Expert Resources for Plastics Manufacturing Innovation

Why real-time control is replacing guesswork, one part at a time.  No two elastomers cure alike.  Elastomer parts can look identical to the naked eye, yet perform dramatically differently under stress, temperature, or time. That’s the reality many manufacturers face in elastomer component production: the unpredictable behavior of a class of materials known for their […]

JEC World 2025 Composites Exchange Discover how collaborative partnerships are revolutionizing composite manufacturing. This presentation ushers in a new era of process innovation, where shared expertise enables a smooth, predictable transition to automation—starting as early as material selection. By aligning the entire value chain, from material manufacturers to end-users, we can achieve smarter, more adaptable […]

Join sensXPERT at SAMPE conference 2025 to explore the latest innovations in plastics technology.

“This award confirms our mission to revolutionize the plastics industry with intelligent, sustainable process control,” explains Dr. Alexander Chaloupka, CEO of sensXPERT.

We operate in an industry where economic pressures, fierce competition, and ever-changing consumer demand challenge plastics manufacturers every day. Despite all this unpredictability, our industry is still expected to run cost-effective, high-quality, and efficient production processes.  Why Material Behavior Matters  From our perspective, the key to a cost-effective process lies in understanding the numbers. In […]

Explore with us how anomaly detection can drive quality, efficiency, and cost-effectiveness in plastics manufacturing.

Discuss how to achieve increased efficiency and quality control in fiber composite production through real-time data and artificial intelligence.

Join sensXPERT at SPE Thermoset TOPCON 2025 to explore the latest innovations in thermoset technology.

Explore contactless in-situ monitoring of hydrogen pressure vessel curing, improving process control and efficiency with real-time dielectric analysis.

Explore the latest advancements in thermoset technology, featuring expert insights, innovative applications, and industry networking opportunities.

Join us at IMCcon 2025 as we presents on real-time InMould Coating monitoring using advanced in-situ sensor technology.

Join us at our first exhibition in China and visit the NETZSCH booth in Hall 10 Booth A05 to learn more about sensXPERT’s cure monitoring technology.

sensXPERT unveils its latest innovation: contactless dielectric measurement technology at JEC World 2025.

Join us at PIAE and learn how we provide a holistic optimization of plastics manufacturing.

Be the first to see our new groundbreaking contactless, high-frequency, dielectric technology FlexCure and try it out for yourself in a chocolaty demonstration at the booth of our new collaboration partner: SAERTEX

Join us and learn how to optimize production through intelligent tool technology with inline senors and machine learning algorithms

Hear from Dominik Riescher how real-time process control for optimized composite manufacturing in the sports industry is possible.

Explore how dielectric sensors and AI-powered analytics help manufacturers overcome the challenges of recycled plastics, ensuring consistent quality and supporting sustainable production practices.

How can you overcome challenges when processing recycled plastics? Find out in our live webinar!

Watch our October 22, 2024 session as industry leaders discussed optimizing plastics production with real-time sensor data and AI.

How does a cutting-edge measurement technology evolve into a solution that drives real-time insights and transforms quality control and efficiency in composites manufacturing?

Explore how to overcome the top concerns in plastics process optimization and turn hesitation into innovation and efficiency.

How you can turn these common concerns into opportunities for growth and innovation in your plastics manufacturing processes.

Join us at KUTENO 2025 in Bad Salzuflen, Germany. The trade fair covers the entire value chain of the plastics processing industry. See the power of sensXPERT Insight for yourself.

Join us at the Thermoplastic Elastomer World Summit 2024 in Vienna, Austria!

Join us at the Automotive Supplier Summit in Wolfsburg!

Win “Free Material Characterization” on the occasion of CAMX Trade Fair in San Diego.

Explore how to tackle recurring challenges and embrace a future-ready approach to plastics manufacturing.

Breaking the mold – This is your invitation to discover plastic manufacturing opportunities that were once considered impossible. Introducing a technology that has the potential to cost-effectively and efficiently increase your production efficiency by 30%!

Join us in Frankfurt/Main, Germany at the Sustainable Plastics Summit and discuss the actions that must be taken to jointly improve the adverse impact of plastics on the environment and health.

In today’s fast-paced industrial environment, particularly within the plastics and composites manufacturing sectors, ensuring product quality and optimizing manufacturing processes are essential. Manufacturers in these fields face unique challenges, such as precisely controlling material properties and promptly responding to process variations. Advanced measurement techniques are crucial to maintaining competitive advantage and operational efficiency in such […]

Electric vehicles (EVs) have rapidly evolved from niche products to mainstream transportation options. The first modern, mass-produced electric cars emerged in the early 2000s, and since then, advancements in battery technology, infrastructure, and consumer acceptance have significantly accelerated their adoption. Governments worldwide are promoting EVs to reduce greenhouse gas emissions and dependence on fossil fuels, […]

Join us at the International Composites Summit in Milton Keynes and listen to our conference speech on September 5, 2024.

