Compact machine design Arburg combines vertical moulding and automated finishing at Fakuma

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Producing decorated car key covers involves more than injection moulding. At Fakuma 2026, Arburg will demonstrate how film decoration, laser marking and robotic finishing can be integrated into a single automated production cell using recycled PC/ABS.

The vertical Allrounder 475 V with a clamping force of 1,000 kN looks predestined for both manual and automated overmoulding of inserts. It showcases high energy efficiency, a small footprint and an attractive price-performance ratio. At Fakuma 2026, Arburg (hall A3, stand 3101) will be using a wireless car key demonstrator to show how this flexible vertical machine can be used to produce products with high-quality designs and finishes for the mobility sector.

The new vertical machine is specifically designed for standard applications, for example for the growth sector of e-mobility as well as for electronics and medical technology. These include the manual or automated overmoulding of cables, contacts and infusion accessories. The also new “Gestica lite” control system ensures particularly simple and intuitive operation.

Efficient way to get a high-quality wireless key cover

The demonstrator at Fakuma 2026 is the cover of a wirelss control key, featuring a design based on the “Generic Keyfob” from company Huf, a global supplier and development partner specialising in vehicle access and authorisation systems for car manufacturers. The material used is a post-industrial recyclate (PIR) based on PC/ABS. A high-quality surface is created using the new PLF technology (Protective Layer Finish) for In-Mould Decoration (IMD) from partner Leonhard Kurz in combination with a structured mould insert. This technology does not use conventional transfer systems, but rather a thin PET carrier which remains permanently attached to the component. The decoration is protected behind this layer, which serves both as a protective layer and a carrier. The wafer-thin PET film, including the decoration system, is fed into the mould from the outside via a feed unit. There, the decorative film is applied to the plastic surface by means of in-mould lamination. The mould is supplied by Kurz’s subsidiary Schöfer; the standardised components by Meusburger; the mould insert design, including the Arburg logo, by Reichle; and the hot-runner technology by Witosa. The cover is punched out rectangularly in the mould, and the remaining film is rolled up in the installation space of the vertical machine. The product can be recycled. The PET layer ensures high resistance to abrasion, impact and everyday wear and tear, thereby helping to extend the product’s lifespan. Different films featuring a variety of designs and colours that can be used flexibly for product variants.

Vertical machine can be automated in a flexible manner

If required, the vertical machine can be automated flexibly, for example with a six-axis robot or a linear Multilift robotic system. Arburg can fulfil almost any customer requirement, including simple sprue removal, difficult component handling or customised automation for complex production cells including upstream or downstream process steps.

A Kuka six-axis robot is used for the complete part handling. It first removes the moulded part from the mould and feeds it to a laser station, where it is labelled with a code. The robot then transfers the part to a milling station and, with the gripper, guides it along the milling path to remove excess film and generate the final contour. In a subsequent cleaning station, the wireless key cover is deburred before finally getting placed on a conveyor belt by the six-axis robot and ejected from the production cell.

The fully automated application is also a successful practical example of the R-Cycle initiative. Data relating to recycling such as the material composition can be retrieved via a code on the component. Such digital product passports lay the groundwork for data-based material flows and a closed plastics cycle.

Small footprint and 60 percent reduced energy consumption

The Allrounder 475 V, with a clamping force of 1,000 kN, has been available since the spring 2026. The new vertical machine is characterised by high energy efficiency, a small installation area and an attractive price-performance ratio. Despite its compact footprint, the Allrounder 475 V offers extra space also for larger moulds. The standard installation height is 250 millimetres with the option of extending it by 100 or 200 millimetres. The table height is 900. For energy-efficient operation, the Allrounder 475 V is equipped as standard with the Arburg servo hydraulics system (ASH). This minimises idling losses and reduces the specific energy requirement by up to 60 percent compared to conventional hydraulic machines.

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