Precision. Power. Productivity

LSR Specialist.

The new IntElect Maximum Efficiency - Highest Precision.
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Fully integrated LSR Solution

To mark the launch of our brand new ready-to-use precision IntElect LSR injection moulding package, we are producing one of the most cHallnging top-end LSR applications on the market today - a matrix headlight delivering adaptive optic distribution for ultra-luxury vehicles.

Combined with the in-built mould safety system and 20% reduced energy consumption compared to competitor systems, the IntElect machine is integral to the processing stability required for handling an optical grade silicone material.

K2019 - LSR Application

SYSTEM
MOULD
PRODUCT
Machine
IntElect 130
  • New LSR-Package
  • Screw, barrel, non-return-valve for LSR
  • Data interface EM 82.3
  • Redesigned vacuum programm and improved pump performance
  • New shut off nozzle design
  • Specific options for water cooling and mould heating
  • Market specific interfaces for dosing and demoulding equipment
Robot
SDR 5-25 S
  • Servo motor driven 3-axis linear units available in 5 sizes
  • Ideal for quick removal as well as precise loading and unloading tasks
  • Stable frame construction of the demolding axis and larger axes profiles compared to the standard
Automation
Nexus Elastomer Systems
  • Pneumatic linear axis for overflow demolding
  • Robot head on linear robot takes parts out of the tool and transfers the overflow between the linear axis and the robot
  • Robot puts down overflow and parts separately
Quality Control
Nexus Elastomer Systems
  • Quality control of parts with camera system to detect air pockets and contaminations
  • Scales control the weight of the parts and provide the closed loop regulation together with the TimeShot balancing system
Dosing System
Nexus Elastomer Systems
  • The Servomix dosing unit guarantees 100% air free material for the process
  • Total material loss unique in the market:
    Nexus total material waste with 20l pails: <1%
    Nexus total material waste with 200l pails: <0,5%
  • Nexus technology guarantees the exact mixture of A & B components as well as additives for the whole process
Mould
Nexus Elastomer Systems
  • Nexus Flowset optimizes the material flow without interrupting the injection process
  • Allows users to control the filling level of every single cavity
  • Nexus Flowset is available with a manual and an electric control system and is the ideal solution for mid-sized (from 2g) to large shot weights above 30g
  • Ensures the best possible material use and the minimization of rejects
Technology
Nexus Flowset electric
  • Regulation system electric and manual
  • Cold deck regulation via the flow quantity
Cavities
4
Application
Matrix Headlight
Part Weight
6.45g
Cycle Time
60s
Material
Dow Silicones
  • Award-winning moldable silicone providing excellent properties and secondary optics solutions for LED lamp/luminaire applications
  • Optimized curing speed for the injection molding process of silicone rubber, enabling production of plastic-like, smooth surface optics with comparatively high hardness and low surface friction
  • High light transmittance with low attenuation coefficient – combined with high Abbe number – enabling lighting companies to design optics for luminaires with high lumen efficiency
  • High thermal stability ensuring retaining of high transparency – even in harsh environments

Moulding LSR requires high precision and process stability, which are the key features of our IntElect series.

Thomas Kottler, Project Manager for LSR

Contact

CONTACT US FOR MORE INFORMATION: sales@dpg.com

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