Mold design series

1_Injection Mold Fundamentals

Introduction

Injection Mold Fundamentals is the first program in our mold design and mold making Series.

These courses provide participants with a working knowledge of the

 Injection mold design process,

 Mold construction
 And many of the new technologies available to today's injection mold designer.

This Series is intended for engineers, mold designers, mold makers or anyone involved in the tool
procurement process.

This Series assumes that participants have a good understanding of the injection molding process
and are familiar with molding machine components.

We strongly recommend that you review our injection molding basics Series before participating in
these courses.

Injection Mold Fundamentals provides an overview of important considerations for the injection,
mold design and mold building process.

Course Objectives:

By the end of this program,

 Participants should have a better understanding of the design and function of an injection
mold.
 Participants will be introduced to some basic part design and mold design concepts.
 Finally, we will cover preliminary considerations such as production requirements and
machine specifications that influence injection mold design.

Definition

Mold design introduction

Designing an injection mold is a creative and complex process.

Mold designers must be familiar with

 The machines in which they run Tool steels,

 The thermal dynamics
 And filling analysis.

They must also be aware of the entire manufacturing process and they must know how to interpret
a part drawing and a part design.

Injection mold definition

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 An injection mold is a high precision tool, designed and built to produce plastic parts in an
efficient and repeatable manner.
 In this program, as on the job, you may notice components referred to by different names.
Don't be confused by this terminology. In the plastics industry the term mold, tool and die
are all used interchangeably and have essentially the same meaning.
 The performance of an injection mold begins with a proper injection mold design.
 The mold designer should be involved in the parts design process to help eliminate potential
problems that may occur during mold design, construction and processing.
 An injection mold performs four basic functions.
o Material transfer (It must 1st provide a conduit for the polymer to flow from the
machine into the mold cavity)
o Part forming (2nd - Form the polymer)
o Part cooling (3rd - Cool the polymer)
o Part ejection (And 4th - Eject the part)

Injection mold functions

Material transfer

The first function of an injection mold is to transfer the polymer from the injection molding machine
nozzle to the mold cavity. This could be done by using one of three methods.

 The first and most common method is to use a cold runner system to transfer the polymer
to the mold cavity. The polymer flows through the screw runner gate and finally to the mold
cavity.
 The second method employees Ah hot runner system, hot tip or heated screw bushing to
transfer the polymer to the mold cavity. The system retains the heated polymer inside the
runner system, using heated or insulated channels.
 The third method uses a shut off nozzle which transfers the polymer directly from the
machine nozzle into the mold cavity.

The mold designer uses factors such as part design, material machine and use and production
requirements to determine which material transfer method is better suited for each application.

Part forming

 After the mold transfers the polymer from the machine to the mold cavity, the second
function of the mold is to pack and form the plastic part.
 Each plastic material has its own flow characteristics, which will determine the velocity and
pressure used to fill the part.
 Any use of material additives such as colorants, lubricants, flame retardants and fillers will
alter how the cavity is filled.
 The injection molding machine governs the rate at which the polymer is injected into the
tool, depending on the machine these velocities can exceed 12 in/sec (approximately 300
mm/sec).
 During packing, pressures can exceed 45,000 psi or 3000 bar. These high pressures require
the injection mold to be clamped with an extremely high force.
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 Some of the newer injection molding machines is equipped with clamping forces in excess
of 10,000 tons. Because of these high forces, the tool must be made of durable construction.

Part cooling

 The third function of the tool is to cool the molded part.

 During injection, the temperatures of the polymer may exceed 900o F or 480o C.
 Water or oil is typically used as a cooling medium to control the temperature of the
injection mold and a cool the heated polymer.
 Therefore, the mold must contain channels called water or oil lines to transfer the heat from
the mold to the cooling medium.
 The cooling time varies depending on the material part thickness and the amount of heat
transfer that takes place in the mold.
 Oil is used to cool higher temperature tools, which are typically over 200o F or 90o C. Since
water is boiling point is 212o F or 100o C.
 Ideally, the mold cools apart as quickly as possible while maintaining the desired dimensions
and physical properties.

Part ejection

 The last function of the injection mold is to remove the part.

 Once the part is cooled, it is typically ejected using features such as ejector pins, stripper
plates, ejector sleeves or air. These systems push the part out of the mold cavity.
 A proper ejection system removes the part without distorting any of its attributes by evenly
distributing the ejection force to help reduce stress is in the part.
 Assuming the ejection mechanism can achieve this objective, it should be kept as simple as
possible to avoid maintenance problems and added expenses.

Part design overview

Part design introduction

 Even the best and most experienced mold designer can’t overcome a poorly designed part.
 It's imperative that the part design be thoroughly reviewed before any steel is cuts.
 We suggest that the mold designer be involved with a part design process wherever
possible.

Relationship of part & mold design

 Although this program concentrates on mold fundamentals, one must understand the
relationship between part design and mold design.
 The mold design process begins with a part drawing or a three dimensional model, proper
dimensions should be included with corresponding tolerances.
 Many drawings will provide general tolerances for the drawings as well as specific tolerances
on critical dimensions.
 3D models must also include critical dimensions as well as some tolerance information.
 Parts with stringent tolerances may require MAWR accurate machining techniques, more
molding trials and several adjustments for the part to meet the specified dimensions.
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 Later in this series, we will discuss the term steel safe and how it relates to molding trials
and part dimensions.
 Part designers are generally not mold designers. For this reason, it is essential that the part
design be carefully reviewed before it is translated into a mold design.
 Although this process may seem unimportant, much time could be saved and unnecessary
mold development and rework can be eliminated.
 The main focus of mold design is moldability. In other words, the emphasis is not on the
aesthetic design of the part, but the ease and efficiency of which the mold can produce
parts.
 There are several factors that affect the overall mold ability of the part design. The
remainder of this section briefly describe some of these factors and will be addressed in full
later in this mold design series.

Part moldability

Gate - Establishing the gate type location and number of gates used should be the first consideration
upon reviewing the part Geometry. A gate is the point at which the polymer melt enters the mold
cavity. A variety of gating options exist, Yet the complexity of the mold itself will dictate the
appropriate gate type and the number of gates to be used.

Parting line - Parting line determination is usually the second consideration in the mold design
process. The parting line determines the division between the core side and the cavity side of the
mold. In all cases, several different parting line options could be used to produce an acceptable part.
Choosing the best parting line for the application involves an understanding of the mold making
process. And the factors which affect mold construction, mold performance and cost.

Draft - Draft is an angle added to a wall to aid in the ejection of the part from the mold. Without
draft, the part scrapes the mold wall during the whole ejection process. Adding draft to the part
walls reduces the friction and vacuum forces, reducing part stress, warpage and distortion during
part ejection, it is recommended. The draft is added to the part during the part design process. If
draft is not specified on the part, drawing the minimum and maximum draft need to be called out
within the notes section.

Surface finish - Surface finish also has to be called out on the drawing. The surface finish can include
information such as texture, EDM finish and polishing qualities surfaces that interact with other
components. Services during assembly should also be noted.

Part thickness - The part thickness should remain constant whenever possible. Changes in the part
thickness affect part cooling and part warpage. If a constant part thickness is not possible, a smooth
transition in the part thickness reduces part warpage during cooling. Thick sections can commonly
be thinned through the use of ribs.

Rounded corners - Sharp corners also promote part warpage and can weaken the corner whenever
possible. Corners should be rounded on both the inside and outside. The part drawing should
include a general radius that refers to all corners on the part, unless otherwise specified.
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Undercuts - Undercuts are features in the mold which interfere with mold opening in part ejection.
Therefore, should be avoided wherever possible to remove undercuts from the molded part.
Internal and external actions such as slides and lifters are generally used.

