A global manufacturer of garden implements and motorised tools has invested in an automated plastic injection moulding and finishing solution for its US production facility to ensure consistent quality for critical engine components. Geometrically complex parts are now de-flashed using a Röslerswing blast chamber, which is fully integrated into the manufacturing line to enable continuous, automated processing.

The German-headquartered company produces its tools and equipment at facilities worldwide and is recognised for the high quality and reliability of its products used in forestry, landscaping and construction. However, two thermoset engine components previously sourced from external suppliers for the US plant did not consistently meet the required quality specifications.

To address this issue, the manufacturer decided to bring production of these parts in-house, including the removal of moulding flash generated during injection moulding. Drawing on positive experience with Rösler technologies in Europe, the project team worked with the company’s US subsidiary to develop an automated de-flashing solution.

The resulting system is based on the RWS 1200 swing chamber machine, specifically designed for the gentle processing of thermoset and highly filled thermoplastic components. The compact RWS 1200-I4-SAT2 machine features two chambers, each equipped with rotating satellite stations that securely hold the components during blasting. This dual-chamber configuration allows loading and unloading to take place in one chamber while de-flashing occurs in the other, effectively eliminating non-productive downtime.

Robotic handling ensures precise placement of the components on dedicated fixtures, while multiple blast nozzles accelerate non-abrasive media on to the rotating parts to remove flash and contaminants. The system achieves a cycle time approximately 15 seconds faster than the 60 seconds specified, reducing energy consumption and operating costs while ensuring reliable, high-quality component finishing.

More information www.rosler.com

Snow-jet cleaning has become a state-of-the-art solution for preparing plastic components prior to coating. To enhance cleaning quality and paint finish even further, automotive components specialist KTX has upgraded the snow-jet cleaning systems integrated into its automated paint shops by replacing conventional nozzles with an innovative rotary system.

Headquartered in Weissenburg, Bavaria, KTX produces interior and exterior trim components for the automotive industry, covering the entire production chain from design to final assembly. The company manufactures its parts using injection moulding machines with clamping forces ranging from 80 to 3200 T and operates advanced paint shops for finishing high-quality trim components.

Clean surfaces are critical to achieving flawless coatings, particularly for high-gloss finishes, such as piano black. Even the smallest dust particles or fibres can lead to surface defects and rejected parts. For this reason, KTX sought ways to further optimise its paint shop cleaning processes.

Working with ACP Systems AG, a specialist in snow-jet cleaning technology, KTX evaluated an alternative cleaning concept. The QuattroClean system uses recycled liquid carbon dioxide that expands through a specialised nozzle to form fine CO₂ snow. Accelerated by compressed air to supersonic speed, the jet removes particulate and filmic contamination, leaving surfaces dry and residue-free.

Tests demonstrated that an array equipped with multiple nozzles would deliver improved paint finishes compared with the existing configuration. As a result, the partners developed a rotary nozzle system that could be integrated into the existing cleaning module. The new rotary unit features three nozzles mounted on the cleaning module’s linear system.

According to KTX, the technology has significantly improved process stability and coating quality while also delivering economic benefits, and the company is now considering deploying the solution in additional paint shops.

More information www.acp-systems.com

Quickparts, a global provider of advanced manufacturing solutions that scale from prototype to production, has introduced two new high-performance plastic materials – DuraKor and ThermaKor, along with vapour smoothing as a core surface-finishing capability. Together, these additions expand the company’s ability to support customers across multiple stages of product development, enabling engineers to validate designs, refine surface quality and transition smoothly from prototype to full-scale production.

Engineering teams often encounter challenges as products move from concept to market, particularly when changing materials, processes or suppliers. The introduction of DuraKor, ThermaKor and vapour smoothing is designed to reduce these discontinuities by offering performance-capable materials and finishing processes that support design validation and production scaling within a single manufacturing ecosystem.

