K 2016 - A highly successful trade fair for IKV

Visitors at IKV stand at K 2016 (photo: IKV)
Visitors at IKV stand at K 2016 (photo: IKV)

For the very first time, IKV demonstrated two running processes at a K fair, underlining its expertise in Industry 4.0 for the plastics industry and additive manufacturing. Professor Hopmann was a sought-after speaker at PlasticsEurope, the VDMA and others. The IKV was also represented on the Science Campus.

"We are completely satisfied with the outcome of K 2016. IKV set out the focal themes for K 2016: lightweight construction, additive manufacturing and Industry 4.0 are the current key topics for the plastics industry, and we covered these in an outstanding manner with our two future-oriented trade fair projects. The positive feedback from our visitors testifies to the fact that we were able to convince a large number of international visitors of IKV's innovation capacity", reports Prof. Hopmann, Head of IKV.

The next K is being held from 16 to 23 October 2019. We are already looking forward to seeing you in Düsseldorf again!

Highlights of "Industry 4.0"

For IKV too, this year's K fair exceeded all expectations: two future-oriented processes for networked production attracted a large number of visitors to the stand and, once again, illustrated the institute's high innovative capacity.

IKV demonstrated, firstly, an injection moulding production cell that can be used to make individualised components fully automatically in a large number of variants with a single injection mould. With the support of twelve partners from industry, IKV developed a production cell allowing the individualised production of locally reinforced hybrid parts in plastic with a PP-LGF foam structure, on the basis of Industry 4.0 criteria. At the K fair, IKV showed a process that varied from shot to shot, based on a combination of thermoplastic foam injection moulding and individualised thermoplastic reinforcement using continuous fibres. The result was a technology demonstrator in the form of a sports saddle. The fully automatic networking of the plant and the measuring technology, which the customer could influence live, clearly illustrated the added value of Industry 4.0 in production.

Visitors to the fair were able to actively control the production process and select a personal component from all the possible variants and have this made. The shot volume, component thickness and type of fibre reinforcement were automatically aligned to the visitor's requirements. In order to emphasise the Industry 4.0 nature of the process, it was possible to feed the personalised saddle into the production process from the different locations of the project partners at the fair.

"Additive manufacturing"

IKV also demonstrated the hybrid production of functionally-integrated plastics products by 3D printing. An integrated process combination of completely different groups of production processes makes it possible to produce components cost-efficiently with a batch size of 1. To do this, an additive plasticising production process is combined, as required, with further processes, such as insertion processes or subtractive finishing processes. In this way, problems like poor dimensional stability, surface finish and material links between additive manufactured parts can be automatically resolved in the hybrid production cell. Downstream painting processes and the precise integration of inserts are possible. The researchers at IKV have thus shown that the aim of customer-oriented and automated production of functionally integrated plastics parts can indeed be achieved.

IKV stand in a new design

The newly designed, open exhibition stand, with a surface area of 132 square metres, offered sufficient space to engage in conversations with visitors, alongside the two running processes. Experts from all over the world were impressed by the networked processes and the overall range of services presented by IKV, which were displayed interactively via touchscreens.

A large number of visitors were also interested in the Institute in general, in the possibilities that exist for working with IKV, in plastics technology university courses and in plastics analysis and testing.

IKV on the Science Campus

In addition to its main stand in Hall 14/C16, IKV was once again, after 2013, represented on the Science Campus in Hall 7. On the Science Campus, visitors were able to acquire an overview of the scientific activities conducted by different research institutes in the plastics and rubber sector.

With IKV, visitors were able to interact, via a monitor, with the production cell on the IKV stand and feed in their production order. Thanks to the code that was supplied, together with the time, each visitor knew precisely when they could pick up their finished saddle at the IKV stand in Hall 14.

Component with a metal insert, produced in a combined deep drawing and back moulding process (IKV/Fröls)
Component with a metal insert, produced in a combined deep drawing and back moulding process (IKV/Fröls)

IKV on the stand Wittmann Battenfeld

At the Wittmann Battenfeld stand, IKV scientists gave a live demonstration of a combined deep drawing and back moulding process with metal inserts.






Guided tour of IKV met with an outstanding response

A group of Asian visitors take a look at the IKV pilot plants during K 2016 (M. Conrad-Franzen)
A group of Asian visitors take a look at the IKV pilot plants during K 2016 (M. Conrad-Franzen)

For the first time, IKV offered a guided tour of its pilot plants during K 2016. This provided foreign members of the IKV Association of Sponsors, in particular, with an opportunity to obtain an overall picture of the extensive research facilities at IKV. On Friday, 21 October 2016, an organised coach transfer ensured that the more than 120 participants arrived safe and sound. The guests then split into seven groups to visit the pilot plants and their systems. IKV is particularly pleased that so many visitors from Asia came, accounting for some 70 percent of participants on the tour.