Material shrinkage

 Shrinkage is a measure of the change between mold size and final part dimensions. The
material and its inherent shrinkage Properties must be included in the part drawing.
 Material shrinkage can be represented in several ways.
 Test Number D955 ASTM (American Society of Testing Materials) requires that shrinkage be
expressed as an in/in ratio.
 ISO (The International Organization of Standards) represents shrinkage as a percentage.
 The ASTM ratio can be multiplied by 100% to achieve the ISO shrinkage value.
 This means that in ASTM shrinkage value of 0.005 in/in X 100% = 0.5% Shrinkage in ISO.
 In ISO standards, the shrinkage factor is used to determine the cavity and core dimensions
required to satisfy the correct part dimensions after molding.
 This is important because the final part will be smaller than the mold cavity and core
dimensions.

Many part designs include inserts which are placed into the mold prior to injection. These need to
be identified on the drawing along with the insert material. The differential shrinkage between the
polymer surrounding the insert and the rest of the part can cause varied shrinkage and stresses.

Communicating the part design

To reduce the chance of Miss-communication. Blueprints should be accompanied by a 3D

representation of the park. This could be in the form of a CAD model or a prototype.

Mold design factors

Injection mold design is an acquired skill that incorporates a number of factors.

These includes,

 The ability to properly interpret a part design,

 Working knowledge of plastics processing,
 Thermodynamics,
 The machining of steel
 And the behaviour of plastic materials.

Optimizing a mold design could be achieved if the tool designer becomes directly involved in the
part design and development processes.

A good mold takes precedence over a perfect machine. This is due to the fact that a well designed
and built mold used in an older machine may still produce an acceptable part.
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Where as a poor mold design, using a machine that employs the latest technology, will often
produce inconsistent results.

Production requirements

Before the mold design process can begin, the mold designer must be given the production
requirements.

These requirements include

 The number of tools needed,

 Cavitation,
 Tool life,
 Lead time
 And the tooling budget.

Number of Tools - Many jobs requires more than one tool to be built factors such as

 The size and complexity of the part,

 Molding machine capability,
 Machine availability
 And the amount of parts needed.

All contribute in determining the number of tools to be built.

Cavitation - Cavitation refers to the amount of cavities best suited for the injection molding
application.

 If the production requirements are low only one cavity may be required.
 If the production requirements are high, anywhere from 10 to hundreds of cavities may be
required.

Tool life - Tool life refers to the amount of cycles run during the tools life.

 Prototype tools may only be needed to produce tens or hundreds of parts. These tools can
usually made by softer materials such as aluminium, Kirk site or ordinary steals.
 The design of such tools can also be more simplistic, since they're not expected to last for a
long period of time.
 High production tools can be required to produce millions of parts. These tools should be
made out of more durable materials such as hardened carbon steels.
 The design of a high production tool is more complex since it is expected to last for a long
period of time.

Lead time - Product lead time refers to the amount of time allotted for the mold or molds to be
constructed. Small production lead times could require the tool to be built out of more components
enabling more people to work on the tools simultaneously. This may also limit the design options as
well, since many desired mold components must be special ordered and the mold construction may
be delayed.
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In some cases, a full production tool cannot be built within the required lead time. If this is the case,
a prototype tool is constructed to meet the short lead time for initial production and then a
stronger, more reliable tool is built before the prototype tool wears out.

Tooling budgets - Tooling budgets and lead times are important constraints that the customer must
consider upon determining their needs. In some cases, a high tooling budget provides the designer
with more freedom to design a better tool for the application.

SPI Classifications - Some industry organizations, such as SPI provide tooling classifications that rate
tool quality on the integrated mold components. These classifications could be used as guidelines for
mold design and construction.

Mold making shops

Many mold making shops have found their own niche and produce molds for a specific field. For
example: Medical, Electronic and Automotive. I guarantee you that if you go out to see one of these
shops; you'll find that they have a tendency to specialize.

Molding machine specifications

Molding machine specifications must be considered during the mold design process.

The injection molding machine has many components that affect mold design.

Platens - The Platens are two large steel plates that the mold is clamped to one of this Platen is the
stationary Platen, while the other Platen moves back henceforth.

Daylight - The maximum distance between the Platen is called the maximum daylight. The maximum
daylight is critical because the mold has to open and eject the par within this space.

Stack height - Most machines will state the maximum and minimum mold height. This indicates the
largest and smallest injection mold that will fit into the molding machine. This mold dimension is
known as the stack height.

Tie bar distance - The tie bars line up the two Platen size and also carry the force. When the mold is
clamped, the horizontal distance between the tie bars can dictate the maximum width of the mold in
many cases. This is because the mold is typically lowered into the machine from above and the mold
has to fit between the tie bars during installation. This is not always a limiting factor, since some
machines have removable tie bars or alternative mold Installation techniques such as hand or side
loading can be used. There are many methods which could be used to secure the mold to the
Platens. Most molders either clamp the mold to the Platen or both the mold directly to the Platen.

Bolt hole pattern - The bolt hole pattern allows the mold designer to determine a mold base, which
can be mounted into the molding machine. Some boulders use quick mold change systems, which
can limit the size of the injection mold or involve additional work to the injection mold.

Knockout hole pattern - The ejection system uses knockout rods to push against the ejector plate in
the mold to eject the part. The location of the knockout holes is important, since the knockout rods
passed through the movable pattern and clamping plate of the mold.
 Mold design series

Locating ring diameter - The stationary pattern has a hole in the center that lines up with the
injection unit of the molding machine. This diameter is also the diameter of the locating ring on the
injection mold.

Additional Constraints - There are other constraints that should be discussed before the tool is
designed.

Robotic part removal - Injection molding machines are sometimes equipped with hydraulic cores
and pneumatic ejection, which could be incorporated in the mold design. Many injection molding
operations incorporate robotic systems to remove the part or runner from the mold. It is best to
discuss the capabilities of these systems before the tool is designed. It may be necessary to handle
the part ejection differently because robots have a limited range of motion.

Design and processing guides

There are several suppliers of mold bases and mold based components in the plastics industry. Their
catalogues contain a wealth of information on molds and are quite useful.

Mold based suppliers include,

 DME
 National
 Hasco
 Progressive (Component suppliers, such as progressive components should also be
contacted to obtain additional information)

It is also a good idea to contact material suppliers and distributors to request product design, mold
design and processing guides.

A listing of suppliers can be found in the

 Plastics Technology Handbook,

 Modern Plastics Encyclopaedia (or on the Internet)

This information is free and would be a valuable asset to anyone involved in the design of injection
molds.

Also obtained a copy of your company's Mold Design Specifications guide. You may wish to refer to it
from time to time or create one. If your company does not have one, we have included a sample of
one with this program.

It is important to understand the mold design and construction process. If you have not spent time
working with mold making equipment, then we strongly recommend that you spend time in tooling
shops to see the tool construction process for yourself. This will complement the mold, making
Series and expose you to some of the concepts discussed in the mold design and mold making series.

Conclusion
 Mold design series

Upon completing this program, you should be more familiar with the design and function of an
injection mold. You have also been introduced to basic part designed and mold design principles, as
well as considerations that must be addressed before an injection mold can be designed.

The next program, entitled Mold Machining Methods Part one, will discuss the various methods
available to today's mold makers and designers.

Machining methods (Part – 1)

Introduction

This program entitled Mold Machining Methods. Part one is the second program in the mold design
and mold making Series. Before beginning this program, you should have already participated in the
first program of the Series entitled Injection Mold Fundamentals

Mold Machining Methods (Part – 1) is the first of two programs which discuss mold machining
methods available to today's mold makers.

The topics discussed in these 2 courses include

 Machining methods,
 Advantages and disadvantages of each machining method,
 Finishes and stresses resulting from each machining method.
 How mold tolerances differ from molded part tolerances,
 Adding draft to the mold
 And steel safe machining

Machining methods

The machining methods that will be discussed in this program are conventional and CNC milling, high
speed milling of hardened steel, conventional and CNC lathes, conventional and CNC surface
grinding, conventional and CNC cylindrical grinding and conventional and CNC jig driving.

