ENGEL Unveils Green Battery Cover Solutions with Duo 5500 Combi M
ENGEL and SABIC, at the St. Valentin technical center during Battery Innovation Day, showcased innovative solutions for electromobility together with leading partners from the plastics and automotive industries in the end of 2024. The highlight was the powerful duo 5500 combi M, a two-platen injection moulding machine, setting new standards in versatility and technological innovation.
Innovations for Electromobility
At the Battery Innovation Day, ENGEL demonstrated the manufacture of an innovative battery cover made of long glass fibre reinforced polypropylene from SABIC. The dimensions of the component, 1.77 x 1.30 meters, underscore the potential of the duo 5500 combi M for large-scale applications. The lid, developed in cooperation with partners, offers up to 30% weight reduction and a significant reduction in CO2 emissions by up to 40% compared to conventional metal solutions.
The use of composite sheets and thermoplastic materials allows for an efficient combination of stability and cost-effectiveness, integrating functionality directly in the injection moulding process, thus minimising material use and post-processing.
The duo 5500 combi M: XXL Technology with Automation
With a clamping force of 55,000 kN, the duo 5500 combi M is the largest injection moulding machine in a technical center worldwide. Its automation capabilities through the use of easix articulated arm robots enable precise process sequences such as the placement of composite sheets and the removal of finished components. This integration ensures maximum productivity and process consistency.
Technologies in Focus
The duo 5500 combi M offers a wide range of technologies that revolutionise the manufacturing process for large components:
- optimelt: Production of high-quality optical components from transparent plastics, ideal for headlights.
- foilmelt: Integration of decorative or functional films directly in the injection moulding process.
- clearmelt: Coating of visible parts with polyurethane directly in the injection mould for painted or decorative surfaces.
- coinmelt: Injection compression moulding for components with thin wall sections and high optical requirements.
- foammelt: Production of light, low-warpage, foamed components with optimised material use, particularly suitable for parts requiring low weight yet high stability.
- organomelt: Combination of thermoplastic composite materials with the injection moulding process, creating strong yet lightweight and functional components, playing a key role in innovative lightweight solutions in the automotive industry.
Collaboration for Sustainable Solutions
The Battery Innovation Day was the result of close collaboration between ENGEL and renowned partners:
- SABIC: Event partner and material supplier for the long glass fibre reinforced polypropylene.
- Forward Engineering: Simulation-based development and load testing.
- Siebenwurst: Expertise in tool making.
- Ensinger: Supply of thermoplastic composite materials.
- Freudenberg: Pressure relief solutions for battery housings.
- DuPont: High-performance materials ensuring thermal and mechanical stability.
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