From the initial idea to stable series production: Under its “End-to-End Injection Molding Solutions” approach, SPECTRIX supports injection molding projects throughout the entire product lifecycle. A key advantage is its broad technological capabilities: Nearly all essential competencies and technologies along the process chain are available within SPECTRIX. At Fakuma, the company will demonstrate how the individual development steps work together using a medical application. Together with several technology partners, SPECTRIX has developed a 6-cavity single-face mold for a pipette tip rack that will be running live at the show.
A high-performance injection molding process does not begin with moldmaking. Decisions regarding material, part design and process concept are made much earlier – and later influence the mold, hot runner, control technology, automation and series production process. At the same time, a project does not end with the delivery of the mold: Qualification, production ramp-up, scaling and lifecycle support all play a decisive role in long-term performance. SPECTRIX therefore considers the entire process as an interconnected development chain:
Early Project Involvement
The earlier mold and process expertise is incorporated into development, the better a part can be prepared for stable and cost-effective series production. As part of its co-development approach, SPECTRIX therefore works closely with customers from the early stages of a project – from the initial product idea and material selection through Design for Manufacturing (DFM). The company can draw on extensive material expertise, with more than 500 polymer grades already tested and documented.
Product Development
Simulation and process engineering then help identify potential challenges at an early stage and evaluate different solution approaches. Across the group, more than 150 mold and hot runner designers as well as over 30 application and mold flow engineers are available to support this work.
Piloting and Production Mold
Depending on the application, pilot molds, pre-series production and initial sample inspections can be used to validate new mold and process concepts before industrialization. For the Fakuma project, this intermediate step was not required due to the manageable 6-cavity configuration.
Based on the development and simulation results, the 6-cavity single-face production mold was built directly by Männer. The 3D-printed cavities are subsequently precision-finished using established moldmaking processes including milling, EDM and polishing.
The hot runner and temperature control technology also come from within SPECTRIX. The application uses the Männer Performance Line. The naturally balanced 6-cavity system is designed to provide uniform melt distribution across all cavities. Temperature control is provided by the Gammaflux G25, which measures temperature 20 times per second and adjusts it with a precision of 0.017°C.
System Validation & Integration
Once the mold is complete, the mold, injection molding machine and automation are integrated into a complete system. SPECTRIX follows a Scientific Molding approach to systematically determine process parameters and define a stable process window.
Depending on customer and industry requirements, SPECTRIX also supports functional verification, process validation including DQ, IQ, OQ and PQ, transfer into regulated manufacturing environments, and Site Acceptance Testing (SAT).
For the Fakuma showcase, the mold will be integrated into an ARBURG 570 H2000-800 and operated as a complete production cell.
Production & Scaling
With Specialty Injection Molding, SPECTRIX is expanding the capabilities of its Tech Centers worldwide. In total, more than 60 injection molding machines are available for testing and ramp-up production. In addition to development, sampling and validation, the company will also be able to provide bridge and temporary production – for example, to bridge the period until series production starts or to enable the controlled transfer of processes to a subsequent production site.
SPECTRIX also offers low-volume and niche production for particularly demanding applications. In selected cases, specialized applications can also remain in permanent series production. Quality-controlled processes, traceability and documentation support production throughout.
Lifecycle Support
A mold project does not end when production starts. Maintenance, spare parts supply, optimization, refurbishment and modernization help ensure availability, process stability and part quality throughout the entire lifecycle.
The Fakuma showcase demonstrates what End-to-End Injection Molding Solutions means for SPECTRIX: not simply placing as many individual technologies as possible alongside one another, but connecting the relevant competencies throughout the entire product lifecycle. With Männer, Foboha, Synventive, Thermoplay, Gammaflux and Priamus, SPECTRIX brings together nearly all essential technologies and competencies along the process chain within one company – from co-development to moldmaking, hot runner, sensing and control technology, system validation and integration, Specialty Injection Molding and Lifecycle Support.
The end-to-end application will be demonstrated live at the SPECTRIX booth at Fakuma, Hall A1, Booth 1208.
Figures:
Fig. 1 SPECTRIX End-to-End Injection Molding live at Fakuma
About SPECTRIX
SPECTRIX brings together the industry-leading brands Männer, Foboha, Synventive, Thermoplay, Gammaflux, and Priamus. Combining more than 50 years of expertise with 2,000 specialists worldwide, SPECTRIX delivers the full spectrum of end-to-end injection molding solutions.
From part design and material science to molds, hot runners, sensing and control technologies, qualification, specialty molding, and lifecycle services, SPECTRIX supports every stage of the injection molding process. Customers can choose individual technologies and services or benefit from a fully integrated end-to-end solution tailored to their specific needs. With a global footprint and strong local expertise, SPECTRIX partners with customers from concept through series production.
SPECTRIX – Enduring Advantage, Engineered.
Contact
Europe:
Lena Haack
Americas:
Brady Richman
brichman@onebarnes.com
Link to press materials (German/English)