Fakuma 2018: Key Innovations and Industry Highlights

With 1,933 exhibitors from 40 countries, Fakuma 2018 in Friedrichshafen, Germany, attracted 47,650 visitors over five days in October. Although primarily focused on injection molding, the show distinguished itself by elevating materials suppliers and unveiling an Extrusion Hall for the first time. Fakuma is held annually, except every third year when the K Show takes place in Düsseldorf. Compared to the larger, more hectic K Show, exhibitors and visitors appreciate Fakuma as a relaxed setting for detailed discussions on plans and projects.

iMFLUX Integration by Milacron

Milacron demonstrated a historic partnership with iMFLUX, a Procter & Gamble subsidiary that pioneered a low‑pressure injection concept. The collaboration integrates iMFLUX’s proprietary process‑control software directly into Milacron machines via the Mosaic controller, eliminating the need for a separate iMFLUX screen. The technology uses low but consistent pressure, allowing variable velocity based on part geometry, delivering up to 50 % faster cycles, lighter parts, reduced stress, and fewer defects.

At Fakuma, iMFLUX showcased an automatic viscosity‑adjustment module that detects melt viscosity changes and adjusts filling to maintain consistent pressure. The feature was live‑tested on a 20 MFI PP and an 8 MFI PE, illustrating its suitability for recycled materials with variable viscosity.

TrexelVision: Rapid Non‑Contact Inspection

TrexelVision introduces a terahertz (THz) spectroscopy system that performs dimensional QC and inspects voids, foreign bodies, foam structure, and material boundaries in under 30 seconds. The STRIPP (Single‑Shot Terahertz Sensing for Rapid Industrial Product & Process Control) technology offers ±3 µm wall‑thickness accuracy, foam density analysis, and virtual cross‑sections similar to CT scans.

The platform also supports multi‑press operations via a satellite dosing unit powered by Trexel’s T‑Series or new P‑Series boosters, enabling cost‑effective MuCell foaming across several machines from a single gas booster.

MES Adoption Across Major OEMs

Industry leaders are embedding MES into their Industry 4.0 strategies. Wittmann Battenfeld acquired a stake in ICE‑flex to launch TEMI+, a modular MES that auto‑detects cell changes, offers KPI dashboards, and integrates ERP, alarms, QMS, and production monitoring.

Engel’s wholly‑owned MES provider TIG is expanding into the U.S., offering subscription‑based packages (TIG 2go and a standard MES) that deliver real‑time OEE, SPC, and historical data via a cloud dashboard at $1/day per machine.

Kistler Group acquired IOS GmbH to deliver MES solutions that automatically capture cycle times, machine status, and reject reasons. Their MES Light version provides a quick start with two pre‑configured modules, while the full system adds traceability, maintenance, and workforce logging.

In‑Mold Decorating (IMD) Innovations

Fakuma highlighted IMD, a technology distinct from in‑mold labeling (IML), targeting durable goods such as automotive interiors and consumer electronics. Engel demonstrated a roll‑to‑roll system that backs‑injects diverse surface structures using Kurz’s new IMD Varioform foils, enabling metalized, wood‑look, or tactile finishes.

KraussMaffei showcased Kurz’s dual‑IMD system, enabling two independent heat‑transfer foils to be indexed within a two‑cavity mold, allowing precise dual‑image deposition. The cell combined dual‑IMD with IML to produce automotive HMI displays featuring integrated electronics and scratch‑proof coatings.

Sumitomo (SHI) Demag presented a two‑step decorating process on an automotive door sill: day/night design via IMD followed by post‑molding hot‑stamping of touch sensors (Kurz’s Functional Foil Bonding). A laser‑marked QR code linked production data to an MES computer.

For further insights, see Fakuma news in the Starting Up and Keeping Up sections of our August‑November issues.