At Fakuma 2026, ENGEL will demonstrate the series production of auto-injector components on the all-electric e-mac 200, which combines an exceptionally small footprint with high output.

All-electric e-mac 200.

Auto-injector component, precision-manufactured in volumes of millions on the ENGEL e-mac.

During live operation, assistance systems from the inject AI family monitor and control the process. They compensate for fluctuations before rejects occur and reduce the required clamping force by up to 33%.

The exhibit will be on display at the stand of French injection molding machine manufacturer Billion SAS – the perfect setting in which to showcase the strategic partnership between the two companies.

Precision in the tenths-of-a-gram range

e-mac 200 features generous tie-bar spacing that provides ample room for sophisticated molds. The dynamic injection unit ensures repeatable processes even with very small shot weights. Options developed specifically for medical applications and the enclosed toggle mechanism support cleanroom-compatible production.

The machine produces a component for a medical auto-injector from PP random copolymer with white masterbatch. The 32-cavity mold produces parts weighing just 0.396 grams each, with a cycle time of less than ten seconds.

iQ weight control optimizes the injection volume in real time: fluctuations in melt viscosity are compensated for within the same shot, thereby ensuring consistent part quality.

Compact cell in cleanroom situation

An ENGEL viper linear robot removes the finished components. Combined with the ENGEL compact cell and its integrated box transfer system, it forms a fully automated, space-saving production cell.

The compact cell can be moved aside to provide unrestricted access to the mold area. The machine and automation are operated via a common control system using a consistent data set.

Greater flexibility in validation

The ENGEL validation assistant uses data from the iQ assistance systems to assess not only a single operating point, but a robust process window. This provides a clear picture of process stability within defined limits, increasing confidence in process stability, significantly reducing the validation effort and accelerating approval for series production.

All regulatory qualification and validation steps remain in place, with the ENGEL validation assistant adding a transparent, data-driven and digitally supported process assessment.

Stable processes thanks to four assistants

Additional functions from the inject AI family stabilize the process and support the operator:

• iQ clamp control automatically regulates the clamping force, reducing it by up to 33%. This protects the mold, extends its service life and lowers energy consumption.

• iQ flow control keeps mold temperature control stable by adjusting the pump speed. This ensures consistent thermal conditions, reduces rejects and cuts energy consumption by up to 18 per cent – with a direct impact on costs and the carbon footprint.

• Parameter Limits prevent settings outside the approved process window, reducing the risk of operator error – even when personnel change.

• iQ process observer uses artificial intelligence to analyze more than 1,000 process parameters, identify deviations at an early stage and provide specific recommendations for corrective action.