Horizontal injection molding machine DuroSet

servo-hydraulicfor thermosetting polymertwo-platen

Overview
With the DuroSet process, KraussMaffei enables production of dimensionally stable components from free-flowing reactive thermoset molding compounds. The process uses injection molding machines equipped with a mechanical back-twist/mechanical screw reverse rotation lock to ensure constant shot weights and high reproducibility. Thermosets cross-link irreversibly in a heated mold, requiring adapted machine design, precise temperature control and tailored processing parameters. Typical mold temperatures range from 150 to 200 °C; molded parts are tempered or cooled with water or heat transfer oil.

Key benefits

• Optimized, wear-resistant screws for gentle processing of fiber-reinforced and highly filled compounds
• Highest process stability and productivity with APCplus process control
• Flexible conversion capability between thermoplastic and thermoset processing
• Reproducible, gentle handling of reactive materials to minimize scrap and dimensional variation
• DuroSet units designed for very large shot weights
• Access to KraussMaffei service network and reactive compound expertise

Machine

• Robust two-platen clamping technology for high process consistency
• Active venting function as standard to prevent air pockets in molded parts
• Linear guides and tie bars protected from burrs, glass fibers and dust by Viton wipers

Plasticizing unit

• Wear-resistant thermoset screw design suitable for materials with up to 85% mineral or filler content
• Precise temperature control of feed and plastification cylinder to avoid premature cross-linking
• Mechanical screw reverse rotation lock prevents pressure-driven backflow of the melt (mechanical back-twist/lock)

Mold

• Wide range of mold equipment options and configurations
• Customized embossing and surface functions available
• Electrical mold heating with high power (up to 7 kW per heating circuit standard) and optional heating-circuit monitoring

Technical specifications

• Process name: DuroSet Technology
• Plasticizing system: mechanical back-twist / mechanical screw reverse rotation lock for constant shot weights and backflow prevention
• Typical tool heating: electrically heated molds, approx. 150 - 200 °C
• Tool heating power: up to 7 kW per heating circuit (standard); heating circuit monitoring available
• Material types: thermosets (reactive molding compounds) — irreversible cross-linking on heating
• Screw and feed: optimized, wear-resistant screws for gentle fibre handling; suitable for very high mineral/filler contents (up to ~85%)
• Cooling/tempering: molded parts tempered or cooled with water or heat transfer oil
• Process control: high reproducibility and constant shot weights; APCplus available for maximum process stability and productivity
• Clamping: robust two-platen clamping technology
• Conversion: machine and process design allow flexible conversion between thermoplastic and thermoset processing