Arburg: Connected Medical Production Cell Adds AI-Based Process Optimization

“NextGen Medical Solution”: At Fakuma 2026, a turnkey system built around an electric Allrounder 570 A will produce caps for injector pens. Working closely together, Arburg, Hack Formenbau, HB-Therm and a major OEM have taken a holistic approach to identifying optimization potential - (Photo: Arburg).

At Fakuma 2026, Arburg will showcase an enhanced version of its “NextGen Medical Solution” production cell for manufacturing plastic components used in medical applications. The turnkey system is built around an electric “Allrounder 570 A” in a cleanroom configuration and integrates the injection molding machine, mold, automation and peripheral equipment through the “Gestica” control system. Project partners include Hack Formenbau, HB-Therm, Plus10 and an unnamed biopharmaceutical OEM.

A key focus of the system is the continuous collection and use of process and quality data. One of the latest additions is Plus10’s AI-based “Hopper” tool, which analyzes machine and process data during production, identifies deviation patterns and learns correlations between process parameters and part quality. Based on this information, the system can generate quality predictions and recommend adjusted process parameters when significant deviations occur. These recommendations can be transferred directly into production.

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The aim is to reduce the need for quality inspections while identifying process deviations at an earlier stage.

At Fakuma 2026, Arburg will use the production of caps for injector pens to demonstrate how medical products can be manufactured cost-effectively and with consistently high part quality through digital connectivity and intelligent control functions - (Photo: Arburg).

Centralized Data Management Through “Gestica”
For the demonstration application, the production cell uses an eight-cavity mold from Hack Formenbau to manufacture polypropylene caps for injector pens using material supplied by Borouge International. According to Arburg, the cycle time is around ten seconds. An overhead-mounted six-axis robot removes the molded parts and deposits them separately according to cavity.

Data from the mold, temperature-control equipment and robot is consolidated into a common dataset within the “Gestica” control system. Production data is also recorded in the “arburgXworld” customer portal and Arburg’s “ALS” host computer system. This is intended to enable data to be clearly assigned to individual shots.

The centralized data architecture also supports a parametric release approach, in which documented process parameters can play a greater role in quality assessment for medical and pharmaceutical applications.

“Smart” communication between the machine and the injection mold is enabled by “aXw Control MoldlifeAssist”, which is fully integrated into the Gestica control system - (Photo: Arburg).

Mold Monitoring With “MoldlifeAssist”
The production cell also uses “aXw Control MoldlifeAssist” for communication between the machine and the injection mold. The system is based on “Moldlife Sense” from Hack Digital Solutions and is integrated into the machine control via the Euromap 82.5 interface.

Sensors monitor parameters including temperature, acoustics, mold breathing and alignment throughout the mold’s service life. The measured values can be visualized, monitored and documented directly in the machine control system.

The system also supports setup, monitoring and maintenance activities. A digital setup assistant guides operators through predefined work steps using image-based instructions. The hardware is designed so that one system can be used across multiple molds.

Assistance Functions for Process Windows and Energy Efficiency
Additional assistance functions are designed to support process development, validation and ongoing stabilization. “aXw Control FillAssist” assists with process setup, while “aXw Control DoEAssist” enables Design of Experiments to be carried out directly on the machine. This allows process windows to be defined systematically and can support validation activities.

Other assistance functions monitor plasticizing, cycle times, energy consumption and process stability. “aXw Control MeltAssist” focuses on plasticizing capacity utilization and material residence times, while “aXw Control CycleAssist” identifies non-productive portions of the cycle.

“aXw Control EnergyAssist” monitors energy demand during heating and shutdown of the cylinder module. “aXw Control StabilityAssist”, meanwhile, continuously tracks defined process parameters and is intended to make gradual deviations visible. Tolerance limits for the process window can be stored directly in the program.

Turnkey Concept With Single-Source System Responsibility
As general contractor, Arburg assumes overall responsibility for both the hardware and software of the production cell. According to the company, early coordination between machine engineering, mold technology, temperature control, software development and the OEM is intended to reduce integration effort and shorten the time required to achieve production readiness.

Arburg also cites lower scrap rates, reduced inspection and operating costs, and fewer unplanned downtimes through condition monitoring and predictive maintenance as key objectives of the concept.

Websites of the Companies Mentioned
Arburg: www.arburg.com
Hack Formenbau / Hack Digital Solutions: www.hack-formenbau.de
HB-Therm: www.hb-therm.com
Plus10: www.plus10.de
Borouge International: www.borougeinternational.com

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

More information: www.arburg.com, www.amk-motion.com/de

Arburg GmbH + Co KG, Loßburg, Germany

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