Join us at CAMX 2024 in September! The Composites and Advanced Materials Expo is the largest, most comprehensive composites and advanced materials event in North America.

Join us at Fakuma 2024, the premier international trade fair for plastics processing and manufacturing. See our new customer success stories and the advanced capabilities of sensXPERT Insight.

In its continuous pursuit of efficiency and performance, the aerospace industry has increasingly turned to plastic and composite materials. Plastics and composites offer significant advantages over traditional materials like metal. Advanced lightweight plastics and composites translate to improved fuel efficiency, while their design flexibility allows for innovative and aerodynamic shapes with reduced part count.   However, […]

The VDI Congress AUTOMATION is the leading automation congress in Germany. Join us from July 2 – 3, 2024 in Baden-Baden and be part of networking, discussions and the exchange of experience and ideas.

Visit us at booth 205C in hall G from May 7 – 10, 2024 at Automotive Hungary in Budapest. Learn how sensXPERT reshapes the landscape of monitoring and optimizing automotive part production with intelligent process control technology.

Germany’s largest injection molding conference in Wiesbaden on April 23-24, 2024, focuses on technology updates and networking. The VDI annual conference, “Injection Molding 2024,” serves as a key platform for insights into plastics processing trends and developments.

Visit us at booth S38182 from May 6 – 10 at NPE 2024 in Orlando, Florida. Discover how sensXPERT transforms the realm of monitoring and enhancing plastics part manufacturing processes for each component manufactured.

How to transform plastics manufacturing into an efficient, cost-effective process while addressing material deviations and more.

Discover how plastics manufacturers can optimize cycles, eliminate scrap, and ensure top quality with Digital Mold solution.

The automotive industry is in the midst of a transformative shift. One of the most significant markers of this shift is the swift rise of electric vehicles (EVs). The transition away from traditional internal combustion engines (ICE) is driven by several factors, among them being:  This shift necessitates a complete rethinking of car manufacturing. New […]

Recent years have seen many factors adding significant pressure on the economic viability of plastics manufacturing. Rising costs across the entire value chain threaten to compromise profit margins and hinder the industry’s ability to deliver cost-effective solutions to customers.  This article investigates the core economic factors driving cost pressures within plastics manufacturing.   One the […]

Discover how machine learning revolutionizes your production processes, delivering unmatched efficiency, precision, and sustainability, surpassing traditional approaches.

In 2023, Siemens released a report that presents ‘The True Cost of Downtime 2022’. According to the report, Fortune Global 500 companies are now losing a staggering 11% of their yearly turnover, or nearly $1.5 trillion, due to unplanned downtime. This figure paints a concerning picture for the plastics industry, where efficient production is paramount.  […]

sensXPERT’s Cornelia Beyer reveals how these technologies speed production, cut waste, boost quality, and ensure safety.

Watch this JEC 2024 conference talk to gain valuable industry insights and learn how to produce cost-efficient, high-quality products.

Meet sensXPERT Application Engineers Dr. Nicholas Ecke and Johannes Roth as they share their roles and insights.

To achieve consistent part quality – regardless of geographical location and seasonal conditions – processors everywhere are seeking out tools that increase stability to more reliably control plastics processes.   Given the number of materials and manufacturing processes currently used in this industry, many of the available tools designed to provide molders with more consistent […]

Enhancing aviation safety with real-time DEA analysis, advanced sensors, and machine learning for quality control and sustainability.

Plastics manufacturing holds immense potential for innovation and advancement across countless industries.   But what happens when the very heart of the production process, the in-mold material behavior, remains hidden behind a ‘black box’? Inconsistent quality, increased scrap rates, and higher energy consumption become costly obstacles, hindering efficiency and profitability.   While the desired outcome is a […]

A guide to material deviations in plastics manufacturing, their causes, defects, and how process control solutions combat them.

Learn more about the sensXPERT program during JEC World.

