Precision injection moulding Elmet brings automated cold runner balancing to Fakuma

Elmet will introduce its Smartshot i cold runner system for LSR injection moulding to an international trade audience at Fakuma 2026. The technology automatically balances cavities, compensates for thermal changes and is designed to shorten mould ramp-up times by up to 95 percent.

At Fakuma 2026, Elmet, an internationally active provider of precise and innovative solutions for liquid silicone rubber (LSR) processing, will present its Smartshot i system to a broad, international audience of industry professionals for the first time. This new generation of intelligent cold runner technology for LSR injection moulding continuously analyzes the injection process, automatically balances the cavities, and independently optimizes the nozzle pin positions.

Smartshot i really shines when used with family moulds featuring cavities of varying sizes. Instead of manually fine-tuning them individually through time-consuming filling studies, as was previously done, the system automatically adjusts the nozzle positions to match the specific filling behaviour of each cavity. In tests with a 16-cavity mould, only 20 shots were needed to perfectly balance the cold runner. This reduced the ramp-up time by up to 95 percent compared to the conventional approach.

High-precision servo-electric needle control

As part of the optimisation process, Smartshot i uses the high-resolution data collected during injection to analyze and control the process. Pressure sensors in the cavities are not required. Thermal changes during the ramp-up phase are also detected and compensated for by continuously adjusting the needle positions. The system’s ability to position each nozzle needle servo-electrically with an accuracy of 2 µm is a key factor in its high balancing speed.

Dr. Thorsten Häuser, Head of R&D at Elmet, comments: “The potential of Smartshot i is particularly evident with complex mold families. Automatically balancing the different cavities significantly reduces setup time and minimizes operator influence on the process. At the same time, we are paving the way for increasingly automated LSR processing.”

Smartshot i is designed to be AI-ready and serves as the technological foundation for further automation steps. Currently under development are features such as online rheometry for real-time measurement of material viscosity and material fluctuation detection without external sensors.

Visitors to Fakuma 2026 can explore Smartshot i from two perspectives. A live demonstration at the Momentive Performance Materials booth in Hall A4, Booth A4-4307, showcases the technology in a real-world production process. Additionally, a digital twin of the Smartshot i at Elmet in Hall A5, Booth A5-5306, provides an in-depth look at the technology and development work behind the system. It reveals functions and interrelationships that are usually hidden during the injection moulding process.

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