In total, visitors can expect 50 expert presentations from OEMs and suppliers, covering topics ranging from recyclable materials and lightweight construction to AI-supported processes and new manufacturing concepts. A key focus will be the effective use of AI in the injection molding of technically complex parts.

KI-Tolo as a Virtual “Machine Setter”

Felix Georg Müller, CEO and co-founder of Plus10 GmbH, a spin-off of the Fraunhofer Institute for Manufacturing Engineering and Automation IPA, explains the benefits of intelligent optimization tools. “The tool suggests situational adjustments to machine settings. These are based on high-frequency process data combined with contextual data on raw materials and environmental conditions. The goal is to prevent scrap,” explains Müller. The live-learning optimization tool Hopper is an example of how AI can function as a “virtual machine setter” by analyzing data in real time and making predictions before errors occur.

AI processes data and optimizes parameters in real time during the process

Müller emphasizes: “Learning a complex process model based solely on the approximately 700 live data points from an injection molding process and the associated peripheral equipment—that is, without manual modeling—is very exciting and offers many opportunities for real-time process optimization.” He will demonstrate two practical examples at PIAE: a two-component injection molding machine for PC-TPE parts and another example involving COC injection molding with an insert. “In both examples, I’ll show how the Hopper optimization tool learns a process model and optimizes it ‘on the fly,’” Müller explains.

AI tool with versatile applications

The Hopper AI tool is already being used in the injection molding of both thermoplastic and elastomer components. Müller explains: “In general, injection molders can use the Hopper AI tool to manufacture sophisticated materials—some of which are difficult to process—where even the slightest fluctuations in raw material quality can lead to scrap during continuous operation.”

Freudenberg, for example, uses it to manufacture radial shaft seals. Other applications include typical engineering plastics such as PA, PBT, PEEK, PC, POM, TPE, and COC/COP.

The use of AI reduces scrap by 6 to 18 percent

Müller highlights the economic benefits: “Feedback on real-world injection molding applications using the Hopper shows a reduction in scrap ranging from 6 to 18 percent. Specifically, this means that the yield rate increases, since both scrap and cycle time can be actively optimized.”

In addition, tool changeover time can be reduced by about 30 minutes, as the machine is immediately configured with a parameter set tailored to the current material batch. This minimizes the need for manual fine-tuning. “This eliminates the need for time-consuming manual fine-tuning, which is particularly difficult for less experienced staff,” said Müller.

Addressing the Skilled Labor Shortage with AI

AI tools like Hopper are not only crucial for efficiency and product quality, but also help address the shortage of skilled workers in the industry. They offer versatile applications and significant cost-saving potential, as the PIAE Congress will impressively demonstrate.