Polymer Processing

The department of Polymer Processing − a field of competence of the Fraunhofer IMWS − has both an extensive know-how in the field of polymer processing, as well as in the characterization of structure property relationships for thermoplastics, thermosets, elastomers and composite materials. We focus on the material, process and component development for long fiber reinforced thermoplastics (LFT), highly filled plastics and blends.

For the processing of these materials, we have extrusion and injection molding equipment. Moreover, the direct compounding possible in one injection molding compounder (IMC). Here extrusion and injection molding carried out in a single-step process in the same machine.

One focus of our activities is placed on the systematic evaluation of the impact of material systems and technological conditions on the component's characteristics. The experimental and numerical results provide information about the performance characteristics and the reliability of the plastic components.

• compounding and pelletizing up to ton scale
• development and manufacture of prototypical components and assemblies for a launch
• production of fiber-reinforced thermoplastic components
• direct compounding of polymers and additives necessary
• use of different types of fibers (glass fibers, polymer fibers, regenerated fibers, etc.)
• variable fiber contents, lengths and distributions set
• production of long fiber reinforced thermoplastic components based on polypropylene and long glass fiber with direct incorporation: direct feeding of glass fiber rovings into the polymer melt and subsequent component molding and injection molding
• evaluation of the influence of the material system and the technological conditions on the component's characteristics
  
• technology, materials and component evaluation on the basis of experiments
• integrated numerical simulation
• review of fibers, matrix polymers and additives
• compounding
• injection molding
• compounding and injection molding as a combined process

• studies on the influence of injection parameters and gate systems on achievable fiber lengths
• technology adaptation and optimization of manufacturing processes
• scale up of manufacturing processes
• optimization of compounding e. g. with respect to screw profiles and fiber feeding points

Injection Molding

• Injection Molding Compounder KM 1300-14000 IMC, with a clamping force of 1.300 tons
• molds with a maximum shot weight of 5300 grams (PS)
• configurable co-rotating twin screw extruder for various processing tasks
• gravimetric dosing for free-flowing granules, powders, continuous roving and chopped strand, various other fibers
• other configurations: compression molding, pneumatic and hydraulic cascade Decoforming, removal of the parts using a robot, vacuum degassing, Ejector Euromap

Injection Molding

• Injection Molding Compounder KM 3200-24500 MX IMC, with a clamping force of 3,200 tons
• molds with a maximum shot weight of 20,000 grams (PS)
• configurable co-rotating twin-screw extruder for various processing tasks
• gravimetric dosing for free-flowing granules, powders, continuous roving and chopped strand, various natural fibers
• other configurations: compression molding, pneumatic and hydraulic cascade decoforming, removal of the parts using a robot, vacuum degassing, Ejector Euromap

Injection

• injection molding machine KM200-1000C2, with a clamping force of 200 tons
• molds with a maximum shot weight of 476 grams (PS)
• other configurations: compression molding, mold temperature to 140 °C.
• separate second SP160 injection molding, vertical, with a max. shot weight of 68 grams (PS)

Extruder

• parallel, co-rotating, modular twin-screw extruder for various process tasks:
• modular structured process part with a length of 48D
• gravimetric dosing for free-flowing granules, powders, continuous roving and chopped strand, various other fibers
• high temperature equipment > 400 °C
• pelletizing: strand, under water, hot air
• vacuum degassing
• throughput of 5 to 400 kg/h
• counter-rotating conical twin-screw extruder
• gravimetric feeders, vertical fiber feeding system
• vacuum degassing
• hot-air pelletizing
• single-screw extruders KME 45XS (Krauss Maffei Technologies GmbH)

Downstream equipment for profile extrusion, pipe extrusion, film extrusion

Polyurethane RIM system-Star 8 / 8 CCM (Krauss Maffei Technologies GmbH) for Clear-Coat Molding

Melt pumps (Witte Pumps and Technology GmbH)

Fiber cutting

• fiber lengths of 1.5−98 mm
• cable thickness for cutting 3 mm gap: 3000-65000 dtex

Gas metering station

• 2 separate gas injection modules, CO₂ and N₂ dosing, initial gas pressure to 420 bar needle valve nozzle

Static Mixers

• for physical blowing agent (CO₂ and N₂) provided

Dry air dryer

• separate drying and regeneration circulation, drying temperature setting to 160 °C, conveyors for granules and regrind

Polymer-powder mill, shredders, rolling mill

Laminate press, size: 400 mm x 400 mm, heatable up to 400 °C, maximum compression pressure of 10 N/mm²