Presentation and Further Development of an Innovative Plastic Forming Process (GITBlow) for Producing Complex, Thin-Walled Moulded Plastic Parts

The innovative, resource-friendly plastic moulding process known as GITBlow (gas injection and blow moulding) enables the production of components, such as large hollow sections, extremely thin-walled channels and complex geometry, by means of a stable process. No further processing steps are required. A large range of materials can be used for a wide variety of applications.

The objective of the joint project was to further refine the innovative gas injection and blow moulding (GITBlow) process for moulded plastic parts and to make it application ready. Large hollow sections with thin residual wall thickness (RWT) can be produced while simultaneously integrating delicate moulded parts, all in one injection moulding cycle.

The project examined the areas of application, prerequisites, process stability, implementable cycle times as also the limitations of the gas injection and blow moulding technique. Both a one-stage and a two-stage process were analyzed.

Results:

• Both processes are stable and able to produce reliable components.
• It is possible to manufacture very large hollow sections.
• Components can be produced using considerably less material as compared to conventional processes. The process is thus both less expensive and less resource-intensive.
• It is possible to produce extremely thin-walled channels as well as bifurcations in the cavity geometry.
• Connector geometry as well as small, delicate moulded parts can be directly integrated on the channels.
• GITBlow can be used to implement complex geometry that is not possible with the core pull technique.
• A variety of materials can be used and there is a wide range of applications.
• No additional processing steps are required. Components can be manufactured on one machine, which saves energy and costs.

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