Smart Injection Molding: Faster Cycles, Lower Energy with S-Concept

ELK GROVE VILLAGE, IL, September 30, 2025 -

Manufacturers need consistent quality, faster cycles, and measurable sustainability—without adding complexity. Smart injection molding with Shibaura Machine’s S-Concept brings adaptive, closed-loop control to all-electric cells, helping teams stabilize processes, reduce energy, and simplify setup. Built on Shibaura Machine’s EC-SXIII platform and V70 controller, it makes expert-level outcomes repeatable across shifts.

The three forces reshaping injection molding

• Labor: Veteran intuition is retiring; newer operators need embedded guidance and tooling protection.
• Speed: Lead times are short; optimization must happen in-cycle, not in offline trials.
• Sustainability: Energy/CO₂ reductions must be auditable—without sacrificing quality.

How Smart Injection Molding Changes the Shift

1) Setup that teaches—without slowing you down

On the V70 HMI, the six core recipe elements live on a single screen, so setups are fast and consistent across shifts. The system captures a reference torque waveform and watches both open and close to protect the mold. It auto-calculates low-pressure clamping (PCL) and LS2, then lets you fine-tune—so guardbands aren’t guesswork. Even purging is guided with recommended conditions to trim resin loss and time.

Why it matters: Less trial-and-error, fewer opportunities for damage, faster path to a stable, repeatable window.

2) Stability—even when the material mix changes

Lot-to-lot variation and higher regrind percentages typically show up as shorts, flash, or weight drift. DST Fill closes that gap. By reading signals such as FPC (transfer) pressure, it adjusts temperature/pressure conditions in real time to hold viscosity steady. Under the hood, the S-Cube injection unit (friction-reduced drive, noise-resistant digital load cell, cross-machine linearization) and the DBG screw (sub-flight separating solid from melt) improve plasticization and weight control—so small changes upstream don’t cascade into scrap.

Why it matters: Dimensional consistency without constant re-tuning; more regrind without quality penalties.

3) Throughput from motion control

Mechanical speedups often bring shock and variability. Here, the gains come from control: moving-platen linear guides, double rigid plates, and a link-line toggle distribute clamping force uniformly, while Shibaura Machine’s dynamic acceleration/deceleration (patented) delivers rapid open/close with reduced shock.

Under representative conditions (10-second cycles, ~200 production hours/month), factories can reclaim up to 168 hours/year—without changing molding conditions.*

Why it matters: Shorter cycles that still hit cosmetic and dimensional targets.

4) Energy and cooldown you can measure (optional heater cover)

For EC55SXIII–EC390SXIII, an optional heater cover encloses the barrel for heat retention; an add-on cooling module accelerates cooldown. Documented results:

• Power: 2.1 → 1.6 kW (–24%)
• Annual CO₂: 5,600 → 4,300 kg (–24%)
• Barrel cooldown: 70 → 30 min (–60%)
• Economic impact: ≈ $285/machine/year

It’s retrofit-ready for SXIII V70 machines now and available for new orders in late 2025.

Why it matters: Lower operating costs and faster changeovers—with measurable numbers.

5) Visibility that fits how your factory runs

A built-in power consumption monitor shows current and cumulative use, trend graphs, and estimated fees; data exports to USB for reporting. Up to 8 analog inputs (0–10 V) let you visualize external sensors—think cavity pressure or thermocouples—alongside machine data on the HMI.

Why it matters: Decisions based on what actually happened at the press, not an end-of-shift guess. 

Example scenario for recovered hours: same injection conditions, 10-second cycles, ~200 production hours/month. Actual results vary by mold, material, and practices.

Looking Ahead in 2025: Predictive Health Indicators

• Amplifier Lifespan Display Function: HMI shows capacitor-life estimate from internal calculations so you can replace before failure and avoid unplanned downtime.
• Health Monitor: Consolidated condition indicators intended to surface emerging issues earlier. 

* Roadmapped features; timing/specs subject to change.

Smart injection molding vs. conventional (at a glance)

Deployment & Integration Notes:

S-Concept is built for practical adoption. Operators follow guided HMI workflows; protection guardbands are built in; data (power trends, analog inputs, exports) fits existing quality, maintenance, and reporting. The heater cover installs as an optional add-on and can be retrofitted to SXIII V70 cells without a full rebuild.

Bring Smart Injection Molding to Your Line

S-Concept advances smart injection molding through servo-driven precision, closed-loop compensation, operator-first controls, and a heater-cover upgrade delivering verified energy, CO₂, and cooldown gains. With predictive indicators on the roadmap, factories can plan replacements before failure and keep production moving.

See it at K-2025 (October, Düsseldorf): in-booth demos of automated optimization, predictive maintenance, and integrated sustainability—and a clear view of how S-Concept can elevate your next program.

FAQ 

What is AI-powered injection molding?
It combines machine learning, predictive analytics, and closed-loop controls to optimize injection molding in real time for quality, speed, and energy efficiency.

How does S-Concept reduce cycle time?
By analyzing thousands of variables each cycle and applying micro-optimizations, factories commonly see 15–30% cycle-time improvement without stopping production.

Can existing machines benefit from S-Concept?
Yes. The heater cover is retrofit-ready for SXIII V70 machines, cutting power use ~24% and cooldown time ~60%, while providing auditable sustainability data.

Register today

Tel: (888) 593-1616

Email: im-success@shibaura-machine.com