Injection molding rethought: Data-based process optimization at KOMOS
May 5, 2026
In the project Injection molding digital KOMOS is working together with partners from research and industry on the next stage of development for plastic injection molding: data-based, predictive, and resource-saving production.
Goal: The digital process twin
At the heart of the project is the development of a digital twin process. This is intended to enable statements about:
- the Component quality
- the Process stability
- the Energy requirement
to meet – and thus to evaluate processes early and to optimize them specifically.
The foundation is classic engineering work, supplemented by data-based methods and artificial intelligence where it creates real added value.
Technological basis
A specially developed experimental tool was used for the project, which is equipped with external sensors and provides high-resolution process data.
Among other things, the following are used:
- Real-time measurements of Pressure and temperature curves
- Analysis of Melting progression in the filling process
- Systematic experimental planningDesign of Experiments, DoE)
- A uniform experimental matrix to ensure a reliable data base
This structured data collection enables a thorough evaluation and forms the basis for the development of the digital process model.
Focus: Recyclates and process robustness
A central component of the project is the processing of Recyclates with high material content.
Since these materials naturally undergo stronger fluctuations, they place particular demands on the process management. However, previous experiments show that:
Through targeted evaluation of the process data, stable and reproducible results can also be achieved even with varying material quality.
With this, the project makes an important contribution to sustainable plastic processing.
Added value for production
The developed approaches lead to concrete benefits for industrial practice:
- Early detection of quality deviations
Instead of an intermediate examination - Reduced energy consumption
through optimized process management - Shorter cycle times
with constant or improved quality - More robust processes
also with fluctuating material properties - Less committee work and higher efficiency
Collaboration within the project consortium
The project is being implemented in close collaboration with strong partners:
- Ernst Abbe University of Jena
- Batix
- Wilhelm Plastic
- Fraunhofer IKTS
- FKT Formbau und Kunststofftechnik Triptis
At the project meeting at KOMOS in Bürgel, experiments with different recycled material percentages were conducted, and a common experimental matrix was agreed upon – as a basis for optimal data analysis.
Perspective
With Injection molding digital KOMOS follows a clear direction: a production that understands processes, evaluates them, and optimises them from a perspective.
Data-based decisions, resource-saving processes and stable quality form the foundation for future-proof industrial manufacturing.
