Gigamoudling Engel builds the world’s largest injection moulding machine

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A new machine size is redefining what is possible in injection moulding. Engel’s duo 12000 US is built for very large-format components and aims to make gigamoulding a viable option for more cost-efficient, integrated and resource-saving production.

With the duo 12000 US, Engel expands the possibilities for the industrial production of large-format injection-moulded parts to previously unattained dimensions. The new two-platen machine is designed for the production of particularly large-area components and aims to reduce part costs while opening up greater scope for integrated product designs. In doing so, it also creates opportunities to cut assembly effort and replace traditional materials such as metal or concrete with plastic in selected applications.

The machine has a clamping force of 110,000 kN and was developed for components with projected areas of more than 2.5 m². It has now been commissioned at a customer site. According to Engel, the system is intended to enable the cost-efficient production of very large components within an integrated manufacturing process. Functional integration, fewer individual parts and reduced assembly effort are among the main advantages cited for this machine class.

For manufacturers, such systems can open up new possibilities in lightweight design, product development and component construction. Large-format structures can be produced in a single step, which simplifies production logistics and can reduce both material consumption and process time. Engel also sees potential benefits for the CO₂ footprint across the product life cycle.

To handle the large shot weights required for these applications, the machine is equipped with two injection units operating in parallel. With screw diameters of up to 210 mm, they provide a shot volume of up to 65,000 cm³ and are designed to ensure homogeneous filling of large projected areas.

The machine installed for this project features an eight-tie-bar design. According to Engel, this configuration was selected together with the customer as the best match for the specific application. Machines of this size can, however, also be implemented with four tie bars.

The dimensions of the system illustrate the technical challenge: with a length of around 24 metres and a height of approximately 8.4 metres, it is among the largest industrial production systems in injection moulding worldwide. The total weight is 551 tonnes, the maximum mould weight 170 tonnes. In total, around 30 kilometres of cables were installed. The total installed power is approximately 2.4 MW with a total current of 2,900 A. Despite these dimensions, the machine remains compact thanks to the modular design principle of the duo series, thereby saving valuable floor space.

High vertical integration and comprehensive process expertise

Injection moulding solutions in this size class are developed exclusively on the basis of specific customer requirements. To implement such projects quickly and efficiently, Engel relies on an extensive modular system and a high level of in-house manufacturing.

A key role is played by the company’s technical centre for large machines, where customers can carry out comprehensive trials for both process and component development. This is particularly relevant for large-volume parts, where shrinkage behaviour can have a major influence on final part quality. According to Engel, the centre allows iterations and targeted optimisations to be carried out before production is scaled up.

The company also points to its long-standing experience in the design and implementation of large-scale systems. In addition to the standard sizes in the duo series, several machines with clamping forces of 74,400 kN have already been installed in the market.

To make projects of this scale feasible, Engel has developed a dedicated machine concept for the efficient design and manufacture of very large systems. Supported by global production structures, these machines can be built not only at the company’s large machine plant in Austria, but also regionally in Asia where required.

Despite their size, the machines are designed for high precision. Engel says options such as injection compression moulding make it possible to define component dimensions with an accuracy of a few hundredths of a millimetre. This combination of precision and high clamping force opens up additional possibilities in lightweight design and in the functional integration of large-format components.

Gigamoulding enables new vehicle architectures

In the automotive industry, demand for gigamoulding solutions for large structural components is growing. This development is being driven by trends such as electromobility, autonomous driving, platform consolidation and stricter CO₂ reduction targets. New production concepts are opening up fresh possibilities for components such as battery housings, underbody panels and hybrid inner door structures. The aim is to lower component costs while enabling greater functional integration, lower weight and reduced assembly complexity. At the same time, such structures can contribute to rigid and safe vehicle architectures, which are seen as increasingly important for future mobility concepts.

New opportunities in technical injection moulding

Large-scale machines are also expanding the scope of technical injection moulding. Engel says it has already established machines with clamping forces of around 11,000 tonnes in various markets, including applications in logistics and infrastructure.

Examples include transport containers for the disposal of e-mobility batteries, large-volume infiltration boxes for rainwater management and water tanks with mould areas of almost six square metres and shot weights of up to 109 kg. In the case of large water tanks in particular, plastics can offer advantages over concrete. The components are easier to transport and install, require less infrastructure and are better able to accommodate ground movement, whereas concrete structures are more prone to cracking under shifting soil conditions. At the same time, such systems can support municipalities and companies in responding to more frequent heavy rainfall events and rising requirements for water storage. According to Engel, large machines make it possible to manufacture these products economically and in new dimensions.

Technology platform for large integrated structures

Beyond its size, the system is also positioned as a platform for new technologies, material substitution and highly integrated component concepts. Engel sees potential for more sustainable product solutions in mobility, infrastructure and industry, and presents the machine as an example of what gigamoulding can contribute to the industrial production of large-format structures.

At the same time, the company stresses that this machine does not represent the technical limit. Based on its development and manufacturing capabilities, Engel says it can realise even larger systems if customer demand requires it. That would give plastics processors further opportunities to produce larger components cost-effectively and expand their competitive position.

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