Digital Technologies for the Plastic Industry

31 May & 1 June 2021
Online via Microsoft Teams

Are you ready to seize the opportunities and utilize current and future technologies related to Industry 4.0?

What solutions are available for injection molding for the plastic industry? What skills do they require? How can digital technologies such as connected sensors, Internet of Things, simulation, polymer and metal additive manufacturing be integrated with plastic processing manufacturing platforms? How can these digital technologies add value and help to optimize time-to-market, quality, capacity and flexibility?

A number of leading companies will present Industry 4.0 technologies, solutions and applications. Speakers will present how different players and technology providers use Industry 4.0 concepts in the plastic industry and discuss opportunities and impact of digital technologies on processes and business models.

This seminar is a continuation of the seminar ‘Digital Technologies for the Plastic Industry – Plastic 4.0’ held in 2019.

31 May 2021

09:00 - 09:10
Welcome and introduction by Guido Tosello, Associate Professor, Dept. of Mechanical Engineering, DTU
09:10 - 09:35
IOT powered machine retrofitting for a fast and cheap 4.0 factory digitalization

Daniele Mazzei, Head of production, Zerynth, Italy

One of the major bottlenecks in 4.0 factories conversion is the difficulty in evaluating the return of investment (ROI). It is very difficult for a manager to evaluate how much the introduction of 4.0 technologies could improve the efficiency of processes thus, it is complicated to justify the required investments.

Retrofitting of existing machines with Industrial-IOT technologies allows gathering of the data necessary for the creation of the 4.0 mandatory digital twin. This fast, cheap and lean approach can really make the difference in the 4.0 revolution by lowering the investment required for factory digitalization thus making the spread of 4.0 faster and disruptive. In the talk, various examples of industrial machines retrofitting will be presented together with specific use cases where plastic injection machines have been retrofitted for real-time monitoring of production performances and power consumption.

09:35 - 10:00
3D-Printing enables distributed production in a digital world

Marius Lakomiec, Team Manager Digital AM Solutions, EOS, Germany

High performing AM factories being used by Material Solutions, Siemens Industrial and EOS for serial AM production will be presented. Such AM factories comprise an optimum combination of 3D printers, powder-handling, support equipment, mobility equipment, automation and software. The AM factories are optimized to achieve manufacturer production, space, quality, cost and automation requirements using simulation tools. They are also optimized within the context of post-processing requirements of the manufacturers’ applications.

Three examples will be presented: a manual facility, a semi-automated facility and a fully automated facility. The optimization of the AM work flow with end-to-end PLM chain, as well as the use of IIoT platforms (like Mindsphere) and data analytics will also be covered, including machine data extraction.

At the end of the presentation, Marius Lakomiec will take you on a digital live tour through the AM factory.

Dr. Marius Lakomiec joined EOS in 2014. He leads the group for Digital AM Solutions in the Digital Manufacture Department, where he and his team are developing state of art AM production solutions, called “AM-Cells”. Before joining EOS Marius Lakomiec worked for six years at Germany's leading aero engine manufacturer MTU, where he was responsible for the industrialization of additive manufacturing processes.
10:00 - 10:20
10:20 - 10:45
Micro additive manufacturing – solutions and trends

Avi Cohen, EVP Sales, Nanofabrica, Israel

Manufacturing is changing the way we make things. Why do industries need precision digital manufacturing? What are the benefits and applications of an industrial Additive Manufacturing system? What micron-resolution with ultra-high features, details, accuracy, and precision can be achieved today? Learn how different customers brings the power of Additive Manufacturing (AM) to applications that require high precision such as: aerospace, electronics, automotive, medical, optics, education and more.

Motivated by a passion for solving tough challenges and guided by a desire to listen to our customers and learn from their experience, Nanofabrica aim high to enable digital mass manufacturing of precise and complex parts. With advanced hardware, software and materials and a team of experts and industry veterans, they are on a mission to transform businesses through micro-part manufacturing innovation.

Avi Cohen is an industry award winner with over 22 years of progressive experience with advanced technology products and services in the Additive Manufacturing (AM) and 3D printing industry.
10:45 - 11:10
The future of electronic protection

Luka Bertoncelj, Head of Research and Development, Iskra ISD, Slovenia

Imagine your electronic components being boiled, oven-heated, or even poured with concrete – and they would survive. Is it possible? Existing technologies such as hot melt and potting were until now the dominant methods for electronic protection using polymer materials; however, long cycle times and expensive polymer solutions were their main drawbacks.

