Every molder needs to save material and energy today – and this trend has put gas injection molding into the spotlight. In gas injection molding, nitrogen is injected into a mould cavity that is partially or completely filled with molten plastic, thus creating a cavity structure in the component itself.

This process saves raw material and makes the components lighter. Nonetheless, these components retain a high-quality surface, since the nitrogen gas takes over the task of maintaining mould pressure and also counteracts any shrinkage of the components from the inside out. Even with thick-walled components, sink marks and warping can be avoided.

The range of applications for this process is very wide. Typical applications for Airmould technology include elongated parts that also require low weight and high cost efficiency. Product examples include automobile handles, sports equipment, and beverage crates. In addition, Airmould is used to efficiently produce media lines and small tubes.

With Airmould 4.0, WITTMANN has developed a patented system for gas injection molding that can be combined with injection molding machines of various designs and brands via a Europmap 62 interface. The hardware consists of a compact central unit as a connection node for the individual machine components, the pressure control module, and also a hand-held control unit. In combination with a WITTMANN injection molding machine, Airmould can be operated via the Unilog B8 or Unilog B8X machine control system and does not require a separate control unit.

The cavity structure means that less material is required.

The parts produced are lighter, which is particularly advantageous in the automotive industry and for sports equipment.

The nitrogen acts as a holding pressure and prevents sink marks and warping, even with thick-walled parts.

Cycle times are shorter compared to compact injection molding. In conjunction with higher material efficiency, this reduces unit costs.

WITTMANN also offers a highly efficient solution for nitrogen supply, which has been developed and produced in-house. N₂easy makes it possible to generate the required nitrogen gas directly from the ambient air at the processing machine. The nitrogen generation and pressure generation systems are available in various sizes and performance grades to supply individual machines or operate as central systems.

In-house nitrogen production is significantly more cost-effective and sustainable than conventional nitrogen supply using gas cylinders or liquid gas tanks. With N₂easy, nitrogen production requires very little energy and eliminates the entire logistics effort. Another advantage is that the compact, soundproofed systems are mobile and therefore flexible in use. N₂easy only requires a simple power outlet.

Even with gas consumption of just one gas cylinder per day, producing your own nitrogen with N₂easy pays for itself.

On-site nitrogen production reduces logistics and energy consumption.

The compact, soundproofed systems are mobile and can be used flexibly.

N₂easy only requires a simple power outlet and takes up little space in the production hall.