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Home > News > Injection

ENGEL’s next evolution of tie-bar-less machine to be debuted at K 2025

Source：Adsale Plastics Network Date ：2025-07-09 Editor ：RC
Copyright： This article was originally written/edited by Adsale Plastics Network (AdsaleCPRJ.com), republishing and excerpting are not allowed without permission. For any copyright infringement, we will pursue legal liability in accordance with the law.

At K 2025, ENGEL will showcase its technologies and solutions in practical operation – from the use of artificial intelligence in the running injection molding process to highly integrated production cells for the automotive, medical, technical molding and packaging sectors. One of the highlights will be the world premiere of a new electric tie-bar-less injection molding machine.

 

World premiere: New generation of electric tie-bar-less machine

 

At the ENGEL stand, one of the highlights will be the world premiere of the latest generation of its electric tie-bar-less victory injection molding machines. This new model is fast, clean, and energy-efficient. It also features a completely new technical design.


ENGEL_K 2025_electric tie-bar-less IMM.jpg

ENGEL’s latest generation of electric tie-bar-less injection molding machines will make its debut at K 2025.

 

On the new victory electric, fittings are produced with a cycle time of just 23 seconds. The mold includes large-volume core pulls, which are optimally supported by the free access provided by the tie-bar-less design. Thanks to ENGEL tie-bar-less technology, even large molds can be used on comparatively small machines, saving space, energy and investment.

 

After injection molding, the fittings are automatically equipped with seals. The production cell is equipped with two easix articulated robots to handle this step.

 

Automotive applications

 

Rear-end-light modules produced on ENGEL duo 700

 

ENGEL will demonstrate the highly integrated series production of innovative rear-end-lights on a high-performance duo 700 two-platen injection molding machine with 7000 kN clamping force. The visible parts are manufactured using a combination of decorative foilmelt and functional clearmelt technologies in a vertical rotary table mold.


ENGEL_K 2025_duo 700.jpg

ENGEL duo 700.

 

In addition to design freedom, downstream processes are integrated into the injection molding cell, and a separate hardcoating process is no longer required thanks to clearmelt. While the color design from a decorative foil is applied to the component on one mold side by back-injection of thermoplastics (foilmelt), the opposite side is overflooded with polyurethane (clearmelt) to form a highly transparent and robust protective layer.

 

A space-saving integrated automation system with a viper 40 linear robot enables short cycle times within a compact and efficient cell. The transfer foil is supplied by LEONHARD KURZ. At the partner’s stand, the component is further processed using an integrated LED function foil.

 

LSR seals for fuel cells manufactured on vertical ENGEL insert 150

 

A production cell with a vertical insert 150 injection molding machine, offering 1500 kN clamping force, demonstrates the fully automated manufacturing of liquid silicone rubber (LSR) seals on sensitive gas diffusion layers (GDL) for fuel cells. The LSR seal is applied with absolute platen parallelism directly in the machine, inspected in the mold and the component is immediately removed.


ENGEL_K 2025_vertical insert 150.jpg

Vertical ENGEL insert 150.

 

The automation system, featuring ENGEL easix articulated robot and a rotary table mold supplied by ACH, ensures short cycle times and high process reliability. To save space, the control cabinet is integrated directly into the machine frame. ENGEL will showcase a highly cost-efficient solution for fully automated overmolding with thin LSR layers in a compact footprint.


Read more: ENGEL to demo overmolding with LSR fuel cell components at K Fair

 

Bicycle handlebar manufactured on tie-bar-less ENGEL victory 180

 

A novel bicycle handlebar is manufactured as a hollow component on a tie-bar-less ENGEL victory 180 injection molding machine with 1800 kN clamping force. The fluidmelt process is used to create the hollow structure, while unidirectional continuous carbon fiber tapes are simultaneously integrated using the organomelt process. This innovative combination of technologies enables maximum part performance with minimal weight and a short cycle time of just one minute. The process is fully automated with an easix articulated robot.


ENGEL_K 2025_tie-bar-less victory 180.jpg

Tie-bar-less ENGEL victory 180.


