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Overview
The Neo.M range of injection moulding machines from Tederic is developed specifically to meet the needs of the packaging, medical and consumer industries for high output, many-cavity moulds and to manufacture containers or components in a variety of materials. The range is comprised of eight model variants with clamping forces from 500 to 1300 tonnes.
Each machine is supplied with a second high-pressure injection unit as standard to facilitate moulding with two materials, or with a single material using two nozzles to effect a cost-saving colour change. Tederic has recognized that simply offering two-shot capability on a standard machine is not effective in achieving the ultimate product quality or process flexibility, and has therefore paid great attention to the detailed design of the high-pressure secondary injection unit and the control system.
For sequential two-shot moulding, the performance and resolution of the check screw is a critical factor in controlling the switch over from the first to the second material, and the resultant position of valve gate, air switch, or hydraulic controllers. Accompanying this is a demand from the moulding industry to minimize the environmental impact of the products being manufactured, which has seen a growth in the use of bio-polymers with their reduced carbon footprint and more recently the introduction of materials with recycled content.
Both of these materials present processing challenges which would best be met with machines that offer the flexibility to vary screw diameter and have good mixing performance over a wide range of shot sizes and pressures. Tederic’s development of the Neo.M N series machines versions N500, N750, and N1100 is aimed at fulfilling this need. The machines are equipped with a shot-to-shot repeatability servo plasticizing unit and a modular selection of screw and check screw designs to match the most demanding of applications. This maximizes the possibility of achieving multiple high-quality results from a single machine and provides a level of economics that is highly attractive to the custom moulder who must invest in tooling biased toward the prevailing ‘run size’ of today’s market.
Introduction to Tederic Neo.M Machines
The capability to utilize multiple barrel and injection units on one machine provides reduced setup times between jobs as well as the optimization of maximum productivity efficiencies. With each machine having a range of platen and tie bar spacing sizes, this allows the most suitable machine to be chosen with a flexible choice in the future between different size machines.
The choice of machine is dependent on the complexity of the mould, the desired cycle time, desired levels of automation and robot control with many other contributing factors taken into account. Tederic Neo-M machines offer a wide range of machines from 50 to 250 tons with an overall choice of 8 machine models. These machines use a special barrel and screw assembly offering the user the flexibility to process all types of thermoplastic in the most cost-effective manner.
The Tederic Moulding machines introduce a new benchmark setting standards of performance and versatility within the injection moulding industry. A key feature of the Tederic multi-material machines is their ability to process high-performance engineering plastics such as PEEK, PPS, and PEI, for example, or any number of other resin systems to high levels of surface quality and preciseness.
Tederic Injection Moulding Machines Technology is a new concept multi-functional integrated system which allows combination of different mould technologies from a standard injection moulding machine to a MAG or SGA machine and into a Tederic N series PET Injection system. The concept has been developed to cover all in-mould labelling or in-mould decoration technologies on the market today.
Benefits of Multimaterial Processing
The manufacturing technology for multi-component injection moulded parts is generally divided into 2 categories: a System-oriented approach using specialised multi-component moulding machines, or a Material/Process focused approach with machines offering modularity and flexibility. Tederic Neo-M represents the latter with Neo-M machines being able to handle a variety of material-focused multi-component processes such as overmoulding, insert moulding, or co-injection.
Example: A medical syringe comprising of a hard polycarbonate body with a soft flexible plunger. This multi-component, multi-material product can be overmoulded using a Tederic Neo-M into a one-shot process. A significant cost per unit of the part in saving tooling, handling, and processing costs incurred in a 2 or 3 shot process can be achieved.
There are several technical advantages in having the capability to process and mould different materials into the same component. With Tederic Neo-M machines, the most obvious of these benefits are the “cost” advantages. Materials in the medical, packaging, and electrical industries can be expensive grade-specific types. Due to health and safety requirements, the medical industry can only use virgin grade material. Moulding components for these industries often result in a 2 or 3 shot process whereby the same component is moulded using different materials.
Neo.Ms Series
The Tederic Neo.Ms series is a two-platen machine with multi-mold configurations. The machine series ranges from 500-4500 tons. Two platen design provides more flexibility for mold designs. This series can provide higher flexibility in a rubber injection production, such as rubber pads for consumer electronics application. Neo M series provides a very high power efficiency with specs 0.35 kwh/cm3. The biggest machine of 4500 ton can handle a shot weight of 120kg. The series uses Tederic’s own accumulator mixed with servo pump to increase response time and energy saving. The machine comes with capability to connect to a central molding system. Neo.M series also comes with a user friendly GUI and mold data save technology. Stepless mold height adjustment is also available up to 100mm.
