ENGEL builds the world’s largest injection moulding machine

With the duo 12000 US, ENGEL expands the possibilities for the industrial production of large-format injection-moulded parts to previously unattained dimensions. The two-platen injection moulding machine enables the reduction of part costs for large-area components.

At the same time, manufacturers can implement innovative product concepts and reduce assembly effort. This creates new design freedoms and additional opportunities to replace traditional materials such as metal or concrete with plastics. ENGEL thus creates the technological prerequisites for competitive and more sustainable solutions in mobility, infrastructure and industry.

The two-platen machine with a clamping force of 110,000 kN was specifically developed for parts with projected areas of more than 2.5 m² and was recently commissioned at the customer’s site. It enables the cost-efficient production of very large-format components in an integrated production process. Through functional integration, a reduced number of parts and lower assembly effort, new degrees of freedom arise in design, lightweight construction and product design.

New products require new production concepts. With injection moulding solutions of this scale, manufacturers can produce large-format structures in a single production step. This reduces material usage, simplifies production logistics and thereby saves time and costs. In addition, it improves the CO₂ footprint over the entire product life cycle. ENGEL thus supports its customers in unlocking new dimensions of cost-efficient production and in implementing innovative, sustainable product solutions.

To enable large shot weights for large-area components, the system is equipped with two injection units operating in parallel. With screw diameters of up to 210 mm, they enable a shot volume of up to 65,000 cm³ and homogeneous filling of large projected areas.

The design with eight tie bars was selected together with the customer as the most suitable solution for its specific requirements. Machines of this size are also possible with four tie bars.

The dimensions of the system illustrate the technical challenge: with a length of around 24 metres and a height of approximately 8.4 metres, it is among the largest industrial production systems in injection moulding worldwide. The total weight is 551 tonnes, the maximum mould weight 170 tonnes. In total, around 30 kilometres of cables were installed. The total installed power is approximately 2.4 MW with a total current of 2,900 A. Despite these dimensions, the machine remains compact thanks to the modular design principle of the duo series, thereby saving valuable floor space.

High vertical integration and comprehensive process expertise
Injection moulding solutions of this scale are developed exclusively on the basis of specific customer requirements. To realise these quickly and efficiently, ENGEL has an extensive modular system and an exceptionally high level of in-house manufacturing depth.

The in-house large machine technical centre enables customers to carry out extensive tests for technology and part development. Especially for large-volume components, shrinkage behaviour plays a decisive role. In this technical centre, ENGEL has the capabilities to carry out iterations and optimisations in order to ensure the required part quality.

Many years of experience in the construction of large machines
ENGEL has decades of experience in the development and realisation of large machines. In addition to the standard sizes of the duo series, several systems with clamping forces of 74,400 kN have already been successfully installed in the market.

A specially developed machine concept enables systems of this scale to be designed and manufactured efficiently. Thanks to global production structures, such machines can, if required, be manufactured not only in the large machine plant in Austria but also regionally in Asia.

Despite their dimensions, the large machines are characterised by exceptional precision. Through options such as injection compression moulding, the component dimensions can be defined with an accuracy of a few hundredths of a millimetre, a level of precision comparable to the thickness of a sheet of paper. This sensitivity, in combination with enormous force, opens up new possibilities in precision lightweight construction and in the functional integration of large-format components.

Gigamoulding enables new vehicle architectures
In the automotive sector, demand for such gigamoulding solutions for large structural components is increasing. Megatrends such as electromobility, autonomous driving, platform consolidation and CO₂ reduction targets are driving this development. Applications such as battery housings, underbody panels or hybrid inner door structures can be rethought through the new production possibilities. The objective is to reduce the costs of components. These enable functional integration, weight reduction and reduced assembly complexity. At the same time, they can contribute to stiff and safe vehicle architectures, as required for autonomous mobility concepts.

New possibilities in technical injection moulding
Large machines also open up new application potential in the field of technical injection moulding. ENGEL has already successfully established machines with clamping forces of around 11,000 tonnes in the market, among others for logistics and infrastructure products.

These include transport containers for the disposal of e-mobility batteries, large-volume infiltration boxes for rainwater management as well as water tanks with mould areas of nearly six square metres and shot weights of up to 109 kg. Especially for large water tanks, plastics offer clear advantages over concrete: the components are easier to transport and install, require less infrastructure and respond more flexibly to ground movements, while concrete structures may tend to crack under soil movement. At the same time, such systems support municipalities and companies in adapting to increasing heavy rainfall events and regulatory requirements for water storage. With the help of ENGEL large machines, these products can also be manufactured cost-effectively and in new dimensions.

Technology driver for sustainable large-scale structures
With the duo 12000 US, ENGEL reinforces its position as a technology leader in injection moulding. The system is not only a record-holder in terms of size, but also serves as a platform for new technologies, material substitution and highly integrated component concepts. It enables more sustainable product solutions in mobility, infrastructure and industry and demonstrates the potential of gigamoulding for the industrial production of large-format structures. At the same time, the machine does not mark the technical limit of what is possible. Based on its development and manufacturing expertise, ENGEL is capable of realising even larger systems if corresponding customer requirements arise. The company thus opens up additional opportunities for plastics processors to produce new component dimensions cost-effectively and to further expand their competitiveness.

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