Freiburg (Germany) Juni 07, 2010 -  "INDUMOLD has revolutionized injection molding production," said Elmar Wrona, product manager at HUETTINGER Electronics, at the International Symposium on Heating by Electromagnetic Sources HES-10, held in Padua, Italy, May 19 - 21. "This is because induction heating of injection molds produces high quality surface finishes while simultaneously speeding up the production process and reducing costs." The INDUMOLD method was developed by the Kunststoffinstitut Lüdenscheid (K.I.M.W.) in collaboration with HUETTINGER Electronics. Wrona introduced the newest findings on this method at the symposium and explained why HUETTINGER induction generators are a perfect fit for it.

INDUMOLD - heats the mold only

Several variothermal methods are used for injection mold production. Conventional methods use water or oil to heat up the mold. The disadvantage of this method is that the cycle times are high and productivity therefore low. INDUMOLD uses induction to heat up the molds, which means cycle times are reduced due to the large heat flux density and the mold can be heated section by section. "INDUMOLD is the method of choice for manufacturers who want to produce plastic molded parts with a better surface quality quickly and cost effectively," said Wrona. "The surface finish is just as good as that of a coated part and the cost per manufactured part is more than 50 percent less."

The arrangement of the induction heating coils integrated into the injection mold is very important for exploiting the potential of this method. For manufacturers interested in exploring the INDUMOLD process, the plastic experts from K.I.M.W. will test the mold to be produced using numerical simulations and analyze the flow characteristics of the injection mold. This enables them to determine how the mold has to be heated in order to obtain the best possible surface finish. Based on the tests, the experts at K.I.M.W. determine the inductor geometry.

In addition to the optimal arrangement of the induction heating coils, the process power supply represents a significant factor in the successful use of INDUMOLD. "It is important for the power supply to be very reliable. Because injection mold production usually runs around the clock," added Wrona. "Also, the generator has to be able to be integrated easily into the existing injection molding machines." Induction generators from the HUETTINGER TruHeat MF 3010 to the 7040 product line best meet the requirement for the optimum process power supply.

The perfect generator for the injection molding process

The TruHeat MF 3010 to 7040 generators are available with a power output of 10, 20, 30 or 40 kilowatts in a frequency ranging from 5 and 100 kilohertz.

Available in three different models, the TruHeat MF 3010 to 7040 generators offer the perfect solution for any user. The standard model is the 19" plug-in unit. The second model is a desktop machine that is suitable for stand-alone operation. This model is best for labs, universities or companies where space is at a premium. The third model is a generator designed in the form of a control cabinet. It is suitable for industrial applications with a large-scale protection, such as induction hardening.

"The generators are easy to operate and configure due to their numerous interfaces. Moreover, they have a parallel resonant circuit, which, compared to series resonant circuits, ensures that changes in the process can be implemented faster. This reduces set-up times and improves productivity and process stability," said Wrona. "The features in the TruHeat MF Series 3010 to 7040 generators are therefore the ideal support for INDUMOLD, and help to make the most of this method's potential."