Innovative injection system for greater design freedom

Husky Injection Moulding Systems, Ltd. has launched the UltraShot^TM  Injection System. This innovative, next generation melt delivery and control system eliminates the deficiencies of traditional injection moulding processes and creates unique value and opportunity for producers by making it possible to mould the perfect part at scale, with unmatched quality.

“With the UltraShot^TM  Injection System, we are re-engineering the injection moulding process. We are breaking down the barriers of traditional injection moulding processes in order to achieve higher levels of capability, control and overall part design freedom. The UltraShot^TM  Injection System is a game changer and provides better control than anything else in the industry. This approach is especially important now with massive, increased demand and speed-to-market, especially in the medical market, for example, where production risks and scalability are critical,” said John Galt, President and CEO, Husky Injection Moulding Systems, Ltd.

The UltraShot^TM  Injection System’s advanced injection control technology enables risk-free scalability with flawless part capability. Identical system behaviour for each injection circuit provides process condition consistency with cavitation scaling. A predictable process from pilot to high cavitation – scalable to 128 cavities, enables producers to maximise cavitation without negative performance on balance or shot-to-shot variation. Brand owners can accelerate from prototype to high cavitation production qualification, thus greatly increasing speed-to-market.

“The UltraShot^TM  Injection System’s precise servo-controlled melt delivery isolates melt injection from the machine screw and relocates control close to the gate where it is required. Higher and repeatable injection pressure can be achieved at the gate. Unmatched mass flow control of cavity filling with tighter synchronized flow front arrival time revolutionises balance and part-to-part consistency enabling risk-free scalability. Identical system behaviour for each injection circuit provides process condition consistency with cavitation scaling. A predictable process from pilot to high cavitation – scalable to 128 cavities, allows for maximised cavitation without negative performance on balance or shot to shot variation. Customers can accelerate from prototype to high cavitation production qualification, thus greatly increasing the speed to market opportunity,” according to Sheldon Alexander, Business Manager, Hot Runners and Controllers at Husky.  

Flexibility: Mould the unmouldable

The UltraShot^TM  Injection System enables brand owners to produce unconstrained, highly functional and validated parts, economically, where conventional injection moulding processes cannot. This revolutionary cavity filling control and process optimisation overcomes traditional constraints of pressure, L/T and difficult-to-mould resins. This enables part lightweighting for resin and process time savings and provides resin selection flexibility. Ultimately, this means greater part design freedom, opening up endless possibilities for brand owners looking to take plastic part designs to the next level.

Compared to conventional hot runners, melt in the UltraShot^TM  Injection System experiences fewer high-pressure injection cycles, thus preserving the original resin properties. This leads to lower mould-in stress and better mechanical and optical properties in the moulded part. With this technology, the best physical properties can be achieved for the moulded part. 

Powered by the Altanium® Mould Controller, the UltraShot^TM  Injection System provides highly advanced process monitoring and control for injection moulding. The Altanium process control provides repeatability and traceability for part dimension consistency, perfect balance and a more stable process. Providing digital analysis creates a measurable discipline around the moulding process, and gives customers full control and trend analysis of various processes resulting in improved, lower risk operations. 

The melt delivery system is the “heart” of the injection moulding process and is essential to mould cell performance. The UltraShot^TM  Injection System masters part filling in a way that provides part design freedom, while reducing risk and improving part quality and speed of mould qualification. With “Husky Inside”, producers ensure that the centre of their system performs optimally, every shot. It offers unmatched OEE and increased productivity, at a reduced footprint, resulting in lowest total part production cost. It is the perfect fit for medical, technical packaging and consumer electronic part producers looking to scale up, implement more efficient process control, address competitive marketplaces, and reduce risk, scrap, waste and cost.