Read more: ENGEL to demonstrate injection molding technologies for lightweight construction


Physically foamed B-pillar trim using MuCell

 

A B-pillar trim component is produced in just 50 seconds using the ENGEL foammelt technology on a t-win 6500 two-platen injection molding machine from the WINTEC brand, part of the ENGEL Group. The foamed part is made of mineral-filled PP from Sabic. ENGEL’s foammelt technology reduces weight and cuts material and production costs while achieving excellent surface replication. Automation is handled by a highly integrated viper 20 robot.

 

Medical applications

 

Cell culture plates with matching PC lids produced in a single shot

 

In the Medical area, ENGEL will showcase a highly efficient injection molding cell built around an all-electric e-motion 260 combi M injection molding machine equipped with two injection units and a central rotary platen. Using a stack mold from Hack, 24-well cell culture plates and matching polycarbonate lids are produced simultaneously in a single shot – with a cycle time of just 11 seconds.

 

The additional injection unit is arranged at an angle to shorten the hot runner path, enabling central injection without weld lines and improving material protection. This manufacturing solution, featuring a side-entry robot from Ilsemann, delivers the entire process including assembly and packaging in a compact, ergonomic setup.

 

A key highlight is the validation solution jointly developed by ENGEL and toolmaker Hack. This system enables structured and digital documentation of all validation phases – from Design Qualification (DQ) to Performance Qualification (PQ). Machine- and tool-integrated sensor technology, combined with products from the ENGEL iQ family and standardized documentation modules, significantly reduce the effort required. As a result, the time- and personnel-intensive validation process is substantially shortened.

 

Technical molding

 

Blocks made from recycled material

 

On an all-electric e-mac 220 injection molding machine with 2,200 kN clamping force, ENGEL will produce thick-walled, foamed construction blocks for the building industry. The material comes from yellow bag household waste, reprocessed by EREMA. Mold and foaming agent formulation are supplied by Moxietec. For optimum foam homogeneity, an optimized mixing screw is used during plasticizing.


ENGEL_K 2025_e-mac 220.jpg

All-electric ENGEL e-mac 220.

 

The resulted components are with up to 30 % weight reduction and 10 % higher strength. This technology is particularly well suited for logistics pallets and as a substitute for concrete in construction applications.

 

As 100 % post-consumer recyclate with corresponding material fluctuations is processed, the new iQ weight control plus plays a key role. After defining just two parameters, the digital assistance system automatically adjusts the switchover point and pressure curve during every injection cycle. This reduces scrap by up to 50 %. An integrated automation solution with servo sprue picker and an integrated conveyor belt inside the machine also makes the cell particularly energy-efficient and compact.

 

Packaging applications

 

Thin-walled cups with 30% rPET produced using stack mold

 

ENGEL will demonstrate a series-ready solution for processing rPET in thin-walled packaging on an all-electric e-motion 420 injection molding machine with 4,200 kN clamping force. A 6+6-cavity stack mold from Plastisud is used to produce yoghurt cups made from 70 % virgin material and 30 % bottle-grade rPET. The rPET is supplied by NGR and upgraded for food contact via Liquid-State Polycondensation.


ENGEL_K 2025_e-motion 420.jpg

All-electric ENGEL e-motion 420.

 

This production setup delivers excellent repeatability at high performance. The combination of injection compression molding, iQ motion control, and iQ weight control plus enables the manufacture of thin-walled, precise cups with minimal material usage.

 

The application already complies with the requirements of the Packaging and Packaging Waste Directive for 2030. Moreover, it illustrates the potential to replace thermoforming as the preferred manufacturing process, enabling producers to save on upstream steps (film production) and material (trimming waste).

 

Digital intelligence

 

inject AI

 

ENGEL will showcase the next step toward self-optimizing machines by integrating artificial intelligence into many new and existing ENGEL products. The iQ process observer monitors up to 1,000 parameters per shot, detects process deviations in real time, and provides AI-supported automatic correction suggestions, contributing to process optimization and scrap reduction. The systems continuously learn from the data of all connected machines, creating added value for every new project.

 

e-connect portal with AI

 

In the event of machine or process faults, a new AI-supported feature in the e-connect portal provides machine-specific assistance – quickly, precisely, around the clock, and in all languages. Thanks to intelligent search functionality in the ENGEL machine manuals, downtime can be significantly reduced. The system will be available as a pilot series in time for K 2025.