Plastic injection moulding allows short cycle times and great cost efficiency, but large filling pressures (500 – 1000 bar) and high melting temperatures (220 – 340 °C) were the main technical obstacles of using the technology as an encapsulation method of electronic components. Until now. With the development of specialized low viscosity thermoset materials, electronic components can be overmoulded with filling pressures of up to 50 bar and melt temperatures up to 100 °C. Not only have the encapsulating thermosets a protective function, but due to their excellent temperature resistance, high mechanical properties (tensile modulus, tensile strength), and their ability to reach complex shapes, they can also turn a conventional electronic housing into a multi-functional, load-carrying, structural part.

A comparison between hot melt, potting and thermoset injection moulding will be presented. Two active case studies of using the thermoset injection moulding process for electronics encapsulation will be shown together with our feasibility analysis and general design guidelines.

Luka Bertoncelj is Head of R&D at the Iskra ISD Group. He manages R&D related projects and activities for the plastic, HPDC, turning and electroplating division while maintaining a customer-based, technical support approach. Before his employment at Iskra, Luka worked as a product development consultant with clients from Canada, China, USA and Germany. His work was primarily related to 3D modeling, preparation of promotional material (rendering, animation videos) and conceptual development of consumer-based products (toys, furniture, accessories).
11:10 - 11:45
Give your employees a powerful tool and experience Netstal's Industry 4.0

Patrick Waldvogel, Deputy Sales Director Europe, Netstal, Switzerland

Particularly in the plastics processing industry many companies are facing a shortage in skilled blue-collar workers. At the same time, requirements for product quality, process validation and overall efficiency of the product equipment are hitting new highs. That is why there is the possibility to equip Netstal injection moulding machines with extras to support that demand accordingly.

At first glance, the „SmartOperation“ tool consists simply of four additional buttons on the control unit. But the real deal is below the surface, following years of consequent software development, massive testing & field tests. The result: After proper preparation by process experts, a machine or production system which can be operated by almost any person. A system that is stable during production and which overall efficiency is almost forced to increase. Using a PET-System, Netstal will showcase this instrument that can unleash further potential to support remote support. Around Industry 4.0 topics further benefits of OPC-UA connectivity in production systems will be highlighted.

A live demonstration will shown.

Since 2011 Patrick Waldvogel has been part of the Netstal family. Formerly, he worked in the Business Unit Caps&Closures and later he moved in the context of a more focused market development into the European Division. In his role as Deputy Sales Director Europe, he and his team manage the business for the complete Netstal portfolio in Europe and support the long-standing subsidiaries and agent network.
11:10 - 11:45
Give your employees a powerful tool and experience Netstal's Industry 4.0 (continued)

Christina Härter, Manager of Application Technology, Kraussmaffei, Switzerland

Christina Härter has studied mechanical engineering at the University of Stuttgart. She completed her PhD under Prof. Fritz in the depart. for chemical engineering of University of Stuttgart. Since 2010, she has worked for Netstal Maschinen AG: first as an engineer specialised in plastification parts, then as Team Leader Process Technology and now as Manager of Application Technology. In this context, she is involved in developments concerning machines and applications for beverages.
11:45 - 11:55
Closing remarks for today

1 June 2021

09:00 - 09:10
Welcome and follow up on day one
09:10 - 09:35
Intelligent and digitized production with GiboSmartSolutions

Mikkel Bjerregaard, CSO, Gibotech A/S, Denmark

This presentation will focus on the recently developed concept GiboSmartSolutions. It includes several aspects from Industry 4.0 such as collaborative and mobile robots, and digital thermoforming / CNC technology for the plastic industry. Mikkel Bjerregaard will also elaborate how maximum flexibility can be combined with maximum output and how robots and machines can optimize themselves during production and without any operator input.

09:10 - 09:35
Intelligent and digitized production with GiboSmartSolutions (continued)

Henrik Thomsen, Product Manager, Gibotech A/S, Denmark

09:35 - 10:00
Digitalization optimizations from the perspective of a machine provider

Michael Kylling, Manging Director, Arburg A/S, Denmark

From the perspective of a machine builder and services provider, we will take a look at possible roadmaps for digitalization.
What are the development steps for a supplier in order to bring value based services to the customer? Naturally the customer needs to see possible step by step possibilities, which encompass the range of current equipment installed, while also being able to benefit from a range of disciplines, such as production efficiency, predictive maintenance and quality control. Finally the services should provide a basis for training, support and the Green agenda (recycling, CO2 etc).