This program is intended to provide the participant with an understanding of the processes and
concepts in today's mold making industry.

Be aware that this program is not intended to be a machinist course and will not prepare you to
operate mold making equipment.

We recommend that all participants visit various mold making shops to better understand the
machining methods mentioned and their functions within the mold making process.

Machining is the removal and shaping of steel in order to produce the base inserts, cavity core and
other mold components.

Without this knowledge, designs could result in requiring excessive machining, inadequate finishes
and unwanted stresses in the steel or a mold design that cannot be duplicated.
 Mold design series

Milling

If you've never worked in a machine shop, we recommend that you take time to perform some of
the basic machining operations. If a tool shop isn't available, find a vocational school or maybe a
general machine shop. When operating any machinery, be sure that you have a qualified machinist
or mold maker to provide you with all the safety equipment and precautions.

 Milling is a procedure that refers to the use of a milling machine to remove material from a
piece of steel.
 Milling machines are available in both vertical and horizontal styles.
 Vertical milling machines are the more common of the two styles and are one of the most
versatile forms of machining.
 Due to its wide range of motion, The vertical milling machine has a smooth ground table
containing grooves used for bolting down the work piece this table could be moved side to
side on the horizontal X axis back and forth on the horizontal Y axis or up and down on the
vertical Z axis.
 The head of the vertical milling machine can also be rotated about the X Y and Z axes.
 Horizontal milling machines have a limited range of motion compared to that of vertical
milling machines.
 On these machines, the table still moves in the X and Y directions, yet the head on Lee
moves vertically in the Z direction.
 Horizontal milling machines allow work pieces to be placed onto the table with a lift or an
overhead crane without interfering with the milling head.
 This makes horizontal milling machines ideal from milling larger work pieces.
 Manual or conventional milling machines typically have an accuracy of ±0.001in. or ±0.02
mm.
 The use of milling machines is sometimes referred to as a chip making process.
 Chips are created by the direct contact between the cutting tool and the work piece.
 The direct contact creates friction, which results in heat and stresses in the work piece.
 If the cutting tool heats up too much, the tool will not cut properly and will push on the
metal instead of cutting it. This will result in a blunt and unusable tool.
 During the milling process, excessive heat and stress caused the work piece to deform and
ultimately reduced mechanical strength and integrity.
 Stresses in the milling process can be reduced using lubricants and coolants using sharpened
balance cutting tools, removing smaller amounts of material per pass.
 An operator skill can also reduce the stresses during machining.
 Additional components, such as
o A coolant system,
o Extended tables, Power feed
o And digital readouts can be added to conventional milling machines to enhance
performance.
 Coolant is usually water based fluid and is required for most milling operations to reduce
overheating. The coolant works best when it is present at the point of cutting, so that both
the cutting tool and the work piece remained cool.
 Mold design series

 Extended tables added to a milling machine can increase the length of a cut, sometimes
eliminating the need to purchase a larger milling machine.
 Power feeds could be added to a milling machine, enabling the mold maker to mill faster
while using less manual interaction. Power feeds allow simple milling operations, such as
cutting down large plates or squaring off large blocks to be performed quickly.
 Digital readouts are commonly added to milling machines, allowing the machinist to
measure the position of the axes with an accuracy of up to ±0.0002 in and ±0.005mm.

Advantages and dis-advantages

 The advantage of conventional milling machines are

o The relatively low cost
o And the versatility of both the table and the milling head.
 The disadvantages to conventional milling machines include
o Manual operation,
o Poor surface finish.
o Low tolerances
o And are not suited for harden materials.
 Roughing operations - Conventional milling machines are usually used for roughing
operations. Roughing operations from milling include
o Cutting down plates,
o Cutting pockets,
o Drilling holes,
o Machining mold components
o Rough cutting of the core blocks, cavity blocks
o And electrodes with simple geometry (for EDM)
 Softer materials, such as 45 Rockwell hardness C and below are generally milled using
conventional milling machines.
 Although, harder materials can be machined using conventional milling machines. Other
machining processes such as electrical discharge, machining and high speed machining are
better suited for these materials.

Manual milling is typically used for machining mold components or solely as a roughing operation for
mold cores and cavities. There are many other machining operations that arm or accurate and better
suited for finishing mold cores and cavities.

Milling Tools

 The cutting tools used in milling machines range in shape, size and function.
 Frequently used cutting tools include end mills, fly cutters, trills, taps, rivers, T slot and radius
cutters.
 End mills come in a variety of shapes and sizes. The most common and mills arethe square,
tapered ball and roughing.
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 The square in mill makes a flat cut on the bottom and a straight vertical cut on the side. The
corners of this cut are at right angles.
 Tapered end mills are similar in shape to square and mills, the exception being that the sides
are tapered and cut a specified angle rather than a 90 degree angle.
 Ball end mills have a radius on the bottom of the end mill. The radius on the bottom of the
cutter allows the cutter to cut a radius from the side or create a semi circular trough with the
full cutter. The surface is left behind from the square tapered, and ball end mills are rough
and contained witness lines from the machining process. The surface left behind from all end
mills is commonly ground or polished further.
 Roughing end mills are equipped with tooth walls and are used to remove large amounts of
material. The surface left behind from a roughing end mill is jagged with a rib texture. This
service needs to be re-machined using another machining process before it could be ground
or polished. As the end mill cuts, the helical flight pattern draws the cut metal to the top of
the end mill eliminating any interference with cutting edge. End mills are designed to run at
high speeds and can remove various amounts of material at a time depending on the
application. Since most end mills leave a rough surface finish on the work piece, the mold
cavity and core are usually finished with a computer numeric controlled milling machine to
help improve surface finish.
 Fly cutters come in several different shapes and sizes and are used to remove large amounts
of material. These cutting elements rotate at very fast rates and could have multiple cutting
inserts. As the cutting elements contact the metal surface, pieces of metal are cut and
thrown from the cutting area. The surface texture from a fly cutter is generally smooth, but
the cut is inaccurate. It is recommended to finish off a fly cutter path with another machining
process, such as grinding or CNC electrical discharge machining. Because of the high
machining rates and rotational speeds, roughing places a large amount of stress on the
cutting element. Most fly cutters used replaceable inserts made of hard materials such as
carbide, ceramic or tin coated high speed steel. These inserts a replaced quite often due to
excessive wear or breakage. Larger cutting tools contain a number of smaller inserts that are
arranged in a helical pattern. Helped draw out the cut metal fly cutters are commonly used
to mill large pockets, cut down plates or when the core cavity block requires a large degree
of machining prior to finishing.
 Along with end mills and fly cutters, drills can also be used in a milling machine. The two
most common types of drills used are fluted and spade drills. As the bottom of the fluted
drill cuts, the helical flute design draws the cut material to the surface, creating more room
for drilling. Fluted drills could be used for all types of drilling. Unfortunately, the cost of
these drills greatly increases as the diameter of the drill increases. Spade drills do not have
helical flights to remove the cut material from the cutting area, which is why these drills are
much cheaper than fluted drills. Spade drills use a shaft with a cutting insert attached to the
end. These high strength inserts are typically made of materials such as high speed steel and
tin coated high speed steel. Because spade drills do not have the long flutes to guide the
drill, the holes are typically rougher and less accurate than holes made from a fluted drill. To
improve the accuracy of the whole, a centering drill can be used. A centering drill is a wide
drill with very short flutes. The short flutes keep the drill straight as it drills a small starter
hole in the work piece. A starter whole helps facilitate accurate positioning for a spade or
fluted drill. Because drilled holes have a rough surface, a reamer should be used to improve
 Mold design series

the surface finish. Rivers are multi fluted shafts that produce holes with accurate diameters
such as ejector pin holes. Holes that need to be reamed should initially be drilled slightly
smaller than the desire diameter. The reamer follows the path of the drilled hole and cut
small amounts of material from the sides, resulting in a smooth and accurate finish.
 Side or T. Slot cutters are mounted on a shaft and cut the work piece from the side cutters
are most commonly used when cutting hard to reach areas such as slots for slides and
undercuts like side cutters.
 Angle cutters are also mounted on a shaft and could be used to cut angles on a surface to
break corners or cut angled slots.
 Radius cutters have a convex shape that are used to Miller Radius on the work piece.
 After a hole is drilled into a work piece, a tap is used to form threads. This is usually done
manually, but experienced machinists can tap holes in a conventional milling machine.
 We have mentioned several cutting tools in this program. Be aware that there are countless
number of specialized cutting tools used for milling operations. These specialized cutting
tools can be found in catalogues provided by industry suppliers.