Tederic’s formal statement at the K2016 report were “Tederic produces more than 500 pieces of two platen injection machine every year since 2014 and this is the best performance that they have since 2006. Neo series is the latest product that we have launched this year. Tederic has been growing and doing quite well for the past 2 years despite the condition of the global market and this is our aim to become better and better”. “This product line has three important points. One, it provides more profitability and more advantages to our customers. Second, it has clean environment and lesser noise to contribute to the global society. The last one is we increase our after sales service and technical abilities to increase our service level.” From the statement we can see that Tederic gives confidence and emphasis on latest Neo series and more attention to global customer.
Features of Neo.Ms Machines
Features start with highly responsive direct driver control motor, quick response oil pressure control with variable displacement pump unit, injector driven by the high torque direct drive motor with high response back pressure control system, and combine in-mold and cooling process in a product. High motor torque direct drive rotary table with accurate speed and located the hydraulic accumulator at the top of the mold that is useful for fast speed and improve the stability of production of PET. These features will be the best in conventional hydraulic machine technology and are now available in Tederic all-electric machines. High speed, efficiency, stability, energy saving, and cleaning are the major features that our customers can get from Neo.Ms product compared to the existing all-electric machines.
The features of Neo.Ms machine explain Tederic technology involved in all-electric driven machines in different aspects.
Center Rotating Platen Design
The rotating platen design installed at the center of Neo M machines provides more access and higher efficiency of the molding area or stations. The platen rotates in 180 degrees to have another access to the molding area. This design is suitable for the machines involved in insert molding process. During the molding process with normal fixed platen machines, there’s a certain area of the mold that is hard to reach or essentially impossible to mold. In this case, the molding process would require additional steps or methods which eventually leads to higher production cost. With the rotating platen design, it is easier to load the insert which is located on the other side just by rotating the platen. Special design can be made to modify the rotary system so that the platen only rotates to one side.
This kind of machine provides convenience to the operator during the molding process and at the same time prevents access from both sides, which is deemed dangerous for some applications. Heating elements, tip bush, and the plasticizing unit can be installed at the central axis of the machine and the mold can be located around it. This would only require a small modification to the machine and the platen can rotate in 360 degrees to equally access the molding area. This design can increase productivity and effectively decrease the idle time of cooling processes.
Applications of Neo.Ms Machines
The Tederic Neo.M machines can be applied for various kinds of molding applications. Given that it fits for the multi-material molding, it can process the multi-materials over-molding such as TPE, TPU, TPR, and thermosetting rubber, hard-and-soft-plastics overmolding. 2-components injection is a highly recommended item to be applied with the Neo.M machines. It can be implemented for automotive parts category, houseware and furniture, electronic parts, and medical equipment. By using the 2-components injection, it can simplify the process and get better output for the 2-components products. And also it can be applied for the insert injection application, the Neo.M machines are able to accommodate various kinds of insert injection of plastic, metal, ceramic, electronic parts, and other materials. Sometimes, there is a customer who needs to have a try-out for their mold in the machine. For the conventional molding, the tryout process is quite risky for the mold if there are some troubleshooting in the machine. Any damages can happen in the mold due to the long process time of the troubleshooting. Now, with the development of the virtual molding and the mold-filling simulation, the Neo.M machines can reduce the risk of the try-out and can get the optimal result for the mold.
Neo.Mv Series
Takeout Robot Linear Guide Ways: The robot has linear guide ways positioned directly over the moving platen. This gives the robot a very stable and balanced structure for takeout operations of heavy molds. The linear guide ways and robot can be positioned totally inside the perimeter of the platen, allowing 100% access to the mold area.
Features of NeoMv Machines: Inline Turntable: The Tederic two-platen design has one slightly longer platen on the moving side. On NeoMv machines, the takeout robot is positioned over the stationary platen. A pocket is machined into the platen, and the turntable is positioned in the pocket. When the mold is closed, the turntable is aligned to the centerline of the platen and mold. Molds with core pull can be loaded over the turntable. The turntable design is a very rigid and simple method of loading a mold. It is efficient in the amount of floorspace it uses, and the robot can transfer the mold inserts using the mold opening time. Additionally, the turntable is synchronized to the clamp unit, so it rotates backwards if a mold crashes during the mold closing phase.
