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Equipment for plastics processing

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Innovation symposium (6)

Tuesday, 21 January 2020

Ultrasonic welding of a toy boat

12:35 - 12:45, Halle 2


Marc Hägele
Sales Manager Automotive & Plastics, SONOTRONIC Nagel GmbH

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True to original replicas

The company from Fürth-Burgfarmbach is a leading manufacturer of plastic toy vehicles in Europe and produces construction, agricultural, forestry, emergency, and commercial vehicles as well as recreational vehicles in Germany and the Czech Republic. The faithful replicas of renowned brands on a scale of 1:16 focus on high product quality and product safety.


Demanding welding task

A "Personal Water Craft" has recently been added to the product portfolio of Mittelfranken. As the first of its kind, it presented the development department at Bruder with new challenges. With the "Personal Water Craft", the "boat" cannot be injection-molded from one part or assembled from several parts, as is the case with land vehicles. No, here the hull and lid of the boat have to be welded absolutely watertight. This is because the hollow space inside the boat is important so that the boat does not sink in the water later on. Of course, the surface of the boat must not be affected by the welding, the weld seam must be virtually invisible. In order to find a suitable process and a welding machine manufacturer, Björn Ferner, head of process development at Bruder, says that he googled first of all... and was thus able to find a suitable welding machine manufacturer. SONOTRONIC attentively. "The discussions with SONOTRONIC were very professional, there was a specialist knowledge available, which is decisive for us when awarding such projects". After the first contact with Hermann Meth, buyer at Bruder, our sales representative Christine Thieringer visited the factory in Fürth and in cooperation with the developers of Bruder and our application technology team headed by Markus Hecht a suitable solution for the welding task was developed.


Welding device with robot interface

A good half a year after the request, production is now up and running: The two parts, made of blue ABS plastic, are produced on an existing injection molding machine in Bruder's plant. The robot handling of the machine removes the two parts from the injection mold and transports them directly in front of the SONOTRONIC welding device, which is located next to the system. This is a special ECO iSONIC equipped with a soundproof hood, robot interface and sliding table. The machine was designed both for manual operation for the production of prototypes and for automatic operation with loading and unloading by robot handling. An interface allows the connection to the existing removal system of Bruder.

In series production, the handling system first places the hull of the boat in the component holder and then fits the lid precisely onto it. The sliding table moves the parts into the welding machine, and the integrated lifting door closes like a safety device. In just a few seconds, the two parts are welded absolutely tightly and firmly together using ultrasound (Fig. 4). The boat parts were constructed according to the groove (in the lid) and tongue (in the hull) principle. The spring, i.e. the contour inside the fuselage, serves as an energy direction transmitter, which establishes the connection between the upper and lower parts by targeted melting. The weld is not visible from the outside and due to the low thermal load, there are no markings on the component. The component is excited by the vibration of the sonotrode at a frequency of 20 kHz and the force applied via the feed unit. According to the principle of "external and internal friction", the energy direction sensor and the contacted area in the groove plasticize. After a very short cooling phase of 0.5 seconds without ultrasonic action, the two parts are firmly connected to each other along the joining zone.

After welding, the feed unit with the welding tool returns to its home position, the lift door opens and the sliding table extends the welded boat. Since the joining zone has already cooled down, the boat can be removed directly from the handling unit and placed on the conveyor belt of the system. In another production step, the seat and steering unit is later mounted on the "Personal Water Craft", but without ultrasonic welding. This means that the toy is then packed into the packaging and finally sold in the shops, with the addition of a driver figure. It was also a very interesting project for SONOTRONIC, to which hopefully many more will follow. 

On the ultrasonic standard machine, ECO iSONIC in special design hull and lid of the toy boat are welded together absolutely tight.



Lichtleiter für LED-Matrix-Scheinwerfer

12:55 - 13:05, Halle 2


Thomas Kottler
Product Planning & Promotion at Sumitomo (SHI) Demag Plastics Machinery GmbH

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Die beste Maschine für diese Aufgabe

Das auf der Swiss Plastics Expo gezeigte Spritzgießsystem ist eine speziell konfigurierte, vollelektrische IntElect 130 mit speziell entwickelter Schnecke, Rückstromsperre, Vakuumsystem und weiteren silikonspezifischen Optionen. Als Basiseinheit hebt sich die IntElect-Reihe bereits von konkurrierenden LSR-Systemen ab und ermöglicht besonders anspruchsvolle Anwendungen.

Das Antriebssystem der IntElect ist auf höchste Dynamik, Präzision und Wiederholgenauigkeit ausgelegt. In Kombination mit dem hochwertigen Werkzeugschutzsystem und einem um 20 % reduzierten Energieverbrauch im Vergleich zu Konkurrenzsystemen ist die IntElect-Maschine von zentraler Bedeutung für die Prozessstabilität, Effizienz und Verfügbarkeit, die für die Verarbeitung eines optisch hochwertigen Silikonmaterials erforderlich sind.


