The new era of injection molding

Z‑System

With the Z‑System, hotset fo­cus­es on sur­face qual­i­ty op­ti­miza­tion and cost-ef­fi­cient process op­ti­miza­tion in plas­tic in­jec­tion mold­ing. Pro­duce high-qual­i­ty, de­fect-free and aes­thet­i­cal­ly so­phis­ti­cat­ed de­sign sur­faces based on a heat­ing speed of 60 K/s with­out longer cy­cle times. And save en­er­gy thanks to low heat­ing pow­er in the in­jec­tion mold­ing process.

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In our Sys­tem Cen­ter for In­dus­tri­al Tem­per­a­ture Con­trol Tech­nol­o­gy (SIT), which has been in ex­is­tence since 2020, you will have the op­por­tu­ni­ty to get to know — and ex­ten­sive­ly test — our lat­est in­no­va­tions in the field of tar­get­ed tem­per­a­ture con­trol of molds and process me­dia as well as se­mi-fin­ished prod­ucts and prod­ucts made of plastic.

High quality surfaces

Z‑System: Spot on, the right tem­per­a­ture at the right time, ex­act­ly in the right place in the cav­i­ty. The re­sult: no vis­i­ble weld line notch­es, flow lines or dull ha­los. In ad­di­tion, you re­al­ize low wall thick­ness­es, fil­i­gree geome­tries or mi­crostruc­tures in top quality.

With the Z‑system, you can pre­cise­ly con­trol the tem­per­a­ture in the in­jec­tion mold where the weld line would oc­cur. The plas­tic flow is op­ti­mized at the prob­lem­at­ic point. As a re­sult, the plas­tic flows in­to each oth­er and joins with­out any vi­su­al­ly vis­i­ble weld line notch. We cus­tomize the Z‑System to your in­jec­tion mold­ing ap­pli­ca­tion and mold.

Do you want to pro­duce fil­i­gree in­jec­tion mold­ed parts with par­tial­ly very thin walls? The Z‑system en­sures that the plas­tic with­in the cav­i­ty pen­e­trates even in­to the nar­row, dif­fi­cult-to-fill areas.

In the in­jec­tion mold­ing process, matt points have var­i­ous caus­es. Among oth­er things, small gates and high in­jec­tion speeds play a cen­tral role. For de­mand­ing de­sign sur­faces, you can avoid matt points with the Z‑system.

In or­der to re­al­ize par­tial op­ti­miza­tion of the mold­ing, the mold wall tem­per­a­ture must be in­creased. This can be achieved through the clever use of the Z‑System.

Func­tion­al­ly de­signed sur­faces with fine mi­crostruc­tures re­quire a high lev­el of mold­ing pre­ci­sion. This is con­ven­tion­al­ly achieved via high mold tem­per­a­tures with longer cy­cle times – or via the Z‑System with par­tial mold tem­per­ing and con­stant cy­cle times.

The shortest top quality cycles

The Z‑System works in an ex­treme­ly dy­nam­ic way. With a heat­ing rate of 60 K/s (at the cav­i­ty sur­face), the in­jec­tion mold­ing tool is quick­ly heat­ed up at the right point and above all, cooled down very quick­ly. Re­move from the mold in the short­est pos­si­ble time and man­u­fac­ture top qual­i­ty plas­tic de­signed sur­faces in short cycles.

The Z‑System par­tial­ly tem­pers tools with a heat­ing speed of 60 K/s. The main ad­van­tage, in ad­di­tion to rapid heat­ing, there is the rapid re­moval of heat­ing en­er­gy and/or rapid cool­ing. You will not reach this via aux­il­iary solutions.

If you want to achieve high-qual­i­ty, de­fect-free plas­tic de­sign sur­faces with­out ex­tend­ed cy­cle times, turn to the Z‑System. It com­bines qual­i­ty and speed. We have al­so al­ready man­aged to even short­en the cy­cle time.

Minimal energy demand

Save en­er­gy, re­duce costs. The Z‑system is high­ly en­er­gy-ef­fi­cient due to dy­nam­ic mold tem­per­a­ture con­trol in com­bi­na­tion with ther­mal in­su­la­tion in the mold. In prac­tice, low heat­ing pow­ers av­er­ag­ing around 100 W are suf­fi­cient. The Z‑System thus stands for ef­fi­cien­cy and sus­tain­abil­i­ty in plas­tic in­jec­tion molding.

The Z‑system brings the amount of heat in­to the mold that is ac­tu­al­ly need­ed. No un­nec­es­sary, ex­ces­sive mold tem­per­a­ture con­trol! You can get by with an av­er­age of around 100 W of heat­ing pow­er per hour. With op­ti­mized part qual­i­ty and high-qual­i­ty de­sign surfaces.

Short cy­cle times, low heat­ing pow­er, high qual­i­ty. In ad­di­tion, the Z‑system op­ti­mizes the flow of plas­tic in the mold and pre­vents the pro­duc­tion of faulty in­jec­tion mold­ed parts — and thus waste. You save en­er­gy, time and ma­te­r­i­al resources.

Range of services

hotset Z-System: ready for integration into the mold

The ba­sic con­cept of the new Z‑system is that it is al­ways de­signed by hotset en­gi­neer­ing as an in­di­vid­u­al­ly con­fig­ured com­plete so­lu­tion with con­trol tech­nol­o­gy adapt­ed to the spe­cif­ic ap­pli­ca­tion. It is com­posed of var­i­ous hard­ware and soft­ware com­po­nents and — sim­i­lar to a hot run­ner sys­tem — is pro­vid­ed ready for in­te­gra­tion in­to the mold.

