Case Study: How we robotized a difficult injection molding process with inserts at Metchem
In the plastics processing industry, rising labor costs and quality requirements, especially in the automotive sector, force manufacturers to take decisive steps toward modern technologies. As Dentec, we have specialized in the automation of production processes and injection molding machine operation using robots since 2016.
We want to show you the behind-the-scenes of our implementation at Metchem, where the use of a 6-axis robot allowed for the realization of a complicated project that was unattainable for traditional methods.
Our client, Metchem, is a modern injection molding plant with over 40 years of experience, possessing a machine park of over 40 machines. In 2019, they made a strategic decision to develop in the direction of six-axis robots, choosing the KUKA brand.
The challenge: A complex detail for the automotive Industry
The project we collaborated on involved serial production of a component for the automotive industry. The challenge lay in the degree of complexity of the element:
- The product required four aluminum inserts (sleeves) mounted using overmolding technology.
- Already at the quotation stage, it was clear that without advanced automation, it would not be possible to achieve the required efficiency or quality necessary to win this contract.
- Traditional linear manipulators cease to be sufficient for such complex details.
The solution: KUKA KR20 robot
As Dentec, we were responsible for the entire automation and integration of the robot. We designed a station based on the KUKA KR20 industrial robot, tasked with handling the process of feeding inserts into a four-cavity injection mold.
What does this process look like in practice?
1. Positioning:
Aluminum sleeves are sorted and positioned by a vibratory bowl feeder.
2. Preparation:
A manipulator arranges them in a spacing that perfectly matches the cavities in the injection mold.
3. Application:
The KUKA robot, equipped with a dedicated gripper, picks up the sleeves and precisely places them on the matrix side of the mold.
4. Collection:
After injection, the robot collects the finished products from the punch side.
Crucially, in a single cycle lasting just 45 seconds, we feed as many as 16 sleeves.
The effects: 100% certainty and efficiency
The automation we implemented brought measurable benefits. Thanks to the precision of the 6-axis robot, the client gained 100% certainty of the product's compliance with their requirements. Every collected detail is automatically checked for the presence of the insert, eliminating the risk of releasing a defective batch.
KUKA industrial robots are evolving, and their ease of programming allows us to implement such solutions quickly and effectively. We are pleased that the cooperation between Metchem, KUKA, and Dentec continues to develop.
Facing a similar challenges in your company? Discover what we can offer!