Zusammenarbeit mit LSR Experten

Entscheidend für die gesamte Bearbeitungszelle ist die spezielle Peripherieausrüstung. Sumitomo (SHI) Demag hat bewusst LSR-Partner ausgewählt, die als die innovativsten gelten und alle einen spezifischen Fokus auf Präzision haben.

Um die Qualität der LSR-Komponenten zu optimieren, installierte Nexus auch die Kaltkanal-Regelungstechnik Timeshot. Durch die Möglichkeit, über einen einstellbaren Nadelverschluss direkt die Füllung jeder einzelnen Kavität zu regeln, wird sichergestellt, dass die Füllung der einzelnen Kavitäten gleichmäßig erfolgt. Dabei wird alles über ein browserbasiertes Gerät gesteuert, um eine optimale Handhabung zu gewährleisten.


Erfahren Sie mehr über diese Showcase von Urs Kocher, MAPAG, im Innovations Symposium der Swiss Plastics Expo 2020. 


This speech will be held in German. 


Integrierte Lösung führt zu höchster Präzision

13:15 - 13:25, Halle 2


Markus Schertler
Managing Director ENGEL Schweiz AG

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Der Schritt zur integrierten Lösung

Ergänzend zu den Glasspritzen erkannte die Schott Gruppe aufgrund der stärkeren Nachfrage nach vorfüllbaren Spritzen aus Kunststoff erweitertes Marktpotenzial. Es stellte sich somit die Frage nach einer Produktionskapazitätserweiterung und gleichzeitig einem Generationenwechsel bei den Spritzgießmaschinen. „Diese Überlegung gab den Ausschlag, uns im Markt umzusehen, wer die für unsere Produktion beste integrierte Lösung liefern konnte. Hier hat ENGEL den Weg geebnet.

Im Showcase-Pitch erzählt Markus Schertler, wie die Schott Gruppe mit der Investition in die ENGEL e-motion höchste Präzision, Sauberkeit und Leistungsfähigkeit in ihrer Produktion erzielte. 

This speech will be held in German. 


Exhibitors (42)


ARBURG is one of the world’s leading manufacturers of plastic processing machines. The portfolio includes ALLROUNDER injection moulding machines with…



Hall 1 / C 1061

Battenfeld (Schweiz) AG

Seit 1980 ist die Battenfeld (Schweiz) AG anerkannter Partner der Schweizer Kunststoffindustrie. Beratung, Planung, Verkauf und Service insbesondere…



Hall 2 / B 2041

bfa solutions ltd

Thanks to our MES competence, we realise sustainable solutions for our customers and are a reliable partner in the Industry 4.0 and IoT environment.…



Hall 1 / B 1031

Biesse Schweiz GmbH

Biesse Schweiz GmbH distributes Machines and integrated Systems for the Wood- and Advanced Materials industry. It is part Biesse Group, founded in…



Hall 1 / C 1073

Busch Vacuum Solutions

Busch Vacuum Solutions is one of the largest manufacturers of vacuum pumps, blowers and compressors in the world. Our product range comprises the…



Hall 1 / B 1043

Christian Fliegel KG

Die Christian Fliegel KG / D-Mannheim vertritt als freie Handelsvertretung in Süddeutschland + dt. Schweiz die Firmen: GEISS AG mit vollmotorischen…



Hall 1 / C 1067

enesty GmbH

Enesty GmbH delivers both additive manufactured parts and injection molding tools from Germany, China and Spain, also the ORCA temperature Control…



Hall 1 / C 1064


ENGEL is one of the global leaders in the manufacture of plastics processing machines. Today, the ENGEL Group offers a full range of technology…



Hall 1 / A 1001

EWIKON Heißkanalsysteme GmbH

Innovative Heißkanal-Systemlösungen



Hall 2 / D 2107

FANUC Switzerland GmbH

With over 60 years experience in the development of CNC technologies, more than 22.5 million installed products and over 6000 employees worldwide,…



Hall 1 / B 1033

FISA Ultraschall GmbH

We are specialists in the design, manufacture and commissioning of manual or fully automated ultrasonic cleaning systems with profound experience and…



Hall 2 / B 2053


The GEISS company offers worldwide equipment for thermoforming and processing of plastics including moulds and jigs from one single source! Design…



Hall 1 / C 1067

GÜNTHER Heisskanaltechnik GmbH

GÜNTHER Hot Runner Technology – innovative hot runner systems for plastic injection moulding



Hall 2 / D 2106

Hans Wittich GmbH

We are specialist in machines and components for Laser-Marking, Laser-Engraving, Padprinting, Plasma- and Corona-Systems



Hall 1 / E 1113


As a world leading manufacturer of temperature control equipment, HB-Therm AG has developed and produced innovative temperature control technology…

St. Gallen


Hall 1 / D 1081

Herbold Meckesheim GmbH

We are your specialist in machines and systems for plastic recycling. We specialise both in the shredding, pulverizing and compacting (agglomeration)…



Hall 1 / B 1035

Herrmann Ultraschalltechnik GmbH & Co. KG

Herrmann Ultraschall is a world leader in ultrasonic welding with five decades of expertise. With our 360 ° ULTRASONIC ENGINEERING we offer…



Hall 1 / B 1054

inmex GmbH

Inmex develops and sells energy-efficient plasticizing units that can be retrofitted to any injection molding machine and lead to heating energy…

Sankt Augustin


Hall 2 / D 2123

Institut für Kunststofftechnik FHNW

Your partner to create sustainable, plastic-based product and processes innovations with a focus on high-performance polymers and composites.