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Source：Adsale Plastics Network Date ：2025-07-09 Editor ：RC
Copyright： This article was originally written/edited by Adsale Plastics Network (AdsaleCPRJ.com), republishing and excerpting are not allowed without permission. For any copyright infringement, we will pursue legal liability in accordance with the law.

At K 2025, ENGEL will showcase its technologies and solutions in practical operation – from the use of artificial intelligence in the running injection molding process to highly integrated production cells for the automotive, medical, technical molding and packaging sectors. One of the highlights will be the world premiere of a new electric tie-bar-less injection molding machine.

 

World premiere: New generation of electric tie-bar-less machine

 

At the ENGEL stand, one of the highlights will be the world premiere of the latest generation of its electric tie-bar-less victory injection molding machines. This new model is fast, clean, and energy-efficient. It also features a completely new technical design.


ENGEL_K 2025_electric tie-bar-less IMM.jpg

ENGEL’s latest generation of electric tie-bar-less injection molding machines will make its debut at K 2025.

 

On the new victory electric, fittings are produced with a cycle time of just 23 seconds. The mold includes large-volume core pulls, which are optimally supported by the free access provided by the tie-bar-less design. Thanks to ENGEL tie-bar-less technology, even large molds can be used on comparatively small machines, saving space, energy and investment.

 

After injection molding, the fittings are automatically equipped with seals. The production cell is equipped with two easix articulated robots to handle this step.

 

Automotive applications

 

Rear-end-light modules produced on ENGEL duo 700

 

ENGEL will demonstrate the highly integrated series production of innovative rear-end-lights on a high-performance duo 700 two-platen injection molding machine with 7000 kN clamping force. The visible parts are manufactured using a combination of decorative foilmelt and functional clearmelt technologies in a vertical rotary table mold.


ENGEL_K 2025_duo 700.jpg

ENGEL duo 700.

 

In addition to design freedom, downstream processes are integrated into the injection molding cell, and a separate hardcoating process is no longer required thanks to clearmelt. While the color design from a decorative foil is applied to the component on one mold side by back-injection of thermoplastics (foilmelt), the opposite side is overflooded with polyurethane (clearmelt) to form a highly transparent and robust protective layer.

 

A space-saving integrated automation system with a viper 40 linear robot enables short cycle times within a compact and efficient cell. The transfer foil is supplied by LEONHARD KURZ. At the partner’s stand, the component is further processed using an integrated LED function foil.

 

LSR seals for fuel cells manufactured on vertical ENGEL insert 150

 

A production cell with a vertical insert 150 injection molding machine, offering 1500 kN clamping force, demonstrates the fully automated manufacturing of liquid silicone rubber (LSR) seals on sensitive gas diffusion layers (GDL) for fuel cells. The LSR seal is applied with absolute platen parallelism directly in the machine, inspected in the mold and the component is immediately removed.


ENGEL_K 2025_vertical insert 150.jpg

Vertical ENGEL insert 150.

 

The automation system, featuring ENGEL easix articulated robot and a rotary table mold supplied by ACH, ensures short cycle times and high process reliability. To save space, the control cabinet is integrated directly into the machine frame. ENGEL will showcase a highly cost-efficient solution for fully automated overmolding with thin LSR layers in a compact footprint.


Read more: ENGEL to demo overmolding with LSR fuel cell components at K Fair

 

Bicycle handlebar manufactured on tie-bar-less ENGEL victory 180

 

A novel bicycle handlebar is manufactured as a hollow component on a tie-bar-less ENGEL victory 180 injection molding machine with 1800 kN clamping force. The fluidmelt process is used to create the hollow structure, while unidirectional continuous carbon fiber tapes are simultaneously integrated using the organomelt process. This innovative combination of technologies enables maximum part performance with minimal weight and a short cycle time of just one minute. The process is fully automated with an easix articulated robot.


ENGEL_K 2025_tie-bar-less victory 180.jpg

Tie-bar-less ENGEL victory 180.


