X2F®’s Lower CostInjection MoldingSolution
X2F® system eliminates the need for mass, power, and complexity
Have you ever asked why traditional extruders need to be so massive to make such small parts?
The Answer: Pressure. MASSIVE pressure.
The conventional injection molding process, unchanged in principal since the 1956 patents, relies almost solely on frictional shear energy to melt materials. That requires large, power-hungry electrical motors (480V) to drive massive steel screws, enclosed in very thick steel barrels, capable of creating the pressures (20,000-30,000 psi) needed to constantly move this mass and generate the friction. In other words, these systems rely on the heat produced as a byproduct of friction.
Once the material is melted, this massive steel screw must plunge forward to blow through the cold slug and inject the material into the cavity. This high injection force demands clamp systems with the mass to withstand high pressures, even though only a fraction of that pressure is required to pack out the cavity.
There is a much better way.
The X2F® system can eliminate the need for mass, power, and complexity by using heat conduction rather than relying on excessive pressures. This results in lower overall cost as the equipment can remain smaller, more energy efficient and easier to operate.
Lower Capital Costs
X2F® machines are less expensive to purchase than conventional machines with an equivalent output, and they also require less supporting infrastructure. That means:
- No reinforced factory floors
- No electrical installations
- Minimal mold cooling requirements.
Although most X2F machines can accommodate your existing steel molds, most new applications can be accommodated with simple aluminum molds, significantly reducing mold cost and further improving cooling times.
Lower Operating Cost
There are three reasons X2F® machines are significantly less expensive to operate:
- Reduced footprint: With lower mass requirements to produce a given part, the X2F machines typically occupy less than 50 percent of expensive factory floor space.
- Reduced energy consumption: The highly efficient material preparation system contributes to lower energy use—often 10-20 percent of that required for comparable output on a conventional machine.
- Reduced downtime: Color transitions (5-15 minutes) and mold changes (10-30 minutes) are simplified, reducing material waste and increasing machine uptime.
Lower Labor Costs
Traditional injection molding machinery requires highly-skilled operators with years of experience.
But X2F® machinery offers simplicity and an output based control system that makes it easy to train, easy to learn, and easy to use. Turn the machine on and the material is brought to the precise processing temperature automatically, with no purging. The X2F machine monitors and provides real-time feedback and automatically adjusts to maintain melt flow and pack pressure cycle to cycle, cavity to cavity, no matter who’s at the controls. Your search for skilled labor is over.