Plastics manufacturing thrives on efficiency; each step, from raw material production to final product processing, requires precise control. However, unwanted material loss, commonly referred to as scrap, is a significant challenge that burdens many manufacturers. Defects, inconsistencies, and unforeseen variations can create out-of-spec parts and disrupt production lines, impacting profitability and sustainability.   Beyond the immediate […]

The plastics industry stands as a formidable economic force, with the global market value reaching 712 billion USD in 2023.   This industry’s extensive applications in critical sectors such as automotive, aerospace, construction, packaging, and healthcare underscore its integral role in global economic growth and innovation. Among these achievements, the plastics industry is experiencing rapid […]

Thermoplastics are integral in various industries due to their versatility, recyclability, and adaptability. From the intricate components within automobiles to life-saving medical devices, thermoplastics are multifaceted polymers. Thermoplastics possess distinctive characteristics, notably the ability to melt and be molded when exposed to heat and revert to a solid state upon cooling.  This article outlines what […]

Visit us at booth T52 in hall 6 from March 5 – 7, 2024 in Paris. Learn how sensXPERT reshapes the landscape of monitoring and optimizing composites manufacturing procsses for every part produced.

Material characterization is an invaluable factor in plastics manufacturing, encompassing the consistent analysis and evaluation of the properties of polymer materials. Material characterization plays a large role in optimizing production processes, ensuring product quality, and meeting industry standards.  This article explores the significance of material characterization in the plastics manufacturing landscape, discusses the various techniques […]

As of 1 January 2024, plastics manufacturers face requirements of transparency, accountability, and sustainable practices as mandated by the CSRD.   This article will guide you through the Corporate Sustainability Reporting Directive and its implications for the plastics manufacturing industry. We will present the regulations and key provisions of the CSRD and explore how these changes […]

Elastomers are a class of polymers that have unique elastic properties. The term for this polymer stems from its ability to recover to its original form after extensive stretching; specifically stemming from ‘elastic polymer’. Elastomers are ideal for applications in which flexibility and resilience are necessary.   The key characteristics of elastomers include flexibility – […]

The two pursuits of economic efficiency and energy conservation are anchors in the plastics industry’s path towards a more sustainable, cost-effective future. Especially amongst a growing demand for streamlined processes and environmentally conscious production practices, plastics manufacturers find themselves divided by a desire to innovate and to carry out responsible production.   This article investigates […]

Polyurethane is an adaptable class of polymers that is used to combat difficulties or challenges in a myriad of industrial and consumer products. The material’s versatility allows it to insulate sensitive components, provide consumer comfort, and resist harsh environmental conditions. Polyurethane can also be molded into numerous sizes and shapes.   We outline what polyurethane […]

Next-Level Composites Manufacturing: A CosiMo Case  With an ever-increasing demand to implement sustainable practices in one’s daily life, such as opting for electric versus gas vehicles, there is also a growing demand for composites manufacturing. In the case of electric vehicles, for example, the car’s total weight influences its driving range. Therefore, engineers are compelled […]

At present, the plastics manufacturing industry faces numerous challenges. One such challenge relates to the changing conditions of production environments and along plastics manufacturing supply chains. Changing conditions, as of late, have been highly attributed to the increasing focus on sustainability and recently introduced legal regulations, such as the Corporate Sustainability Reporting Directive (CSRD) which […]

sensXPERT Digital Mold is a process control solution that empowers manufacturers to optimize and digitize their plastics manufacturing processes. Predictive machine learning models are central to this technology, as they determine the exact point at which processed materials will have reached a certain degree of cure or crystallization. Therefore, Digital Mold relies heavily on the […]

In-mold material data in real-time allows for a new generation of material data sheets based on varying and industrial production environments.

Learn how electronics encapsulation protects components, optimizes processes, and addresses manufacturing challenges.

As industries advance new bio-based, faster reacting and increased recycled content materials and faster processes, how can manufacturers quickly establish and maintain quality control?

Electronics encapsulation is a pivotal process in the safeguarding of electronic components to ensure their longevity, functionality and their protection from the environment. However, manufacturing encapsulated electronics components can come with a number of challenges, including material variability and electronic vulnerability. Furthermore, striking a balance between quality and cost, while simultaneously addressing location-to-location process inconsistencies, […]

Meet us at smart production solutions 2023 in Nuremberg, Germany. From November 14 – 16, you can experience our dynamic process control solution for the plastics industry live.

sensXPERT is headed to Mexico. Join us at Plastimagen 2023 and visit our booth 1431 to explore our process control technology

We are proud to announce that it has been selected as a finalist in the prestigious Awards for Composites Excellence (ACE) competition.

