Sustainability Meets Lightweight Construction at K 2025

At K 2025, ENGEL will demonstrate the capabilities of its innovative injection moulding technologies for lightweight construction with a simple and cost-effective production solution. In the manufacture of cockpit bicycle handlebars for CANYON Bicycles, aluminium is replaced by plastic and production time is reduced to a fraction. This is made possible by combining local reinforcement with continuous fibre-reinforced tapes and fluidmelt technology for the production of hollow bodies – all within a closed process.

The fully automated production cell is based on a tie-bar-less ENGEL victory 180 injection moulding machine with a clamping force of 1800 kN. It combines the overmoulding of locally inserted continuous fibre tapes with the formation of a hollow structure in a single, continuous process step. While the equivalent aluminium process involves multiple time-consuming steps, this solution achieves a cycle time of just 60 seconds. This leads to a significant increase in production capacity and considerable cost savings. The resulting handlebar demonstrates that, with the right engineering, plastic solutions can replace aluminium – offering shorter cycle times, better functional integration, and greater design freedom. These are decisive advantages for demanding applications in the sports and leisure sectors as well as in the automotive industry.

The components themselves are made from a polyamide 6 with 50% glass fibre reinforcement supplied by DOMO Chemicals to ensure the required stiffness and strength. By integrating four unidirectional carbon fibre tapes (UD tapes), which are placed in the mould prior to injection moulding, the part withstands high mechanical loads despite its low wall thickness and hollow structure. During the process, fluidmelt is used to inject gas and push the plastic core of the component back into the plasticising unit, creating a hollow space within the part. The displaced material is reused in the production of the next component. The complete integration of both processes into a continuous injection moulding cycle ensures short cycle times and high reproducibility. This combination of local UD tapes and the fluidmelt process enables complex hollow-body geometries with high design freedom and functional integration, while at the same time reducing material usage and energy consumption.

The handlebar has already passed all required approvals, complies with all relevant ISO standards as well as CANYON’s internal specifications, and will enter series production in 2026.

ENGEL’s manufacturing concept represents a significant advancement over traditional aluminium handlebars by making local production in Europe economically viable while significantly reducing environmental impact thanks to a highly improved carbon footprint. For CANYON, this overall concept means a technical enhancement of the product combined with improved sustainability and a substantial increase in production efficiency.

Automation of the production cell is handled by an ENGEL easix articulated robot. It is responsible for the precise insertion of threaded inserts and continuous fibre tapes, as well as for removing the finished parts. All movement sequences and process steps are coordinated via the central CC300 control unit of the injection moulding machine, simplifying operation and increasing process reliability.

The ENGEL victory 180 wide-platen machine demonstrated in operation at the trade fair is an injection moulding machine specifically designed for large and complex components or moulds. Thanks to its tie-bar-less design with a generously sized, unobstructed mould area, the victory series enables the use of large and complex moulds on compact machine sizes. This offers a distinct advantage when working with high-volume, demanding moulds and complex automation systems.

Both the technology combination and the production solution can be modularly adapted to other component geometries and industry requirements. This makes the system suitable not only for sports and leisure products, but also for structural vehicle components or technical parts with hollow geometries. ENGEL thus demonstrates how well-conceived combinations of established processes can open up new possibilities for energy-efficient, resource-saving, and economically attractive lightweight construction solutions.

www.engelglobal.com

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Supply Chain Security Boosted with Polyimide Doubling Plan

Diversified global manufacturer Asahi Kasei will increase PIMELTM photosensitive polyimide (PSPI) production capacity at its Fuji City facility in Shizuoka Prefecture, Japan. PSPI is a key material for the global electronics industry, mainly used for buffer coatings and passivation layers in semiconductor applications. By doubling its capacity by 2030, Asahi Kasei underlines its commitment to growing its Electronics business and reinforcing its position as a key supplier for the global semiconductor industry.

With the global semiconductor industry entering a new growth cycle and projected to surpass US$1 trillion in revenue by the mid-2030s, as reported by consulting firm Alvarez & Marsal, Asahi Kasei has forecasted that the demand for next-generation semiconductor interlayer insulation will continue to grow rapidly at an average annual growth rate of 8%.

In response to this quickly rising demand, Asahi Kasei completed the construction of a new plant producing PIMELTM photosensitive polyimide in Fuji City, Shizuoka Prefecture, in December 2024. Since then, the company has decided to expand production in Fuji City further, doubling the 2024 capacity by 2030. This expansion is expected to significantly improve the supply resilience of essential materials in the manufacturing of semiconductors. Asahi Kasei will invest approximately ¥16 billion in this expansion.

