Optimization of the thermoset injection molding process at Ottronic: An innovative application example of MoldFront sensor technology

In today's industry, the focus is on optimizing production processes in order to reduce costs, minimize waste and maximize quality. An excellent example of this is the collaboration between Ottronic E-Systems, a leading company in the field of medical technology.

The challenge: Precise control of the flow front in the injection molding process

Ottronic, known for manufacturing highly sensitive electronic components, was faced with the challenge of optimizing its thermoset injection moulding processes. This is a complex process in which sensitive components are encased in a resistant plastic. The process previously used was time-controlled and led to fluctuations in product quality. Different injection volumes, influenced by different product types and external conditions, made it difficult to control the process consistently.

The main challenge was to find a reliable sensor system that could detect the flow front of the thermoset in the cavity precisely and without contact in order to optimally control the switchover point from injection pressure to holding pressure. The sensor system also had to withstand the extreme conditions, in particular the high temperatures of up to 160°C during the production process.

The solution: MoldFront sensor technology from Moldsonics

Ottronic opted for MoldFront sensor technology from Moldsonics. This sensor system enables non-contact, highly dynamic detection of the flow front in the injection mold. As soon as the thermoset melt passes the sensor, a constant base signal drops and the sensor emits a 24-volt signal. This signal automatically controls the switchover point of the injection molding process and activates or deactivates a vacuum pump to optimally vent the cavity.

The advantage of this solution lies in its high precision and speed. Unplanned downtimes and rejects were minimized thanks to the precise control, and the component quality remained consistently high. In addition, the production process did not have to be recertified as the sensors were integrated into the process in a non-invasive manner.

Results: Higher efficiency and product quality

The implementation of MoldFront sensor technology has brought remarkable improvements to the thermoset injection molding process at Ottronic:

• Reliable detection of the flow front: The sensor system precisely detected the point at which the melt reached the end of the flow path. This allowed the switchover point to be optimally controlled.
• Seamless integration: The sensors were integrated into the existing system without any adjustments to the tool design. Cable management and the electronic connection to the machine control system ran smoothly.
• Consistent product quality: The quality of the electronic components was ensured regardless of external influences.
• No recertification: As the sensor technology did not have an invasive effect on the process, no recertification was required, which saved time and money.

Conclusion: Innovation through sensor technology for optimal processes

The partnership between Ottronic and Moldsonics impressively demonstrates how advanced sensor solutions can take industrial processes to a new level. The MoldFront sensor technology not only enabled more precise process control, but also helped to minimize waste and production interruptions. For companies operating in the field of medical technology or other sensitive industries, this is a prime example of how efficiency and quality can be sustainably increased through the targeted use of technology.

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