Overmolding Cell

Challenge

Our robotic cells for plastic overmolding machines allow the input of all types of components and their post-processing to deliver finished and tested injected parts. With this implementation, we provide solutions for plastronics through advanced technological processes such as IME (In-Mold Electronics) and IMD (In-Mold Decoration).

Implemented Solution

Main Module Features

  1. Component feeding for overmolding:
    1. Bowl feeder systems. These feeding systems can even be interchangeable for different models.
    1. Conveyor belt feeding systems with vision selection, known as Bin Picking technology.
    1. Gravity-fed transport boxes.
    1. Stackable trays transported by conveyor belt.
  2. Pre-processing of components before loading them into the injection machine:
    • Preparation and positioning of components according to mold.
    • Vision systems and QR code reading to report to traceability systems.
    • Cleaning of component by side A and/or B using ionized air blowers or brushes.
    • Electrostatic In Mould Labeling (IML)
  3. Post-processing:
    • Sprue cut using air nippers with waste removal to a shredder.
    • Sprue cut using milling with chip suction.
    • Resistance/conductivity testing.
    • Laser marking.
    • Vision systems for component verification.
    • Unloading into boxes/conveyor belts or stackable trays.

Production adaptability with quick changeover model for robots as well as tooling inside and outside the cell. Multiple parking positions for grippers or interchangeable parking. For safe production, mold codification is implemented.

Results

The robotic overmolding cell provided a fully automated solution for loading and unloading models into the injection machine, significantly improving production efficiency. The integration of two specialized robots, along with the suction system, ensured safe handling of both lightweight and heavy components. The model cleaning system enhanced the quality of the final products, while the HMI parameterization feature offered flexibility for different models. The 60-second cycle time maximized throughput without compromising quality.

Keep exploring our case studies!