In the ever-evolving landscape of industrial manufacturing, innovation often comes from the most unexpected places. A recent breakthrough in modular injection moulding technology, spearheaded by Andrzej Zacharski from the Łukasiewicz Research Network – Institute for Sustainable Technologies, is set to revolutionize the production of hydraulic filter housings, particularly for the marine energy sector. This development, published in ‘Technologia i Automatyzacja Montażu’ (Technology and Assembly Automation), promises to streamline production processes, reduce costs, and enhance the durability of critical components.
HYDROMEGA, a leading provider of specialized marine hydraulic systems, faces a unique challenge. Their annual demand for hydraulic filters hovers around 1,000 units, with two distinct sizes sharing the same housing connection dimensions. Traditionally, producing such specialized components would require two separate moulds, a costly and inefficient approach. Zacharski’s innovative solution addresses this issue head-on with a modular injection mould designed to press two types of polyamide housings.
The key to this breakthrough lies in the modular design of the mould. “Changing the shape of a moulded part requires removing or installing modules that change the die and punch dimensions,” Zacharski explains. This flexibility allows for the production of different housing sizes without the need for separate tools, significantly reducing production costs. The design process was meticulously supported by numerical analyses of plastic injection, cooling, moulded part shrinkage, and mould cavity deaeration, ensuring both precision and durability.
The implications for the energy sector are profound. Hydraulic systems are the backbone of many marine energy solutions, from offshore wind turbines to subsea pumps. The ability to produce high-quality, durable filter housings efficiently and cost-effectively can enhance the reliability and longevity of these systems. This, in turn, can lead to reduced maintenance costs and downtime, making marine energy solutions more viable and attractive.
But the potential impact of this research extends beyond the marine sector. The modular injection moulding technology could be adapted for various industries requiring specialized, small-scale production. From aerospace to automotive, the ability to produce different parts with a single, flexible mould could drive innovation and cost savings across the board.
Zacharski’s work, published in ‘Technologia i Automatyzacja Montażu’ (Technology and Assembly Automation), is a testament to the power of interdisciplinary research and innovation. By combining advanced numerical analyses with practical engineering solutions, he has paved the way for a more efficient and sustainable future in manufacturing. As the energy sector continues to evolve, technologies like these will be crucial in meeting the demands of a rapidly changing world. The modular injection mould is not just a tool; it’s a stepping stone towards a more flexible, efficient, and sustainable industrial landscape.