„I and everybody who attended the lab tour really appreciate IKV's effort for the open-lab tour.”

Prof. Hopmann a sought-after speaker

Prof. Hopmann on Industry 4.0 at Plastics Europe (Hanser/Stein)
Prof. Hopmann on Industry 4.0 at Plastics Europe (Hanser/Stein)

In the reporting in the run-up to K, the two IKV trade fair projects received gratifying coverage in the specialist press, which also continued while K was actually running. A large number of articles were published in both the print media and the web. The K trade fair newspaper “K-Aktuell” reported twice within the first two days of K on the IKV's future-oriented processes. Professor Hopmann was additionally a sought-after interview partner. In a Messe Düsseldorf film contribution, Professor Christian Hopmann was asked how he rated the Science Campus. At the VDMA he took part in the talk “Industrie 4.0 plus – shaping the future”. At PlasticsEurope he moderated the discussion round on the theme day “Kunststoffindustrie 4.0”. At the HRS booth, he also contributed to “Industrie 4.0”. And KUNSTSTOFFE interviewed him on the reissue of the book “Extrusion dies for plastics and rubber”.

Promoting young engineers – sponsoring visits to K

For this K too, a large number of companies in the IKV Association of Sponsors sponsored entrance tickets for a visit to K. With the aid of these entrance tickets, IKV was able to organise a trade fair visit for some 120 plastics engineering students. The students were divided up into eight groups, and guided around the fair by IKV assistants, being taken to many of the companies that had supported the campaign. Representatives of the companies were pleased to receive the young engineers on their stands and explained their companies to them, together with their trade fair highlights.

Maintaining and extending contacts: the alumni evening

As in the past, an alumni meeting was also held on the occasion of K 2016. IKV invited former students to the "Rheinterrassen Uedesheim" in Neuss on the Tuesday evening. With around 180 visitors, even more alumni took up the invitation than in 2013 and spent an informative and sociable evening together.

Thanks from Prof. Hopmann go to everyone who supported IKV at K 2016!

Dear sponsors and partners of IKV at K 2016,

I would like, also on behalf of all the IKV staff, to thank very warmly indeed all the sponsors and project partners for their generous and varied support, without which our highly successful participation at K 2016 would not have been possible.

I would like to single out in particular Messe Düsseldorf for its support with the IKV stand. Other key players were, of course, the project partners in the exhibition highlight “Industry 4.0 and Additive Manufacturing”. Only by working so closely together were we able to realise this challenging and – at the same time – technologically very interesting project. I would also like to thank the many companies, institutions and individuals from the Association of Sponsors, who sponsored entrance tickets and thus enabled students to visit the show.

After all the very positive feedback we received this year from various sectors of industry, and in view of the enormous interest we derived from the many technical discussions held at K, IKV already has its eyes on K 2019.

Above all, we are looking forward to working together with you this year!

Kind regards,

Prof. Dr.-Ing. Ch. Hopmann

Our special thanks go the following companies, institutions and individuals, in particular

Trade fair stand:
Messe Düsseldorf

Partners in the "injection moulding production cell" trade fair project:
ARBURG GmbH + Co KG, ASS Maschinenbau GmbH, Georg Kaufmann Formenbau, gwk Gesellschaft Wärme Kältetechnik mbH, HASCO Hasenclever GmbH + Co KG, HRS flow, IOS Gesellschaft für innovative Optimiersoftware mbH, Kistler Instrumente AG, Krelus AG, motan holding gmbh, Sabic Innovative Plastics, SensoPart Industriesensorik GmbH

Entrance ticket sponsors:
3D Core/ESC GmbH, ARBURG GmbH + Co KG, BASF Polyurethanes GmbH, Brabender GmbH & Co. KG, BRITA GmbH, Brückner Maschinenbau GmbH & Co. KG, Covestro Deutschland AG, Dohlen & Krott GbR, Döllken-Kunststoffverarbeitung GmbH, Dr. Collin GmbH, DuPont International Operations Sarl, Ensinger GmbH, Fachverband Schaumkunststoffe und Polyurethane e.V., gwk Gesellschaft Wärme Kältetechnik mbH, Harburg-Freudenberger Maschinenbau GmbH, Klöckner Desma Elastomertechnik GmbH, KraussMaffei Gruppe, Marubeni Europe plc, Messe Düsseldorf, Reifenhäuser GmbH & Co. KG, Sabic Innovative Plastics, simcon kunststofftechnische Software GmbH, VDI-Gesellschaft Materials Engineering, Wegener International GmbH, Windmöller & Hölscher KG

For information on IKV's projects at K 2016
Nicolai Lammert, M.Sc. RWTH

For information on IKV's overall presentation at K
Dipl.-Ing. Leo Wolters