Kistler presents new software features for quality assurance in medical injection molding
Winterthur, April 2026 – Building on user feedback from the medical device manufacturing sector, Kistler is placing even greater emphasis on usability and standardization options with its new software versions for quality assurance in injection molding. The ComoNeo 9.0 process monitoring software makes it possible for the first time to standardize process templates across multiple locations. At the same time, AkvisIO 9.0, the process and production management software platform from Kistler, receives an update to provide an even faster overview of key production data, simplifying data-driven troubleshooting in day-to-day manufacturing. The ComoNeo hardware also features a significantly more powerful processor that better supports AI applications such as ComoNeoPREDICT as well as analysis functions for multi-cavity injection molding.
Centralized production data management for easy troubleshooting
The first immediately visible new feature in AkvisIO 9.0 is a customizable dashboard on the platform’s Home screen. It provides production and quality managers with an instant overview of all connected ComoNeo process monitoring systems. Color-coding allows users to understand machine utilization, production quality, and current scrap rates at a glance. If an injection molding machine exceeds the defined quality limits, the platform automatically triggers an alarm. Users can then switch directly to the production history and select time windows by shift change or production batch, which helps them to quickly identify the cause of error.
“It was important to us not only to provide injection molding companies with greater clarity, but also to give them more flexibility to customize the dashboard to their own needs and to simplify its use. Anyone who spots an anomaly can now dive right into root cause analysis with a single click – making the dashboard a direct gateway to troubleshooting. This makes troubleshooting in real-world production significantly easier and faster,” reports Martial Willimann, Product Manager for Medical Products & Data Solutions and responsible for AkvisIO at Kistler.
Multi-cavity injection molding: visualization as the key to rapid process optimization
There have also been significant changes to the visualization features, which are crucial for usability. AkvisIO 9.0 now allows users to overlay multiple production trends during multi-cavity injection molding and quickly draw conclusions about individual cavities using color coding. Pre-configured trend presets based on key process values enable quick results and can be adapted to the relevant parameters at any time. To compare the process control of different machines using the same mold, the production data management software AkvisIO offers an additional visualization option specifically tailored to this use case.
AkvisIO 9.0 guides users through the visualization options more effectively. There are two different approaches: while the system offers process engineers a visualization path optimized for troubleshooting, quality management staff have access to a workflow tailored to OEM reporting and traceability – a decisive advantage for quality assurance in the injection molding of medical devices. Users can easily zoom into graphics or switch back and forth between part and cycle views.
“All views are linked, making it easy to understand relationships across the system. For example, if a particular error keeps recurring after a certain number of cycles, I can easily identify it and, with just a few clicks, track what is happening in the process at that point,” says Martial Willimann, summarizing the benefits of the new user interface.
ComoNeo 9.0 process monitoring software focuses on usability
To better support users operating across multiple locations in their standardization efforts, the ComoNeo software now allows templates for trends and evaluation objects (EOs) to be created centrally and individually. These templates can then be used across locations and production lines on different ComoNeo process monitoring systems to ensure complete traceability. The new balance view immediately highlights relative differences between individual cavities. This makes even minimal deviations in the process immediately apparent. ComoNeoMULTIFLOW continues to support the automated control and balancing of individual cavities in multi-cavity injection molding.
On the new, customizable dashboards, users can now choose which parameters they want to see at a glance. In the trend-table view, actual deviation values, target values, and EO limits for all cavities are clearly displayed on a single page. Here, too, the view – including the reference values – can be saved so that the entire team has the same points of reference for evaluation.
For the first time, firmware management for all ComoNeo process monitoring systems is handled via AkvisIO 9.0. Users plan updates centrally, select specific devices or all devices, and start the process with just a few clicks. The platform automatically waits until ComoNeo is no longer in production mode and performs the update without disrupting ongoing production.
New CPU boosts computing power for AI-driven quality assurance
Alongside the new ComoNeo 9.0 process monitoring software, Kistler is introducing more powerful system hardware. This hardware delivers higher performance for current and future AI applications and is equally suited for multi-cavity setups commonly used in medical device manufacturing. A faster processor (CPU) ensures that users can view pressure curves from multiple cavities smoothly, even when other processes are running in the background. Users who need additional load inputs can also flexibly expand ComoNeo with a new extension kit. The new hardware is being launched alongside the new software versions but is not strictly necessary for their use.