NeoMv series is an advanced multi-component plastic molding machine. The advanced design of the series features a takeout robot with an inline turntable to take out and position inserts in the mold. Both the injection unit and the clamp unit are of the two-platen design. The two-platen design is an optimized version of the three-platen design.
Features of Neo.Mv Machines
With Tederic’s advancements in the development of the intelligent injection molding machine, the Neo.Mv series of pIMM represents the worldwide most technically successful design for multimaterial injection molding. Over 200 patents have been granted in the last 20 years, most of which are related to pIMM technology. This is unequalled by any other pIMM supplier. Tederic has established offices in the UK, Germany, Italy, and Mexico to support the local delivery and service of its multishot machines. The first generation of the Neo.Mv series was released in 2006 and was successfully delivered to overseas customers, and led to a sharp increase in the orders from overseas. Since then, the Neo.Mv series has experienced large technological advances and commercial success in the Asian market, especially China. The latest generation of the Neo.Mv series was released at the beginning of 2011, with the first delivery of the new technology taking place in 2012. The figures below show the continued advancement of the Neo.Mv series with 128 machines being delivered between the beginning of 2013 and the end of 2015. During this period, substantial technology breakthrough has been achieved, and it is expected that this technology will be released to the market within the next few years. This upcoming technology will enhance the current technological capabilities of the Neo.Mv series and continue to increase the requirements for innovative multimaterial injection molding in all target sectors.
Standard Rotary Platen Design
The number one design consideration in choosing a machine to produce a multi-material component is that of the platen or table space on which the two mold halves sit. Tonnage requirement for molding multi-material parts often means one machine may only be able to accommodate one mold size. The present standard platen design approach of orientating one mold half in a vertical plane over the other takes up a large amount of platen space. With the increasing cost of land and floor space, a major factor for all manufacturers, new machinery installations are always looking to minimize space usage per molding machine. Tederic’s shuttle and rotary table design provides a more space-effective method by allowing one mold to be mounted on the platen while the other is oriented face down on the moving platen. This facilitates significant space savings as a single machine now has the capability to mold with two different molds. The machine on which these tests were conducted was the Tederic TH150SD M machine with an 18mm screw, material PA6.6 and PP, and with a shot weight of 110g and 165g.
Tederic Neo.Mv series machines offer a variety of design options to accommodate the production of a wide array of multi-component and multi-material insert molding parts. The design concept employed differs from the standard platen for producing multi-material components cited by most other injection molding machinery manufacturers. Tederic’s shuttle and rotary table design yields three advantages: 1. Space Saving, 2. Flexibility, and 3. Automation.
Advantages of Neo.Mv Machines
Programmable Plasticating and Injection Tederic’s Neo Eos/Mv/ML Multi-Material Molding machines utilize a 10.4″ TFT colour LCD screen, which displays the state of the machine. By implementing a LNC3-F control system, which features a menu selectable screw speed and back pressure control, that consists of a proportional valve to set a precise opening position and a High Response A15S servo controller, with the capability of storing and retrieving injection parameters using a USB port, control of each injection unit is precise and fully programmable. This ensures that duplicate tool runs or changes over to a different tool are quick and efficient, producing higher profitability. High precision servo motors on both the B and C axes of the injection platen ensure fast and accurate screw alignment and nozzle touch operations. Both of these features will significantly reduce setup and changeover times when compared to conventional machines with hydraulic controlled injection units, and the precise position control of the screw and valve gates will also save time and labor costs usually incurred when adjusting runner and gate sizes.
Extended lifespan of injection unit componentry Each of the Tederic Neo Eos/Mv/ML Multi-Material Molding Reliability injection devices utilize closed-loop barrel temperature control which applies independent heating and cooling to each 50mm section of the injection barrel. Closed-loop temperature control only applies heat when needed, eliminating hot spots, and greatly increasing the lifespan of the barrel heater bands. Compared to conventional injection units with open nozzle tips, the use of a valve gated cold runner system will minimize material degradation in the nozzle tip and eliminate drooling at the nozzle to prevent unnecessary mold contamination, which could compromise the quality of the final product. In addition to the valve gated cold runner system, the MH33G II Type III screw and barrel assemblies for both 51mm and 57mm injection units utilize mixing nozzles and check rings to greatly reduce shear rates and screw recovery times, providing a wider processing window for sensitive polymers and reducing overall wear of the screw and barrel, which would occur in conventional injection units.
