Applications

Perfect results in all areas Special injection moulding procedure using BOY

In addition to the processing of thermoplastic material, continuous research and developments, as well as close cooperation with customers and renowned specialists helped BOY to become an established supplier for special applications. In nearly all industrial sectors, many different materials are processed:

  • Electrical, computer, office, telecommunications, and clock-making industries
  • Automotive, cosmetics and packaging industries
  • Mechanical, equipment, and apparatus engineering
  • Pharmaceutical industry
  • Aviation, space and defence industries

BOY offers special machine configurations for various applications and materials.

The versatility of BOY injection moulding machines is demonstrated by their ability to process a multitude of special applications:

  • Insert moulding
  • Micro injection moulding
  • LSR (Liquid Silicone Rubber)
  • Elastomer processing
  • Thermoset processing
  • CIM (Ceramic Injection Moulding)
  • MIM (Metal Injection Moulding)
  • Clean-room technology
  • PET preforms

Expert know-how

The specialists at BOY are at all times available to you for working out individual concepts and procedures. Alternatively, you may test your materials and moulds under real-life conditions in the showroom at BOY.

BOY injection moulding machines: solutions for all plastic processing applications

In five decades, BOY has sold nearly 50.000 injection moulding machines worldwide. During this time, BOY has become a well-known supplier of machines designed for many applications. Besides the processing of thermoplastics, BOY designed special machine configurations for different applications and special materials through continuous research and the support of customers and well-known specialists. These special designs and technical development capabilities has enabled BOY to meet every special application in the plastics industry.

The following applications and special solutions are possible on BOY injection moulding machines: Thermoplastic, elastomer, silicone, PIM, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Thermoplastic material

The plastic parts shown were manufactured on BOY injection moulding machines. The gear wheel, produced on a BOY XS, has a part weight of only 0.001 g. With the BOY 125 E, parts with a weight of up to 263.4 g (PS) – like the Frisbee shown here – can be precisely manufactured.

These examples of applications show the range of products that can be manufactured on BOY injection moulding machines.

High-End plastic processing with BOY injection moulding machines

During 50 years, BOY has became a well-known supplier of numerous special techniques. In this time, BOY has become a well-known supplier of machines designed for many applications. Besides the processing of thermoplastics, BOY designed special machine configurations for different applications and special materials through continuous research and the support of customers and well-known specialists. These special designs and technical development capabilities has enabled BOY to meet every special application in the plastics industry.

The following applications and special solutions are possible on BOY injection moulding machines: Elastomer, silicone, PIM, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Elastomer

 

Well known rubber manufacturers have proven that all common rubber materials can be processed fully automatic and cost effectively using a special plasticizing unit.

BOY injection moulding machines for processing elastomers.

Application: Processing of elastomer moulding compounds in strip or round form and suitable for vulcanization
Application examples: Elastomer engineering parts, O-rings, seals, diaphragms.

  • Cylinder temperature-controlled by a heating-cooling fluid, via external control unit
  • Special feeding zone for strip-like moulding compounds
  • Plasticizing screw with non-return valve
  • One-component solid silicone, using staffer unit
  • Coining and venting are available as options (BOY 50/60 and BOY 80/100/125) standard
  • Mould temperature control via control loops in the machine (electrical heating elements are part of the mould)
  • Brushing for de-moulding and mould cleaning is optional

Quite, fast, efficient: plastic processing with BOY injection moulding machines 

With the experience of having sold about 50.000 injection moulding machines, BOY has become a well-known supplier of numerous special techniques.During this time, BOY has become a well-known supplier of machines designed for many applications. Besides the processing of thermoplastics, BOY designed special machine configurations for different applications and special materials through continuous research and the support of customers and well-known specialists. These special designs and technical development capabilities has enabled BOY to meet every special application in the plastics industry.

The following applications and special solutions are possible on BOY injection moulding machines: Thermoplastic, silicone, PIM, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Processing of liquid silicone rubber (LSR) and one-component solid silicone

The BOY sprueless nozzle, among other things, increase the number of possible LSR applications including the production of seals and baby bottle nipples. BOY quotations for LSR applications include dosing and pump units.

Applications: Moulded technical parts, seals, spark plugs, anode caps, baby bottle nipples

  • Cylinder temperature-is controlled by a heating cooling fluid via external control unit.
  • Hydraulically actuated needle shut-off nozzle. Open nozzle is optional.
  • Non-return valve with reduced stroke (optional).
  • Material feed via separate mixing pump connected to the injection cylinder.
  • Mould temperature control via control loops in the machine (electrical heating elements are part of the mould).