CNC Milling

 Many of today's milling machines are available with computer do bear a control or CNC and
arm or accurate than conventional milling machines.
 These machines are also available for both vertical and horizontal milling.
 CNC milling machines use an on board computer to control hydraulic or electric motors that
move the table and spindle along the X, Y and Z axes.
 Optical encoders and linear potentiometers are located on the movable X, Y and Z axes to
measure their positions. This information is then relayed back to the computer.
 Cutting paths are the channels in which the cutting element follows during milling. This are
programmed into the controller, either manually or through the use of a computer program.
 When program manually, the operator enters each portion of the program into the
controller and the sequence creates a cutter path.
 More complex cutter paths need to be programmed using a computer aided machine or cam
program.
 The programmer exports a computer aided drafting or CAD file to the CAM program and the
CAM program then generates the necessary cutter paths to machine the mold.
 Most CNC milling machines have automatic tool changers that hold multiple cutting tools.
This feature allows for a work piece to be machine from start to finish using a wide array of
cutters demanding little or no operator attention.
 The spindle holds and rotates the cutting tool. Many CNC milling machines have the ability
to control the rotational speed of the spindle when cutting helical paths such as threads.
 CNC milling machines can also be equipped with a rotating table. This feature allows the
computer to accurately control the rotational speed and position of the work piece. Some
CNC milling machines can also angle the machining head to improve its range of cutting.
 The advanced controls of a CNC milling machine produced better surface finishes than a
conventional milling machine, requiring only light finishing before being used.
 The controlled movements of the CNC milling machine reduce the amount of stress applied
to the work piece.
 Most CNC milling machines can achieve an accuracy of ±0.0001 in and ±0.002 mm.
 Mold design series

 The advantages of CNC milling compared to conventional milling are

o More accurate machining
o The ability to import cam data
o Smooth and repeatable surfaces
o Less operator attention
o And faster production increasing productivity.
 The only disadvantage to CNC milling compared to conventional milling is
o The large increase in cost
 CNC milling machines can be used in place of conventional milling machines, yet can handle
complex geometry.

High speed machining

 Since the heat generated in high speed machining is dissipated within the chip, very little
stress is applied to the work piece. This makes high speed machining ideal for the machining
of high hardness steel.
 High speed machining of hardened steel is relatively new and couples the latest
advancements in milling machine spindle technology. Along with the latest CNC computer
technology. This process uses specialized CNC milling machines to shape hardened steel at
extremely high cutting rates.
 High speed machining uses inaccurately balanced spindle mounted on the CNC milling
machine.
 Many of these high speed spindles are capable of speeds up to and in excess of 40,000 rpm.
 Some high speed machining processes can cut aluminium at spindle rates in excess of
150,000 rpm.
 The on board computer allows the milling machine to receive and interpret the cam data at
a faster rate than standard CNC milling machines.
 In addition, the milling table has to be able to move at a very fast rate, generally up to 160
ft/min or 50 m/min.
 In high speed machining the spindle does not vibrate. Therefore, the amount of heat
generated is much less than that of conventional or CNC machining.
 The passes of the cutting tool or smaller, typically removing less than ±0.008 in or ±0.02 mm
per pass. The chip is thrown from the work piece and the heat is dissipated within the chip,
eliminating the use of coolant. In most cases, the work piece could actually remain cool to
the touch.
 High speed milling machines can achieve an accuracy of ±0.0001 in or ±0.002mm and in
some cases higher.
 Work pieces with Rockwell C hardness of 60 and higher can be machined in the hardened
state, saving hours of heat treatment and preserving the accuracy of the machining.
 The advantages of high speed machining of hardened steel compared to conventional and
CNC milling are
o The ability to machine hardened steel,
o Lower stresses
 Mold design series

o Smoother surface finishes

o And higher tolerances.
 The disadvantages of high speed machining of hardened steel compared to conventional and
CNC milling are the machines are
o More expensive
o In all, cutting tools required time consuming balancing before use.
 High speed machining can be used to roughing and finishing applications, allowing for some
cores and cavities to be completed on one machine.

Conventional Turning (Lathe)

 Turning is a machining process that is performed on a Lathe.

 Lathes are used to rotate the work piece, allowing the cutter to shape the part from several
different angles.
 Like milling machines, lathes are considered a chip making process.
 The work piece is typically round, symmetrical or square and is mounted in a chuck.
 The chuck centers the work piece and holds it in place.
 The chuck and work piece are then rotated, and the cutting tool cuts on either the inside or
outside of the part.
 A tool bit is used to cut the part and could be moved in either the X or Y direction to adjust
the length and depth of the cut.
 The tool bid is typically a sharpened bit of hard metal such as carbon steel or carbide.
 Most lathes have a feed mechanism to move the tool along the X axis.
 When engaged, the cutting tool will travel along the X axis at a constant speed, creating a
more consistent finish on the final part.
 Many lathes have a center attachment. This attachment allows the operator to drill
accurately centered holes in the work piece.
 The lathe is very useful in making round inserts for the mold or applications that require very
concentric circles.
 Turning processes create high rotational stresses in the work piece, which can cause the
peace to twist or bend during turning.
 As in milling, turning generates heat during the cutting process. Coolant is necessary to keep
the cutting tool operating properly.
 Lathes leave a radial surface finish on the work piece, and as a result the part requires
further finishing and polishing.
 Conventional turning usually requires a large amount of measuring to provide the necessary
accuracy. As a result, the overall accuracy of conventional lathes depends on the experience
of the operator.
 The conventional lathe is accurate to approximately ±0.001 in and ±0.02 mm.
 The advantages of the conventional lathes are
o The machinery is inexpensive
o And is ideal for roughing round mold components and inserts.
 The disadvantages of conventional lathes are
o Large amounts of stress is applied to the work piece
 Mold design series

o And accuracy relies heavily on operator experience.

 Conventional lathes are commonly used for making round mold components such as
o Round core blocks
o Support pillars
o And inserts.

CNC Turning Lathes

 The CNC lathes are more accurate than the conventional lathes. Because it’s equipped with a
computer to control the X and Y movement of the cutting tool.
 Most CNC lathes have the ability to control the rotational speed of the chuck.
 The cutting paths for a CNC lathes are the courses of movement for the cutting tool in both
the X and Y axes.
 Simple paths can be programmed into the CNC controller manually.
 More complex cutting paths will need the help of a camp systems such as those used for
CNC milling.
 The accurate controls of the CNC lathes create more consistent cutting paths, resulting in
less stress on the work piece compared to that of the conventional lathes.
 The CNC lathe is more repeatable and accurate than the conventional lathe and could
typically reach tolerances of ±0.0005 in and ±0.01 mm.
 Like the conventional lathes, the CNC lathes also leave a radial surface finish. Yet this finishes
smoother and requires less polishing
 The advantages of CNC lathes compared to conventional lathes are
o Surface finishes require less polishing
o Increase accuracy
o And less stress apply to the work piece.
 The disadvantage of CNC lathes compared to conventional lathes is that
o The machinery is more expensive
 The CNC lathe is commonly used for roughing complex core in cavity inserts.

