Starting point
VIAOPTIC manufactures high-precision plastic optics for the automotive, sensor technology and medtech industries. The optics are designed to meet high-precision requirements in their various applications. For this reason, a high level of particle cleanliness and clean separation of the lenses are essential.
However, it is not always possible to use a hot runner system. Hot runner systems produce small particles, especially with thick-walled optics. In these cases, a cold runner sprue is required. This is usually separated with nippers, a saw or a milling machine. Separation with nippers is limited to relatively thin sprue systems. In addition – as with sawing – only a straight cut is possible. Saws also generate a lot of debris and are therefore not suitable for use directly next to the injection moulding machine. Milling is the most expensive process and is generally only used for special contours.
The advantages of laser cutting are therefore obvious:
- No chips as with sawing
- Thick sprues can be cut very cleanly and quickly
- Even special, non-straight contours can be produced
- No micro-cracks
- Can be automated inline
The challenge
The disadvantage of the laser compared with mechanical separation processes is the higher initial cost. Production volumes in optical injection moulding are generally not high enough to amortize the cost. In addition, the size of such systems makes them very inflexible, so they can only be used at a single injection moulding machine.
The solution: Compact Door 550 – LCS 180C
A turnkey CO₂ laser system that is mobile and can be changed over very quickly to many different articles at different injection moulding machines.
Process highlights
- Mobile system
- Easy to move with a pallet truck. Plug connector for communication with the injection moulding machine.
- Custom nesting tool
- Positions up to 8 lenses per loading carrier and reduces handling time.
- Non-contact laser cutting
- 10.6 µm CO₂ beam, focused precisely on the sprue seam.
- Inline fume extraction & shielding gas
- Prevents soot deposits and keeps the optic crystal clear.
- Optional process monitoring
- Inline camera check (OK/NOK) can be integrated.
The result
With the Compact Door 550, VIAOPTIC achieves a level of flexibility that was previously impossible.
With the Datronik laser cell, we have succeeded for the first time in developing a mobile laser system for many different articles. With the system, we can offer our customers laser cutting without high additional costs. We don't buy a dedicated injection moulding machine for every article – we simply change the mould.
Outlook
The system is currently designed for larger machines and parts. The next step is to develop a smaller, even more flexible laser solution so that even the smallest optical parts can be laser-cut.
