MD Elektronik: Maximum Flexibility for New LSR Applications with Customised PX Technology

With an individually developed all-electric PX injection moulding machine, MD Elektronik and KraussMaffei are creating the conditions for developing new multi-component parts made of thermoplastic and liquid silicone rubber (LSR). The jointly developed, all-electric PXL 201-100/55 SilcoSet combines maximum flexibility with high process reliability and supports MD Elektronik as it enters the LSR processing market. 

Only a few months have passed from the initial concept discussions to delivery. The result is a machine configuration that is unique worldwide and was tailored precisely to the company’s requirements.

MD Elektronik develops and manufactures cable systems and connectors for the international automotive industry. For the development of a new connector concept made of PBT and liquid silicone rubber, the company was looking for a platform that would enable entry into LSR technology while providing maximum flexibility for future projects.

“All we knew was that we wanted to enter LSR processing and keep as many technical options open as possible. Together with KraussMaffei, we developed a completely customized all-electric PX machine configuration that is precisely aligned with our requirements.” Christian Heilmann, Team Leader of Plastics Technology at MD Elektronik.

Customised Technology for Maximum Development Flexibility

Together with KraussMaffei, an all-electric PX with two injection units was developed for flexible use with either thermoplastics or liquid silicone rubber. Due to the adaption system screw sizes from 12 to 28 millimetres can be interchanged and allow a wide variety of applications. A particular highlight is the 12-mm LSR screw for micro injection moulding applications with shot weights far below one gram. The silicone dosing system is fully integrated into the MC6 machine control system.

“It is precisely these kinds of customised projects, that allow us to explore innovative approaches together and contribute to our customers’ success.” Florian Pell, Head of Sales Germany, Injection Moulding Technology & Automation at KraussMaffei.

In addition to the fully equipped PXL 201-100/55 SilcoSet machine for a technical centre, the current project also includes an efficient production PX of the same size for the plant in the Czech Republic.

Process Stability from Development to Series Production

For multi-component applications, the system is equipped with a turntable, index drive, and widened clamping platens. This allows for the implementation of a broad range of mold concepts and part geometries.

A key component of the solution is APCplus. The adaptive process control system compensates for fluctuations in material viscosity and ensures reproducible cavity filling. Particularly with liquid silicone, whose shot weight cannot be corrected via holding pressure, this enables high process stability right from the first shot. This approach reduces start-up times and increases production reliability both in the technical centre and later in series production.

Development Partnership with Added Value

In addition to the technology, close collaboration between the two companies was a decisive factor in the project’s success. The partnership between MD Elektronik and KraussMaffei has existed for more than 25 years. Short communication paths, regular exchange, and a shared understanding of the requirements accelerated the implementation of the customized solution.

KraussMaffei also supports the development of LSR processing expertise with tailored training in application technology, process control, and cleaning. This prepares employees specifically for the requirements of the new technology.

Partnership as the Basis for Innovation

With the PX machine for the technical centre, MD Elektronik is creating the basis for future multi-component applications made of thermoplastic and liquid silicone rubber. The project demonstrates how close partnership and a jointly developed machine configuration, which consistently focused on customer benefit, can help transfer new technologies efficiently into industrial practice. The jointly developed platform therefore forms the basis for additional innovation projects and future series applications.

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