The Customer:

AKsys is a systems supplier working in the areas of absorption, insulation and plastics - with a core focus on structural components for the automotive industry. With the start of production of components for the new VW Golf A5, AKsys launched an innovative production technology. At its Peine (D) production plant, AKsys started series production of frontend carriers using an IMC (injection moulding compounding) process.

The Task:

Requirements for this structural component are influenced by a number of factors: crash behaviour, weight reduction, functional integration and design optimization. Ideally, AKsys wanted to satisfy all these requirements using just one technology.

The Challenge:

To deliver all the required properties in an inline process.

The Solution:

Injection moulding on a KM 2000-14000 IMC compounder. A sharply targeted R&D project was part of the process that delivered a frontend carrier with the required crash behaviour made of reinforced plastic. The new approach is a competitive alternative to conventional press-moulding.

The Outcome:

Teaming process engineering know-how and an inline production process delivered a component with substantial added value. AKsys was able to tap into considerable cost-saving potential in large-series production of the VW Golf and VW Passat.