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Netstal will debut the latest generation of its Elion MED line of all-electric injection molding machines at K 2025, promising greater energy efficiency and a smaller footprint. Netstal says the toggle lever’s geometry has been optimized for the fastest dry cycling, while a new injection gearbox with a compact metering drive has been added, as well as a two-part control cabinet and a modified protective cover. These design choices enable a much smaller footprint, a Netstal spokesperson tells Plastics Technology. The Elion 1200 on display at the show measures 5.1 m in length; 1 m shorter than the previous model, while maintaining the same clamp force. The maximum injection speed for the new presses is 450 mm/sec., according to the spokesperson.

The new Netstal Elion MED all-electric injection molding machine model will be on display at K 2025 is 1 m shorter than its predecessor. Source (all images): Netstal

Netstal says this is the first stage in a complete conversion of the Elion line, launching with four variations and two clamp forces: 135 and 200 tons. More model variations will become available over time for the full line, which will eventually range in clamp force from approximately 90-470 tons.

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High-precision sensors and a sampling rate of 2 kHz are said to give the new Elion MED greater shot-to-shot consistency. Injection control is based on direct injection-force measurement and Netstal’s responsive filling control (RFC). A newly revised quality monitoring system supports higher production quality.

In terms of other design changes, Netstal says the clamping unit area offers better accessibility for maintenance work, while the newly designed toggle lever features a double connecting rod, which distributes the closing force over two bearing points and has also been separated from the axis for the electric ejector.

The new Elion MED’s robust design enables it to maintain consistently high speeds at high pressures in 24-hour continuous operation for many years, according to the company. To increase energy efficiency compared to its predecessor, Netstal has designed a new type of direct drive for the unit movement and the application of the nozzle-contact pressure. Depending on the application, the spokesperson tells PT that estimated potential energy savings range from 3-5% over the previous model.

In support of clean room operations, the fully encapsulated and water-cooled drive motors and hermetically sealed control cabinet enable the new Elion MED to run virtually emission-free. The machine’s protective cladding has been redesigned for optimum cleanability, including smooth surfaces and screws that are not visible from the outside. The new Elion MED can be used in clean rooms up to class ISO 7 without any additional precautions. With additional equipment options, higher requirements can be achieved, according to customer needs.

The Elion MED also offers a wide range of OPC-UA-based interfaces, such as EUROMAP 77 for networking with a central control system and EUROMAP 82 for the various peripheral components. HTML 5 integration means that more complex system components, including automation, can be integrated into the Axos 9 machine control. Depending on the application, the optional four-button Smart Operation control gives molders a wide range of possibilities for automating process sequences.

At K 2025, Netstal will mold autoinjectors from ABS using a four-cavity Zahoransky tool with indexing.

At the show, a 135-ton Elion MED will mold ABS autoinjector housings in a 12-second cycle using a four-cavity Zahoransky mold with indexing technology. The tool, which features a Ewikon hot runner with servo-electrically controlled valve gate nozzles, includes a rotary unit with a fully integrated servo motor. Indexing enables the cycle time to be significantly reduced compared to conventional mold concepts. A six-axis, machine-mounted robot removes the finished housing parts with the mold closed. The Saxe automation design features optical quality control and a production-ready design, including the ability to automatically change part containers. Water flow rate and temperatures in the mold are recorded and monitored in real time via a Mouldflo system. Other partners for the cell include Petek (cleanroom technology), HB Therm (temperature control units), Piovan (material feeding), SABIC (resin), SAX Polymers (masterbatch) and bfa solutions (MES).