Michael Kylling is the Managing Director of Arburg A/S. He holds a Bachelor of Computer Science from Copenhagen University and an MBA from Henley Business School. Before joining Arburg A/S, he was Scandinavian Manager at Rockwell Automation, and previously a Nordic Manager at IBM. He has extensive knowledge of IT systems and the digitalization agenda of the industrial sector.
10:00 - 10:20
10:20 - 10:45
Upfront simulation with Autodesk Moldflow

Torbjörn Jansson, Vice VD, NTI Sweden AB, Sweden

Autodesk Moldflow is part of the Autodesk business area MAKE, which contains Moldflow for simulation of the injection molding process, PowerMill for advanced 5-axis milling and Netfabb for simulation of 3D Printing in metal. Together, this software makes it possible to develop mold tools with conformal cooling and thus shorten cycle times.

This presentation will show examples of how important it is to do simulations early in the product development process instead of subsequently trying to save a tool that does not work. With Moldflow simulations you will reduce both costs and above all “time to market”.

Torbjörn Jansson is founder of the Swedish part of NTI Group, one of Autodesk's largest reseller in Europe with operations in Denmark, Norway, Iceland, Germany, the Netherlands and Sweden and a total turnover of 100 million Euros.
10:45 - 11:15
ENGEL launch - Next generation of process quality monitoring

Paul Kapeller, Product Manager for Digital Solutions, ENGEL Austria GmbH, Austria

The latest smart solution from ENGEL is iQ Process Observer, which is currently running in pilot phase at a few selected customers. The solution is unique inside the injection moulding industry and is another step towards taking advantage of the digital technology in order to provide improved performance to our customers. iQ Process Observer is:

  • First proactive process monitoring system
  • Always up-to-date
  • A solution that integrates ENGEL’s expert know-how
  • A solution with a unique system architecture

The system offers quicker troubleshooting, optimisation hints and early detection of drifts providing downtime reduction, Process quality improvement and scrap rate reduction as main customer benefits.

The new iQ Process Observer will be demonstrated after the presentation.

11:15 - 11:40
Additive manufacturing for direct tooling applications in plastic injection moulding

Guido Tosello, Associate Professor, DTU Mechanical Engineering

Metal additive manufacturing (MAM) of mould components is associated with cost-intensive post-process finishing operations, which are currently one of the main drawbacks preventing wider industrial adoption of MAM. This work analyses the current possibilities and limitations of MAM for plastic injection moulding tool applications, demonstrating the opportunity to limit post-processes to heat treatment and the machining of the MAM insert outer geometry, which was only intended to ensure the assembly of the insert in the injection moulding frame. The results focus on evaluating the as-built insert cavity geometrical characteristics and the dimensional replication performance of the injection moulding process. The as-built cavity surface texture was comparable to a surface roughness that usually would be manufactured by electrical discharge machining (EDM). The cavity texture and features were replicated into the plastic injection moulded samples with an average replication fidelity higher than 95 %, enabling the direct production of inserts with integrated enhanced surface properties and aesthetics. The study is completed with a fatigue tool life assessment and a production costs comparative analysis.

Guido Tosello has 12+ years of research experience in the analysis, characterization, monitoring, control, optimization and simulation of precision molding processes of thermoplastic materials from conventional size down to micro and nano scales. He is currently the coordinator of the European project DIGIMAN4.0 ‘Digital Manufacturing Technologies for Zero-defect Industry 4.0 Production’ (2019-2024) (
11:40 - 11:50
Closing remarks

Digital Technologies for the Plastic Industry

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Registration fee

 DKK 1,795  Members of ATV-SEMAPP and promoting partners listed in the registration form
 DKK 2,295  Non-members
 DKK 995  PhD Students
 DKK 200  BSc and MSc students (Membership is free of charge – register here. Early bird discount does not apply)

All prices are exclusive of 25 % VAT.

Early bird discount of DKK 500 when registering before 5 May 2021.

Binding registration
Registration is binding, however substitutions are accepted at any time.

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