PIMELTM is used worldwide for various semiconductor applications, such as buffer coatings that improve adhesion between different semiconductor materials and act as protective barriers. These coatings help protect delicate semiconductor devices from mechanical stress and contamination during post-processing steps, such as mounting the chip onto a substrate.

PIMELTM is also used for passivation layers for bumping, which protect the semiconductor surface from damage or oxidation. Additionally, PIMELTM is used in redistribution layers (RDL), optimizing electrical connections and enabling high-density circuit designs by adjusting terminal spacing for package integration. These attributes have made PIMELTM an essential part of the global semiconductor supply chain and an enabling material in the development of next-generation generative AI.

Nobuko Uetake, Senior Executive Officer of Asahi Kasei and key leader in the company’s electronics materials business, commented, “The rapid growth of generative AI and other advanced technologies is driving unprecedented demand for semiconductor materials like PIMELTM PSPI. This investment positions Asahi Kasei to capture that growth by enhancing our supply capability and reinforcing our role as a reliable partner to global semiconductor manufacturers. It supports our broader strategy to build long-term value in high-growth, high-impact sectors.”

Asahi Kasei positions its electronics business in the “First Priority” category, one of the key drivers for future company growth. For many years, PIMELTM has been highly regarded as a key component for producing semiconductors. In 2024, Asahi Kasei received the TSMC Excellent Performance Award for “Excellent Technology Collaboration and Production Support in Advanced Packaging” at TSMC’s 2024 Supply Chain Management Forum.

In April 2025, Asahi Kasei announced its new medium-term management plan, “Trailblaze Together.” This plan continues the path of structural transformation and pursues carefully selected investments in strategic growth fields. By doing so, the company aims to maximize profitability and company value by 2030 and beyond.

www.asahi-kasei.com

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Integrated Production Technology for Interior Efficiency

At K 2025, ENGEL is presenting a state-of-the-art manufacturing solution from its WINTEC brand for interior automotive components. At the heart of the exhibit is the t win 6500 twoplaten injection moulding machine with 6500 kN clamping force, equipped with MuCell technology for physical foaming. This combination enables the cost-effective production of a B-pillar trim made of mineral-filled polypropylene in just 50 seconds, while achieving significant material savings.

MuCell works with nitrogen or carbon dioxide, which is introduced into the plastic melt. The screw geometry, specially optimised for MuCell, ensures uniform gas distribution, resulting in a fine cell structure within the mould. The result is a lighter component with outstanding dimensional stability and visible surface quality – ideal for high-end automotive interior parts.

The exhibit part has a shot weight of around 290 grams and is moulded from SABIC’s polypropylene grade F9015. The tool from SIMOLDES demonstrates that complex interior components can be manufactured more sustainably and cost-effectively – without compromising on design. The use of MuCell reduces both weight and material consumption, resulting in a lasting reduction in unit costs.

While ENGEL stands for tailored solutions that meet the highest demands in precision, efficiency and digitalisation, WINTEC offers proven standard solutions with ENGEL DNA. ENGEL primarily targets customers seeking high levels of innovation and customisation, whereas WINTEC delivers cost-optimised, readily available machines for reliable, smart applications. Both brands guarantee high quality, with WINTEC benefitting from ENGEL’s extensive expertise.

The t-win from WINTEC is distinguished by its robust two-platen design. Short-stroke pressure pads enable short cycle times, while a synchronous locking system and servo-hydraulic drive ensure fast and energy-efficient operation. Its high energy efficiency, compact footprint and optimised maintenance access reduce overall operating costs and ensure a fast return on investment.

WINTEC injection moulding machines are equipped with the intuitive C3 control unit, which ensures clear process management with high performance. The new model of a fully integrated viper 20 linear robot handles part removal and relieves the workload on operating personnel. The close integration of robot and machine within a single control system enhances process stability and shortens cycle times by optimising motion sequences.

The digital assistance system iQ hold control supports the optimisation of the holding pressure time during initial process setup. With just one click, it automatically determines the sealing point for the respective component. The result is a significant time saving and optimised cycle times without manual effort, while providing reproducible values.

During ongoing production, the integrated digital assistance system iQ weight control responds in real time to changes in melt viscosity. For each cycle, it analyses the filling behaviour and automatically adjusts the switchover point to ensure consistent part weight. This enables scrap rates to be reduced by up to 85 percent and improves process reliability – a crucial benefit when dealing with fluctuating batch properties.

