Smart Mold Unveils AI-Based “Aria” System at SMAU Milano 2026 to Transform Injection Moulding Processes
Smart Mold Unveils AI-Based “Aria” System at SMAU Milano 2026 to Transform Injection Moulding Processes
The artificial intelligence-powered software combines computer vision and intelligent defect analysis to optimise injection moulding parameters, potentially reducing setup trials by 88% and scrap rates by 94% while improving production efficiency and quality consistency.
MILAN, Italy | November 2, 2026 – Smart Mold, an Italian technology company specialising in plastic injection moulding process optimisation and part of the Sirmax Group, is presenting its latest artificial intelligence innovation, “Aria,” at SMAU Milano 2026, taking place on November 3–4 at Allianz MiCo in Milan. The AI-based assistance system is designed to help injection moulding manufacturers optimise production parameters, accelerate process adjustments and improve the consistency and repeatability of manufacturing operations.
Exhibited at Stand D20, Aria combines computer vision and artificial intelligence (AI) algorithms to analyse moulded component quality, identify defects and recommend corrective actions. By translating quality inspection data into practical process recommendations, the software aims to reduce the time and resources required to establish optimal injection moulding conditions.
The introduction of Aria addresses a persistent challenge in plastics manufacturing: maintaining stable production conditions when machines, moulds, materials or operating parameters change. In conventional injection moulding operations, adjustments following a mould change, machine stoppage, material variation or the appearance of defects frequently depend on the experience and judgement of individual machine operators.
Although operator expertise remains important, inconsistent adjustments can result in extended setup periods, rejected components, unnecessary machine downtime and increased energy consumption. These challenges can become particularly significant in manufacturing environments where production schedules are demanding and experienced process specialists are increasingly difficult to recruit.
Smart Mold‘s Aria system seeks to address these issues by introducing an intelligent, data-driven approach to process optimisation. Rather than relying exclusively on manual inspection and operator experience, the software analyses component defects and provides guided recommendations to help operators return the injection moulding process to the desired quality conditions more efficiently.
AI and Computer Vision Enable Intelligent Process Optimisation
At the centre of Aria is an integrated quality monitoring and decision-support system that measures component quality, identifies visible defects and evaluates their severity throughout the process adjustment stage.
Using industrial computer vision and AI algorithms, the software continuously analyses moulded parts to determine whether production quality is improving, deteriorating or requiring further intervention. Based on this assessment, it recommends corrective actions intended to help operators identify the most effective adjustments to injection moulding parameters.
This approach extends the role of automated inspection beyond simply determining whether a component meets predefined quality requirements. By connecting defect detection with process recommendations, Aria provides operators with information that can support faster and more informed manufacturing decisions.
The system is particularly relevant during mould trials, production restarts and process fine-tuning, when manufacturers may need to make multiple adjustments before achieving consistent component quality.
Another important capability is its potential to preserve and share process knowledge. Experience accumulated during mould testing and production optimisation can be transformed into a structured knowledge base, allowing manufacturers to retain valuable technical information and make it accessible to other operators.
This can help reduce dependence on individual expertise, improve consistency between production shifts and make advanced process knowledge more accessible to less experienced personnel.
Significant Reductions in Setup Trials and Production Scrap
Smart Mold reports that Aria has already undergone successful industrial testing, delivering measurable improvements in the number of trials required to achieve the desired component quality and the quantity of rejected parts during process restart.
According to the company, the average number of trials needed to reach the required quality level decreased from 25 to just three. Similarly, the number of rejected components fell from 128 to eight.
These results represent:
- 88% reduction in setup trials: Fewer adjustments are required to establish the desired production conditions.
- 94% reduction in rejected parts: Scrap generated during process restart can be significantly reduced.
- Faster return to quality: Intelligent defect analysis helps operators identify appropriate corrective actions more quickly.
- Improved production continuity: Reduced setup requirements can help minimise unproductive machine time.
- Better resource utilisation: Lower scrap generation and shorter adjustment periods can contribute to more efficient use of materials and manufacturing resources.
The reported improvements highlight the potential of AI-assisted process optimisation to address some of the operational inefficiencies associated with injection moulding.
Reducing setup trials is particularly important because every additional adjustment can extend machine occupation without generating saleable components. During these periods, manufacturers may consume additional raw materials and energy while delaying the start of stable production.
By accelerating the process of reaching the desired quality level, technologies such as Aria can help manufacturers improve equipment utilisation and reduce avoidable production losses.
Designed for Integration with Existing Injection Moulding Machines
A key feature of Aria is its compatibility with different generations of injection moulding equipment. The system can be integrated with existing machines, including older models and equipment that does not have network connectivity.
This flexibility is significant for manufacturers operating mixed production environments, where replacing older machinery or implementing extensive digital infrastructure may involve considerable investment.
