Performance Polymers
Reducing Cycle Time and Boosting Efficiency: TE Connectivity’s Success with BASF’s High Productivity Plus (HPP) Materials
The Challenge: Reducing Cycle Time in Injection Molding
TE Connectivity, a leading manufacturer of connectors and sensor solutions, continuously seeks ways to optimize production efficiency. One major challenge was reducing cycle time in injection molding—a key factor that directly impacts productivity, energy consumption, and overall costs. While advancements in tooling and machine technology contributed to improvements, TE Connectivity recognized that material selection played a crucial role in further optimizing cycle time.
The Solution: A Collaborative Approach with BASF and Engel
To tackle this challenge, TE Connectivity partnered with BASF, a global leader in technical plastics, and Engel, a specialist in injection molding machines. The goal was to develop and test High Productivity Plus (HPP) materials, an evolution of BASF’s "High Speed" product line. These materials were engineered for:
✔ Faster crystallization and earlier demolding
✔ Shorter cooling times
✔ Improved flow behavior at lower melt temperatures
The Transformation: Measurable Cycle Time Reduction
Initial trials at TE’s production site in Dinkelsbühl, Germany, showed immediate benefits. Using BASF’s optimized PBT-GF15 HPP material, TE Connectivity was able to achieve:
✔ Up to 36% reduction in cycle time
✔ 30% increase in material throughput
✔ 15–22% lower specific energy consumption
✔ Consistently high product quality
CT scans confirmed that dimensional accuracy remained unchanged, despite the significantly reduced cycle time. The material’s improved heat deflection temperature allowed for higher-temperature demolding, further accelerating production.
The Results: Increased Efficiency, Lower Costs
By integrating BASF’s HPP materials and optimizing processing parameters, TE Connectivity significantly enhanced its production process. The material switch not only reduced costs but also lowered carbon emissions, contributing to more sustainable manufacturing
Looking Ahead: The Power of Material Innovation
Encouraged by these results, BASF expanded its HPP portfolio to include various glass fiber contents and PA6-based options, broadening its potential applications across industries.
Want to achieve similar efficiency gains in your injection molding process?
Contact BASF today to explore how material innovations can help optimize your production.