According to Quickparts, the transition from validation to production is one of the most complex stages in manufacturing. The new materials and finishing capabilities provide engineers with greater continuity throughout the development journey, helping maintain performance, quality and speed to market.

DuraKor is a high-performance engineering plastic with mechanical characteristics similar to polypropylene, offering high impact resistance, excellent chemical resistance and low permeability. These properties make it suitable for demanding functional and end-use applications, including fluid-handling components, enclosures and ruggedised housings. When combined with vapour smoothing, DuraKor parts achieve improved sealing performance and a refined surface finish.

ThermaKor, meanwhile, is a high-temperature nanocomposite material designed for tooling and manufacturing aids that require dimensional stability and thermal resistance. Typical applications include wind tunnel models, composite lay-up tools, mould inserts and test fixtures.

With the addition of vapour smoothing, Quickparts further enhances the performance and appearance of additively manufactured and cast plastic parts, delivering improved surface quality, reduced porosity and production-ready finishes.

More information www.quickparts.com

With over 430 exhibitors from 28 countries, the GrindingHub trade fair for grinding and surface finishing technologies (Stuttgart, 5-8 May) is sending out a powerful message to the industry: despite falling production and export figures, grinding technology remains highly innovative, with GrindingHub positioning itself as the sector’s central platform.

Economic conditions remain challenging, as confirmed by Dr Markus Heering, executive director of organiser, VDW: “Statistics clearly show that the industry is navigating a challenging environment. Yet we’re also seeing strong innovation momentum across many companies. In times like these, the sector needs guidance, avenues for information sharing and tangible business opportunities, which is exactly what GrindingHub delivers.”

Across three halls at Messe Stuttgart, exhibitors from Germany, China, Switzerland and Italy in particular will present their innovations from every stage of the valued chain, from grinding machines and abrasives, process peripherals and software solutions, to measuring and testing technology.

“GrindingHub is so much more than just a product show,” states Heering. “It’s the international stage for grinding technology and a place where partnerships are forged, investments are prepared and future technologies are set in motion.”

The fact that Switzerland is one of the most strongly represented countries among the exhibitors highlights the importance of grinding technology for its industry at home.

Says Christoph Blättler from Swissmem, the association for the Swiss technology industry: “Grinding machines make up around a fifth of Swiss machine tool exports. This underscores the critical role of such technology for our member companies. The Grinding Pavilion Switzerland gives smaller companies in particular an efficient way to shine at the trade fair.” 

More information www.grindinghub.de/en

The new UG series of universal grinding machines from EMAG combines proven grinding technology with a cost-efficient machine base, delivering a flexible and reliable solution for internal, external and out-of-round grinding applications. Designed for precision manufacturing tasks, the machines offer high levels of accuracy and process stability while maintaining versatility.

EMAG’s UG series comprises four models with grinding lengths of 400, 630, 1000 and 1500 mm, enabling users to select the appropriate configuration for applications ranging from compact toolroom work to the production of longer shafts and complex geometries. Workpieces can be clamped between centres or in a chuck.

A rigid machine structure forms the foundation of the series. Linear guides in the X and Z axes, servo drives with recirculating ball screws and direct-drive motorised grinding spindles ensure stable and accurate machining performance. The grinding head uses direct-drive motor spindles with up to 11 kW of power, eliminating belt drives and reducing vibration. As a result, torque is transmitted efficiently, improving surface quality and process reliability.

A swivelling B-axis enables positioning from -15° to +225° with an accuracy of 0.0005°, allowing precise contour and surface grinding.

The work-head is equipped with precision tapered roller bearings to deliver high rigidity and a concentricity accuracy of 0.5 µm. A swivel range of 0° to +30° supports various grinding strategies, while optional AE sensor technology detects grinding wheel contact with the workpiece to minimise idle time. An optional workpiece spindle with C axis is available.

Machines in the UG series are equipped as standard with the FANUC 0i-TF control, providing intuitive operation and reliable global support, with the more powerful FANUC 31iB Plus available for highly complex machining applications.

More information www.emag.com