Dopak Sp. z o.o. » New machines » Technologies

Increased demand for advanced technologies that meet the high quality requirements of moldings or specific strength properties
and aesthetics is constantly growing, especially in industries such as electronics, electrotechnics and automotive. We meet the expectations of customers with special technologies.

Technologies

MuCell (foaming technology)

MuCell is a technology for the production of microporous materials. The technology of microcellular foaming of thermoplastic polymers consists in feeding a physical foaming agent (SCF) to a plasticizing cylinder, where, under appropriate temperature and pressure conditions, controlled nucleation, growth and stabilization of bubbles occur. The manufacturer KraussMaffei is an expert in process engineering and a supplier of production systems. In the field of technology, Mucell cooperates with Trexel.

Benefits:

  • Part weight reduction by up to 20%;
  • Cycle time reduction by up to 40%;
  • Reduction of the clamping force by 30-50%;
  • High fatigue resistance and high strength of moldings;
  • No downforce required;
  • High dimensional stability of the molded parts;
  • Reduction in the amount of material used.

Advantages:

  • One-stop solution from one supplier;
  • Full integration with the MC6 control system;
  • Optimized plasticizing system.

CleanForm (Cleanroom Technology)

CleanForm is an advanced clean room and zone technology based on process development and machine engineering that meets the high cleanliness requirements of the medical and optical industries. The manufacturer KraussMaffei has successfully implemented many solutions around the world in accordance with DIN EN ISO 14644-1 and meeting ISO 5 air cleanliness class. Therefore, it is the perfect partner for the implementation of energy-saving cleanroom solutions.

Benefits:

  • Flexibility with high performance at the same time;
  • Confirmed qualifications according to DIN EN ISO 14644-1, class 5;
  • Plug-and-Play concept for mobile automation units;
  • Possibility to implement the GMP (Good Manufacturing Practice) system.

Advantages:

  • Limiting the number of moving parts and the need for lubrication;
  • Reduction of the number of wearing parts;
  • Quick and easy mold change with railings;
  • Sterile mold zone free from airborne particles
    in the closing system;
  • Hermetic casing with a filtering and ventilation device.

ColorForm (in-mold varnishing)

ColorForm technology is based on the principle of multi-component injection. The movable mold is equipped with two injection units. In the first stage, the base thermoplastic detail is formed in a mold, and in the next stage it is covered with a PUR or PUA layer, using a special process (RimStar Flex ColorForm) and a mixing head. This provides a high-quality and extremely scratch-resistant surface.

Benefits:

  • Reduction of production costs;
  • Minimization of logistics costs;
  • Elimination of conventional painting steps;
  • Radical reduction of the amount of missing parts;
  • Quick color change;
  • Compact design;
  • An economical way to obtain a very high-quality surface;
  • One slot.

Advantages:

  • Very high gloss surface obtained in one production process;
  • Aesthetic scratch-resistant surface;
  • Ability to present images, logos on the surface;
  • Resistant to UV radiation and chemicals;
  • Uniform layer obtained around the edges;
  • Elimination of solvents and release agents during production.

DMH (Dynamic Mold Heat-Balancing)

DMH – is an induction heating technology used in injection molds, consisting in dynamic temperature changes,
also in selective places of the mold cavity. It allows for the elimination of defects caused by conventional injection molding, such as the joining lines of plastic plows. Induction heating allows you to obtain decorative surfaces with precise structures: holograms, shading effects, gloss, mats, just with the use of special inserts
with a laser structure, and everything is done during one technological treatment, which does not require technical and financial outlays related to additional stages.

Benefits:

  • Obtaining a high gloss surface;
  • Reduction of the level of internal stress when producing lenses;
  • Manufacture of thin-walled parts, e.g. flexible hinge films;
    high-strength;
  • Short cycle times and no temperature limitation for any plastic materials, even with glass fibers;
  • Hologram or laser surface treatment effect;
  • High level of production efficiency;
  • One-step process without the use of foil;
  • Precise mapping of the microstructure.

FiberForm (lightweight construction)

FiberForm technology is the integration of two processes: thermoforming
and injection molding. The technique is dedicated to the production of hybrid, lightweight composite structures, extremely resistant
on load. Primarily used in the automotive industry
and aviation.

Benefits:

  • An alternative to steel and aluminum;
  • A very significant reduction in the mass of details;
  • Manufacturing components of high complexity;
  • Very good mechanical properties, ability to absorb kinetic energy;
  • Adjusting the reinforcement depending on the needs by using glass, aramid or carbon sheet prepregs;
  • Efficient capacities allowing serial production.

Advantages:

  • All process steps performed by one gripper: transfer of the blank to the furnace – heating – transfer to the injection mold – thermoforming by closing the mold – injection of thermoplastic material;
  • Possible integration with technology (IMC);
  • One-step process, in-mold thermoforming;
  • Compact and fully automated production line;
  • Integrated heating station (IR infrared oven);
  • Can be placed in the form of inserts.

IMC (Injection Molding Compounding)

IMC technology is a combination of a continuous extrusion process and injection molding. During compounding on twin-screw extruders, polymer blends with various additives are obtained, such as mineral fillers, wood chips, long or chopped glass fibers, reinforcing agents characterized by excellent homogenization and plasticization.