The ENGEL iQ process observer is also integrated into the production cell. This digital assistance system continuously monitors a wide range of machine and process parameters throughout the injection moulding process, detects deviations at an early stage and automatically provides concrete recommendations for action. As a result, it helps to further increase process stability, ensure consistent part quality and sustainably improve the productivity of the system.

With this fully automated production solution, WINTEC demonstrates what modern interior part manufacturing can look like: reduced material consumption, low energy usage, and consistent performance and quality. Injection moulders benefit from short cycle times, durable machine components, and a compact system solution that can be easily integrated into existing production lines. WINTEC offers efficient plug-and-play solutions with high availability, delivering excellent value for money without compromising performance – a clear competitive advantage for its customers.

https://www.engelglobal.com/

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Plastics Processing Reimagined at K-2025

At this year’s K-Show in Duesseldorf, the MAAG Group will unveil a host of innovative technologies for the plastics industry from October 8-15, 2025 in hall 9, booth A02, all centered around integrated system solutions in pelletizing, extrusion, filtration, recycling as well as measurement and controls. Visitors can expect a wide range of new products and technological developments.

“Our systems stand for innovation, quality, and efficiency. At K-2025, we will show how technical excellence and smart design are transforming the future of plastics processing.” Says Ueli Thuerig, President of MAAG Group.

Debut of the PEARLO CS – Compact Excellence in Underwater Pelletizing

The new PEARLO CS marks a milestone in compact pelletizing systems. Drawing on the proven PEARLO series, it features the familiar tangential cutting chamber and optimized cutter design. Offered in two sizes, it targets production scales where flexibility and efficiency are essential. “We developed the PEARLO CS specifically for manufacturers who need top-tier performance in a streamlined footprint,” explains Product Manager Rico Sandmann.

NG-USG Redefined – Enhanced Design for Maximum Throughput With an enlarged rotor diameter and improved water flow, the next generation NG-USG underwater strand pelletizing system enables greater throughput and superior pellet quality. Additional sensors boost process stability. These design enhancements help to achieve consistent quality with increased performance.

EBG – Dust-Reducing Dry Cut Strand Pelletizing System

This semi-automated system offers flexible process control with reduced strand breaks, low moisture content, and minimized dust formation – a reliable solution for demanding applications.

Global Innovation: extrex⁶ EC – Gear Pump for Rigid PVC Processing

MAAG unveils a world first: the extrex⁶ EC gear pump, designed for conveying rigid PVC. It delivers unprecedented levels of process safety, product quality, and resource efficiency. “With the extrex⁶ EC, a new chapter in PVC extrusion technology is opened.” Says Jonathan Hummer, Head of Product Management Pumps.

BRF & ERF – Double-Stage Melt Filtration for Sustainable Recycling

MAAG introduces double-stage filtration for advanced polymer recycling. As the BRF coarse melt filter enhances downstream equipment protection and ensures stable operation, the ERF fine filter guarantees exceptional pellet quality with minimal material loss. These filters offer a powerful combination for efficient, low-cost recycling solutions.

CSC-R-DV – Streamlined Screen Changer for Increased Output

The new curved, continuous screen changer CSC-R-DV with integrated start-up position offers up to 50% higher throughput and energy savings, while significantly shortening the production line. Its compact design reduces investment costs and fits perfectly into temperature-sensitive extrusion processes.

Virgin Polymers in Focus: PEARLO 350 & CIS System

MAAG introduces the largest underwater pelletizing system for PET production with the PEARLO 350 pelletizer equipped with EAC technology and new die plate design, ensuring long tool life, precise cutting and reduced fines for premium granulate. For high throughputs, the Central Injection System (CIS) die plate introduces water centrally through the die plate to reduce agglomerates and improve pellet cooling for high-MI polymers.

New Centrifugal Dryer Lab in the US

MAAG has commissioned the new centrifugal dryer lab as a key part of the Centrifugal Dryer Center of Excellence in Eagle Rock, VA. The lab will enable MAAG to further optimize and innovate centrifugal dryers for virgin polymer, recycling, and compounding systems. Focus for the lab include improved energy efficiency, drying performance, noise reduction and to build application specific knowledge for future innovation. For customers, the Centrifugal Dryer Lab can be utilized for drying tests up to 72,000 kg/hr.

Welcome to the MAAG Group Family: Sikora GmbH

Since June 2025, Sikora GmbH has joined the MAAG Group. Sikora will present their innovative measurement, control, inspection, and sorting technologies for quality control in the plastics industry at K-Show in Hall 10, Booth F14.

https://maag.com/

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