SONDERHOFF 3E FLEX with
DM 50x Technology

The SONDERHOFF 3E FLEX can be flexibly configured according to your different manufacturing needs. You can choose whether you want to use the 3E FLEX to process and dispense polyurethane- or silicone-based 2K material systems with asymmetrical or symmetrical mixing ratios. All system components are installed on one chassis, which considerably simplifies transport and commissioning: set up, connect, and produce – place, plug & work!

The dynamic high-performance mixing heads MK 800 PLUS or MK 825 PLUS available for the 3E FLEX are guided by the linear robot of the dosing cell in a maximum traversing range of 2,500 x 1,250 x 300 mm (x/y/z). The 2K material system used is mixed dynamically and homogeneously in the mixing head and precisely dispensed in the defined mixing ratio – a prerequisite for high quality.

If desired, the optionally available hand scanner can be used to select the dispensing and CNC program for the part to be processed. The CNC-controlled mixing head then ensures repeat-accurate and fully automatic Formed-In-Place (FIP) material application to the part.

The machine operator is separated from the working area by an automatic high-speed door which makes the dosing cell CE-compliant.

The material pressure tanks on the chassis of the dosing cell are available in two sizes and can be flexibly combined, either both tanks with 24 or 44 liters each or as a combination with 24 and 44 liters. For a continuous material supply, automatic refilling stations for drums or containers are optionally available.

The parts are positioned either manually in the work area of the dosing cell or on the optionally available sliding/shuttle table. For oversized parts, the two sliding tables can be connected to form a large worktable.

Another advantage for more flexibility is the variable table height in the dosing cell, allowing part heights from 300 to 600 mm. The standard work/table height is 1,000 mm and can be reduced to 700 mm, for example, to integrate manufacturing automation. If required, a transfer belt running through the cell can be installed for clocking in and out the parts.

3E FLEX Dosing Cell at a Glance

Configurable Mixing and Dosing Machine in Cellular Design for the Processing and Dispensing of 2K Polyurethane or Silicone Systems

The Compact Class for 2K Polyurethane or Silicone Applications

Operation of the 3E FLEX Dosing Machine

The machine operator places one or more parts in the work area of the dosing cell on the prepared workpiece fixtures. He then closes the high-speed door by pressing a button so that the fully automatic material application can start. For this purpose, the CNC-controlled MK 800 PLUS or MK 825 PLUS precision mixing head moves over the part contour to apply the material.

3-Axis Linear Robot

The linear robot with toothed belt drive features good stiffness and acceleration values for repeatable guidance of the mixing head over the part being processed.

Maximum Traversing Range and Part Size 

The MK 800/825 PLUS is precisely guided by an integrated 3-axis linear robot in the traversing range of 2,500 x 1,250 x 300 mm (x/y/z).

MK 800 and 825 PLUS

2-Component Mixing Head with Dynamic Mixing and High-pressure Water Rinsing

In the SONDERHOFF 3E FLEX dosing cell, the MK 800/825 PLUS precision mixing head is used for processing a 2K material system. In the mixing head, the material components are mixed dynamically and homogeneously and dosed onto the part in precise quantities.

Dosing Machine Components and Material Pressure Tanks

In the SONDERHOFF 3E FLEX dosing cell, the dosing machine components are attached to the left side of the cell, for example: the precision gear pumps, the compressed air connection and dryer, the maintenance unit as well as the optional Peltier device for mixing head cooling and the high-pressure water unit for ecological mixing head rinsing.

The double-walled material pressure tanks in the optimized sizes are also mounted on the cell chassis on the left side, either for the asymmetrical mixing ratios of the A and B components of the 2K polyurethane systems or for the symmetrical mixing ratios of the 2K silicone systems. The material pressure tanks of the 3E FLEX can be flexibly configured as required, either for both material components 24 or 44 liters or in combination for one component 24 and the other 44 liters.

For heating or cooling the material in the pressure tank, we offer an optional precision temperature control unit, which can be used to influence the reactivity behavior of the 2K material systems.

The material pressure tanks are equipped with various sensors that indicate whether the pressure tank needs to be refilled or is completely empty. For the material pressure tanks, an optional extension with an automatic refilling station for continuous material supply is possible on request. For this case, there is an overfill protection on the pressure tanks. 

At a Glance:

3E FLEX for 2K Silicone Systems

3E FLEX for 2K PUR Systems

Air Loading, Temperature Control and Material Evacuation

Air Loading in the Thin Film Process

Material Evacuation in the Thin Film Process

Automation and Configuration of the 3E FLEX Dosing Cell

Another advantage for more flexibility is the variable work/table height in the dosing cell, allowing part heights from 300 to 600 mm. The work/table height is 1,000 mm as standard and can be reduced to 700 mm, for example, to integrate production automation.

For this purpose, the cover plate on the front and rear of the dosing cell can be removed so that, if required, a transfer belt running through the cell can be installed for clocking in and out the parts.

Further Components of the 3E FLEX Dosing Cell