Engel to present efficiency, precision and AI solutions at K 2025

Schwertberg, Austria – ENGEL is showcasing the highly integrated, series production of innovative rear-end light modules using a high-performance duo 700 two-platen injection molding machine with 7,000 kN clamping force. The visible components, measuring 600 x 240 mm, are produced using a combination of decorative Foilmelt and functional Clearmelt technologies in a vertical rotary table mold.

In addition to offering design flexibility, downstream processes are integrated directly into the injection molding cell—eliminating the need for a separate hardcoating step thanks to Clearmelt. On one side of the mold, the color design is transferred from a decorative foil to the part via thermoplastic back-injection (Foilmelt). On the opposite side, the part is overmolded with polyurethane (Clearmelt), creating a highly transparent and durable protective layer.

A space-saving, integrated automation system with a Viper 40 linear robot enables short cycle times within a compact, efficient cell. The transfer foil is supplied by LEONHARD KURZ. At the partner’s booth, the component is further enhanced with an integrated LED function foil.

With this application, ENGEL demonstrates how visible automotive parts can be both functional and decorative—cost-effectively, with high precision, and in a compact production setup.

A production cell featuring a vertical insert 150 injection molding machine with 1,500 kN clamping force demonstrates the fully automated manufacturing of liquid silicone rubber (LSR) seals on sensitive gas diffusion layers (GDLs) for fuel cells.

The LSR seal is applied with perfect platen parallelism directly in the machine, inspected in the mold, and immediately removed. The automation system—featuring an ENGEL easix articulated robot and a rotary table mold from ACH—ensures short cycle times and high process reliability.

To save space, the control cabinet is integrated directly into the machine frame. ENGEL presents a highly cost-effective solution for fully automated overmolding with thin LSR layers in a compact footprint.

This innovative combination enables maximum performance with minimal weight and a short cycle time of just one minute. The process is fully automated using an easix articulated robot. With these technologies, ENGEL sets new standards in production efficiency and sustainability—opening new opportunities for plastic components in markets traditionally dominated by metal.

A key highlight is the validation solution co-developed by ENGEL and toolmaker Hack. This system enables structured, digital documentation of all validation phases—from Design Qualification (DQ) to Performance Qualification (PQ). Integrated sensors in the machine and mold, combined with ENGEL’s iQ software and standardized documentation modules, significantly reduce the time and labor required for validation.

On the new victory electric, fittings are produced with a cycle time of just 23 seconds. The mold includes large-volume core pulls, which are optimally supported by the open access of the tie-bar-less design. This allows even large molds to be used on relatively small machines—saving space, energy, and capital investment.

After molding, the fittings are automatically fitted with seals. Two easix articulated robots handle this step within the production cell.

ENGEL is producing thick-walled, foamed construction blocks for the building industry on an electric e-mac 220 injection molding machine with 2,200 kN clamping force. The material—sourced from post-consumer household waste (yellow bag)—is reprocessed by EREMA. The mold and foaming agent formulation are provided by Moxietec.

An optimized mixing screw ensures excellent foam homogeneity during plasticizing. The result: components with up to 30% weight reduction and 10% higher strength. This technology is ideal for logistics pallets and as a concrete substitute in construction.

Because the process uses 100% post-consumer recyclate with variable material properties, ENGEL’s iQ weight control plus plays a crucial role. After setting just two parameters, the system automatically adjusts the switchover point and pressure curve during each cycle—reducing scrap by up to 50%.

An integrated automation solution with a servo sprue picker and built-in conveyor belt makes the cell especially compact and energy-efficient.

With inject AI, ENGEL is advancing its inject 4.0 program by integrating artificial intelligence into many new and existing products. At K 2025, ENGEL will showcase the next step toward self-optimizing machines.

The iQ process observer monitors up to 1,000 parameters per shot, detects process deviations in real time, and provides AI-driven correction suggestions—helping optimize processes and reduce scrap. The system continuously learns from all connected machines, adding value to every new project and boosting quality and efficiency.

A new AI-powered feature in the e-connect portal offers machine-specific support for faults—quickly, accurately, and in any language. With intelligent search functionality in ENGEL’s machine manuals, downtime is significantly reduced. This feature will be available as a pilot release in time for K 2025.

ENGEL views AI not as a replacement for human expertise, but as a complement. Adaptive assistance systems reduce operator workload, stabilize processes, and increase machine availability—especially valuable in times of skilled labor shortages. Step by step, the self-regulating machine is becoming a reality.