In our technology-driven world, there is an ever-increasing reliance on electronics; take smartphones and electric vehicles as examples. However, electronic components can be highly sensitive to various environmental factors, including but not limited to moisture, dust, corrosive chemicals, and physical stress.  Fortunately, a technique called encapsulation is applied to sensitive electronic components to shield them […]

In 2022, the estimated market size of the global aerospace plastics industry was $7.14 billion. On top of that, heightening demand for various aerospace structures manufactured out of composite materials is predicted to propel the continued growth of the industry. The increasing demand for the production of aerospace structures can be attributed to growing consumer […]

The aviation industry is ripe-full of advancements and transformation. Materials and processes have evolved ever since the development of the first powered flight by the Wright Brothers in 1915, which was built out of wires, canvas, wood, and steel. The 1920s and 1930s saw a material transition to metals such as aluminum. This was seen […]

Explore the impact of COVID-19 on aviation manufacturing, industry recovery strategies, and how automation optimizes processes.

Challenges, trends, and process optimization strategies in automotive manufacturing, including ZF’s innovative approach.

This article will navigate the various production-specific and industry-wide challenges faced by the automotive plastics manufacturing industry.

Put material knowledge at the heart of process enhancement: How to digitze automotive composite manufacturing

How does the EU taxonomy impact SMEs in the plastics industry? Read about the financial effects and new technologies for sustainable production.

We are an exhibitor at CAMX 2023 in Atlanta, Georgia. Meet us at booth T63 and experience sensXPERT Insight.

How beneficial is plastic in automotive manufacturing? Read on to learn about the latest automotive plastics manufacturing trends.

Exploiting energy savings and waste reduction potentials supports customers in reaching ESG goals and achieving more sustainable composite part production processes

The European Union has outlined its goals for a carbon-neutral society within the next 10 years, yet a major hurdle remains. The production of non-biodegradable materials is growing, and its industries are looking for more ways to tackle the ever-important objective: ‘net-zero’.    Plastics: A Growing Industry The first fully synthesized plastic polymer to pioneer global […]

Discover the Building Blocks of a Dynamic Process Control Solution with the sensXPERT solution.

Join us in Hall B5 Booth 5412 at Fakuma 2023, the premier international trade fair for plastics processing and manufacturing.

How the European Green Deal’s impact and strategies for sustainable, cost-effective plastics production under new taxonomy.

Unveil plastics innovation at Interplas 2023. Join us in Birmingham, Booth C92, for demos, insights, networking, and an exclusive speech.

See how sensXPERT’s process control solution aligns with the European Green Deal.

In the last two weeks, we introduced three components of our Equipment-as-a-Service sensXPERT Digital Mold solution. Specifically, we covered the sensXPERT material characterization sensors, Edge Device, and WebApp. To round out this series, we will take a closer look at the final element of Digital Mold – the sensXPERT Digital Cloud Service.    Developed in collaboration […]

If you have read up on our sensXPERT Digital Mold solution or tried out our illuminating AR Experience, then you might be aware of the vital role played by the sensXPERT Edge Device in collecting and transferring process data. You might have also learned about on the WebApp, an interface to the Edge Device which […]

Material characterization is invaluable in plastics manufacturing. Through the implementation of material characterization tests, manufacturers can ensure the quality, performance, and safety of their final products. There are numerous material characterization techniques and tests that can be conducted at different stages of production. This article will examine in-mold material characterization in specific. Additionally, we will […]

At Interplas 2023, explore how plastics production can be sensor-based, and dynamically controlled through an AR.

With more industries advancing with the rapid trend of digitization, thermosetting has become a key manufacturing focus for its ever-growing demand. The question stands: how can thermoset production be optimized to maintain supply and demand from some of the globe’s largest sectors? Thermoset Production in 2023 The world of manufacturing has changed dramatically over the […]

To be well-informed in plastics manufacturing environments, considerable understanding of the materials involved is paramount. Found in daily consumer products and components used in significant industries such as automotive, aviation, and electronics, plastic use is widespread. So, what makes plastic so versatile and functional? The answer can be found in the careful selection and application […]

In the efficiency-driven world of plastic part manufacturing, yielding products of the highest quality is integral to customer satisfaction, product reliability, and securing a competitive edge. Implementing quality control (QC) measures is one way for manufacturers to guarantee final part quality. However, there are several factors that might impede the ability to successfully conduct quality […]

Quality assurance is paramount in the plastics manufacturing industry. If a manufacturer’s plastic part production proved unreliable and substandard, customers would be left unsatisfied, manufacturers would not meet industry standards, and they would be unable to compete effectively in such a demanding industry.    To wrap up our series on ‘The Problem with Plastic,’ our final […]

Process stability is essential in plastic part manufacturing. By maintaining a stable process, challenges such as manufacturing defects are less likely to occur. However, it is not always easy to foresee deviations or issues that would otherwise require immediate process adaptation.   Last week we looked at various types of manufacturing defects and how to deal […]

Manufacturing defects, fluctuations in part quality, and the manufacturing ‘black box’ are a few pain points that plastic part producers face in their day to day. Not only do these challenges limit productivity, but they can also be costly and energy inefficient.   To help plastic manufacturers combat these difficulties, our new blog series ‘The Problem […]

Visit us in Hall B6 Booth 509 and discover how our groundbreaking technology boosts efficiency by 30%.

