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Success Story:

Fantastic plastic

Since its invention in 1872, plastic injection moulding has become a multi-billion dollar business, with 32 % of all plastics processed in this way. Now, after three years of recent research and with the help of EU funding, a group of researchers has designed a radical new concept of injection moulding, making the process cheaper and faster for the entire plastic supply chain.

On October 1, 2006, with a budget of EUR 3.7 million - EUR 2.2 million of which was provided by the EU - 16 highly motivated research groups from eight different European countries joined forces to achieve their goal of improving the efficiency of the plastic injection moulding process. Injection moulding is the method of injecting molten thermoplastic polymer into a cavity within a hardened steel mould tool, which opens to reveal a plastic moulding. It is the mould tool which is the basis for the EMOLD project - a collective research project funded under the Sixth Framework Programme (FP6). EMOLD proposes a new concept of plastic injection processes in which moulds would be equipped with sensors and embedded computers to monitor process and production parameters and communicate this information via wireless technology. This will improve the efficiency of the whole life cycle of plastic parts production, from mould-making to the production process itself.

Many hands make light work

Never underestimate the power of collective research. That is the message from project coordinator Joan Guasch, who should know after three years of working closely with a large and diverse group of stakeholders to create EMOLD. "When you work with people from other countries you discover one good thing, which is that you are not alone, and especially for SMEs, this is a very good feeling," said Mr Guasch. "On the other hand, when you have to cooperate with people from abroad, you have to take into account cultural issues and different ways of doing business in other countries."

The countries involved in the project are Austria, Belgium, Finland, Germany, the Netherlands, Slovenia, Spain and the United Kingdom. As well as the support of the industrial associations in each country, there are eight SMEs steering the research of the project to ensure that the results are applied in the industrial environment. There are also four research performers responsible for undertaking the research required to develop the technology for the prototype on behalf of the industrial associations. The four associations which will determine how to use the results of the project are: Feamm, the Spanish Federation of Managerial Associations of Mould and Die Manufacturers; Tecos, the Slovenian Tool and Die Development Centre; VKC - Flanders' Centre for Plastics in Belgium; and GTMA, a UK-based online directory of suppliers in tool making. "All the partners have participated in a very active way," said Mr Guasch. "They knew this was a very challenging project, but everybody has played their role."

All partners have had to make similar contributions to the project, which shows their commitment and confidence in the prototype succeeding. "The benefit of working with several partners on a research project is that it saves time, even though it may not save any more money than if you were doing it on your own," said Mr Guasch.

Light at the end of the tunnel

The EMOLD project was due for completion at the end of September this year, but the group has been granted a three-month extension from the European Commission. "If we had one more year, we could implement more gadgets, but the hard work is done," said Mr Guasch. "This extension will help us to finish the most interesting part of the project." The group is planning a launch event in Barcelona in November to present EMOLD to SMEs and industry representatives. It also plans to release scientific publications about the prototype and develop training programmes for technicians and for the European mould-making community.

The next step is to get the EMOLD prototype trademarked and to put it to market. "It hasn't been decided how or when at this stage," said Mr Guasch. "The four associations are in discussion now. If this succeeds, it will help mould makers throughout Europe deliver revolutionary service, giving them an important advantage in this competitive marketplace."

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