Conventional Grinding

 The most common forms of grinding includes surface cylindrical and jig this are very
accurate and are used as a finishing operation.
 Since they only remove a small amount of material with each pass.
 Grinding is the most accurate form of machining available. Surface grinding is the most
common form of grinding used in the mold making industry. Conventional service grinders
use the high speed rotating grinding wheel to grind a flat surface.
 The table moves under the grinding wheel in the X and Y axes. The X axis runs back and forth
across the wheel to perform the grinding.
 On conventional service grinders, the X axis is not measured. The Y Axis moves the work
piece along the grinding wheel on conventional service grinders, the Y axis is accurate to
±0.001 in or 0.02 mm.
 The Z axis moves the grinding wheel up and down on conventional service grinders. The Z
axis of the grinder has an accuracy of ±0.0001 in or ±0.002 mm.
 Mold design series

 Conventional service grinding places high stresses on the work piece. To reduce this stress
smaller grinding paths, lubricants and coolants can be used.
 The surface finish left behind from a service grinder is acceptable for use unless a near
mirror services required.
 A fixture can be used to accurately grind ejector and core pins to length.
 Fixtures keep thin and long work pieces from deflecting while being ground.
 Sign plates could be used to angle the work piece, allowing for accurate angles to be ground.
 A turning fixture can be added to the surface grinder to grind accurate diameters onto
around ejector pin or core pin.
 This method produces a smoother surface finish than a lathe.
 Form grinding is performed on a surface grinder and is very useful for grinding simple angles,
Radii and Contours.
 Wheel dresser is used to shape the grinding wheel, which then grinds the desired shape
onto the work piece.
 Surface grinders can also accommodate controls which allow automated grinding in the X
and Y axes, minimizing operator tension. This reduces operator interaction and fatigue.
 The advantages of conventional surface grinders are
o Flat surfaces can be grind with high accuracy
o High surface finishes can be ground
o And conventional surface grinders are relatively inexpensive.
 The disadvantages to service grinding is
o The high stress is applied to the work piece
 During machining surface grinders are used for most smooth and flat surfaces
 The grinder is used to smooth surfaces for inserts, parting lines, core services, ejector pins,
ejector blades, mold plates and most mold components.

CNC Surface Grinding

 CNC surface grinders could be used to grind both flat and contoured surfaces without
manual intervention.
 The CNC service grinder uses a computer to control the movement of the X, Y and Z axes.
 Simple paths could be programmed manually, while more complex paths are programmed
using cam software, the CNC surface grinder can produce surfaces that are accurate to
±0.0001 in and ±0.002 mm.
 The advantages of CNC service grinders compared to conventional service grinders are
o The ability to grind complex services
o And less manual interaction
 The disadvantage of CNC service grinders compared to conventional service grinders is that
o The machinery is more expensive.
 CNC surface grinders are commonly used for grinding, contoured parting lines, electrodes
and cores.

Conventional Cylindrical Grinding

 Conventional cylindrical grinding is considered both a form of grinding and turning.

 A cylindrical grinder typically uses a magnetic chuck and a grinding wheel.
 Mold design series

 The work piece rotates about the X axis, while the grinding wheel rotates and moves along
the X and Y axes.
 The grinding wheel is used in a similar manner as a cutting tool is used on a lathe.
 Both internal and external grinding wheels are available for grinding internal and external
part detail.
 Cylindrical grinding can place a great deal of stress on the work piece.
 Cooling fluid and smaller passes can be used to reduce the stress during grinding.
 The surface finish from a cylindrical grinder requires minimum polishing, such as when a
reflective surface is desired.
 The conventional cylindrical grinder can reach diameters accurate to ±0.0001 in and ±0.002
mm.
 The advantages of conventional cylindrical grinders are
o Cylindrical surfaces can be ground to a high accuracy
o And high surface finishes can be grind.
 The disadvantages to conventional cylindrical grinding is
o The high stress is applied to the work piece during machining.
 This process is ideal for making round core blocks, core pins and cavity blocks.

CNC Cylindrical Grinding

 CNC Cylindrical grinders could be used to grind complex profiles on round parts without
manual intervention.
 CNC Cylindrical grinders Use a computer to control the movement of the X and Y axes.
 As with most CNC operations, simple profiles can be manually programmed while complex
profiles are transferred into the computer using CAM data.
 The C N C cylindrical grinder can achieve diameters accurate to ±0.0001 in and ±0.002 mm.
 The advantage of CNC cylindrical grinders compared to conventional cylindrical grinders is
o The ability to grind complex profiles
o And less manual interaction.
 The disadvantages of CNC cylindrical grinders compared to conventional service grinders is
that
o The machinery is more expensive.
 This process is commonly used for grinding complex profiles on round core pins, core blocks
and cavity blocks.

Conventional Jig Grinding

 Conventional jig grinders are used to grind smooth and accurate holes.
 The jig grinder uses a grinding stone that rotates at speeds of up to 100,000 rpm.
 Jig grinder attachments could be added to most milling machines. The attachment rotates a
grinding stone at different diameters to accurately grind holes.
 The head of the milling machine is used to raise and lower the attachment.
 Mold design series

 Conventional jig grinders are similar to manual milling machines in appearance but use a
high speed spindle and are designed to machine only in the Z direction.
 The jig grinder could reach tolerances of up to ±0.0001 in and ±0.002 mm.
 The advantages of conventional jig grinding are
o Holds could be ground to high accuracy
o Smooth surface finishes
o And inexpensive jig grinding attachments could be purchased for simple
applications.
 The disadvantage to conventional jig grinding is that
o High stresses are applied to the workpiece during machining.
 This process is ideal for making accurate ejector pin and core pinholes.

CNC Jig Grinding

 A CNC jig grinder is similar to the CNC milling machine, the work pieces mounted on a table
that moves in both the X and Y directions.
 The grinding wheel is mounted on a high speed rotating spindle moving in the Z Direction.
 A Computer is used to control the X Y and Z directions. The CNC jig rider could be used to
grind complex shapes and features on the work piece with little manual interaction.
 The CNC jig grinder could be used to grind complex cores and cavities and requires only
minimal polishing. After completion, the CNC jig rider could reach tolerances of ±0.0001 in
and ±0.002 mm.
 The advantages of CNC jig riders compared to conventional jig riders are
o The ability to grind complex geometry
o And less manual interaction.
 The disadvantage of CNC jig riders compared to conventional jig riders is that
o The machinery is expensive.
 CNC jig grinders are commonly used for grinding, complex cores, cavities, ejector pin holes
and pockets.

Conclusion

Upon completing this program, you should have an understanding of the milling, turning and
grinding methods available to today's mold makers.

These machining methods include

Milling - Conventional and CNC milling, high speed machining of hardened steel,

Turning - Conventional lathe, CNC lathe

Grinding - Conventional surface grinding, CNC surface grinding, conventional cylindrical grinding,
CNC cylindrical grinding, conventional jig grinding and CNC jig grinding.
 Mold design series

You've also learned some of the typical uses for these machining techniques, along with the
tolerances and stresses associated with each method. You should now participate in Program three
of the mold design and mold making Series entitled mold machining methods - part 2.

This program further discusses machining techniques such as EDM and polishing is one of the
important machining considerations.

Mold Machining Methods – Part 2

Introduction

The topics discussed in this course include

 Machining methods
o Conventional Die sinker EDM
o CNC Die sinker EDM
o CNC wire EDM
 Polishing
o Machining tolerances vs molded part tolerances
o Seal offs
o Tooling inspection equipment
 Machining trade-offs with examples of how different machining methods can be substituted.

