From Glow to Stargate Oerlikon showcases hot-runner solutions for all industries

At Fakuma 2026, Oerlikon HRSflow will showcase its cross-industry expertise. Among the highlights will be the Stargate HRS needle-free concept, with which the manufacturer is now also targeting processors of difficult-to-process plastics. 

At Fakuma 2026, Oerlikon HRSflow will highlight its cross-industry expertise in hot-runner injection molding. This includes developments related to the needle-less Stargate-HRS system, new applications for the Xp nozzle series in thick-walled cosmetic jars, and the use of Glow HRS to minimize post-processing steps for visible component surfaces in the automotive industry. Visitors will also have the opportunity to experience Oerlikon HRSflow’s hot-runner applications firsthand at the booths of partner companies.

Stargate HRS: Field-tested and compatible with a wide range of polymers

The new Stargate HRS hot-runner nozzle concept, unveiled for the first time at K 2025, is based on a mechanically operated central gate. Initially, the focus was primarily on applications using polypropylene (PP) and recycled PP (rPP) to comply with the requirements of the new EU Packaging Regulation (PPWR).

In Friedrichshafen, the processing of plastics such as PMMA and ABS is now also being showcased. This expands the range of applications across various market segments. Compared to conventional solutions, the innovative design enables quick color changes and optimal cooling performance, thereby shortening cycle times and increasing productivity.

“Less than a year after the official market launch, we have already received a great deal of positive feedback from customers. Compared to conventional production, they were able to achieve thinner part walls, lower component weight, and a significant reduction in cycle time,” explains Matteo Badella, Global Sales Director for Pac-Med, Consumer Goods, and Logistics at Oerlikon HRSflow.

Nozzle Solution for Thick-Walled, Crystal-Clear Cosmetic Packaging

Following their success at Luxe Pack 2026 in New York, the needle-valve nozzles of the new Xp series will also be a highlight at Fakuma. Designed for a wide range of applications, they have been specifically optimized to meet the high demands of the cosmetics industry.

Precise thermal control of the nozzle, combined with a new end ring solution, ensures optimal injection molding quality for thick, transparent parts with shot weights of up to 70 g. The new Xp nozzle series is equally suitable for manufacturing such parts from (r-)PET and recyclable copolyesters such as PETG, PCTA, and PCTG. Additional materials are currently being tested.

At its booth, Oerlikon HRSflow is showcasing application examples in the form of several cosmetic jars with different geometries. These are made from Eastman’s Cristal One Renew IM812 polyethylene terephthalate (PET) and are characterized by a crystal-clear appearance and a flawless surface. 

The use of this material ensures a high degree of sustainability, as its recycled content—determined by mass balance—can be as high as 100 percent. In addition, this rPET enables the injection molding of parts with wall thicknesses of up to 12 mm. Development partners included Cromes, a leading mold maker for the cosmetics industry, and Technicaps, a manufacturer of high-quality, refillable packaging.

Precision Parts for Medical Technology

In the medical technology sector, the focus is on the use of recycled PET (rPET). One example is a precision Luer-Lock component manufactured using direct injection molding and made from LNP Elcrin W1000JiQ. Sabic’s polybutylene terephthalate (PBT) is derived from chemically recycled PET by Guztec Polymers. For special requirements, the component can also be produced from the high-performance plastic polyetheretherketone (PEEK).

The corresponding multi-cavity mold is equipped with Techflow-HRS needle-valve nozzles, whose external end rings offer increased wear resistance. This makes them suitable for processing abrasive, reinforced thermoplastics, including flame-retardant grades, which require a narrow processing window at high processing temperatures. A uniform temperature profile enables a wider processing window and, combined with high dimensional accuracy, ensures an easy machine restart during the production of Luer-Lock connectors.

The mold manufactured by C.P. Stampi is equipped with an automatic unscrewing system from Moulding Devup, enabling precise demolding of the Luer-Lock internal threads.

High-quality automotive parts straight from the mold

The automotive industry is calling for a reduction in post-processing steps to increase process efficiency. To meet this requirement, Oerlikon HRSflow has introduced the compact Glow HRS solution for the direct injection molding of high-quality molded parts made of amorphous plastics. It prevents halos around the gate and ensures a flawless surface finish. 

In addition, a scratch-resistant bumper will be on display, featuring a polyurethane (PUR) coating combined with decorative film technology in a single, efficient process. This reduces both production time and capital costs compared to the two-step process, made possible in part by the optimal configuration of the Oerlikon HRSflow hot runner system. This system was specifically developed for the seamless integration of both technologies and features nine conical needle-valve nozzles. Project partners include Borealis, Cannon, DNP, Engel, Inveo, and the Inabata Group.

Live on-site at partner companies (list)

Visitors will be able to experience the performance of Oerlikon's hot runner systems firsthand at the booths of partner companies:

Fanuc (Hall A7 – Booth 7304)

As an example of the production of small, precision engineering parts, an injection molding machine from Fanuc produces parts with a shot weight of 1.2 g for a cable holder made of PA6.6-GF30. The 16-cavity mold used for this application is equipped with Techflow HRS needle valve technology and Sa-series nozzles. 

Oerlikon HRSflow developed this system specifically for processing glass-fiber-reinforced plastics. The machine’s real-time monitoring system tracks the filling behavior of all cavities and automatically adjusts the process parameters to ensure uniform filling. Another partner, alongside Fanuc, is Cavity Eye, a specialist in measuring internal cavity pressure in injection molds.

Haitian (Hall B1 – Booth 1205)

As an example of a high-quality application in the automotive sector, a injection molding machine from Haitian is used to produce a trunk light strip. The servo-driven Flexflow HRS needle valve technology enables the smooth, direct injection of transparent materials and minimizes warpage.