Arburg adds AI optimisation to medical production cell

Arburg will present the expanded "NextGen Medical Solution" project at Fakuma 2026 in Hall A3, Stand 3101. The turnkey production cell was developed with Hack Formenbau, responsible for mould engineering, HB-Therm, supplying temperature control units, and a leading biopharmaceutical OEM. The partners jointly assessed optimisation potential across the complete system. Centred around an electric Allrounder 570 A, the cell digitally networks the injection moulding machine, mould, automation and peripheral equipment. As the main contractor, Arburg assumes overall responsibility for the hardware and software. The coordinated system is intended to reduce the burden on the OEM during implementation, shorten time to market and time to production, and lower the total cost of ownership. The integration of essential peripheral devices into the central Gestica machine control system is also designed to simplify operation and improve reliability. Further objectives include reducing energy consumption, floor space requirements and quality inspection costs.

The application produces caps for injector pens and demonstrates how early cooperation between the key project partners can support the implementation of a complex medical production cell. The machine, mould and ancillary equipment share process information through defined interfaces, while central data handling provides the basis for process monitoring, quality documentation and clear allocation of individual shots. A new element is Plus10's Hopper software, which has been integrated into the Gestica control system. The artificial intelligence tool uses machine learning to analyse process behaviour, identify deviations and recommend parameter changes.

Central data management and parametric release

The cell is based on an electric Allrounder 570 A in a cleanroom version and focuses on parametric release for medical and pharmaceutical production. An eight-cavity mould from Hack processes polypropylene supplied by Borouge International into caps for injector pens, with a cycle time of approximately ten seconds. A suspended, space-saving six-axis robot, integrated into the control system, removes the moulded parts and deposits them separately according to cavity.

A shared data set in Gestica consolidates information from the mould, temperature control units and robot system. According to the project description, this makes the production cell easier to control and faster to bring into production, while reducing scrap. Data is logged centrally in the control system, the digitally networked arburgXworld customer portal and Arburg's ALS manufacturing execution system. This architecture enables each shot to be allocated clearly.

Hopper analyses process and quality data

Plus10's Hopper software analyses machine and process data in real time and automatically detects deviating patterns. It also learns correlations between process parameters and product quality, enabling it to predict part quality. If relevant deviations occur, the tool suggests optimised process parameters that can be applied immediately.

The approach is intended to reduce the need for time-consuming quality inspections. Key quality parameters can be viewed at any time and documented directly in the Gestica control system. Arburg plans to demonstrate the integrated Hopper system live at Fakuma 2026.

Communication between the mould and machine

The cell also incorporates aXw Control MoldlifeAssist, based on the Moldlife Sense computer system from Hack Digital Solutions and fully integrated into Gestica. Intended particularly for complex moulds and high-volume production, it enables communication between the injection mould and the machine or production cell via the Euromap 82.5 interface.

The associated hardware comprises a connector on the fixed mould base and a box at the rear of the machine, allowing one system to be used with multiple moulds. MoldlifeAssist supports mould set-up, monitoring and maintenance, with the aim of improving availability and operator safety. Its Set-up Assistant uses images and a digital alignment aid to guide operators through the procedure step by step.

Integrated sensors monitor the mould throughout its life cycle in terms of temperature, acoustics, breathing and alignment. Readings from the sensors can be displayed and monitored in the control system. The same environment also supports the logging and documentation of mould data.

Assistance functions for process validation

Defined interfaces, assistance systems and pilot functions are used to accelerate processes, reduce errors and support consistent part quality. The aXw Control FillAssist function supports process optimisation, while the new aXw Control DoEAssist helps determine the appropriate process window. It also provides structured validation using Design of Experiments directly on the machine.

Other functions address plasticising, cycle efficiency, energy use and process stability. aXw Control MeltAssist is intended to optimise utilisation of the plasticising unit and material dwell times. aXw Control CycleAssist identifies and eliminates non-productive periods within the cycle, while aXw Control EnergyAssist supports energy-efficient heating and shutdown of the cylinder module. Tolerance limits for the process window can be defined in the program.

aXw Control StabilityAssist continuously monitors key parameters and detects gradual deviations to improve process stability. The system also combines integrated maintenance management, extensive sensor use and predictive maintenance. These functions are intended to reduce maintenance requirements and unscheduled downtime.

At Fakuma 2026, Arburg will demonstrate the production of caps for injector pens using digital networking and intelligent control functions to control costs and maintain part quality.