Die sinker EDM

 Electrical discharge machining, referred to as EDM.

 Is a stress free form of machining since there is no direct contact between the machining
element and the workpiece.
 There are three types of EDM commonly used in today's mold making industry
 Conventional die sinker EDM
 CNC Die sinker EDM
 And CNC wire EDM
 Conventional die sinker EDM machines use electrodes which contained the detail that is to
be machined into the metal work piece electrodes are made from conductive materials such
as graphite or copper.
 The electrode is placed into the machine. A positive or negative electrical charge is applied
to the electrode and the opposite charge applied to the work piece.
 One restriction of the conventional die singer EDM machine is that the burning can only take
place in the Z direction.
 As the electrode lowers and nears the work piece, electrical spark jumps from the electrode
to the metal. This sparked burns. The metal and die electric fluid is used to flush out the
 Mold design series

burnt pieces, allowing the electrode to burn uninterrupted until the desired depth is
reached.
 When the burning is complete, the result is an impression of the electrode in the metal. The
distance between the electrode edge and the bird medal is referred to as over burn or spark
gap.
 Overburdened typically ranges from 0.02 in or 0.5 mm down to about 0.002 in or 0.05 mm.
 Higher voltages and amperage is result in a larger spark, therefore increasing the amount of
over burn.
 To compensate for overburdened electrodes are built undersized.
 For example, a 1 in or 25.4 mm square is to be burnt using an over burn of 0.001 in or 0.025
mm. The over burn has to be subtracted from both sides of the desired square. Therefore,
the electrode would have to be 1 in or 25.4 mm sq minus twice the over burn.
 The result would be an electrode of 0.98 in square for 24.9 mm. If a one half in or 12.7 mm
circle was desired in the middle of the square, the circle cut in the electrode also has to
compensate for the over burn.
 Thus, the circle in the electrode must be larger than the desired circle on the work piece. The
diameter of the electrode would be the desired 0.5 in or 12.7 mm plus twice the 0.01 in or
0.25 mm over burn.
 In this case, the result in circle within the electrode would have a Ø 0.52 in or 13.2 mm.
 Unfortunately, the deeper the electrode burns, the more it wears. One way to avoid
excessive wear is to build multiple identical electrodes to be used interchangeably. Another
method is to build multiple electrodes that are designed to perform at different over burn
rates. One electrode is used to compensate for higher over burn rates with this electrode
less where occurs yet a rough surface texture is produced. Two or three electrodes are
designed for lower over burn rates and used to clean up the rough surfaces and to finish off
the desire detail.
 The surface finish left behind from a conventional die sinker EDM machine is generally
rough. Using lower over burns settings improves. The resulting surface finish yet requires
considerably more machining time. Unless the rough EDM texture is desired, the surface
requires polishing.
 The conventional die sinker EDM Machine can achieve tolerances of ±0.0005 in or ±0.01
mm.
 These tolerances however are dependent on the accuracy of the electrode.
 The advantages of conventional die sinker EDM are
o Complex and intricate detail could be machined
o And the EDM processes a stress free machining method.
 The disadvantages of conventional die singer EDM
o Multiple electrodes must be built.
o The accuracy of the process relies heavily on the electrodes
o And extensive polishing is required for a smooth finish.
 Conventional EDM machines are commonly used for
o Roughing mold cavities and cores
o Machining hardened steels
 Mold design series

o And complex geometry such as sharp corners, ribs, small holes, textures and
lettering.
 This process is also ideal for working on thinner more intricate work pieces.

CNC Die Sinker EDM

 The CNC Die Sinker idiom machine is an extraordinarily versatile machine. This machine
operates under the same principles as the conventional Die Sinker EDM machine, but is
equipped with a computer to control burning in the X Y and Z axes.
 The advantage to full 3D movement is that the machine can also perform Loren functions.
Loren functions allow the electrode to move in a pattern perpendicular to the direction
being burnt.
 The CNC Lauren patterns typically move in circular square or spherical patterns to help
smooth out the rough surface. These patterns can produce a near mirror finish if a highly
polished electrode is used.
 The computer compensates for the difference between the undersize and the over burn
using the Lauren function. This lowers the amount of where on the electrodes and allows for
the same electrode to be used under various burn settings.
 This example uses the same electrode to burn the cavity with high over burn settings and
smooth out the rough texture using low over burn settings.
 Many CNC Die Sinker EDM machines are available with automatic tool changers allowing the
machine to run for hours unattended.
 The CNC Die Sinker EDM could reach tolerances of ±0.0001 in or ±0.002 mm.
 The advantages of the CNC Die Sinker EDM machine compared to the conventional die
sinker EDM machine are
o Near mirror surface finishes could be achieved
o Minimal operator attention is needed
o And fewer electrodes are used.
 The disadvantage of the CNC Die sinker idiom machine compared to the conventional die
sinker idiom machine is that
o The machinery is much more expensive.
 This process can be used for machining details on cores, cavities, inserts and most mold
components.

CNC wire EDM

 CNC wire EDM is a form of electrical discharge machining that uses an electrically charged
copper wire to burn away metal from the work piece.
 A spool of wires threaded over tensioner's and guides and then either through or next to the
work piece.
 Where an electrical spark is created and burns the designated path.
 As with all CNC machines simple cutting paths are program manually and more complex
paths programmed using cam software.
 Mold design series

 Since the copper wire is very thin, it often breaks requiring it to be re-threaded.
 Many newer machines are self threading, allowing it to run for several hours unattended.
 Some of them are advanced wire EDM. Machines are capable of angling the wire over 45
degrees. This allows the machine to cut drafted and complicated holes and contours.
 The wire EDM process is a stress free machining method.
 Making it ideal for machining thin mold components such as ejector pins, long cores and
electrodes.
 Resulting surface finishes vary depending on the over burn setting used.
 As in Die sinker EDM, overburn is the distance between the cutting tools in this case the wire
and the work piece.
 Although higher over burn settings provide faster machining times, the surface finishes
typically rough and requires extensive polishing.
 Lower over burn settings are much more time consuming, yet can produce near mirror
finishes.
 CNC Wire EDM machines can reach tolerances as tight as ±0.0001 in or ±0.002 mm.
 The advantages of CNC wire EDM is
o Machining methods are the ability to machine
 Accurate holes
 Deep cavities
 And pockets
o And is also a stress free method of machining.
 The disadvantages to CNC wire EDM
o Only through holes could be machined
o And a CNC wire EDM machine tends to be expensive.
 The CNC Wire EDM processes commonly used for machining die seeker EDM electrodes, thin
mold components, ejector, pinholes, contoured and drafted cores, cavities, pockets and
profiles.

Polishing

 Polishing is used solely as a finishing operation. Polishing involves smoothing out of surface
using stones or compounds.
 Most polishing operations a very time consuming and require a great deal of skill and
experience.
 Polishing stones come in a variety of textures ranging from course to extra fine course.
 Polishing stones are used primarily at the start of the polishing stage and remove machining
marks as well as rust and any other surface defects.
 Extra fine polishing stones could provide a fairly smooth surface, which is suitable for most
applications.
 Polishing compounds are used to create a highly polished mirror finish known as an A1
finish.
 Polishing compounds contains small particles of abrasive materials such as diamond and
stone.
 These compounds are applied to the surface with a non abrasive medium, such as cotton felt
or wood.
 Mold design series

 High speed rotary vibrating and reciprocating machines could be purchased to minimize the
time and strain of the polishing process and also to improve the desired finish.
 Polishing is a very common finishing operation. Polishing could be used to smooth any
surface from a rough pocket to a ground surface.

