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Home > News > Injection

K 2025: ENGEL to demo injection molding for lightweight construction

Source：Adsale Plastics Network Date ：2025-08-01 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 demonstrate the manufacture of cockpit bicycle handlebars for CANYON Bicycles, proving the capabilities of its innovative injection molding technologies for lightweight construction.


ENGEL_tie-bar-less victory 180.jpg


tie-bar-less ENGEL victory 180 injection molding machine.

ENGEL_handlebar.jpg


The newly developed bicycle handlebar for CANYON Bicycles.

 

The ENGEL victory 180 wide-platen machine demonstrated in operation at the trade fair is an injection molding machine specifically designed for large and complex components or molds.

 

Thanks to its tie-bar-less design with a generously sized, unobstructed mold area, the victory series enables the use of large and complex molds on compact machine sizes.

 

Demonstration: tie-bar-less ENGEL victory 180 IMM with automation

 

The fully automated production cell is based on a tie-bar-less ENGEL victory 180 injection molding machine with a clamping force of 1800 kN. It combines the overmoulding of locally inserted continuous fiber tapes with the formation of a hollow structure in a single, continuous process step. This solution achieves a cycle time of just 60 seconds, leading to a significant increase in production capacity.

 

Automation of the production cell is handled by an ENGEL easix articulated robot. It is responsible for the precise insertion of threaded inserts and continuous fiber tapes, as well as for removing the finished parts. All movement sequences and process steps are coordinated via the central CC300 control unit of the injection molding machine, simplifying operation and increasing process reliability.

 

The handlebar, produced with plastic instead of aluminum, shows that with the right engineering, plastic solutions can replace aluminum, offering shorter cycle times, better functional integration, and greater design freedom.

 

Plastic replacing aluminum

 

The handlebar is made from a polyamide 6 with 50% glass fiber reinforcement supplied by DOMO Chemicals to ensure the required stiffness and strength. The part completely replaces an aluminum solution, with a shorter cycle time, around 15% less weight, and improved vibration damping.

 

By integrating four unidirectional carbon fiber tapes (UD tapes), which are placed in the mold prior to injection molding, the part withstands high mechanical loads despite its low wall thickness and hollow structure.

 

During the process, fluidmelt is used to inject gas and push the plastic core of the component back into the plasticizing unit, creating a hollow space within the part. The displaced material is reused in the production of the next component.

 

The complete integration of both processes into a continuous injection molding cycle ensures short cycle times and high reproducibility.

 

This combination of local UD tapes and the fluidmelt process enables complex hollow-body geometries with high design freedom and functional integration, while at the same time reducing material usage and energy consumption.

 


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Injection molding machines
K Fair
ENGEL
 Ningbo Xinbaile Intelligent Machinery Manufacturing Co., Ltd.      
 HENAN HENGFEI BIOLOGICAL TECHNOLOGY CO.,LTD      
 GUANGDONG HALFON MACHINERY EQUIPMENT TECHNOLOGY CO.,LTD      
 ZHOUSHAN DEMAJI INDUSTRIAL CO., LTD.      
 YUYAO KAWAGUCHI Manufacturing Co., Ltd.      
 NINGBO UNION POWER MACHINERY CO., LTD.      
 BRUECKNER MASCHINENBAU GMBH      

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Source：Adsale Plastics Network Date ：2025-08-01 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 demonstrate the manufacture of cockpit bicycle handlebars for CANYON Bicycles, proving the capabilities of its innovative injection molding technologies for lightweight construction.


ENGEL_tie-bar-less victory 180.jpg


tie-bar-less ENGEL victory 180 injection molding machine.

ENGEL_handlebar.jpg


The newly developed bicycle handlebar for CANYON Bicycles.

 

The ENGEL victory 180 wide-platen machine demonstrated in operation at the trade fair is an injection molding machine specifically designed for large and complex components or molds.

 

Thanks to its tie-bar-less design with a generously sized, unobstructed mold area, the victory series enables the use of large and complex molds on compact machine sizes.

 

Demonstration: tie-bar-less ENGEL victory 180 IMM with automation

 

The fully automated production cell is based on a tie-bar-less ENGEL victory 180 injection molding machine with a clamping force of 1800 kN. It combines the overmoulding of locally inserted continuous fiber tapes with the formation of a hollow structure in a single, continuous process step. This solution achieves a cycle time of just 60 seconds, leading to a significant increase in production capacity.

 

Automation of the production cell is handled by an ENGEL easix articulated robot. It is responsible for the precise insertion of threaded inserts and continuous fiber tapes, as well as for removing the finished parts. All movement sequences and process steps are coordinated via the central CC300 control unit of the injection molding machine, simplifying operation and increasing process reliability.

 

The handlebar, produced with plastic instead of aluminum, shows that with the right engineering, plastic solutions can replace aluminum, offering shorter cycle times, better functional integration, and greater design freedom.

 

Plastic replacing aluminum

 

The handlebar is made from a polyamide 6 with 50% glass fiber reinforcement supplied by DOMO Chemicals to ensure the required stiffness and strength. The part completely replaces an aluminum solution, with a shorter cycle time, around 15% less weight, and improved vibration damping.

 

By integrating four unidirectional carbon fiber tapes (UD tapes), which are placed in the mold prior to injection molding, the part withstands high mechanical loads despite its low wall thickness and hollow structure.

 

During the process, fluidmelt is used to inject gas and push the plastic core of the component back into the plasticizing unit, creating a hollow space within the part. The displaced material is reused in the production of the next component.

 

The complete integration of both processes into a continuous injection molding cycle ensures short cycle times and high reproducibility.

 

This combination of local UD tapes and the fluidmelt process enables complex hollow-body geometries with high design freedom and functional integration, while at the same time reducing material usage and energy consumption.

 


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K 2025: ENGEL to demo injection molding for lightweight construction

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