Details for the processing of one-component silicone using stuffer unit you can find in our brochure “Elastomer processing”.

Injection moulding in all designs: individual applications with BOY injection moulding machines

In  five decades, BOY has sold about 50.000 injection moulding machines worldwide. During the long company history, BOY has developed many different special techniques for the plastic industry. Besides the processing of thermoplastics, BOY designed special machine configurations for different applications and special materials through continuous research and the support of customers and well-known specialists. These special designs and technical development capabilities has enabled BOY to meet every special application in the plastics industry. Due to their special design, BOY machines can be easily integrated into automated production lines.
The following applications and special solutions are possible on BOY injection moulding machines: Thermoplastic, elastomer, PIM, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Thermoset processing

Thermal resistance and electrical insulation are the advantages of thermoset parts. We offer special plasticizing units for the production of such parts. With geometries developed for this purpose, all mouldable thermoset materials can be processed on BOY injection moulding machines.

Application: Granulated, chemically crosslinked thermoset moulding compounds.

Application examples: Bobbins, parts for the electrical industry (e. g. fuse boxes), pot handles, belt tensioners, and other high-security applications.

Cylinder temperature is controlled by a heating-cooling fluid via external control unit.

  • Screw without non-return valve.
  • Coining and venting are available as options (BOY 50/60 and BOY 80/100/125).
  • Mould temperature control via control loops in the machine (electrical heating elements are part of the mould).
  • Air blast programs for mould cleaning is optional.

Innovative injection moulding techniques for all applications in plastic processing

BOY sold about 50.000 injection moulding machinesall over the world during 50 years. Today, BOY is a well-known supplier of numerous special techniques in the plastics industry. During this time, BOY has become a well-known supplier of machines designed for many applications. Besides the processing of thermoplastics, BOY designed special machine configurations for different applications and special materials through continuous research and the support of customers and well-known specialists. These special designs and technical development capabilities has enabled BOY to meet every special application in the plastics industry.

The following applications and special solutions are possible on BOY injection moulding machines: Thermoplastic, elastomer, silicone, PIM, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Processing of PIM

Plasticizing units especially developed by BOY are available for the processing of ceramic and metal powder. Working closely together with the users, solutions were developed which turned out to be very effective.

Small mass-produced articles and articles with complex shapes can be produced economically with these techniques.

The following process stages are involved:

  • Preparing the mixture of binder system and powder
  • Granulating the prepared moulding compound
  • Injection moulding of a green part in the injection moulding machine
  • Debinding in the oven
  • Sintering by baking in an oven

The injection-moulded green parts and the so-called brown parts (after debinding) must be handled with utmost care, as the moulded parts do not possess any particular mechanical strength and can be easily damaged.

Plastics, ceramics, metal: versatile solutions for all applications in injection moulding 

During 50 years, BOY has sold about 50.000 injection moulding machines worldwide. During this time, BOY has become a well-known supplier of machines designed for many applications. Besides the processing of thermoplastics, BOY designed special machine configurations for different applications and special materials through continuous research and the support of customers and well-known specialists. These special designs and technical development capabilities has enabled BOY to meet every special application in the plastics industry. BOY has also developed numerous special technologies for ceramic and metal powder processing.

The following applications and special solutions are possible on BOY injection moulding machines: Thermoplastic, elastomer, silicone, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Hotmelt

The Hot Melt processing with hot melt adhesives can technically be settled between injection moulding and casting technique.

The possible applications of injection moulded parts are almost unlimited. However, the following main areas can be named:

–    Overmoulding of plugs
–    Overmoulding of protective sleeves
–    Overmoulding of electronic components

Generally, a standard equipped BOY machine can sufficiently process hotmelt. Options are available to optimize individual applications.

The small amounts of hotmelt that need to be melted per cycle and its superior adjustability provide many advantages.

Compared to customary embedding machines, those are:

  • Rapid colour change
  • Little material loss
  • Favourable for long flow distances
  • Advantages regarding difficult wall thickness conditions
  • Less material strain because of short well times
  • Easy attainability of high injection speeds
  • Good filling properties for voluminous parts
  • Generally reduced investment cost
  • Pratically all thermoplastic material (e.g. PVC, TPE and PA) can still be processed

Insert moulding technology / Insertion process

For almost 45 years, BOY has been constructing insert moulding machines with vertically arranged clamping units for the overmoulding of inserted parts.