Tolerances

 During the injection molding process, plastic material does not shrink consistently.
 With this in mind, the machining tolerances must be tighter than the molded part
tolerances.
 Machining tolerances should be one quarter or less of the molded part tolerance.
 For example, if the tolerance on a given molded part was ±0. 008 in or ±0.2 of a mm, then
the tolerance for the machine mold cavity has to be at least ±0.002in or ±0.05 of a mm.
 Many of the newest machining centers can accomplish tolerances of up to 5 decimals in ines
and 4 decimals in millimetres.
 The tolerances need to be calculated and reviewed before the mold making process begins.
To determine whether or not, they could be achieved.
 It is very difficult to maintain tight tolerances for large parts, since variations in material
shrinkage multiply as part dimensions increase.
 This example shows two parts. The first is 10 in square or 254 mm.
 The second is 1 in square or 25.4 mm.
 Both parts have a tolerance of ±0.005 in, or ±0.01 mm enter to be molded out of a material
with a shrinkage factor of 1 to 1.2%.
 In most cases, the tooling vendor calculates the mold dimensions, using the average
shrinkage value of the material. Here, 1.1% would be used for both parts.
 After factoring in the shrinkage, the smaller part could differ by ±0.001 in from the desired
dimension, or ±0.025 of a mm. Therefore, this cavity should produce parts within
specifications.
 The larger part however, may have difficulty achieving acceptable dimensions. Using the
same material and shrinkage as the one in part. The 10 in part can differ by 0.01 of an in or
0.254 of a mm.
 In order to produce an acceptable part, this tool must be built steel safe steel safe refers to
leaving additional metal on the tool so that if adjustment needs to be made, the metal can
later be removed.
 Steel safe is commonly practiced for the simple reason that it is easier to remove metal than
it is to add it back to the mold.

Seal-Offs

 During injection molding most plastic materials can’t low through areas thinner than 0.001 in
or 0.0254 of a mm.
 Silicone and liquid crystal polymers could even flow through spaces as thin as to 0.0002 in or
0.005 mm.
 Even very small gaps between mold components can produce flash, which the unwanted
excess polymer is found on the edges of the part.
 Mold design series

 To prevent flash from occurring, the two halves of the injection mold must be either sealed
off or shut off.
 The simplest and most common form of seal is the butt seal. This consists of two flat
surfaces that meet perpendicular to the direction of the closure. This seal is extremely
effective because the clamping force is applied directly to the parting line.
 The angular seal is used to shut off in an angle. When using an angular seal, the corners must
meet exactly if the angles do not properly seal the whole angled service can flash.
 When designing an angular seal, it is important to consider the machining method to be
used. For example, if a ball end mill is used to machine both of the mating surfaces. The
corner radii can’t be less than the radius of the ball end mill.
 This example shows a radial seal. In order for this seal to work correctly, the radius on both
sides must be equal. In-consistent radii can result in unwanted gaps, which can flash or
where prematurely.
 The most complex form of shut off is a contour seal. Contoured parting lines require the use
of cam software and a machine using CNC milling wire or die sinking EDM. A spotting press
could be used to check the parting line. This is a large hydraulic press that opens and closes
the mold.
 Spotting fluid is placed on the parting line and the mold is closed under pressure areas
where the spotting fluid transferred from one half to the other are areas where the parting
line is shutting off successfully.
 A parting line mismatch exists in areas where the spotting fluid does not transfer from one
side to the other. If the party line has areas where it is not sealing off, then there are
different ways to fix it. One method is to adjust the parting line on the computer file and re
cut the parting line using CNC Milling Die Sinker or Wire EDM.
 Manual grinding tools could be used to grind down areas that prevent the mold from
shutting off. This method could be fast but requires an experienced mold maker to prevent
damage to the mold.
 Lastly, the core and cavity blocks could be placed into the idea machine, and one block can
be used as an electrode for the other. This compensates for variations between the seal off
of the core and the cavity blocks. This method cannot be applied to molds that have high
angled parting lines or high radius shut off.

Inspection Equipment

 Tooling shops use inspection equipment to verify the quality of their work.
 Calipers are simple measuring devices and can be used to measure the inside outside or the
depth of the subject. Calipers have an accuracy of ±0.001 in or ±0.02 mm calipers are used
for rough measurements and are not recommended as a final inspection tool.
 Micrometers are more precise and could measure with an accuracy of ±0.0001 in or ±0.002
mm. These devices are available as outside inside step, depth and height micrometers. Bore
gages are used to measure the diameter of the hole. These also measure ±0.0001 in or
±0.002 mm. Height gauges measure the height of an object and have an accuracy of ±0.001
in or ±0.02 mm. More Advanced height gauges include digital readouts and touch sensors
that can improve the accuracy to ±0.0001 in or ±0.002 mm.
 Mold design series

 Optical comparatives magnify an image and projected onto a screen. This can either be a
detailed image or a silhouette of the object. The Comparator uses a table, which moves on
both the X and Y axes. The operator visually aligns the image with a point or line on the
screen and then measures the movement by graduations on the handles of the table. These
comparatives could be used to measure objects with an accuracy of ±0.0001 in and ±0.002
mm without actually touching the peace being inspected. Various overlay screens available
for Comparator is to measure angles, Radii and Screw threads. The comparator is very useful
for measuring work pieces and cutting tools used for CNC applications.
 One of the most accurate measuring devices used in mold making is the coordinate
measuring machine, or CMM. These devices are interface with a computer and use touch
probes that initiate measurements.
 The CMM can measure in all three axes and is accurate up to ±0.00005 in, or ±0.001 mm.
These systems could be used to measure lengths, widths, diameters, surfaces, angles and
flatness.
 Many tool shops at a video camera to the CMM measuring head to take measurements
without contact. The cross hairs on the video screen are aligned with the object being
measured. This can only be done for measurements in the X and Y directions. Since the
camera cannot accurately perceived depth.

Machining Tradeoffs

 Similar results can be produced using different machining methods. When choosing
machining method, it is important to consider the cost estimated machining time surface
finish and resulting stresses.
 In most cases, accommodation of processes must be used to achieve a better final result
than using one process by itself. The following sections include examples discussing possible
combinations of machining methods.
 One example is an ejector pin hole. The fastest and least expensive method is to drill the
hole using a milling machine. The drawback to this is that a rough surface left behind on the
inner walls and a bur is left behind on top of the whole.
 Unwanted stresses from the cutting tool in work piece could result in an inaccurately sized
hole. Ah, crooked hole or a non concentric hole. The diameter of a drilled hole is usually
accurate to ±0.001 in, or ±0.025 mm.
 To minimize the rough surface, sizing and concentrate city of the whole, a reamer can be
used. This uses a hole drilled, undersized and then followed by a reamer, which improves
the whole quality with a diameter accuracy of about ±0.0005 in, or ±0.001 mm.
 Even a reamer places stresses on the steel and can leave behind bur and still does not
provide a straight whole. This method requires more time, but the operations can both be
performed on a milling machine.
 The next method is to drill a starter hole and use a wire media machine to burn out the
whole. The starter hole drilled in a milling machine, places little stress on the work piece as
compared to the larger drill which is the diameter of the ejector pin. The wire EDM machine
then burns the round ejector pin hole. Since the EDM process does not touch the work piece
 Mold design series

directly, there are no stress is placed on the work piece. This process can provide a straight
concentric whole without bur caused by machining.
 This process can provide holes accurate of up to ±0.0002 in, or ±0.005 mm. This process
could be much more expensive, since the process requires setting up on drilling in a milling
machine as well as burning in an EDM machine. The wire EDM machine requires more time
to make the whole and the equipment is much more costly than a conventional milling
machine.
 Lastly, if a high tolerance is required on an ejector pin hole, the hole could be drilled wire
EDM and then ground to size in a jig grinder. The jig grinder can polish the ejector pin hole
with an accuracy of ±0.0001 in or ±0.0025 mm. This provides the best surface finish sizing
and concentricity, but could be very costly and time consuming. Since the process requires
the use of a milling machine wire EDM machine and jig grinder.