Z-System cavity sensor: thermal sensor for high process accuracy

A new ther­mal sen­sor with an ex­treme­ly short re­sponse time gives the hotset Z‑system for par­tial and cyclic cav­i­ty tem­per­a­ture con­trol even greater process ac­cu­ra­cy.

Thanks to its fast re­sponse be­hav­ior, the new cav­i­ty sen­sor de­tects even the small­est tem­per­a­ture changes and de­vi­a­tions in near re­al time. In a frac­tion of a sec­ond, the mea­sured val­ues are then for­ward­ed to the Z‑system con­troller and graph­i­cal­ly processed.

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Es­pe­cial­ly for plas­tics with a small ther­mal pro­cess­ing win­dow or for 3D con­tours, the de­sign of the Z‑system by means of ther­mal sim­u­la­tion is es­sen­tial. For this pur­pose, hotset us­es spe­cial­ly adapt­ed sim­u­la­tion soft­ware. This al­lows the ef­fects of dy­nam­ic tem­per­a­ture con­trol to be pre­dict­ed very ac­cu­rate­ly. Al­ready in the de­sign phase, an in­suf­fi­cient tem­per­a­ture dis­tri­b­u­tion is de­tect­ed by the sim­u­la­tion. It can be com­pen­sat­ed by con­struc­tive mea­sures and adap­ta­tion of the Z‑system.

Benefit from the new era of injection molding.

Mechanics of the Z-System: Optimization of surface quality and process optimization in plastic injection molding

Nu­mer­ous sen­sors con­trol and mon­i­tor the dy­nam­ic tem­per­a­ture control.

No ad­di­tion­al ef­fort in the op­er­a­tion of the Z‑system.

Con­troller is set dur­ing com­mis­sion­ing — easy adap­ta­tion to dif­fer­ent machines.

Cus­tomized de­vel­op­ment per hotset engineering.

Works with any in­jec­tion mold­ing ma­chine — even old­er systems.

Pro­fes­sion­al sup­port dur­ing the in­stal­la­tion of the system.

Com­plete ready-to-in­stall sys­tem with stan­dard­ized technology.

High­est se­cu­ri­ty for da­ta exchange.

Com­mu­ni­ca­tion with oth­er de­vices pos­si­ble via open interface.

Dif­fer­en­ti­a­tion through clear qual­i­ty and cost advantages.

There are no fol­low-up costs af­ter commissioning.

In­ten­sive train­ing and support.

Three steps to the Z‑System

In­di­vid­ual, non-bind­ing fea­si­bil­i­ty check and quotation.

Cus­tomized im­ple­men­ta­tion based on the process pa­ra­me­ters and pro­duc­tion of the ready-to-in­stall system.

Mak­ing the con­troller set­tings and brief em­ploy­ee training.

Recommended by experts

Prof. Dr.-Ing. Paul Thienel, Department of Plastics Engineering, South Westphalia University of Applied Sciences

With its Z‑system, hotset pro­vides mold­mak­ers with an im­por­tant fur­ther de­vel­op­ment of the pre­vi­ous var­io­ther­mal mold tem­per­a­ture con­trol in in­jec­tion mold­ing tech­nol­o­gy as a fu­ture-ori­ent­ed high-speed tem­per­a­ture con­trol sys­tem. With a heat­ing rate of 60 Kelvin per sec­ond and a min­i­mal en­er­gy in­put, cav­i­ties can be heat­ed and cooled in a very tar­get­ed and pre­cise man­ner in very short cy­cles.

The re­sults im­press every in­jec­tion mold­er: High-qual­i­ty mold­ed parts with ex­cel­lent sur­faces with­out weld lines and mat­te ha­los, such as are de­sired or re­quired in au­to­mo­tive en­gi­neer­ing, light­ing tech­nol­o­gy or the con­sumer in­dus­try.

In ad­di­tion, par­tic­u­lar­ly low wall thick­ness­es can al­so be re­al­ized, open­ing up new per­spec­tives for the pro­duc­tion of mi­crostruc­tures and minia­ture components!

Prof. Dr.-Ing. Paul Thienel
De­part­ment of Plas­tics Technology
Uni­ver­si­ty of Ap­plied Sci­ences South Westphalia 

Our partners speak for themselves

In a large au­to­mo­tive project, we had a vi­su­al­ly vis­i­ble weld line prob­lem in an ex­posed area of the ve­hi­cle. With the help of the Z‑System, we were able to elim­i­nate the prob­lem and pro­vide the cus­tomer with a high­er-qual­i­ty sur­face component.

Pe­ter Lochn­er
Head of Tool Tech­nol­o­gy
Preh GmbH

Our ex­pe­ri­ence is that the Z‑System is very easy to as­sem­ble. It re­quires lit­tle space in the mold. The con­trol on the ma­chine is easy to in­te­grate in­to our process. The co­op­er­a­tion with the hotset tech­ni­cians is very pleasant.

Markus Beck­er
Man­ag­ing Di­rec­tor
Jo­hannes Beck­er Werkzeug­bau GmbH 

When the Z‑System was pre­sent­ed to us tech­ni­cal­ly, we al­ready found the idea su­per. The at­trac­tion for us as a sim­u­la­tion soft­ware pro­duc­er was of course to be able to sim­u­late this new tech­nol­o­gy, which we suc­ceed­ed in do­ing with­in a very short time with the sup­port of hotset. With the ex­pe­ri­enced open­ness in this de­vel­op­ment the foun­da­tion stone for the part­ner­ship with hotset was quick­ly laid. We are very pleased that we can now joint­ly con­vince the mar­ket of the Z‑System!

Thorsten Strauß
Di­rec­tor of Sales
sim­con kun­st­stofftech­nis­che Soft­ware GmbH 

Z‑System Partner

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