Yaskawa enables fully automated multi-stage injection moulding for radome production

Automotive manufacturing, plastics processing, and industrial automation increasingly require highly integrated production systems to meet strict quality and throughput demands for safety-critical components. In this context, Yaskawa six-axis robots are deployed in a complex, fully automated injection moulding line for radome production at Weißer + Grießhaber, with system integration by EGS Automation GmbH.

The production system manufactures approximately 1.4 million radomes annually across two interconnected lines. These components protect radar sensors used in advanced driver assistance systems (ADAS) in premium vehicles, requiring consistent dimensional accuracy, electrical functionality and complete traceability.

The manufacturing concept is based on a highly integrated 2K injection moulding process combining multiple upstream and downstream operations within a compact footprint, supported by synchronized robotics and in-line quality assurance.

Simultaneous engineering for complex system integration
The production line was developed using a simultaneous engineering approach, where automation planning and system design progressed in parallel with product development. This enabled early definition of flexible process modules despite incomplete initial data, reducing time-to-production.

Automation cells and process stations were designed with adaptability in mind, allowing replacement or modification of components without disrupting the overall system. This approach was critical in meeting tight project timelines while maintaining system scalability.




Two-stage injection moulding with integrated preprocessing
The manufacturing process begins in the first injection moulding cell, where plastic base units with integrated contact pins are produced. This stage includes:

Following inspection, parts are placed into trays and stacked automatically before being transferred to the second production cell.




Functional integration: winding, welding and overmoulding
In the second cell, the process complexity increases significantly. Each base unit is first wrapped with a fine copper wire, which will later serve as a heating element within the radome. This step is performed by a dedicated winding system that also:

A SCARA robot manages handling within this station. The prepared component is then transferred to a two-stage overmoulding process using an all-electric 2K injection moulding machine, forming the final radome structure.




Six-axis robotics for coordinated material flow
The interconnection of all stations is managed by five six-axis robots from Yaskawa’s GP series:

All robots are equipped with vacuum grippers to ensure controlled handling of sensitive components. Their high precision and dynamic response are essential for maintaining cycle times and consistent positioning across multiple process stages.

A central transfer station with buffering capacity allows temporary storage of components, enabling continued operation during upstream disruptions. This ensures thermal stability within the injection moulding process and reduces the risk of production interruptions.




Multi-stage inspection and micrometre-level quality control
Quality assurance is fully integrated into the production line through multiple inspection stages:

Following inspection, each component is laser-marked with a data matrix code containing detailed production and quality data. This enables full traceability and documentation for every radome produced.




Data-driven monitoring and AI-based optimization
All process and quality data are captured through a data acquisition system and visualized in real time. This allows operators to monitor production conditions continuously, detect deviations and implement corrective actions immediately.

To further reduce defect rates, the system is being extended with artificial intelligence capabilities. By analysing historical and real-time production data, future implementations aim to enable predictive adjustments and self-optimizing process control.

High-volume production with integrated automation
The production system combines six robots, multiple inspection stations, advanced material handling and manufacturing IT within a compact layout. This high level of integration enables continuous 24/7 operation while maintaining strict quality requirements for safety-relevant automotive components.

By integrating multi-stage processing, robotics and data-driven quality control, the system demonstrates how advanced injection moulding lines can achieve both high production volumes and precise functional performance in complex applications.

Edited by Natania Lyngdoh, Induportals Editor — Adapted by AI.

www.yaskawa.eu.com