Where digital communication interfaces are unavailable, Aria can retrieve relevant information directly from the machine’s monitor. This allows the system to support process optimisation without requiring every machine to have advanced connectivity capabilities.
Its installation involves a dedicated vision system comprising industrial cameras, controlled lighting and a local processing unit. The configuration is designed to operate without requiring modifications to the injection moulding press itself.
By avoiding extensive changes to existing machinery, Smart Mold aims to make AI-based process assistance more accessible to manufacturers seeking to introduce digital technologies into their production facilities.
The ability to work with both connected and non-connected machines also offers potential advantages for companies gradually advancing their digitalisation strategies.
Supporting the Digital Transformation of Plastics Manufacturing
The introduction of Aria reflects the growing role of artificial intelligence, machine vision and data-driven decision-making in plastics processing.
Injection moulding manufacturers face increasing pressure to improve productivity, maintain consistent quality and reduce material waste while managing operational costs. At the same time, the industry is experiencing a gradual shift towards smarter manufacturing systems capable of monitoring production conditions and supporting more accurate process control.
Traditional injection moulding optimisation often involves repeated parameter adjustments based on operator observations and established manufacturing experience. While this approach remains widely used, it can create variations in production outcomes, particularly when different operators handle the same mould or machine.
AI-assisted technologies offer an alternative by analysing production outcomes systematically and translating inspection information into actionable recommendations.
In this context, Aria is designed to connect component quality assessment with process improvement. Its ability to identify defects, evaluate their severity and support corrective actions could help manufacturers establish more consistent production practices.
Furthermore, preserving knowledge generated during mould trials and process adjustments can support continuous improvement across manufacturing operations.
As manufacturers increasingly explore smart factory technologies, solutions that can be integrated into existing production infrastructure without requiring extensive equipment replacement may become particularly relevant.
Giovanni Lucchetta Highlights the Importance of Accessible Process Intelligence
Commenting on the development, Giovanni Lucchetta, Founder and CEO of Smart Mold, highlighted the importance of making specialised manufacturing knowledge more accessible to injection moulding companies.
“In an industrial context where specialized skills are becoming increasingly hard to find, ‘Aria’ helps companies standardize the process, reduce reliance on individual expertise and make quality management more accessible. The aim is to bring process intelligence directly to the press, making molding more efficient, stable and repeatable. We are proud to have achieved this result, the outcome of years of research and experimentation, and to now be able to offer our customers such a high level of innovation,” said Lucchetta.
The company’s approach reflects a broader industry requirement to combine experienced engineering knowledge with digital technologies capable of supporting everyday production decisions.
By bringing AI-based assistance closer to the injection moulding machine, Smart Mold aims to help manufacturers make process optimisation more systematic and less dependent on individual operator experience.
Smart Mold: Combining Materials Engineering and Manufacturing Innovation
Founded as a spin-off of the University of Padua, Smart Mold is part of the Sirmax Group, an Italian multinational headquartered in Cittadella, Padua. Sirmax is among Europe’s established manufacturers of thermoplastic compounds, supplying materials for a broad range of industrial applications.
Smart Mold operates across two principal business areas, both focused on improving the efficiency and performance of plastics manufacturing.
The first area involves facilitating the processing of recycled plastics through advanced mould surface technologies. The company has developed and patented a nanostructured surface coating for plastic injection moulds, designed to reduce injection pressure by up to 25%.
The technology is intended to improve mould filling, particularly when processing materials containing high concentrations of post-consumer recycled plastics. By facilitating material flow during injection, the coating can help address certain processing challenges associated with recycled polymer formulations.
The company’s second business area focuses on reducing plastic consumption in manufactured products while enabling the use of higher-value-added raw materials.
Smart Mold supports manufacturers from the product engineering and design stages, analysing application requirements and mechanical performance characteristics. Using advanced simulation software, the company evaluates mechanical behaviour and develops design solutions aimed at reducing component weight and overall plastic consumption.
Together, these activities demonstrate Smart Mold‘s broader focus on improving plastics manufacturing through material engineering, mould technology, process optimisation and product design.
SMAU Milano 2026: Showcasing AI Innovation for the Plastics Industry
The presentation of Aria at SMAU Milano 2026 provides Smart Mold with an opportunity to introduce its technology to businesses, industrial decision-makers and technology professionals interested in manufacturing innovation.
The event will take place on November 3–4, 2026, at Allianz MiCo in Milan, with Smart Mold exhibiting at Stand D20.
Through the demonstration of Aria, the company aims to highlight how artificial intelligence and computer vision can be applied to practical manufacturing challenges, particularly in injection moulding process setup, defect identification and production quality management.
As the plastics processing industry continues to pursue greater automation, operational efficiency and manufacturing consistency, AI-based assistance systems could become an important part of the industry’s digital transformation.
With Aria, Smart Mold is seeking to bring these capabilities directly into the injection moulding environment, helping manufacturers reduce setup complexity, limit material losses and establish more repeatable production processes.