At K 2025, ENGEL will present an integrated, fully automated production solution for the diagnostics market, highlighting the premiere of a new validation assistant in the cell.

The system achieves an increase in overall efficiency of approximately 25 % compared to conventional production methods. In a single cell, well plates and lids are produced and packaged in a validated manner. At the heart of the solution is an all-electric ENGEL e-motion 280 WP combi MW injection molding machine with 2800 kN clamping force.

ENGEL e-motion 280 combi MW.

Well plates with lids.

Two machines in one

ENGEL’s compact system concept combines with the innovative high-performance Variotwinstack mold technology from HACK Formenbau GmbH to implement the principle of two machines in one.

The mold is designed for the simultaneous production of up to four polystyrene well plates with 24 wells and their matching lids. For optimal media connection, the e-motion features a movable center platen. The two injection units operate in parallel, reducing the cycle time to just 11 seconds. The shot weight for the well plates is 42.6g, and 13.2g for the lids.

The angled arrangement of the moving injection unit brings the nozzle closer to the hot runner, reducing its volume and thus increasing process reliability. Valve gate hot runner injection without a sprue optimizes material usage while completely eliminating weld lines and flow marks. A multi-stage demolding process with intelligent cooling and optimal part orientation further provides a particularly wide process window.

In addition, integrated HACK moldlife sense sensor technology continuously monitors the mold mechanics, increases system availability and detects faults at an early stage. This system also supplies data to support digitally assisted process validation.

Premiere: New validation assistant in the cell

ENGEL will premier its new validation assistant in this cell – a system for digitally assisted qualification and validation of injection molding processes. Developed in collaboration with HACK Formenbau and Professor Thomas Seul, the solution combines ENGEL’s iQ assistance systems, moldlife sense technology and structured software modules.

It supports all validation phases from DQ to PQ, accommodates future release methods such as parametric release, and simplifies the transfer of validated processes to additional machines or sites. As a result, both time and staffing requirements for validation are significantly reduced, leading to a much shorter time to market.

Compact, precise and cleanroom-ready

One of the key advantages of this production solution lies in its reduced system height by the newly designed layout, with overall footprint of the production cell is reduced by 40%.

ENGEL’s e-motion series has been specifically developed to meet the most demanding requirements in injection molding for medical technology and sets new standards in precision, efficiency and long-term cleanroom performance.

Automated post-processing

After demolding, a side-entry robot from Ilsemann removes the molded parts. Two arms simultaneously grip the parts from both sides of the mold and transfer them either to a sampling station or to a laser marking station where a QR code is applied. The parts are then automatically assembled, stacked and sealed in sterile packaging.