Hall 2 / A 2005

KK Werk GmbH

Wir planen, entwickeln, produzieren und denken für UNSERE KUNDEN mit.



Hall 2 / A 2007

KKT Kunststoff Kompetenz Team

Your competent and motivated partner who specializes in services in the field of plastics processing!



Hall 1 / D 1094

KraussMaffei (Schweiz) AG

Die Produktmarke KraussMaffei steht international für wegweisende und technologieübergreifende System- und Verfahrenslösungen in der Spritzgieß- und…



Hall 2 / D 2101

Leister Technologies AG

Die Leister Technologies AG ist seit über 70 Jahren weltweiter Markt- und Innovationsführer für Plastic Welding, Process Heat und Laser Plastic…



Hall 1 / B 1052

MAPAG Maschinen AG

Your satisfaction is our motivation. MAPAG Maschinen AG is representing Sumitomo (SHI) Demag in the injection moulding sector for over 20 years and…



Hall 1 / B 1031

MS Ultraschall Technologie GmbH

Hall 2 / B 2059

Plastics Innovation Competence Center

PICC Vision is to be a leading and internationally recognized plastics competence center that provides advanced and innovative materials, processing…



Hall 1 / D 1099

poesia gruppe

Unter dem Namen „poesia-gruppe.ch“ präsentieren sich fünf Firmen. Sie alle sind bestrebt, ihre Kunden kompetent zu beraten, sie bei der…



Hall 2 / E 2136

PRIAMUS SYSTEM TECHNOLOGIES, branch of Barnes Group Suisse Industries LLC

PRIAMUS SYSTEM TECHNOLOGIES is specialized in the developmentand production of sensors, electronics and software-based monitoring- and closed…



Hall 2 / A 2034

ProByLas AG

ProByLas AG offers machines and machine modules for plastic welding with laser. Thanks to their modularity, the ready-to-use Turnkey machines can be…

Root D4


Hall 2 / D 2111


RINCO ULTRASONICS is a leading company in the field of ultrasonic welding and cutting technology. With over 130 employees, a presence in more than 40…



Hall 2 / B 2049

Sarac Plastic Technologies

SARAC manufactures a wide range of new generation ServoTech injection molding machines built to European standards utilizing proven high-quality…



Hall 1 / A 1007

SFS intec AG, Kunststoffwerk

SFS intec verfügt über langjähriges Know-how und umfassende Fertigungskompetenz auf dem Gebiet der Spritzgiesstechnik. Dadurch sind wir in der Lage…

Hall 1 / A 1008


SONOTRONIC develops and builds machines for joining injection moulded and extruded plastic parts. For this, we deploy either ultrasonic, infrared or…



Hall 2 / A 2021

Stamixco AG

StaMixCo AG calculates and supplies static mixers for the laminar flow range, especially for plastics processing in injection moulding and extrusion…



Hall 2 / C 2077

STM Stahl Vertriebs GmbH

Are you looking for steel which is best for your tools, contains the most important characteristics and therefore contributes to the success of your…



Hall 2 / A 2020

Sumitomo (SHI) Demag Plastics Machinery GmbH

Sumitomo (SHI) Demag has shaped the development of the plastics industry from its very beginning. As a specialist for injection moulding machines for…



Hall 1 / B 1031


The Swiss Telsonic Group has been offering its industrial ultrasonic solutions through representation in Europe, America and Asia since 1966.…



Hall 2 / D 2105


20 Jahre Erfahrung in der industriellen Reinigungstechnik in speziellen Oberflächen-Beschichtungs- und Aktivierungsverfahren, zeichnen unsere Firma…



Hall 1 / A 1014

Thomatech GmbH

Thomatech ist die schweizer Vertretung von MORETTO & Dr. Boy und wird Sie von der Beratung über Verkauf bis zum Service begleiten.



Hall 2 / A 2005


the specialist for devices for the physical material characterization: thermal analysis (DS / TGA, etc), rheometer / viscometer, melt index, residual…



Hall 1 / C 1069

WAG Wernli AG

Wir bieten Ihnen das komplette Programm für Ihre Projekte im Bereich der Faserverbundwerkstoffe!



Hall 2 / B 2057

Werner Koch Maschinentechnik GmbH

Werner Koch Maschinentechnik GmbH (KOCH-TECHNIK) is one of the world's leading complete suppliers of peripheral equipment for plastics processing.…



Hall 1 / A 1004

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