Arburg: ‘Allrounder 475 V’ combines compact footprint with 1,000 kN clamping force and automated decoration technology

A production cell centred on a vertical Allrounder 475 V produces high-quality remote-key covers from recycled PC/ABS using in-mould decoration (IMD) - (Photos: Arburg).

At Fakuma 2026, Arburg will showcase its vertical ‘Allrounder 475 V’ injection moulding machine with a clamping force of 1,000 kN in a fully automated application for overmoulding and decorating a car remote-key cover. The machine is designed for standard insert-moulding applications, including those in e-mobility, electronics and medical technology, and can be used for both manual and automated production.

Available since spring 2026, the ‘Allrounder 475 V’ has been designed to minimise floor-space requirements while still accommodating comparatively large moulds. The standard mould installation height is 250 mm, with optional extensions of 100 or 200 mm. The table height is 900 mm.

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As standard, the machine is equipped with Arburg’s ‘ASH’ servo-hydraulic system. According to the company, the system reduces idle losses and can cut specific energy consumption by up to 60% compared with conventional hydraulic machines. Operation is via the ‘Gestica lite’ control system.

In the mould of the vertical Allrounder 475 V, the decorative film is back-moulded with recycled PC/ABS.

The demonstration application produces a remote-key cover whose design is based on Huf’s ‘Generic Keyfob’. The material used is a post-industrial PC/ABS recyclate. For the surface finish, the application combines Leonhard Kurz’s ‘PLF’ technology for in-mould decoration with a textured mould insert.

A thin PET carrier film is fed into the mould and back-moulded with the plastic material. The decorative layer is protected behind the PET film, which remains permanently bonded to the component. According to the companies involved, this eliminates the need for additional protective coatings.

The high-quality surface of the cover is produced using IMD film technology in combination with a textured mould insert. The injection-moulded part, punched to a rectangular shape together with the film, is subsequently milled to its final contour in a downstream station.

The injection mould is supplied by Schöfer, with Meusburger providing the standard mould components, Reichle the structuring of the mould insert and Witosa the hot-runner technology. Inside the mould, the cover is punched to a rectangular shape, while excess film is subsequently wound up within the machine enclosure.

Different film variants enable a range of designs and colours to be produced without fundamental changes to the injection moulding process.

According to Arburg, the new vertical Allrounder 475 V with a clamping force of 1,000 kN is energy-efficient, compact, cost-effective and flexible for insert-overmoulding applications.

Part handling is carried out by a six-axis Kuka robot. After removal from the mould, the component is marked with a code at a laser station. The robot then transfers the part to a milling station, where excess film is removed and the final contour is machined.

Following a cleaning stage, the finished cover is placed on a conveyor belt and discharged from the production cell. Alternatively, the ‘Allrounder 475 V’ can also be automated using linear robotic systems.

The application additionally integrates the ‘R-Cycle’ initiative. The code applied to the component can be used to provide recycling-relevant information, including details of the material composition.

In this way, the production cell demonstrates how injection moulding, surface decoration, automated post-processing and digital product information can be combined to support material-related circular-economy processes.

Websites of the companies mentioned:
Arburg: www.arburg.com
Huf: www.huf-group.com
Leonhard Kurz: www.kurz-world.com
Schöfer: www.schoefer.at
Meusburger: www.meusburger.com
Reichle: www.reichle.de
Witosa: www.witosa.de
Kuka: www.kuka.com

Fakuma 2026
Friedrichshafen, Germany
12–16 October 2026
Hall A3, Stand 3101

Arburg GmbH + Co KG, Loßburg, Germany

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