Long-standing experience is the basis for the precision and efficiency of these insert moulding machines with a clamping force range of 100 to 550 kN. The design advantage of this series is the fixed lower platen, which inhibits a shifting of the inserted part during mould closing.

With the ideally suited basic concept of a two-platen clamping unit, the continuously improved variable delivery pump system, and the latest-state-of-the-art Procan ALPHA control, the insert moulding machines are an excellent means of production.

For parting line applications, we also offer the BOY 22 VH with a horizontal injection unit. With this machine, cavities placed in the middle of the mould can be gated on one side in the split area, so that no gate marks will be visible on the surface of the moulded part.

BOY: Fully developed designs for horizontal and vertical injection moulding

BOY also has insert moulding capabilities due to the versatile design of their injection moulding machines. The BOY designers benefit from the practical experiences of moulders. They have always been an integral part of the continuous improvement and optimization of BOY injection moulding machines. Due to the easy accessibility to all parts of the Boy machine, short changeover times are normal and due to the innovative Procan ALPHA control, a smooth machine operation is standard.

The following applications and special solutions are possible on BOY injection moulding machines: Thermoplastic, elastomer, silicone, PIM, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Micro injection moulding

Using machine components that are designed to manufacture micro parts and well proven standard technologies has resulted in a favorable means to produce moulded parts with very small shot weights.

The ever increasing need for precisely moulded parts with weights less than one milligram has required each step in the injection moulding process to adapt accordingly.

Consequently, the processing steps from feeding the granulate to shaping the outline of the part are accomplished today with a few, but highly functional components including the reciprocating screw.

Separating the plasticizing function and the metering allows increased metering accuracy and a more dynamic injection process. A critical point of micro injection moulding is the dwell time. Due to the low parts weights, injection volumes, and throughtput, the chance for thermal deterioration of the material is increased when using larger plasticizing units.

The first in, first out principle, which is accomplished perfectly with a reciprocating screw, is less effective when using machines equipped with separate plasticizing and plunger injection units.

BOY injection moulding machines: Also great for small parts

BOY injection moulding machines also enable the production of plastic parts under one milligram. The precise production of every single machine element and the continuous optimization of the production processes enable the production of the smallest parts with a minimal shot weight.Besides the processing of thermoplastics, BOY designed special machine configurations for different applications and special materials through continuous research and the support of customers and well-known specialists. These special designs and technical development capabilities has enabled BOY to meet every special application in the plastics industry.

The following applications and special solutions are possible on BOY injection moulding machines: Thermoplastic, elastomer, silicone, PIM, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Clean room technology

 

The design concept of BOY injection moulding machines with cantilevered two-platen clamping unit is ideally suited for the production of medical parts and cosmetics under clean room conditions.

The operating elements, hydraulics, water cooled drive motor, and material feed system can be left outside the clean room.

Due to the use of modular system components, different clean room classes can be accommodated.

An overview of the available clean room concepts, you can find in our special brochure “Economic Clean Room – Technology”.

On request we will send you a pdf. file or a brochure.

BOY injection moulding machines: Optimal for medical technology

Through the modular assembling of BOY injection moulding machines, applications in clean-room conditions can be realized. Also here, BOY injection moulding machines illustrate their advantages by the capability to process many different materials. Besides the processing of thermoplastics, BOY designed special machine configurations for different applications and special materials through continuous research and the support of customers and well-known specialists. These special designs and technical BOY injection moulding machines: Optimal for medical technology

The following applications and special solutions are possible on BOY injection moulding machines: Thermoplastic, elastomer, silicone, PIM, hotmelt, insert moulding, micro injection moulding, and clean room techniques.

Efficient multi component injection moulding

 

The injection unit for the 2nd component is based of the ultra compact BOY XS. It is equipped with its own hydraulic drive and control. Depending on the execution this unit offers a plasticizing volume of up to 141.8 cm³ as well as injection pressures up to 3128 bar.

The drive unit, which includes the control, is positioned next to the basic machine. Fixed wheels make the unit easy to move to other BOY injection moulding machines or machines from other suppliers that are processing a 2nd component.

Depending on the application, the 2nd injection unit can be arranged in various positions. This is done space-saving in vertical position on horizontal machines; also a lateral mounting of the injection unit is possible (see graphic representation on the right)

The open nozzle plasticizing unit is connected to the injection unit for the 2nd component through a corresponding adjustable high-pressure hose line.

