Undercut Injection Mould Tools

12.6.2 Straight Action Form Pins

Figure 12.15 Straight action form pin

This type of pin is constrained to move parallel to the main tool axis only. No angled
movement relative to the tool axis takes place. Figures 12.15 and 12.16 show the usual
design for this type of action form pin.

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Mould Design Guide

Figure 12.16 Form pin

12.6.3 Key Design Features

x Used for localised internal undercuts only.
x Lift split must locate on a taper.
x Main core A and lift split B must be hardened.
x The forward movement of the lift split should normally be sufficient to allow the
moulding to be clear of the core (distance S).
x Unless the part will fall freely from the tool, a secondary-stage ejection will be
necessary to ensure complete ejection from the tool.
x Air ejection is often used for secondary ejection purposes.

Note: In the example shown, the moulding is very likely to rest on ejector pin C after
ejection takes place. The other possibility is that it remains firmly stuck in the undercut in
the form pin, refusing to fall free.

It is bad design practice to assume the moulding will fall free in such circumstances. In
any design, the designer must never design on the basis of such assumptions.

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 Undercut Injection Mould Tools
There are three options available prevent the moulding sticking in the undercut:
x Two-stage ejection as described in Chapter 10 and shown as pin D in Figure 12.15
x An air blast at the end of the normal ejection stroke
x Removal by robot

Two-stage or secondary ejection would guarantee that the part is positively ejected from
the form pin. This is the more expensive option but the most positive.

The air blast option is by far the cheaper option but cannot be guaranteed. This option
may entail several tweaks (including design changes) and possibly more polishing on the
undercut before it works.

The robot option will also guarantee effective removal from the form pin but again this
can be expensive and is usually restricted to high-volume production.

Whatever option is chosen the designer must be certain that the moulding will be freed
from the mould and not assume that the moulding will fall free from the lift split
without assistance.

12.6.4 Angled Form Pins

Figure 12.17 Incorrect undercut design

With a straight action form pin, there is always the danger that the moulding may not
free itself from the form pin when ejection takes place. To recapitulate, there are two
conditions in which satisfactory ejection may not take place with a straight action form
pin, as previously discussed:
x Moulding left hanging on to form pin undercut and refusing to fall free
x Moulding left hanging on ejector pin

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