Inline sensor technology in injection molding: Moldsonics live at ENGEL & Smart Plastify

April 2025 | General, info@moldsonics.at, MoldFront, Injection molding

What no one could see before, we are now making visible

Moldsonics and Smart Plastify work together

Making hidden data visible - directly in the plasticizing cylinder.

Last week, the machine acceptance of the Smart Plastify system took place at ENGEL in Schwertberg. In the course of this, we were also able to hand over our Moldsonics sensor system and successfully put it into operation. In the center: SonicScan, the new sensor system from Moldsonics, mounted on the protective grid on the right above the plasticizing unit.

For the first time, SonicScan delivers live data directly from the screw flights - inline, contact-free and without influencing the process.

Innovation in action: Our experience at ENGEL

What sensors have we supplied?

Smart Plastify is all about energy-efficient melting during injection molding.ßmolding. According to Sebastian Pütter the Smart Plastify technology - specifically specifically with the internally heated screw - can up to 30% energy savings.

To also demonstrate how the melting behavior and homogeneity of theähomogeneity of the meltäWe have installed a sensor system on the system that is unique in the world:

Inline measurement of the degree of melting in the individual screw flights
Analysis of the homogeneity of the melt at the nozzle flange
Most completeäcompletely contactless and process-neutral

The special feature: SonicScan can be used to determine how the screw temperature affects the quality of the plastic melt - directly during the plasticizing process.

Electronics on the system scaled Moldsonics inline sensors

Why this is important: Lessons learned from the project

Clearly, the less energy consumed, the better for the environment.üenvironment, resources and economic efficiency. At the same time, in the highlyäplastics processing, it must be ensured that the components meet all requirements.ürequirements. The qualityäquality of the melt is a decisive factor here.

Our aim is therefore to use sensor technology to ensure that the melt quality is maintained despite reduced energy input during melting.äquality is maintained - and deviations can be detected immediately.öcan be detected immediately.

Immediate quality control of the plastic melt
Early detection of deviations
Reduction of rejects and material waste
Energy efficiency with verifiability

The result: a step towards digital üsustainable and reproducible plastics processing.

What happens next: The nextänext milestone

The system enters theäon its journey to its destination - to the Smart Demonstration Factory Siegen (SDFS Smarte Demonstrationsfabrik Siegen GmbH).

After commissioning, theßt is then forüfor Sebastian Pütter: measure, analyze, evaluate . and we at Moldsonics will, of course, support him in this.äof course continue toäactively supportüsupport.

In the future, there will also beßalso möbe possible for external interested parties to use the facility.öuse the system. So if you are interested in the topic and would like to see for yourself, please contact us.öyourself, please contact Sebastian or me directly.

And as a little extra: we are also planning to use the injection moldingßmold with our ultrasonic sensor technology. This will make it possible toüthe entire process - from plasticizing to demoulding - throughäThe process can be analyzed continuously with our sensor technology.

Sensors that turn data into value.

Thanks to Smart Plastify forüfor the strong cooperation and trust!

Contact us to find out more!

Revolutionizing injection molding: Smart Plastify validates heating technology with Moldsonics' ultrasonic system

March 2025 | General, info@moldsonics.at, MoldFront, Injection molding

"With their technology, Moldsonics will provide us with crucial insights for which I have not yet seen a technical solution - so I am very excited about the results."
- Sebastian Pütter, Founder & CEO, Smart Plastify

Image rights: Green Tech Startups Austria

Injection molding technology is changing: Smart Plastify is setting new standards with its innovative heating technology. This solution significantly reduces energy consumption and increases process stability - especially when processing recyclates. But how can this revolution in plastics processing be precisely validated in terms of measurement technology?
This is where Moldsonics comes into play.

Redefining plastics processing

Smart Plastify has developed an innovative, internal heating technology based on high-performance heaters. These are integrated directly into the plasticizing screw and supplement the conventional, external heating bands that continue to be used.

The additional dissipative heat input of the heated plasticizing screw means that the heat energy is introduced into the melting process in a targeted manner. This significantly increases the efficiency of the heat transfer, as the heat is applied exactly where it is needed.

The result:

Higher heat transfer efficiency for an optimized plasticizing process
Reduced waste heat losses, as the external heating tapes require less energy

This further development takes energy-efficient plastics processing to a new level. However, high-precision measurement data is essential in order to prove the benefits of the technology and make optimum use of them.

Precise measurement and validation with Moldsonics' ultrasonic technology

To validate the performance of Smart Plastify's internal heating technology, Moldsonics uses state-of-the-art ultrasonic measurement technology.

