Digital Technologies for the Plastic Industry

– Plastic 4.0 –

1 February 2024

AFVENTER NYT PROGRAM FRA GUIDO – Har sendt en reminder om at det vil være fint at få på plads efter sommerferien

Are you ready to seize the opportunities and utilize current and future Industry 4.0 technologies for the digitalization of the plastic industry?

What solutions are available for injection molding, extrusion, tooling, prototyping? What skills do they require? How can digital technologies such as connected sensors, Internet of Things, simulation, data analytics, polymer and metal additive manufacturing be integrated with plastic processing manufacturing platforms? How can these digital technologies add value and help to optimize time-to-market, quality, productivity, resource management and flexibility?

Leading companies and research institutions will present Industry 4.0 technologies, solutions and applications. Speakers will present how different players and technology providers use Industry 4.0 concepts in the plastic industry. They will discuss opportunities and impact of digital technologies on processes, business models and value chains.

This seminar is a continuation of the previous seminars ‘Digital Technologies for the Plastic Industry – Plastic 4.0’ held in 2021 and 2019.

Seminar organizers: Guido Tosello, Carsten Lund and Rasmus Grusgaard from ATV-SEMAPP’s plastic steering group



09:00 - 09:30
Registration and breakfast
09:30 - 09:35
Welcome and introduction by Guido Tosello, Associate Professor, Department of Civil and Mechanical Engineering, DTU Construct
09:35 - 10:00
The power of MES in a Digital Production Environment: Enhancing workflows, knowledge transfer and future visions

Raffaele Gualandris, Chief Commercial Officer, Wittmann Digital

The manufacturing industry is undergoing a digital transformation. While the main tasks and workflow in a production may remain the same, the approach in a digitalized company can significantly enhance efficiency and maximize benefits.

The main tool for achieving digitalization in production is the Manufacturing Execution System (MES), which can support standard workflows and offer more sophisticated functionalities to facilitate this change. An efficient and well-designed MES can also improve interconnectivity between the users by recording the data and offering a usable interface. This tool is the key point in transferring the experiences from a skilled employee to another employee, reducing the effort of employee training.

But how will this system be affected in the future? Considering the inevitable improvements in the digital world, we can expect MES systems to evolve and become even smarter. With the help of artificial intelligence and optimization logic, the system can become even more insightful, helping companies to grow to their full potential.

Raffaele Gualandris if the Chief Commercial Officer at Wittmann Digital. He is responsible of sales, marketing and customer service efforts of the organization.
10:00 - 10:25
Automatic finetuning of hotrunner tip temperatures– Improve process stability

Erik Nielsen, Head of Sales Center Nordic OEM, Kistler

To meet the increasing demand for high quality production in the Injection Moulding process it is important to keep a stable process, despite the changes in viscosity coming from changes in melt index, tool temperature and other external parameters. These parameters can be compensated by adjusting manually the tip temperatures of the hotrunner, but this is a time-consuming task.
Kistler has now developed and fine-tuned Multiflow, an automatic hotrunner fill-balancing technology based on the cavity pressure sensors. The system can run with most hotrunner controllers and we have optimized the ease of installation and use together with the German hotrunner controller manufacturer Fiege.

Erik Nielsen is a specialist in dynamic measurements and has more than 30 years of experience in measurement of cavity pressure in the Injection Moulding process.
10:25 - 10:50
Digitize your mould cooling with Mouldflo’s MouldLive and Mould Analytics underpinning factory scale energy optimizations and enhanced QA and QC processes

Martin Hansen, Owner/CEO, Mouldflo A/S

Mouldflo is ready to take a step into IOT with Mouldlive, to support cooling processes and mould maintenance QA and QC processes for organizations requiring high quality standards.
Mouldflo will show how Mouldflo products can support the processes and how Mouldlive makes data acquirable on a big scale.

Martin Hansen (MSc from DTU) is founder and owner of Mouldflo and Move Innovation, and is also the CTO in both companies. Martin has a background from the MedTech industry and more than 10 years of experience in the plastics industry.
10:50 - 11:20
Coffee and networking break
11:20 - 11:45
Digitalization shouldn't be binary

Louise Svenstrup Hellmund, Customer Success Manager, Gluu

Too many opportunities are missed when successful digitalization is only measured in terms of ERP, AI, or RPA implementations. In fact, ‘go big or go home’ is a common misconception when it comes to digitalization. Barely any organization can swallow a whole elephant all at once, but almost all organizations can eat it bite for bite. The key to successful digitalization is starting small, being aware of your business’ daily operation and involving frontline employees in identifying the best areas for improvement.
At Gluu we argue that digitalization comes in many forms and business processes can bridge the gap to the truly revolutionary digitalization – with incremental improvements towards the goal.

