MD Elektronik adopts customized PX for LSR processing

MD Elektronik and KraussMaffei have jointly developed a customized all-electric PXL 201-100/55 SilcoSet injection molding machine for new multi-component parts made of thermoplastics and liquid silicone rubber (LSR). The platform is intended to enable MD Elektronik to enter LSR processing while retaining flexibility for future development projects. Only a few months elapsed between the initial concept discussions and delivery of the machine.

MD Elektronik develops and manufactures cable systems and connectors for the international automotive industry. The company required a development platform for a new connector concept made of polybutylene terephthalate (PBT) and LSR. The resulting machine configuration was tailored to these requirements and designed to support both development work and the subsequent transfer of applications into series production.

"All we knew was that we wanted to enter LSR processing and keep as many technical options open as possible. Together with KraussMaffei, we developed a completely customized all-electric PX machine configuration that is precisely aligned with our requirements," said Christian Heilmann, Team Leader Plastics Technology at MD Elektronik.

Flexible injection units for thermoplastics and LSR

The all-electric PX is equipped with two injection units that can be used with either thermoplastics or liquid silicone rubber. An adaptation system allows screw diameters from 12 to 28 mm to be interchanged, extending the range of potential applications. The configuration includes a 12 mm LSR screw for micro injection molding with shot weights well below one gram. The silicone dosing system is fully integrated into the MC6 machine control system.

"It is precisely these kinds of customized projects, that allow us to explore innovative approaches together and contribute to our customers’ success," said Florian Pell, Head of Sales Germany, Injection Molding Technology & Automation at KraussMaffei.

Alongside the fully equipped PXL 201-100/55 SilcoSet for the technical center, the project includes a production PX of the same size for MD Elektronik's plant in the Czech Republic.

Process control for multi-component production

For multi-component applications, the machine is fitted with a turntable, index drive and widened clamping platens. This equipment supports a broad range of mold concepts and component geometries.

The solution also incorporates the APCplus adaptive process control system. It compensates for variations in material viscosity to maintain reproducible cavity filling. This is particularly relevant for liquid silicone because its shot weight cannot be corrected through holding pressure. According to the companies, the system provides process stability from the first shot, shortens startup times and supports production reliability in both the technical center and subsequent series production.

Training and long-term cooperation

MD Elektronik and KraussMaffei have worked together for more than 25 years. In the current project, regular technical exchanges and short communication paths supported the rapid implementation of the customized machine configuration.

KraussMaffei is also providing tailored training in application technology, process control and cleaning. The program is intended to prepare MD Elektronik employees for the specific requirements of LSR processing.

The technical-center machine provides MD Elektronik with a platform for developing further multi-component applications combining thermoplastics and liquid silicone rubber. Together with the production machine in the Czech Republic, it is intended to facilitate the transfer of future projects from development into industrial series production.