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

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?

At Smart Plastify, it's all about energy-efficient melting in injection moldingß. According to Sebastian Pütter , Smart Plastify technology— specifically with the internally heated screw – up to 30 % in energy savings.

To also demonstrate how the melting behavior and homogeneitytpolymer melt ä, we have installed a sensor system on the plant that is unique worldwide:

  • Inline measurement of the degree of melting in the individual screw flights
  • Analysis of the Homogeneity of the polymer 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

It's clear: The less energy is used, the better fitthe environment, resources, and cost-effectiveness. At the same time, in the highly competitiveäprecision plastic processing, it must be ensured that the components meet all requirementsü. The qualityäpolymer melt is a decisive factor in this regard.

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 bonus: We're planning to include injection molding as wellwithmold with our ultrasonic sensors. This will allow us toinin the future, the entire process – from plasticizing to demolding – bebeanalyzed throughout the process using 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

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

Moldsonics and Smart Plastify work together

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 complement the conventional external heating bands, which continue to be used.

The additional dissipative heat input from the heated plasticizing screw directs thermal energy specifically into the melting process. This significantly increases the efficiency of heat transfer, as the heat acts 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.

  • Measuring the Degree of Melting and Inhomogeneity of the polymer melt: Direct Analysis Inside the Plasticizing Cylinder and the Die
  • Non-contact ultrasonic sensors: The sensor does not come into direct contact with the polymer melt , making it 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

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.

Green Tech Startups Austria 2025

Image credit: 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

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.
Moldsonics-Axxicon partnership

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 here to support you with innovative, customized sensor solutions. Contact us to learn more!
Contact us to find out more!
New use case: Flow front detection in the processing of thermoset

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 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.

Moldsonics-MoldFront-inclusive-Sensor-2

©Ottronic E-Systems

The Challenge: Precise Control of the flow front s 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 e of the thermoset resin in the mold cavity in order to optimally control 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 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 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 sensor system precisely detected the moment when the polymer melt reached the end of the conveyor path. This allowed for optimal control of the switching 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.

Would you like to learn more?

Download the full use case here and discover how MoldFront sensor technology can optimize your production processes as well:

Picture of the front page Moldsonics inline sensorik
Download Use Case english
Download Use Case German

Moldsonics is here to support you with innovative, customized sensor solutions. Contact us to learn more!

Thomas Mitterlehner in an interview at Toolplace

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.

In addition, Thomas discussed the importance of monitoring setting behavior in mold. These measurements are crucial for ensuring the structural integrity and consistency of the final product. With our sensors, manufacturers can identify and correct potential problems early on, 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 remain competitive on the international stage over the long term. The platform offers a digital procurement solution specifically tailored to the needs of “ mold ” procurement. This relieves companies of administrative burdens and frees up their specialists to focus on value-added 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