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News Hotset GmbH
Dec 12 2018
Partial precision landing in short cycles
Flexible tool temperature control solution Z-System from hotset impresses injection molders
The thermodynamics engineers at hotset have hit the jackpot with the development of the Z-System for partial-cyclical cavity temperature control. More and more injection molders and tool manufacturers are choosing to use this high-speed method thereby optimizing the surface and structural design of their products. Most recently, the interest of trade visitors exceeded all expectations at Fakuma. In Friedrichshafen, reputable players from the consumer industry and automotive manufacturing were fascinated with the advantages of the Z-System.
Satisfied faces and cheerful experts from injection molding technology and tool manufacturing were seen at hotset's Fakuma trade fair stand in mid-October. This may have been due to the exceptionally charming performance of famous pantomime Bastian, or it certainly could have been because of hotset's Z-System, the innovative solution for the targeted and cyclical temperature control of injection molding tools. "Since the initial introduction barely two years ago, a number of well-known plastics processors have chosen to use our high-speed method for process-integrated surface optimization and wall-thickness reduction of injection molded parts. Reputable big players from the consumer industry and automobile manufacturing also expressed their great interest", Ralf Schwarzkopf, General Manager of hotset, reported. According to Schwarzkopf, the conversations at the trade fair weren't only about the visual quality improvements of injection molded parts, but also about the new possibilities of micro-structuring and miniaturization that result from application of the Z-System.
Perfect surfaces and fine structures
The Z-System from hotset is considered to be a technological forerunner for a new generation of highly flexible and dynamic temperature control systems for injection molding technology. Professor Dr. of Engineering Paul Thienel, founder and former General Director of the Plastics Institute Lüdenscheid, considers it to be "an important further development of vario-thermal temperature controlling". It gives tool manufacturers in the industry an innovative system solution for the accurate temperature-control of cavities, where process-related weld lines and dullness on the surface of molded parts are reliably prevented. In addition, the integration of the Z-System in the tool also enables injection molding of very thin walls, as is typical for partial thin-wall injection molding.
As hotset presented at the last Fakuma, the Z-System is available as a complete solution that is custom-tuned and ready for use, including matching control technology with color touchscreen. It consists of various hardware and software components and is integrated in the tool - comparable to a conventional hot runner system. Synchronized with the injection molding process, the cavities can be selectively or partially heated or cooled. This is done with a near record-breaking heating rate of up to 60 Kelvin per second, which is why experts like Professor Dr. of Engineering Paul Thienel speak of a "high-speed temperature control system". It allows for very fast changes in temperature in very short cycles.
What's more: during a recently implemented customer project, it was also revealed that its use substantially improved the flow of the casting compound in construction-related "bottle-neck" areas. It is very well possible that the Z-System from Lüdenscheid will get a satisfied smile from tool manufacturers or injection molders in the future as well.
Oct 29 2018
The results will impress every injection molder
With its Z-System for the partial and cyclical temperature control of cavities, the thermodynamics specialist hotset is currently delighting tool manufacturers, injection molders and designers in very different branches. Wherever the realization of high-quality surfaces or thin-walled microstructures are of paramount importance, this high-speed solution from Lüdenscheid opens up completely new perspectives. At the Fakuma in Friedrichshafen, the company is providing information in Hall B3 on the practical application of its Z-System during the injection molding of molded parts for the consumer industry and automotive construction.
Above all for injection molders and tool manufacturers who have not up until now found satisfaction in the possibilities offered by the variotherm temperature control systems used so far, a visit to trade fair booth 3005 in Hall B3 at this year’s Fakuma could be very much worth their while. Here, hotset is once again presenting its future-orientated Z-System for the targeted partial and cyclical temperature control of injection molding tools. Since its initial launch in autumn 2016, many users have decided for the application of this high-speed solution, and have in this way substantially improved the surface quality of their products. Even acknowledged branch experts such as Professor Paul Thienel have been enthused by the performance capacity of this further development on previous tool temperature control systems. “The results will impress every injection molder”, says the former founder and Managing Director of the Kunststoff-Institut (Plastics Institute) Lüdenscheid, who is of the opinion that above all “high-quality molded parts with excellent surfaces and without weld lines and dullness can be achieved, such as those desired in automotive construction, in lighting technology or in the consumer industry”. Thienel views the fact that the Z-System can be used to “realize particularly thin walls, therefore opening up new perspectives for the manufacture of microstructures and miniature components” as a further advantage.
Highly dynamic temperature control
At the Fakuma, hotset will present to trade fair visitors its Z-System as an individually customer-tailored and ready-to-install complete solution, including the control technology especially adapted for the purpose. The cavities of the molding tools are thus selectively heated and cooled, or heated and cooled in sections, whereby above all one thermodynamic value makes prospective clients prick up their ears: the heating rate of 60 Kelvin per second measured on the tool wall. Andreas Filler, who as the hotset Project Manager always plays a leading role in the customer-specific design of the Z-System, explains: “This exceptional performance parameter makes it clear that our system is a highly dynamic, high-speed solution which is able to realize very rapid temperature changes in very short cycles”.
Over and above this heating rate of 60 K/s (on cavity surfaces), the Z-System by hotset is characterized by two further efficiency advantages. Firstly, the partial temperature control of small masses is made possible using only minor heat quantities, whereby the thermal insulation takes place within the tool. Secondly, the heating performance is not only aligned precisely to the shape of the component due to the highly accurate parameterization, but also to the specific conditions of the production procedure. Seen overall, the Z-System is not only able to run on very low energy requirements, but in ideal cases even makes it possible to reduce the basic temperature of the tool. In practice, a rise in productivity results through the implementation of faster injection molding cycles.
Specific to the respective tool, and individual
Hotset always designs the Z-System individually, and supplies it as a ready-to-install solution for the respective tool. It is comprised of several hardware and software components and is – similar to a hot runner system – inserted into the tool. Andreas Filler explains: “We accompany the customers from system integration via commissioning, right up to user training. This service is part of our product and ensures that everything runs smoothly from the start. On starting the system, the operator just has to follow the menu items on the Z-System touchscreen”.
With the Z-System, hotset offers injection molding tool manufacturers a future-oriented temperature control solution through which they can reliably avoid the typical surface defects on components (weld lines, dullness) and also realize very thin walls (partial thin-walled injection molding). In addition, several of the Z-System projects implemented so far have revealed that its use also substantially improves the flow of the casting compound in construction-related “bottle-neck” areas. Visitors to the hotset trade fair booth in Hall B3 (Booth 3005) at the Fakuma can also find out why this innovation from Lüdenscheid is able to support smaller and smaller batch sizes.
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