Louise Svenstrup Hellmund is the Customer Success Manager at Gluu helping customers succeed with process work on the business process management platform Gluu delivers. Louise has a background as Quality and Environmental Manager at Berry Superfos in Randers, an injection moulding site producing plastic packaging mainly to the food industry.
11:45 - 12:10
The journey from manual to digital - understand your process and interpret your data

Carsten Lund, Owner, EpsilonPlus

Digitalization is a great buzz-word, but if we copy our manual behavior into an automated process, we will miss the opportunity of improving the process. Digitalization requires process know-how and valid data to succeed. The transition from human error to automated error should be avoided by knowledge and analysis. The knowledge of your process, your data, and you customer’s expectations.

One of my questions is – do you know the difference between correlations and causalities? I will try to give you at least part of the answer.

Carsten Lund is the owner of EpsilonPlus supporting customers with quality management, injection moulding expertise and statistical analysis. He has a mechanical engineering background and is specialized in injection moulding. He is also a Six Sigma black belt and has been helping companies across Europe with data analysis and process validation for more than a decade as EpsilonPlus.
12:10 - 13:10
Lunch and networking
13:10 - 13:35
Disrupting Micro-Molding with Highest-Precision Micro-3D-Printing

Domenico Foglian, CEO & Founder, NanoVoxel

Additive manufacturing of soft-tools for injection molding is becoming a standard process to increase speed of prototyping and reduce costs of tools manufacturing. Standards have been developed over the past years, but the process had shown some limitations in precision, resolution, and surface quality, which limited its use in the micro-manufacturing world.

Integrating high-speed 2PP micro-3D printing and a unique micro-injection molding expertise, NanoVoxel is the first company worldwide to offer micro-molded parts with fastest delivery time down to two weeks, precisions down to single digit micrometers, freedom of design with radii potentially below 1 µm, surface roughness down to 10 nm and production quantities ranging from few prototypes to mass production.

Domenico Foglia is CEO of NanoVoxel and brings 10+ years of technical and commercial experience in the composites and consumer electronics business, with strong expertise in the micro-acoustic market. He founded Foliumtec (a technical consultancy) and NanoVoxel (a micro-manufacturing service provider) and he is playing tough in the world of micro manufacturing.
13:35 - 14:00
Transformative design freedom with 3D-printed soluble tooling

Lasse Staal, Co-founder /Business Development, AddiFab

3D-printed injection mold tooling is emerging as an attractive cross-over from 3D-printed prototypes to injection-molded parts. However, conventional 3D-printed tooling solutions have been based on the same design principles and design constraints as conventional injection mold tooling. Addifab is pioneering the use of soluble 3D-printed injection mold tooling elements to dramatically accelerate advanced product development and remove design constraints. Lasse Staal, co-founder of Addifab, will share key learnings from researchers and companies using soluble tooling to transform their product management.

Lasse Staal, co-founder of Danish start-up AddiFab, is a passionate believer in the transformative potential of Additive Manufacturing (AM). He is equally passionate about addressing the key limitations that prevent AM from becoming a cornerstone in global manufacturing. The AddiFab key focus – to merge key qualities from AM and injection molding and create the ultimate manufacturing platform – reflects this passion.
14:00 - 14:25
Value chain comparison of additively and conventionally manufactured mould component for high-volume production injection moulding.

Mandaná Moshiri, Senior Technology Manager, The LEGO Group

The manufacturing of mould components for high-volume production injection moulding today can be conducted with only subtractive-based technology, or integrating metal additive manufacturing, to increase the moulding performance with improved designs. However, effective methods are missing for the selection of the most suitable technology for a given tooling project.
In this presentation a method to compare the two process chains (based on additive and conventional subtractive technologies) is shown. The comparison is based on a technology focused-performance analysis through computer simulation, highlighting potential bottlenecks for production, and a cost analysis, to reveal the major drivers in the final cost of the manufactured mould component.

