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EnviroTech Custom Injection Molders

EnviroTech Custom Injection Molders have developed an injection molding method for manufacturing heavy-walled, large-volumed and complex components. Components are made to requirements with shot weights ranging from 0.1kg to 240kg and wall thicknesses of up to 150mm.

EnviroTech injection molding enables the profitable manufacture of components with complex geometries, variable wall thicknesses and integrated metal parts such as bushings or specialized reinforcements. Because injection molding allows very thick walls to be produced, rib structures normally required for strengthening a component can be reduced or eliminated thereby reducing tooling costs. If the geometry is correctly designed, the process delivers tension- and void-free molded components.

The method uses materials such as PP, PE, PA, PVDF, PFA, PC and PEEK. If required, glass fibres and thermoplastics reinforced with minerals can also be used as well as other thermoplastic compounds. Components that need to meet explosion-proof requirements are manufactured using antistatic materials.

Klinkau GmbH + Co. and EnviroTech Custom Injection Molders have a total of almost five decades of experience in the manufacturing of heavy-walled, large-volumed specialized components. Modern facilities in a number of locations are available to you for the manufacture of your requirements. Large- and small-series production is made profitable through components and tools designed to specific requirements.

Tools can also be made for developmental projects, prototypes and small-series production. Technicians and engineers from the KLINKAU group provide support and consultation from the development phase through to the manufacture of your components.

Cockpit canopy made of polycarbonate, 21 kg

Cockpit canopies for jet aircraft are subject to extreme stresses and require regular replacement. Optics, surfaces, dimensions and stability need to be of the highest quality. Standard construction methods stretch thin thermoplastic sheets over a mould in an autoclave and then bond them together. The sheets are stretched by up to 300 %–400 %. This is a costly process that not only requires time but is also prone to errors in dimensions, sheet bonding and optical quality.

The injection method from EnviroTech Molded Products enables this 21 kg polycarbonate optical component to be manufactured in a single process. Injection molding has the advantage of delivering high-precision, blister-free production with highly variable wall thicknesses ranging from 19 mm to 51 mm, high-quality surfaces, tension-free components, short cycle times and all within budget. Collaboration takes place with partners and customers to adapt the required tools to the injection molding procedure.

Impact protection made from HDPE, 60 kg

Impact protection is required in some states of the USA (e.g. on bridge pillars) to provide additional protection to vehicle occupants in the event of an accident. New and innovative impact protection products are made of multiple-layered spring elements to absorb impact forces. The spring elements can be re-used after a collision. They measure 1.25 m high and haver a surface area of around 1.6 m². The element's wall thicknesses range from 30 mm to 40 mm and weigh around 60kg. The material chosen was therefore an impact-resistant, high-density polyethylene to meet all the technical requirements.

Standard production methods were either incapable or unprofitable so EnviroTech Molded Products became involved at an early stage in the development of the elements. The injection molding method was able to reliably manufacture the voluminous and heavy-walled design. To ensure consistency in the spring element's properties, they are manufactured free of tension and voids. Each element undergoes strict quality control with ultrasound testing for voids.

Valve casings made from polyethylene, 81 kg

Many industries use pipes made from corrosion resistant plastics. The pipes need to be chemically resistant and also possess long-term rigidity and elasticity over a wide range of temperatures. Pipes and valves are also becoming increasingly larger and walls thicker to meet changing requirements. 

EnviroTech Custom Injection Molders use injection molding for the profitable manufacture of valves from high-density polyethylene (HDPE ) weighing 81 kg with 80 mm wall thicknesses and integrated bushings. This method also enables the manufacture of internal and large-volumed valve gates free of tension and voids. Ultrasound is used to test the valves for voids prior to delivery.

Diaphragm pump made of polyethylene, 15 kg

Diaphragm pumps in many applications need to have high levels of chemical resistance. For some applications, e.g. in the chemicals industry, high-quality steels need to be used to ensure secure and long-term pump operation. Pump components then need to be machine-manufactured in one-off production runs. However, certain plastics such as polyethylene and PVDF offer high levels of chemical resistance and are an alternative to steel.

EnviroTech Custom Injection Molders enables heavy-walled and large-volumed pump components to be profitably manufactured in plastic even in small-series production. The largest component in the pump shown here is made from polyethylene and weighs 15 kg with wall thicknesses from 25 mm – 40 mm.

Connecting element made from polyamide and 30 % glass fibres, 22 kg

The elements have complex geometries, wall thicknesses of 20 mm to 45 mm and integrated metal connecting sleeves and therefore represent a major manufacturing challenge. Components need to be free of tension and deformities to ensure precision fitting with other parts. A high level of rigidity is required so glass-fibre reinforced polyimide is used. The large-volumed connecting element manufactured using injection molding by EnviroTech Custom Injection Molders weighs more than 22 kg.

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