Advantages:

  • Excellent dispersion of long glass fibers;
  • High quality of products obtained by the stability of the plasticizing process;
  • High mechanical strength of products with the addition of recyclates;
  • Low temperatures of the plasticized mass;
  • Highly resistant components exposed to abrasion;
  • Short cycle times;
  • High design freedom, high complexity of construction elements.

Benefits:

  • Cost reduction thanks to the integrated functional concept;
  • Low processing temperatures of recyclates;
  • The highest quality of products thanks to constant plasticizing properties;
  • Saving material costs through the use of additives;
  • High plasticization efficiency for recyclates, additives, fibers.

IMD (In-Mold Decoration)

The technology of decorating in the form allows for obtaining aesthetic surfaces in one production process. The technology of the process consists in placing an insert in the form of a decorative foil, which is fed from a roll using a feeder. The decor placed on the foil is precisely positioned. The mold is equipped with special vacuum ports, which allows it to be perfectly adapted to the mold cavity and prevents displacement. After plastic injection, the product is transferred to a UV station, where the surface is dried and hardened by means of rays.

Benefits:

  • Manufacture of enhanced products with special effects and integrated electronics;
  • Surfaces resistant to aging, peeling off;
  • Manufacture of ready-to-install components in a one-step process;
  • High surface quality of manufactured products, perfect coverage of entire surfaces, photographic quality of graphics;
  • Minimal amount of generated production waste – environmentally friendly technology;
  • 100% recyclable products.

Advantages:

  • Full automation in a small space;
  • 8 production cleanliness class;
  • Perfect integration of peripheral devices for KraussMaffei machines;
  • A very significant reduction in production costs, lower electricity consumption.

Multinject (multi-component injection)

Mulinject is an advanced technological process that enables the production of details from two or more components, which consists in injecting successive combinations of thermoplastics, polyurethanes and elastomers into the socket of one injection mold. As a result of the synergy of the properties of the materials used, an attractive, high-quality product is obtained. A comprehensive system solution of multi-component injection requires the selection of the most optimal technology, a machine equipped with appropriate components and a mold adapted to the multi-component injection technology.

Advantages:

  • Perfect function integration;
  • Consolidation of the properties of the materials used;
  • Integration of process steps;
  • High quality of products;
  • Great freedom of design.

Benefits:

  • Improved functionality and quality of moldings;
  • Increased production efficiency thanks to advanced process engineering;
  • The combination of excellent material properties;
  • More design freedom;
  • Integration of individual production stages.

Polyset & Duroset (processing of duroplasts)

The PolySet technology is based on the processing of thermosetting plastics, reinforced polyester compounds and vinyl esters to produce technical details of the highest quality.

Benefits:

  • Constant process conditions thanks to the raw material feeding system Polyload AZ;
  • Cycle time reduction through the use of cold runners;
  • Self-cleaning AZ unit reduces maintenance costs;
  • High homogenization and quality of the material achieved by pressure regulation
    in plastic;
  • Savings in plastic consumption.

Advantages:

  • Self-cleaning and maintenance-free AZ feeders;
  • Cavity ventilation with flashes for better surface quality;
  • Patented AZ feeder augers;
  • Gentle feeding of material with low shear stress thanks to special PolySet screw feeders.

Silcoset (LSR processing)

Silicones, and in particular the new generation of liquid silicones (LSR), offer great development opportunities and are gaining newer and newer areas of application thanks to their excellent physical properties. They are transparent, easy to install, resistant to high temperatures and antibacterial. KraussMaffei injection molding machines: hydraulic, electric or hybrid with clamping forces from 25 to 420 tons, can be easily adapted to the Silcoset technology.

Advantages:

  • Safe and stable processing of low-viscosity material due to the absolute parallelism of the plates;
  • Accurate injection weights even with a 256 cavity mold;
  • The highest quality of details and “zero-scrap” production with the APC plus technique continued;
  • Total transparency of the entire process thanks to digital solutions;
  • Easy transition from thermoplastic processing to processing silicone;
  • Uninterrupted cooling to maintain a stable temperature to exclude the possibility of premature cross-linking;
  • Precise injection thanks to non-return valves for low-viscosity materials;
  • The precision APC plus micro injection ensures a flawless process with a part weight of 0.03 g.

Advantages of LSR:

  • Biocompatible;
  • Resistant to bacteria;
  • Temperature resistant (ideal for crystallization);
  • Permanently flexible;
  • Free from plasticizers;
  • Long service life.

SpinForm (Swivel Platen Technology)

The SPINFORM technology enables the rational production of multi-component products using a rotary mold. The center plate of the mold is on a rotating unit that supports it and rotates between the two injection systems. Successive injections allow for the production of details with a very aesthetic surface. The technology also enables the use of multi-cavity molds.

Benefits:

  • Convenient access to rotary unit, fixed plate and middle mold;
  • Manufacture of profiled large-format products;
  • Possibility to integrate special processes, e.g. forming by stamping;
  • Doubling the production efficiency for a given type of machine;
  • Cleanroom compliance.

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Technologies

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