At Fakuma 2026, Oerlikon HRSflow will highlight its cross-industry expertise in hot-runner injection molding on its booth as well as booths of partner companies, including Fanuc, Haitian, and Wittmann.

STARgate HRS: Suitable for extensive range of processable polymers

The innovative STARgate HRS hot-runner nozzle concept, which uses a diaphragm-like mechanical system, will present for PP and r-PP applications to comply with the new PPWR regulations, as well as for processing resins such as PMMA and ABS, expanding its range of applications across market segments.

STARgate HRS hot-runner nozzle.

The innovative hot-runner nozzle concept uses a mechanical system that operates like a diaphragm.

Compared with conventional solutions, this design enables a fast color change and optimal cooling performance resulting in a significant reduction in cycle time and increased productivity.

“Less than a year after the official market launch of STARgate HRS, we’ve already received many positive reports from customers who have achieved reduced part wall thicknesses, lower component weight and a significant reduction in cycle time compared with conventional production,” commented Matteo Badella, Global Sales Director Pac-Med, Consumer Goods, and Logistics at Oerlikon HRSflow.

Xp nozzle: Optimal injection quality for thick, transparent parts

Oerlikon HRS flow will also show the new Xp series of valve gate nozzles, engineered for a wide range of applications and enhanced to meet the demanding requirements of the cosmetics industry.

Accurate thermal control of the nozzle, combined with a new gate seal solution, ensures optimal injection quality for thick, transparent parts with shot weights up to 70 g. The new Xp nozzle series is specifically designed for thick-walled injection-molded parts, made from (r-)PET and recyclable copolyesters such as PETG, PCTA, and PCTG with further materials to be tested.

At the show, Oerlikon HRSflow will showcase an impressive application example in the form of multiple cosmetic jars with different challenging shapes, made from Eastman’s PET Cristal One Renew IM812, featuring a crystal-clear appearance and a flawless surface.

Using this material ensures a high level of sustainability because its recycled content, as determined by mass balance, can be as high as 100%. Additionally, this r-PET enables the injection molding of parts with wall thicknesses of up to 12 mm.

Using rPET in medical applications

Another highlight will be the use of rPET in medical applications. One key example is a precision, direct-gated, Luer-lock component manufactured by using LNP ELCRIN W1000JiQ, the next-generation medical-grade PBT from SABIC is derived from chemically recycled PET. The part will also be produced using PEEK technopolymer for demanding applications.

The related multi-cavity mold is equipped with an Oerlikon HRSflow TECHflow HRS valve gate line.

Thanks to its innovative external nozzle end rings, it offers increased wear resistance when processing abrasive, reinforced thermoplastics, including those with flame-retardant additives, that combine a narrow processing window with high processing temperatures.

A uniform temperature profile ensures a wider processing window combined with high dimensional stability and easy machine restart of the Luer-Lock connectors.

High-quality automotive parts straight from the mold

The automotive industry, among others, demands reduced post-processing steps to increase process efficiency. To address this challenge, Oerlikon HRSflow will show GLOW HRS, a compact solution for direct injection molding of high-quality parts that prevents halos and enables superior surface aesthetics.

Additionally, a scratch-resistant bumper will be presented, that combines polyurethane (PUR) coating and decorative film technology in a single, efficient process, reducing both production time and investment costs compared to the two-stage process. This is also made possible by the optimal configuration of the Oerlikon HRSflow system. It was developed specifically for the seamless integration of both technologies and features nine conical needle-valve nozzles.