molding machine. In a single process step, the Varysoft process devised by Georg Kaufmann Formenbau will make dashboards for the Hyundai Kia Automotive Group from a thermoplastic substrate, a decorative overlay and a layer of polyurethane foam. In this process, TPE-foils are preheated in an integrated infrared oven. Once again, the PUR system will be provided by BASF, with polyurethane processing equipment supplied by Hennecke. Varysoft reportedly provides even greater softness while allowing undercuts in the mold design. The integrated production process features an Engel viper 40 double robot and an Engel easix multi-axis robot, for trimming the overlapping foil with an ultrasonic cutting head. To reduce component weight, Trexel’s MuCell technology is used in the injection molding of the thermoplastic substrate structure.

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