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 to reduce costs, minimize waste, and maximize quality. A prime example of this is the collaboration between Ottronic E-Systems, a leading company in the medical technology sector.

The Challenge: Precise Control of the Melt Front in the Injection Molding Process

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

The main challenge was to find a reliable sensor system capable of precisely and non-contact detecting the flow front of the thermoset resin in the mold cavity, thereby enabling optimal control of the transition from injection pressure to holding pressure. In addition, the sensor system had to withstand extreme conditions, particularly the high temperatures of up to 160°C during the production process.

The solution: MoldFront sensors from Moldsonics

Ottronic opted for Moldsonics’ MoldFront sensor system. This system enables contactless, 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 system outputs a 24-volt signal. This signal automatically controls the switching 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 downtime and scrap were minimized thanks to the precise control system, and component quality remained consistently high. Furthermore, there was no need to recertify the production process, as the sensor technology was integrated into the process in a non-invasive manner.

Results: Increased efficiency and product quality

The implementation of MoldFront sensor technology has led to significant improvements in the thermoset injection molding process at Ottronic:

• Reliable detection of the flow front: The sensors precisely detected the moment when the melt reached the end of the flow path. This allowed for optimal control of the switchover point.
• Seamless integration: The sensor system was integrated into the existing system without any modifications to the tool design. Cable management and the electronic connection to the machine control system went smoothly.
• Consistent product quality: The quality of the electronic components was maintained regardless of external factors.
• No recertification: Since the sensor technology did not interfere with 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 is a striking example of 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 minimize scrap and production downtime. For companies operating in the medical technology sector or other sensitive industries, this is a prime example of how targeted use of technology can sustainably increase efficiency and quality.

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