Mandaná Moshiri is a Materials Engineer, researching and working in the field of additive manufacturing since 2015. Today she is Senior Technology Manager in the LEGO Group covering the research and development of metal additive manufacturing technologies.
14:25 - 14:55
Coffee break and networking
14:55 - 15:15
High Productivity of Plastic Selective Laser Sintering (SLS) by Integration of Active Cooling Channels

Guido Tosello, Associate Professor, Department of Civil and Mechanical Engineering, DTU Construct / DIGIMAN4.0

With polymer selective laser sintering (SLS) is possible to produce highly customized plastic components. However, the long cooling time of the powder matrix limits the maximum system productivity.
In this talk a method to reduce the cooling time of SLS without compromising on quality will be presented. The method is based on the integration of in-printed cooling channels within the powder matrix. A cooling solution is realized using printed channels, and corresponding thermal simulations are developed to predict cooling rates for different channel configurations. Experimental and simulation results show that a 45% cooling time reduction can be achieved while maintaining the same geometrical quality characteristics in terms of dimensions and form error of parts obtained with long cooling times.

Guido Tosello has 15+ years of research experience in the analysis, characterization, monitoring, control, optimization of plastics processing technologies of thermoplastic materials from conventional size down to micro and nano scales, including simulation, tooling and metrology. He is currently Associate Professor at the Section of Manufacturing Engineering, Department of Civil and Mechanical Engineering, Technical University of Denmark, Head of Studies of the Master of Science program ‘Materials and Manufacturing Engineering’, and Coordinator of the Horizon2020 European project DIGIMAN4.0 ‘Digital Manufacturing Technologies for Zero-defect Industry 4.0 Production’ (2019-2024)
15:15 - 15:35
Inject 4.0 - How to predict injection defects based on geometry and process settings

Alireza Mollaei Ardestani, Ph.D. Student, DTU Construct

Increasing demand for plastic parts in today’s world leads to more focus on plastic parts’ manufacturing methods. The old empirical methods have been replaced with different modern techniques including digital twins, statistical models, and machine learning approaches. These are the key enabling techniques connecting injection molding to industry 4.0.
This talk will revolve around the manner and the results of adopting these techniques for a case study (Blush defect).

Alireza is a mechanical-manufacturing engineer with a focus on plastic injection molding. Now as a Ph.D. student, he is a part of DIGIMAN4.0 project, funded by EU H2020 MARIE SKŁODOWSKA CURIE ACTION. His PhD thesis is titled ‘Digital Molding 4.0 – Advanced Process Analytics for Zero-Defect Injection Molding Technology’.
15:35 - 15:55
Extrusion 4.0: The integration of polymer additive manufacturing (AM) and process simulation in polymer extrusion

Arhimny Hasdi Aimon, PhD Student, DTU Construct

Polymer extrusion is a well-established technology due to its high productivity and the ability to manufacture complex cross-section products. However, for highly customized products and small batches, the die design and manufacturing are lengthy processes that limit new products development and their production. Recent development in polymer AM have enabled composite materials and tough polymers to be manufactured. AM offers flexibility by enabling streamlined die design which results in more flow balance and lower die head pressure. Flow simulations were performed to predict the die head pressure and melt flow velocity across the profile extrusion section. Furthermore, simulation contributes to process die design since the objective function of die geometry optimization is performed based on the average velocity and velocity distribution of polymer melt across the profile cross section in the die channel and the die exit. Therefore, the opportunity is foreseen to integrate additive manufacturing and simulation into the extrusion process and value chain.

Arhimny is an Electromechanical Engineer with a background in instrument, control and micro electromechanical systems (MEMS). Currently she is a PhD student in manufacturing engineering at the Technical University of Denmark (DTU). Her PhD project title is Digital Manufacturing Technologies for Extrusion 4.0.
15:55 - 16:00
Final comments and conclusion

Digital Technologies for the Plastic Industry, 2023

  • When registering for an ATV-SEMAPP event, you also sign up for ATV-SEMAPP's newsletter. You can unsubscribe at any time.
  • Required on the invoice by some organisations
  • Needed for E-invoices to Danish State Organisations

Registration fee

 DKK 2,625  Members of ATV-SEMAPP and promoting partners listed in the registration form
 DKK 3,125  Non-members
 DKK 1,025  PhD Students
 DKK 325  BSc and MSc students (Membership is free of charge – register here. Early bird discount does not apply)

All prices are exclusive of 25 % VAT.

Early bird discount of DKK 300 when registering before 24 March 2023.

Binding registration
Registration is binding, however substitutions are accepted at any time.

Please do not hesitate to contact ATV-SEMAPP by e-mailing