ENGEL has expanded the scope of large-format injection moulding with the launch of its duo 12000 US, a two-platen machine designed for industrial-scale production of large components. With a clamping force of 110,000 kN, the system is engineered for parts with projected areas exceeding 2.5 sq m and has already been commissioned at a customer site.

The machine enables cost-efficient production of very large components in a single, integrated process. By supporting functional integration and reducing the number of parts and assembly effort, it offers greater design flexibility, lightweight construction advantages and improved product development possibilities. It also allows manufacturers to replace traditional materials such as metal and concrete with plastics, improving lifecycle CO2 performance.

To handle large shot weights, the system is equipped with two injection units operating in parallel. With screw diameters of up to 210 mm, it achieves a shot volume of up to 65,000 cu cm, ensuring uniform filling of large projected areas. An eight tie-bar configuration, selected in collaboration with the customer, supports specific application requirements, although four tie-bar designs are also possible.

The scale of the system underscores its engineering complexity. Measuring approximately 24 m in length and 8.4 m in height, it is among the largest injection moulding machines globally. The total weight is 551 tonnes, with a maximum mould weight of 170 tonnes. The installation includes around 30 km of cabling, with an installed power of 2.4 MW and a total current of 2,900 A. Despite these dimensions, the modular design of the duo series ensures a compact footprint.

ENGEL has developed the system using a modular platform and high in-house manufacturing capabilities, enabling efficient execution of customer-specific requirements. Its large machine technical centre supports testing and optimisation, particularly for critical factors such as shrinkage behaviour in large components.

The company brings decades of experience in large machine construction, with several systems of up to 74,400 kN already installed globally. Its production network enables manufacturing in Austria as well as regional production in Asia when required.

Despite their size, these machines deliver high precision. Through technologies such as injection compression moulding, component dimensions can be controlled to within a few hundredths of a millimetre, enabling advanced lightweight construction and functional integration.

The duo 12000 US also supports emerging applications across automotive, logistics and infrastructure sectors. In automotive, it enables the production of large structural components such as battery housings, underbody panels and hybrid inner door structures, supporting cost reduction, weight optimisation and simplified assembly. In infrastructure and logistics, applications include transport containers for e-mobility batteries, infiltration boxes for rainwater management and large water tanks with mould areas of nearly six square metres and shot weights of up to 109 kg.

Plastic components offer advantages over concrete, including easier transport and installation, lower infrastructure requirements and better adaptability to ground movement, while supporting water storage needs amid increasing rainfall and regulatory requirements.

ENGEL stated that the duo 12000 US not only represents one of the largest systems of its kind but also serves as a platform for new technologies, material substitution and integrated component design. The company added that it is capable of developing even larger systems based on future customer requirements, further expanding opportunities for cost-effective production of large-format components