Measurement of the degree of melting and inhomogeneity of the melt: direct analysis inside the plasticizing cylinder and nozzle
Non-contact ultrasonic sensor technology: The sensor does not come into direct contact with the melt and is therefore extremely robust
Energy-efficient and high-precision measurement: no influence on the melting process

Ultrasonic technology detects even the smallest changes in the melting process that would be impossible to measure with conventional sensors.

Do you have a similar measurement task for us? Let's find the best solution for your application together. Get in touch with us!

Contact us to find out more!

Moldsonics is part of Green Tech Startups Austria 2025: Ultrasound technology for the circular economy

March 2025 | General, info@moldsonics.at, MoldFront, Injection molding

Moldsonics is proud to be recognized as one of the Green Tech Startups Austria 2025 - especially in the Circular Economy category. This recognition underscores our commitment to energy-efficient manufacturing technologies, resource-saving production processes and digitalization in plastics processing.

Bildrechte: Green Tech Valley

The Green Tech Valley Initiative showcases 215 innovative companies focused on sustainability - a 10% growth over the previous year. Moldsonics is part of this dynamic and growing community that is accelerating the transition to greener industrial practices.

The growing green tech movement

The demand for innovative, environmentally friendly technologies is growing rapidly. According to a recent study by Green Tech Valley, the green tech startup ecosystem in Austria has expanded by 71% since 2022.

Important business areas of green tech startups:

Energy (38%) - Solutions for optimizing energy consumption
Circular economy (21%) - promotion of resource-conserving processes
Digitalization (17%) - Increased efficiency through digital technologies

These developments are particularly relevant for injection molding and plastics processing, where sustainable solutions are urgently needed. As a Circular Green Tech startup, Moldsonics plays a key role in reducing waste, improving energy efficiency and promoting sustainable production methods.

Why our ultrasonic technology fits in with the Green Tech movement

Our high-precision ultrasonic technology enables non-invasive, real-time monitoring of melting processes in plastics processing. This leads to numerous sustainable benefits as manufacturers reduce waste, save energy and optimize material usage.

Important advantages of the Moldsonics ultrasonic measuring system:

Reduced material consumption - high-precision process control minimizes raw material waste
Extended product service life - improved material analysis ensures greater durability and reliability
Increased energy efficiency - optimized process parameters lead to lower energy consumption per production cycle
Minimization of production waste - non-invasive ultrasonic measurement prevents unnecessary material loss

"We are proud to be part of Green Tech Startups Austria 2025. Our technology helps companies to make their production more sustainable without sacrificing efficiency"

Dr. Thomas Mitterlehner

Chief Executive Officer, Moldsonics

Experience Moldsonics in action

We invite companies in the injection molding and plastics industries, as well as technical engineers and production managers, to discover how Moldsonics' ultrasonic measurement systems can optimize their production processes while improving sustainability.

Let's shape the future of resource-conserving, energy-efficient and sustainable production together.

Contact us to find out more!

Find out more about green tech initiatives in Austria and our role in the circular economy: 🔗 Green Tech Startups Austria

Axxicon & Moldsonics present unique solution for measuring flow velocity in injection molding

February 2025 | General, info@moldsonics.at, MoldFront, Injection molding

Axxicon and Moldsonics have jointly developed a new flow velocity measurement system for injection molding. MoldFront flow velocity measurement enables non-contact and reliable monitoring of the material flow during the injection molding process. Thanks to continuous real-time data acquisition, deviations can be detected at an early stage and corrected in a targeted manner.

Thomas Mitterlehner, CEO of Moldsonics, and Niels Bons, Business Development Manager at Axxicon, finalize their collaboration to combine AIM Quick Change technology with Moldsonics' non-contact flow velocity measurement.

Easier control for the operator

The new solution significantly simplifies the monitoring and control of the manufacturing process for tensile test specimens. Operators benefit from an intuitive speed display, as the MoldFront sensor system precisely records the flow speed without calibration and displays it in real time. This reduces incorrect settings and improves the reproducibility of production results.

Three Components Moldsonics inline sensors

Advantages of MoldFront flow velocity measurement in injection molding

Greater precision in the production of tensile test specimens and therefore more accurate material data.
No risk of contaminationas the sensor does not come into contact with the material.
Fewer customer complaints due to highly accurate material data
ISO-compliant tensile test specimenswithout sensor markings that could influence the test result.
Simple installation and seamless integration into existing injection molding systems.

Axxicon and Moldsonics focus on innovative solutions to improve quality and efficiency in injection molding and material testing. This cooperation makes it possible to become even more precise in the production of test specimens and thus ensure highly accurate material data.

About Axxicon

Axxicon specializes in the manufacture of precision moulds and tools for the production of test specimens according to international standards such as ISO, UL94 and ASTM. The company offers modular injection molding solutions that enable efficient and precise production of test specimens. In addition, Axxicon has extensive experience in the production of ultra-precise components with extreme flatness and low roughness.

