Sustainability and lightweight construction in product development

From computer-aided engineering, 3D designs and simulations to design for manufacturing - Barlog offers support throughout the entire development 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, which brings sustainability goals into focus. In addition, the experts support their customers in optimizing existing processes, be it through consulting, simulations, capability analyses or CT analyses.

Frank Barlog, Managing Partner of Barlog Plastics, emphasizes that it is crucial in today's world to focus more on sustainability and the reduction of_{CO2 emissions}. He explains: "Our goal is not only to reduce our own_{carbon footprint}, but also to ensure improvements along the entire supply chain." Eco-Consultingwas introduced for this purpose - which is divided into three service modules: Eco-Selection, Eco-Design and Eco-Simulation. The aim is to achieve sustainable product development for customers.

Barlog also offers additional development services to support its 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 series

The Protosys division specializes 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 competencies is the production of high-quality plastic prototypes," explains Frank Barlog. "Thanks to the use of the rapid tooling process, our customers receive prototypes of optimum quality in the shortest possible time. By using aluminum mold inserts and flexible master mold 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 an important pillar of plastics processing technology. "We have been working with additive processes ourselves for years and also offer our customers these technologies and the necessary expertise," says Frank Barlog. "However, even the latest 3D printers cannot always handle typical injection molding granulates smoothly, especially when it comes to fiber-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. We then work with our customers to 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 presents a metal replacement project realized together with the customer Viebahn Systemtechnik. Here, an adapter plate for transporting motors in transport racks was manufactured 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 just 4 kg.

Thanks to topology optimization and FEM structural simulations, 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 proactively in the simulation and optimized using suitable rib structures and wall thickness adjustments.

Formnext, Hall 12.1, Stand E08