The requirements for traceability, quality assurance and automation in industrial production are constantly increasing. Companies are looking for innovative solutions to make their processes not only more efficient, but also future-proof. This is precisely where our joint research project SmartMold comes in: In cooperation with the Ernst Abbe University of Applied Sciences Jena and PRIME-tec, we are developing a process that integrates the benefits of RFID technology directly into the injection molding process - a decisive step towards the smart factory.

The Problem

Plastics processing faces key challenges: Components must be traceable, production data must be reliably recorded and, ideally, each individual product must be clearly assigned. Conventional solutions such as printed codes or subsequent markings are often susceptible to damage or manipulation - and do not provide a secure link between the component and digital production data.

At the same time, the move towards Industry 4.0 calls for solutions that can be integrated directly into existing processes without negatively impacting the production flow.

The Solution

In the SmartMold project, we are pursuing a novel approach: RFID chips are embedded in specially developed, 3D-printed support structures that fuse completely with the plastic component during the injection molding process. The chips are heat-resistant and survive the injection molding process undamaged - the result: a component with an integrated, unique identity.

This creates a digital twin - a virtual image of the component that is linked to its real properties and production data. This digital link allows data on material, tool, batches or areas of application to be retrieved directly and securely - at any time and throughout the entire product life cycle.

Adding value

The combination of additive manufacturing, structural-mechanical optimization and intelligent data connection takes plastics processing to a new level. SmartMold not only enables seamless traceability, but also opens up new avenues for automated quality assurance, data-driven maintenance and efficient series production.

With this project, we and our partners are making a concrete contribution to the implementation of Industry 4.0 - practical, forward-looking and technically sound.

Are you interested in intelligent manufacturing solutions or would you like to find out more about the project? Feel free to contact us - we will share our experience and work with you to develop the next generation of industrial processes.