Now, in our final article on the sensXPERT way of AI, we would like to bring you along as we take a closer look at our technology and use of AI to address challenges in the plastics manufacturing industry.

Learn how an aerospace company validated the benefits of digitizing a well-established manufacturing process with sensor-based and data-driven technology

Rewatch our Composites Exchange presentation at JEC World 2023.

Managing Director Dr. Alexander Chaloupka received the Innovative Car Manufacturing Award at the ICM Summit 2023.

In a world of ever-growing technological advancements, data science, artificial intelligence (AI), and machine learning (ML) have become commonplace yet intermingled terms. In part two of our series on the sensXPERT way of AI, we will explore data science as a significant collaborator of AI and ML.   In part one of our series, we looked […]

The plastics industry is one of the many industries currently being transformed by artificial intelligence (AI). Inspired by human cognitive behavior, this revolutionary technology enables machines to perform tasks such as recognizing speech, images, and patterns. The potential applications of modern AI and machine learning (ML) are expansive. Still, in the plastics industry, their use […]

We have a lot to unpack. We have told you a lot so far, but now we want to share how sensXPERT technology really works. Hence, we are now on a mission: Demystifying sensXPERT. We’d like to get straight to the point by clearing up a misunderstanding. sensXPERT is our brand. Our company name is […]

sensXPERT Digital Mold enables the plastics industry to reach governmental and environmental sustainability goals.

Learn how to make plastics manufacturing more predictable with new technology

Learn how a global automotive supplier achieved up to 8% cycle time reduction in a short cycle process

sensXPERT invites visitors at Automatica 2023 to an AR Experience with its intelligent sensor technology.

Catch our keynote at the conference hosted by the Polymer Engineering Center in Madison on March 31, 2023

Visit us in Hall 6 – R32 and catch our composites exchange on Wednesday, April 26, 2023 in Agora 6

sensXPERT presents continuous process optimization in real-time at JEC World 2023.

Learn how sensXPERT Digital Mold increases your business’ economic efficiency.

Get introduced to market and process dynamics of the plastics industry that requires the adoption of smart manufacturing solutions as well as a collaborative mindset

Rewatch our global launch event, and discover manufacturing opportunities that were once considered impossible, but can now be implemented cost-effectively and efficiently

AVK honours the data-driven production solution for the plastics industry: sensXPERT Insight.

Watch how ZF Friedrichshafen tackled manufacturing challenges in reactive resin production using sensXPERT technology.

Transforming molds to become direct production communicators in various industries to solve plastics manufacturing challenges

Transforming domain knowledge into business value through real-time process optimization

Political demands for more sustainable manufacturing processes are a major challenge. In addition to the associated risks, there are great opportunities for companies that are open to these changes.In the world of thermosets, process optimization is key to meeting these challenges. In this article, you will learn how you as a thermoset processor, but also […]

Usage of AI and smart machines for in-situ polymerization of lightweight fiber-reinforced polyamide 6 parts

Explore a real-time in-mold monitoring system delivering key data to optimize control, boost productivity, and compete globally.

Continuous process optimization driven by real-time sensor-based machine, mold and material data.

In order to produce quality thermoset parts quickly and consistently, processors need real-time access to four pieces of data at any given point in each molding cycle: These four important sets of material characterization data are available in real time from sensXPERT’s in-mold dielectric monitoring system. Gel Point Knowing how close you are to the […]

The plastics industry has seen significant changes in the last years – both at the macro and micro level. We have closely looked at current industry trends in two webinars and shed light on the challenges of processing thermosetting materials. Utilizing the multi-faceted opportunities that digitization and collaboration have to offer allows the transformation of […]

Excerpt Polymer processing with thermosets is the key to high-performance parts regarding mechanical strength and durability. However, the material causes many challenges in production. In a customer-centric approach, the new sensXPERT solution provides a state-of-the-art solution to tackle lacking transparency and high scrap rates. sensXPERT delivers a unique solution for processors in the polymer and […]