Read more: ENGEL to demonstrate injection molding technologies for lightweight construction


Physically foamed B-pillar trim using MuCell

 

A B-pillar trim component is produced in just 50 seconds using the ENGEL foammelt technology on a t-win 6500 two-platen injection molding machine from the WINTEC brand, part of the ENGEL Group. The foamed part is made of mineral-filled PP from Sabic. ENGEL’s foammelt technology reduces weight and cuts material and production costs while achieving excellent surface replication. Automation is handled by a highly integrated viper 20 robot.

 

Medical applications

 

Cell culture plates with matching PC lids produced in a single shot

 

In the Medical area, ENGEL will showcase a highly efficient injection molding cell built around an all-electric e-motion 260 combi M injection molding machine equipped with two injection units and a central rotary platen. Using a stack mold from Hack, 24-well cell culture plates and matching polycarbonate lids are produced simultaneously in a single shot – with a cycle time of just 11 seconds.

 

The additional injection unit is arranged at an angle to shorten the hot runner path, enabling central injection without weld lines and improving material protection. This manufacturing solution, featuring a side-entry robot from Ilsemann, delivers the entire process including assembly and packaging in a compact, ergonomic setup.

 

A key highlight is the validation solution jointly developed by ENGEL and toolmaker Hack. This system enables structured and digital documentation of all validation phases – from Design Qualification (DQ) to Performance Qualification (PQ). Machine- and tool-integrated sensor technology, combined with products from the ENGEL iQ family and standardized documentation modules, significantly reduce the effort required. As a result, the time- and personnel-intensive validation process is substantially shortened.

 

Technical molding

 

Blocks made from recycled material

 

On an all-electric e-mac 220 injection molding machine with 2,200 kN clamping force, ENGEL will produce thick-walled, foamed construction blocks for the building industry. The material comes from yellow bag household waste, reprocessed by EREMA. Mold and foaming agent formulation are supplied by Moxietec. For optimum foam homogeneity, an optimized mixing screw is used during plasticizing.


ENGEL_K 2025_e-mac 220.jpg

All-electric ENGEL e-mac 220.

 

The resulted components are with up to 30 % weight reduction and 10 % higher strength. This technology is particularly well suited for logistics pallets and as a substitute for concrete in construction applications.

 

As 100 % post-consumer recyclate with corresponding material fluctuations is processed, the new iQ weight control plus plays a key role. After defining just two parameters, the digital assistance system automatically adjusts the switchover point and pressure curve during every injection cycle. This reduces scrap by up to 50 %. An integrated automation solution with servo sprue picker and an integrated conveyor belt inside the machine also makes the cell particularly energy-efficient and compact.

 

Packaging applications

 

Thin-walled cups with 30% rPET produced using stack mold

 

ENGEL will demonstrate a series-ready solution for processing rPET in thin-walled packaging on an all-electric e-motion 420 injection molding machine with 4,200 kN clamping force. A 6+6-cavity stack mold from Plastisud is used to produce yoghurt cups made from 70 % virgin material and 30 % bottle-grade rPET. The rPET is supplied by NGR and upgraded for food contact via Liquid-State Polycondensation.


ENGEL_K 2025_e-motion 420.jpg

All-electric ENGEL e-motion 420.

 

This production setup delivers excellent repeatability at high performance. The combination of injection compression molding, iQ motion control, and iQ weight control plus enables the manufacture of thin-walled, precise cups with minimal material usage.

 

The application already complies with the requirements of the Packaging and Packaging Waste Directive for 2030. Moreover, it illustrates the potential to replace thermoforming as the preferred manufacturing process, enabling producers to save on upstream steps (film production) and material (trimming waste).

 

Digital intelligence

 

inject AI

 

ENGEL will showcase the next step toward self-optimizing machines by integrating artificial intelligence into many new and existing ENGEL products. The iQ process observer monitors up to 1,000 parameters per shot, detects process deviations in real time, and provides AI-supported automatic correction suggestions, contributing to process optimization and scrap reduction. The systems continuously learn from the data of all connected machines, creating added value for every new project.

 

e-connect portal with AI

 

In the event of machine or process faults, a new AI-supported feature in the e-connect portal provides machine-specific assistance – quickly, precisely, around the clock, and in all languages. Thanks to intelligent search functionality in the ENGEL machine manuals, downtime can be significantly reduced. The system will be available as a pilot series in time for K 2025.


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ENGEL’s next evolution of tie-bar-less machine to be debuted at K 2025

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