Langzauner (Lambrechten, Austria) and Engel (Schwertberg, Austria) have jointly developed composite processing technologies for lightweight construction, with Engel specializing in injection molding technology and Langzauner specializing in the development of hydraulic presses and custom machines.

This collaboration has resulted in a combined system for processing composite semi-finished products, integrating press and injection molding technology. This technology enables the forming and back-injecting of semi-finished products in a single process step, which can make production more efficient and energy-saving for applications in e-mobility and urban air mobility.

The control is managed by Engel’s CC300, which provides real-time process monitoring and integrated safety systems. This is said to improve user-friendliness and enhance the efficiency of manufacturing processes.

The fully integrated bolt-on-injection unit from Engel is capable of coping with both standard and high-performance plastics (including ABS, PC, ABS/PC, PEEK, PA and more) which can be processed at temperatures higher than 450°C. The consistent use of thermoplastic materials is said to enable a high degree of process integration for worry-free functionalization of the parts. Therefore, this can reduce time, raw material input and energy requirements. Langzauner and Engel are customizing and fully integrating the bolt-on injection units for the individual requirements of customers.

A recent project was successfully implemented at the Technology Center Thermoplastic Composites of the Leibniz-Institut für Verbundwerkstoffe GmbH (IVW), whereby an injection unit from Engel with a screw diameter of 70 mm was selected.

The typical process sequence is as follows: (1) Loading of a preheated reinforced semi-finished product (organosheet, GMT, LFT and so on) by hand or using an automated Langzauner transfer frame; (2) closure of the press; (3) connecting the injection unit to the mold (simultaneously to the closure of the press); (4) injection of thermoplastic material; (5) well time for cooling (composite compound); (6) disconnection of the injection unit; (7) opening of the press; (8) removal of the component.