AI 통합 사출 제어
Eta One-Cycle Solution — AI-Integrated Smart Injection Platform
An intelligent injection platform where AI integrates foam, mold, and cooling control. Defect rate below 2%, productivity increased by 60%.
Key Message / Overview
Eta One-Cycle Solution integrates EtaSolid’s core technologies, EcoFoam (supercritical nitrogen foaming) and EcoMold (electric rapid heating & cooling mold), into an AI-controlled next-generation injection system.
The single control platform (based on WIM Vision + EverySim) collects and learns foam, mold temperature, pressure, cooling, and quality data every 0.5 seconds, with AI performing closed-loop optimization automatically.
Key Features
- AI Automatic Temperature & Pressure Control: Real-time analysis of 24-channel sensor data for automatic foam and mold process correction
- Self-learning Process Conditions: AI recommends optimal settings after learning over 100 cycles
- Predictive Maintenance: Early detection of sensor anomalies, heater imbalance, and temperature deviation
- One-Cycle Smart Injection: AI fully automates foaming, heating, rapid cooling, and quality control
- IoT-based Monitoring: Real-time data upload to cloud server and remote diagnostics
- Inline QA Auto Inspection: Predicts defects and controls the process in real time (5% → 2%)
- AI-PC Integrated Control: Manages entire process (foaming → cooling → inspection) from a single control PC
Process Steps
- Charging — High-pressure nitrogen injection and supercritical mixing
- Injection — Uniform bubble formation and injection filling
- Heating (EcoMold) — Rapid heating of mold surface up to 130°C
- Cooling (EcoMold) — Rapid cooling of surface down to 40°C
- Ejection & Inspection — Automatic ejection and AI quality analysis (AI uses each cycle’s data for the next cycle, completing optimization loop)
Performance Summary
| Item | Value | Effect |
|---|---|---|
| Foaming Rate | ≥ 40% | Twice the foaming efficiency compared to conventional methods |
| Strength Retention | ≥ 70% | Maintains structural strength even with weight reduction |
| Defect Rate | 5% → ≤ 2% | Improved process stability |
| Productivity | +60% | Reduced cycle time (120s → 50s) |
| Process Setup Time | 30 min → 5 min | AI self-learning applied |
| Temperature Uniformity | ±1.2°C | Minimizes quality variation during long-term continuous operation |
Technical Value
- AI-PC Closed-loop Control: Real-time correction of injection conditions, foaming pressure, and cooling rate
- Sensor Fusion Data Analysis: Integrates temperature, pressure, and vibration data
- IoT Smart Factory Integration: Automatic connection to MES, ERP, and cloud server
- Modular Upgrade Ready: Integrated operation of EcoFoam/EcoMold systems possible
Validation & Application Cases
- DMS (Detroit Manufacturing Systems): PoC for North American OEM integrated injection line
- Tensho Tenki (Japan): EcoMold mold + Eta integrated MOA agreement planned (July 2025)
- LG Electronics, Hanwha Q-Cells: AI control demonstration (temperature stability ±1°C)
- Hyundai/Kia / Gentex / Harman: Smart injection technology validation based on integrated system
ESG & Industrial Value
- CO₂ reduction: ≥55% / Energy efficiency: +30%
- Wastewater: 0 / VOC emissions: 0
- Production efficiency + ESG performance: Compliance with industry environmental regulations (LEED, ISO14001, REACH)
Commercialization Roadmap
- 2025: Completion of integrated prototype, setup of EcoFoam + EcoMold test line
- 2026: PoC and initial export, applied to DMS / Tensho Tenki, AI demonstration completed
- 2027: Supply to North American Tier-1 OEMs for automotive interior & electronic housings
- 2028 onward: AI-based Smart Factory standardization, launch of Eta Cloud Platform
Conclusion
Eta One-Cycle Solution is a fully integrated system of process, data, and quality. This technology shifts the injection molding industry paradigm from “human control” to “data control,” enabling intelligent manufacturing.