The TFT display of the 2nd injection unit is equipped with a longer cable. Therefore, the placement of the monitor can be arranged at the user-side of the basic machine – directly next to the basic machine’s Procan ALPHA® monitor.

 

Information about the injection units can be found here: BOY 2C XS/S & BOY 2C M

Multi component
 
 
 
 

3D Mould Inserts

The alternative in the additive manufacturing

3D-printed metal tool inserts impose higher demands on mould design

If only small batches of a plastic part are required or if the component is still in the development phase, modern 3D-technology can help to save mould costs. Instead of the complex construction of expensive steel moulds, more flexible and cost-efficient solutions are required, especially in prototype construction and in the increasingly individualized design of components.

Direct or indirect

However, a direct part production from the 3D-printer differs significantly from an injection moulded part. For example, the physical properties of a 3D-printed component of injection-moulded parts are sometimes significantly different. The solution is 3D-printed mould inserts (installed in a cassette mould), which can be used for a very cost-effectively production of plastic parts.

Based on the CAD data of the plastic part, the print data of the mould inserts can be prepared accordingly and 3D-printers create the mould. Depending on the size of the components, this can already be done within minutes, for larger designs longer processing times are required. Nevertheless, these mould inserts are prepared much faster and cheaper than their “steel competitors”.

From the plastic mould to the metal mould

Over the past two years, 3D-plastic mould inserts have revolutionized mould manufacturing in the plastics processing industry. Low mould costs due to 3D-printed mould inserts as well as the rapid implementation of modifications are the decisive advantages for the users. A drop of bitterness, however, is their durability. Higher temperatures of the materials and high injection pressures have a negative impact on the lifetime of the mould inserts. The operating cycles of the 3D-printed moulds decrease. Especially for small series and medium quantities, many users would like to have more stable solutions. This is guaranteed by the use of 3D-printed metal mould inserts. Higher stability and the possibility of a sometimes required mould temperature control / cooling are given with these metal mould inserts and thus represent the next stage of additive manufacturing.

A good preparation is most important

However, the layered pressure of the moulds made from plastic or metal differs significantly in terms of preparation and planning. In the case of metal mould inserts, a large number of marginal conditions have to be considered in advance. For example, for complex 3D-dimensional parts, tempering channels with the corresponding connections must already be provided in the planning stage of the mould inserts. In the case of the metal-printed moulds the parting line still has to be finished processed, because the structure of the surface of the mould part arises from the printing process. For the achievement of a defined or desired surface this additional processing step is therefore required.  

Mould inserts

If the technological and financial expenses of 3D-printed mould inserts for small quantities are manageable and significantly more efficient than conventional steel moulds, this is not the case for metal mould inserts, depending on their structure and complexity. At the beginning of the planning phase of the moulds or the metal mould inserts, decision should be made to either use a metal mould insert or a conventional aluminum- or steel mould. The design engineer should therefore be familiar with the potential of 3D-technology to create to a good and cheap mould, based on the additional possibilities.

Blow injection moulding on BOY- injection moulding machines – two processes on only one machine

Whereas injection moulding and air-blowing processes were used on different machine designs up to now, BOY now combines both processes on a BOY injection moulding machine. With the support of the European Regional Development Fund and the State of Rhineland-Palatinate, the development of this combined process was completed. As a pilot project, small bottles for eye drops were manufactured on a BOY 60 E in clean room design.

In the first step, four preforms are injection moulded, rotated 180 degrees around an index plate and then inflated with compressed air to produce the finished bottle contour in the same mould. The finished eye drop bottles are packaged directly after demoulding in the clean mould area of the clamping unit and carried off by a conveyor belt.

Air-blowing on an injection moulding machine is suitable for smaller hollow bodies, such as cosmetics, food or pharmaceutical bottles. The cost of the production machine – in this case a BOY injection moulding machine – is significantly below the cost of a pure injection moulding machine. One benefit of air-blowing is the possibility of manufacturing even more complex contours at the bottle neck extremely precisely, which is only possible to a limited extent in traditional blow mould processes. 

Using a manifold system developed specifically for this application, the preforms are injected without sprue so that no waste is produced in bottle production. Unlike with blow moulds, the bottle is finished at the end of the blowing process. No material used to seal the mould body needs to be cut and removed.

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