About Moldsonics

Moldsonics was founded in Linz in 2021 and develops high-precision, non-contact ultrasonic sensors for industrial applications. Moldsonics' sensors enable the precise monitoring of quality parameters such as flow fronts, flow speeds, solidification behavior and wear in injection molding and extrusion processes. This technology makes a significant contribution to reducing rejects, lowering production costs and increasing efficiency.

Moldsonics is at your side with innovative, customized sensor solutions. Contact us to find out more!

Contact us to find out more!

New use case: Flow front detection in the processing of thermoset

September 2024 | General, info@moldsonics.at, MoldFront, Injection molding

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.

Would you like to find out more?

Download the complete use case here and discover how MoldFront sensor technology can also optimize your production processes:

Picture of the front page Moldsonics inline sensorik

Download Use Case english

Download Use Case German

Moldsonics is at your side with innovative, customized sensor solutions. Contact us to find out more!

Thomas Mitterlehner in an interview at Toolplace

August 2024 | General, info@moldsonics.at, MoldFront, MoldUni, Injection molding

Thomas Mitterlehner from Moldsonics at Toolplace: How our innovative ultrasonic sensor technology is revolutionizing the injection moulding process

At Moldsonics, we are always striving to push the boundaries of manufacturing technology. That's why we're particularly pleased that our Co-Founder and one of the two Managing Directors, Thomas Mitterlehner, recently had the opportunity to speak to Toolplace about our latest innovations. In an in-depth interview, Thomas shed light on the revolutionary developments we are driving in the field of ultrasonic sensor technology and explained how this technology is changing the injection molding process from the ground up.

Moldsonics: Pioneering work in ultrasonic sensor technology

Since Moldsonics was founded in Linz in 2021, we have established ourselves as innovators in the field of ultrasonic sensor technology. What began as an interdisciplinary team of plastics engineers, mechatronics engineers and measurement technicians has developed into a company that offers highly specialized sensor solutions for the manufacturing industry. Our roots lie in twelve years of intensive research, which has enabled us to transfer state-of-the-art measurement methods from science into practical applications.

Our ultrasonic sensors have been specially developed to meet the requirements of injection moulds and plasticizing units. They offer a unique way to measure quality parameters such as flow fronts, flow velocities, solidification behavior and wear without contact. This precise data acquisition and analysis is crucial for optimizing the injection moulding process, as it enables a drastic reduction in rejects, lower production costs and greater efficiency.

The advantages of our ultrasonic sensors in the injection molding process

One of the biggest advantages of our ultrasonic sensor technology is its ability to monitor the production process in real time. This allows manufacturers to react quickly to changes and optimize the process before major problems occur. This real-time data provides insight into the condition of tools and production lines, resulting in improved control and efficiency.

Our sensors are designed to ensure high precision and reliability even in the harshest industrial environments. This is particularly important in the injection molding process, where the smallest deviations can have a significant impact on product quality. By continuously monitoring and adjusting the process with our sensors, manufacturers can not only improve the quality of their products, but also reduce their production costs and increase their productivity.

Insights from the interview: How our sensor technology is used in practice

In an interview with Toolplace, Thomas Mitterlehner discussed the practical applications of our ultrasonic sensors and explained how this technology is already being used in the industry. He described how our sensors help to accurately monitor the flow fronts and flow speeds in the injection molding process and how this information is used to adjust the process in real time. These adjustments lead to a significant improvement in product quality and a reduction in material waste.

Thomas also spoke about the importance of recording the solidification behavior in the tool. These measurements are critical to ensuring the structural integrity and consistency of the end product. With our sensors, manufacturers can identify potential problems early and correct them before they lead to costly production downtime.

Discover how our ultrasonic sensors can optimize your injection moulding processes:

Find out more about our applications

Toolplace: A strong partner for the injection molding and toolmaking industry

Toolplace is an innovative platform that helps injection molders and toolmakers in the DACH region to hold their own against international competition in the long term. The platform offers a digital procurement solution that is specially tailored to the needs of injection mold procurement. This relieves companies of administrative processes and frees up their specialists to concentrate on value-adding tasks.

Toolplace also uses an AI algorithm that adds additional toolmakers from an extensive database to project inquiries. The result: an expanded market view and the fast, targeted identification of new suppliers. At the same time, toolmakers registered with Toolplace benefit from direct access to potential new customers.

By partnering with Toolplace, we can ensure that our ultrasonic sensor technology is integrated into manufacturing processes in a targeted and efficient manner. Together, we are working to make the manufacturing industry smarter, more efficient and more future-proof.

Website: https://toolplace.de/
Contact to Christian Götze: Linkedin profile