Formnext 2023: BARLOG Plastics with focus on sustainability and lightweight construction in product development

Overath, 30.10.2023 BARLOG Plastics, a family-owned company based in Overath, Germany, will once again be present at this year’s formnext, which will take place from 07 – 10.11.2023 in Frankfurt am Main. In Hall 12.1, Stand E08, the plastics expert will present its services, which cover the entire development process from the idea to series production and show how this can increase economic efficiency and quality, as well as reduce environmental impact.

BARLOG Plastics GmbH, based in Overath near Cologne, is presenting itself at this year’s formnext in Hall 12.1, Stand E08, under the motto “From the idea to series production”, with an increased focus on sustainability aspects. The materials experts will be presenting their expanded range of services, which covers the entire spectrum of plastic component development. These include the realisation of injection-moulded prototypes, pre-series and small-series production, an in-house toolmaking shop and an injection moulding production facility that has 16 machines with clamping forces ranging from 6 to 450 tonnes, including multi-component injection moulding, liquid silicone processing and the production of plastic-metal composite components.

Close and agile collaboration with customers is central to every project. From computer aided engineering, 3D design and simulation to design for manufacturing – BARLOG Plastics offers comprehensive support throughout the entire development process. In the process, the material data required for the simulation is determined in the company’s own test laboratory – and not only for standard materials, but also for recycled plastics, bringing sustainability goals into focus. In addition, the experts at BARLOG Plastics support their customers in optimising existing processes, whether through consulting, simulations, capability analyses or CT analyses.

The entire service portfolio of BARLOG Plastics is designed to increase economic efficiency, improve component quality, optimise sustainability aspects and reduce CO2 emissions. With a clear focus on innovation and sustainability, BARLOG Plastics presents itself as a competent partner for companies looking for customised solutions for plastic components.

BARLOG-ECO-Consulting stands for sustainability in product development

Frank Barlog, managing partner of BARLOG Plastics GmbH, emphasises that in today’s world it is crucial to pay increased attention to sustainability and the reduction of CO2 emissions. He explains: “Our goal is not only to reduce our own CO2 footprint, but also to ensure improvements along the entire supply chain.”

To this end, BARLOG Plastics has introduced ECO-Consulting – which is divided into three service modules: ECO-Selection, ECO-Design and ECO-Simulation. The goal is sustainable product development for customers. Of course, BARLOG Plastics also offers other development services with which they can support their customers in the various process stages in order to bring components to market quickly and cost-effectively. All services are available as a complete package or individually.

High-quality plastic prototypes and small batches

The protosys® business unit of BARLOG Plastics specialises in the production of injection-moulded prototypes as well as pre-series and small series and processes all thermoplastics from PE to PEEK, thermoplastic elastomers and even liquid silicone (LSR). “One of our core competences is the production of high-quality prototypes made of plastic,” explains Frank Barlog. “Thanks to the use of the rapid tooling process, our customers receive prototypes of optimal quality in the shortest possible time. By using mould inserts made of aluminium and flexible master mould concepts, machining times and tool costs are significantly reduced compared to steel tools.”

Spoilt for choice: rapid tooling or 3D printing?

Additive manufacturing is now a significant mainstay of plastics processing technology. “We have already been working with additive processes ourselves for years and also offer our customers these technologies and the necessary know-how,” says Frank Barlog. “However, even the most up-to-date 3D printers cannot always handle typical injection moulding granulates smoothly, especially when it comes to fibre-reinforced types,” he adds. “This clearly shows that rapid tooling and 3D printing are not necessarily in competition with each other, but complement each other perfectly. In cooperation with our customers, we then decide which solution best suits their project,” adds Frank Barlog.

Steel replacement: project to reduce the CO2 footprint

As a case study for the successful use of its engineering services, BARLOG Plastics presents a metal replacement project realised together with the customer Viebahn Systemtechnik. Here, an adapter plate for transporting engines in transport racks was produced with a total weight saving of 80 % through the intelligent use of plastic. The original steel version weighed 19.5 kg, while the plastic version weighs only 4 kg.

Thanks to topology optimisation and FEM structure simulations, among other things, the geometry of the adapter plate was adapted to the plastic and tool in several iteration loops. With the help of these techniques, mechanical weak points could be analysed early and in advance in the simulation and optimised via suitable rib structures and wall thickness adjustments.

You will find BARLOG Plastics in Hall 12.1 on Stand E08.