Gas Injection (gas assist molding) Machines

Kaken Geneqs has the largest installation base in Japan

Backed by Kaken Geneqs' years of experience and achievements, its one-of-a-kind gas injection machines represent an innovation in gas injection (gas assist molding) systems.

All basic technologies used in the system — from the N₂ gas generator and the ultra-high pressure gas booster to the controller — were developed in-house at Kaken Geneqs. The compact system configuration helps offer user-friendliness at affordable prices, and the one-of-a-kind booster realizes impressive savings in power consumption and maintenance costs. The system can accommodate a variety of customer needs including product quality improvement, lower cost of molding, and novelty in design.

What is gas injection?
Mechanism
Applications and Utilities

Features
Main Specifications

What is gas injection (gas assist molding)?

Gas assist molding is a plastic molding process characterized by injection of high-pressure nitrogen gas in the resin pressure-keeping step to maintain a constant internal pressure, enabling the reduction of such defects as sinks, warps and deformations in the finished products. It also provides a way to produce products with thinner walls and reduced weight far beyond the scope of conventional molding methods. These merits allow introduction of novel designs and structures, giving rise to significant economic benefits.

Mechanism of gas injection (gas assist molding) machines

System principle

Gas injection steps

System configuration

Applications and utilities of gas injection (gas assist molding) machines

Best suited for large moldings (automobiles, major appliances, etc.) and precision molding machines (OA equipment, etc.)
Can support complicated and difficult moldings
Low mold-clamping pressure can be used even in a large-scale molding, leading to cost reduction
Hollowed thick-walled moldings help shorten molding cycle
Thinning of walls and trimming of weight without compromising rigidity
Near elimination of sink, warpage, and internal distortion guarantees improved dimensional precision and high-quality products
Greater freedom of product design

Gas Injection (Gas Assist Molding) Machine Features

Features of gas injection (gas assist molding) machines
Capable of 28 MPa

Kaken Geneqs' gas injection (gas assist molding) machines features 2-stage compression and a double-acting water-cooling booster. It enables gas injection at a very high pressure (max. 28 MPa), and allows a wide range of gas molding using programmable timer settings. Delivered in a compact package at an affordable price, it allows easy relocation and is compliant with the High Pressure Gas Safety Act.

Other customized gas injection machines (e.g. 37 MPa ultra-high pressure version) available by request.

List of features

Impressive savings in power consumption
Low-cost regular/on-demand maintenance (end-user maintenance possible)
More than 200 units already in use as gas injection (gas assist molding) machines in injection molding machines
Compact size with a small footprint
Oil-free design enables compression of a variety of gas types
Low noise (≦ 45 dB) and easy maintenance
Integrates a nitrogen generator that outputs 99% purity N₂ at high discharge pressure (28MPa)
Can be synchronized with the molding machine using just three signals (automatic/semi-automatic, start injection, and mold opening complete)
Touch panel control—gas molding parameters and other information can be saved for easy retrieval and display
Compliant with the High Pressure Gas Safety Act (KHK tested)

We provide the following ancillary services: preparation of application forms for installation of high pressure gas, maintenance after installation, regular voluntary inspection, opening inspection, facility relocation, and technical guidance.

Gas Injection (Gas Assist Molding) Machine Main Specifications

[ All-in-one type (with an integrated controller) ]

Type	KGM90 N-1	KGM90 N-2	KGM200 N-1	KGM200 N-2	KGM300 N-1	KGM300 N-2	KGM400 N-1	KGM400 N-2
Compatible molding machine	Approx. 800 t		Approx. 2000 t		Multiple units controllable
Discharge pressure (MPa)	28
Capacity (Nm3/day)	90		200		290		400
Nitrogen generator	Built-in	Built-in	Built-in	Built-in	Built-in	Built-in	Built-in	Built-in
Pressure control	1 Line	2 Lines	1 Line	2 Lines	1 Line	2 Lines	1 Line	2 Lines
Power source	AC200V

[ Non-integrated controller type ]

Type	KGM90N	KGM200N	KGM300N	KGM400N	(controller type)	(controller type)	(controller type)
Compatible molding machine	Approx.　800 t	Approx. 2000 t	Multiple units controllable		-	-	-
Discharge pressure (MPa)	28
Capacity (Nm3/Day)	90	200	290	400	-	-	-
Nitrogen generator	Built-in	Built-in	Built-in	Built-in	-	-	-
Pressure control	Controlled by KST				1 Line	2 Lines	6 stages
Power source	AC200V				AC100V