Product Descriptions
General Overview - Industrial Positioning of the BOY 100 E Platform
The BOY 100 E is Dr. BOY's injection molding machine with a clamping force of 1000 kN and represents one of the company's most powerful and versatile solutions in the medium-to-high tonnage segment. Developed under the philosophy of "some more of everything," this model is designed for applications requiring larger molds, higher shot volumes, and wider process windows.
The BOY 100 E is a multi-disciplinary production platform suitable for processing thermoplastics, elastomers, silicones including LSR, thermosets (duromers), as well as metal and ceramic injection molding feedstocks used in PIM technology. Despite this broad capability, it maintains a highly compact footprint of approximately 4.0 m².
Clamping Unit - 1000 kN Four Tie-Bar, Two-Platen Cantilever System
The BOY 100 E features a four tie-bar, two-platen clamping system with a cantilever design. This structure combines high clamping force with excellent accessibility to the mold area.
Clamping unit technical data:
- Clamping force: 1000 kN
- Tie-bar spacing (H × V): 430 × 360 mm
- Maximum daylight between platens: 725 mm
- Maximum adjustable mold opening stroke: 475 mm
- Minimum mold height: 250 mm
- Maximum mold weight on moving platen: 500 kg
- Mold opening force: 70 kN
- Mold closing force: 51.1 kN
- Maximum ejector stroke: 130 mm (optional 150 mm)
- Ejector forward / return force: 20.4 / 13.5 kN (optional 42.7 / 30 kN)
Thanks to the cantilever design, robots, pick-and-place units, unscrewing devices, core pulls, and cellular automation systems can be integrated with ease.
Injection Units - SP 220 and SP 400 Thermoplastic Units
The BOY 100 E is available with two primary thermoplastic injection unit options: SP 220 and SP 400. These units support large and technical parts through high injection force and a wide range of screw diameters.
SP 220 injection unit technical data:
- Screw diameter: 36 mm
- Screw L/D ratio: 23
- Maximum theoretical stroke volume: 162.8 cm³
- Maximum theoretical shot weight (PS): 158.3 g
- Injection force: 137 kN
- Theoretical injection rate: 266.0 g/s
- Maximum specific injection pressure: 1,348 bar
SP 400 injection unit technical data:
- Screw diameters: 36 / 42 / 48 mm
- Screw L/D ratios: 23 / 20 / 17
- Maximum theoretical stroke volume: 162.8 / 221.6 / 289.5 cm³
- Maximum theoretical shot weight (PS): 158.3 / 215.9 / 280.6 g
- Injection force: 249 kN
- Theoretical injection rate: 146.4 - 260.0 g/s
- Maximum specific injection pressure: 2,450 - 1,378 bar
Common injection unit data:
- Maximum screw stroke: 160 mm
- Nozzle contact force: 65 kN
- Nozzle retraction stroke: 243 mm
- Screw torque: 500 / 530 Nm
- Screw speed: 250 - 280 rpm, continuously adjustable
- Screw recovery force: 53 kN
- Heating power (nozzle + barrel): 11,250 W
- Material hopper capacity: 20 liters
These parameters ensure a stable and reliable process for high filling speeds and large part geometries.
Servo-Hydraulic System and Energy Management
The BOY 100 E operates with a servo-motor-driven hydraulic pump system. Hydraulic power is generated only when required by the process. Dr. BOY's patented pressure intensifier system maintains clamping force during injection and cooling phases without the need for an additional pressure-holding pump.
Energy and hydraulic system data:
- Installed drive power: 15 kW
- Total installed power: 26.3 kW at 400 V
- Hydraulic system pressure: 195 bar
- Oil tank capacity: 200 liters
- EUROMAP 6 dry cycle time: 2.1 s at 301 mm stroke
This configuration provides high energy efficiency and very quiet operation within the 1000 kN class.
EconPlast Technology - High Wear Resistance and Extended Service Life
The BOY 100 E can be optionally equipped with the EconPlast plasticizing unit. This technology extends screw and barrel service life while reducing energy consumption, particularly when processing glass-fiber-reinforced and abrasive materials.
Key benefits of EconPlast technology:
- More homogeneous melt structure
- Reduced energy consumption
- Lower material degradation
- Extended maintenance intervals
Control System - Procan ALPHA
The BOY 100 E operates with Dr. BOY's advanced Procan ALPHA control system.
Control system capabilities:
- 8-stage injection speed control
- 2-stage injection pressure control
- 8-stage holding pressure control
- Holding pressure switchover based on pressure, stroke, or time
- Closed-loop injection and back-pressure control
- Production monitoring, part and cycle counting
- USB, Ethernet, and OPC interfaces
- EUROMAP 67 robot interface
Machine Dimensions and Layout Advantages
Compared to competing machines, the BOY 100 E offers a very compact installation footprint.
Physical dimensions:
- Dimensions (L × W × H): 3,401 × 1,177 × 2,117 mm
- Footprint: 4.0 m²
- Net weight (without oil): 2,865 kg
- Gross weight: 2,985 - 3,365 kg
Application Fields and Material Compatibility
The BOY 100 E is widely used in the following applications:
- Large and technical plastic parts
- Electrical and electronic housings
- Automotive and industrial components
- Elastomer and LSR applications
- Thermoset and PIM processes
- High-volume production requiring large shot sizes
Conclusion - Why Choose the Dr. BOY 100 E?
The Dr. BOY 100 E injection molding machine delivers a top-segment production platform with its 1000 kN clamping force, large mold space, high injection capacity, and servo-hydraulic energy management. The cantilever clamping design, EconPlast technology, and advanced control architecture ensure stable, repeatable, and economical production even with large molds.
For applications where high tonnage, broad process flexibility, and long-term production reliability are critical, the BOY 100 E represents a powerful and dependable injection molding solution.
