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Technology | optical moulding


machinery maker Engel is also investigating multi- layer optical moulding techniques. The company demonstrated its original Optimelt system for produc- tion of multi-layer optical components back in 2011. During the K show, the company will demonstrate a further refi nement of this multi-layer moulding process that runs on a standard single-shot moulding machine. It uses an intermediate external cooling phase to further shorten the cycle. The process, developed together with German mouldmaker Krallmann, will be producing a 15mm thick automotive collimator lens using a Bayer MaterialScience polycarbonate. It will be running on a standard e-Motion 200/110 T moulding machine equipped with a Viper 12 Engel robot. “Polymer optics is going to be a key technology for the


future in automotive, electronics and illumination,” says Engel senior vice president of R&D technologies Georg Steinbichler. The challenge, he adds, is to be able to produce these demanding thick wall parts economically. Steinbichler says conventional three-layer moulding of thick wall lenses involves production of a centre element, which is cooled to below the glass transition


Left: Taking cooling outside the moulding process saves cycle time on this PC collimator lens, claims Engel


temperature (Tg) of the polymer before it is demoulded and then overmoulded to create a three-layer structure. He says using this method it is possible to produce parts of a high optical quality on much shorter cycle times than using standard injection compression moulding. For a 30mm thick acrylic lens he estimates a total cycle time of 440s compared to 1,550s. The new Krallmann technology opens up further cycle


reduction opportunities by introducing the intermediate cooling phase and exploiting the fact that the surface quality of the part produced in the fi rst step – prior to


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K 2013 Hall 01


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