Conclusion

 Tooling shops tend to specialize in certain areas.

 Therefore, we recommend that you visit different shops to see their equipment and to get a
feel for their tooling methods and their techniques.
 After finishing this program, you should have a better understanding of
o Mold machining methods including
 Conventional and CNC Die sinker EDM
 CNC wire EDM
o Polishing
o Tolerances
 Machining tolerances versus molded part tolerances
 Seal offs
 Tooling inspection equipment
o And machining tradeoffs.

Upon completion of this program, you should be familiar with the machining methods available to
today's mold makers.

The next program entitled 2 Plate, 3 Plate and hot runner systems, will discuss the three major types
of injection molds most commonly used in the industry.

2-Plate, 3-Plate, and Hot Runner Molds

2-Plate, 3-Plate, and Hot Runner Molds is the fourth program in the mold design and mold making
series.

You should have already participated in the first three programs before beginning this course.

To play three plate and hot runner molds provides participants with an in depth look at the three
most common types of injection molds used in the plastics industry.
 Mold design series

This program covers

 2 plate mold configuration

 3 plate mold configuration
 Hot runner system configuration
 The advantages and disadvantages of each mold type
 And an introduction to specialized molds.

2 Plate Mold – B Slide

 The two plate mold is the most common mold design used today because of its simplicity
and low cost.
 This mold uses a cold runner system to transfer the material from the injection barrel into
the mold cavity. As the part cools, so does the runner system and rejected from the mold
simultaneously.
 The following sections describe the movable or behalf of the two plate mold configuration.
The clamp plate is either bolted or clamped to the movable Platoon.
 Ejector rails are bolted to the clamp plate and are either recessed in the sides or have
grooves to allow room for the mold clamps. Buttons are pressed into the clamp plate and
served as a landing or stop for the ejection system.
 The ejection system of the two plate mold consists of an
o Ejector plate
o Retainer plate
o Screw puller
o And return pins.
 The ejector played is bolted to the retainer plate toe hold the screw polar and the return
pence in place. The return pins are ground flush with the parting line and are designed to
ensure that the ejection system is retracted as the mold closes. The screw polar is ground
below. The parting line of the two plate mold detail is later ground on the screw polar or
core to act as an undercut to remove the screw from the screw bushing during mold
opening.
 Guided ejection should be used on all production molds. This consists of placing guide pins in
the clamping plate and guide pin bushings into the ejector plates. Guided ejection prohibits
the ejector plate from twisting or wobbling and extends the life of the ejection system.
 Ejector pins and stripper plates are the two most common methods of ejection used with
the two plate mold. The support plate and the core retainer plate are mounted to the
ejector rails. The core retainer plate houses the core detail as well as the leader pin
bushings. The support plate provides added support to the core retainer plate and reduces
deflection during injection and packing.
 Supports pillars are bolted to the clamping play passed through the ejector plates and are
usually ground flush with the support plate. These provide additional strength to the support
plate and reduce mold wear. When the core detail is machine directly into the two plate
mold base it is not uncommon for one mold plate to function as both the support plate and
the core retainer plate.
 Mold design series

2 Plate Mold – A Slide

 This section discusses the components of the stationary or ‘A’ half of the two plate mold.
 As with the behalf, the clamp plate is either bolted or clamp to the stationary Platoon.
 The cavity retainer plate is bolted to the clamp plate and is either recessed in the sides or
has grooves to allow room for the mold Clamps.
 Leader pins passed through the cavity retainer plate and are used to align the A in behalf of
the mold.
 One leader pit is offset to ensure proper mold alignment during mold assembly.
 A screw bushing is placed through the clamp plate and his ground flush with the parting line.
 The screw bushing and the meeting nozzle must have the same radius to create a proper
seal.
 The orifice diameter or oh, dimension of the screw Bushing should be larger than the nozzle
whole orifice to ensure that the screw pulls out without interference, the locating ring is
bolted to the clamp plate and aligns the screw bushing with the injection barrel nozzle.
 Most molding machines use standardized locating ring diameters of either 4 or 5 in for US
standard machines and 100 or 150 mm for metric machines.
 The advantages of the two played mold design are
o Mold Design is simple
o Versatile
o And Inexpensive.
 The disadvantages of the two plate mold design are
o Runner scrap is ejected with the part
o The part may need to be delegated
o An extra time is required for sorting runners and parts.
 The two plate mold design could be used for most molding applications, where runner scrap
can be tolerated.

3 - Plate Mold

 The 3 plate mold is similar in design to the two plate mold, yet a floating Center plate is
added and the behalf does not contain a screw puller.
 Leader Pin bushings allow the Center plate to glide along the leader pins.
 The parting line of the runner system is located between the floating Center plate and the A
half of the mold, while the parting line of the molded part is found between the floating
Center plate and the B half of the mold.
 As the three plate mold begins to open the Center plate and the behalf of the mold
remained together, opening the cold runner parting line. This separates the runner from the
part.
 The Center plate is usually pulled from the behalf using either shoulder bolts or a mechanical
latch system.
 Mold design series

 Shoulder bolts are attached to the A plate and catch the Center plate as the mold opens.
This separates the Center plate from the B side of the three plate mold.
 A mechanical latch, such as the DME Jiffy Latch lock uses a latch system to separate the
Center plate from both the A and the B half of the mold. These systems are more durable
than the shoulder bolt assembly and extend the life of the mold.
 Because the runner and part cavity have different parting lines a smaller three plate mold
base could be used in place of a larger 2 plate mold.
 One restriction of the three plate mold is that the cavities must be top gated. One arm or
pinpoint gates per part can be used anywhere on the cavity surface.
 The advantages of the three plate mold design compared to the two plate mold design are
o The runner is de-gated from the part
o Multiple parts could be top gated
o The runner could be easily sorted and a smaller mold base can be used.
 The disadvantages to the three plate mold design compared to the two plate mold design
are
o The runner has to gate on the cavity surface.
o More design consideration is required
o And the mold base is more expensive.
 The three plate mold design is ideal for round and concentric parts, which are top gated and
parts where the runner needs to be sorted from the part.

Hot runner system

Overview

 Hot runners remain heated during part cooling and stay in the mold during part removal.
 Since the runner system does not have to be cooled, most applications will notice a decrease
in cycle time.
 The most common hot runner systems available are the
o Insulated,
o Externally heated,
o Internally heated
o And hybrid
 The movable or B side of the hot runner mold base is similar in design to the behalf of the
two plate mold containing the core retainer plate, the support plate and the ejection
assembly.
 The main difference is that the hot runner mold does not contain a screw polar. The A half
differs by the addition of a hot runner system located between the clamping plate and the
cavity retainer plate.
 Hot runner systems are constantly captain direct contact with the machine nozzle.
 By keeping the polymer in the melted state, the hot runner acts as an extension of the
machine barrel.
 Since the heated runner requires less pressure to inject and packed the part, both the stress
on the polymer and the clamp tonnage are reduced.
 Mold design series

 Although more difficult to implement when used properly. Hot runner systems can improve
both process control and process consistency.
 Hot runner systems simplify automation and part removal, since the runner does not have to
be removed from the mold.
 The advantages to the hot runner mold design compared to the cold runner mold design are
o Runner scrap is not generated during production.
o Faster cycles, better process, consistency and control can be achieved.
o Lower injection and packing pressures,
o Less machine tonnages needed
o And part removal is simplified.
 The disadvantages to the hot runner mold design compared to the Cold runner mold design
are
o They are expensive,
o More difficult to implement
o And require additional design and manufacturing considerations.

Insulated Hot Runner System

 The insulated hot Runner system is the simplest form of hot runner systems available to
today's mold makers.
 Insulated hot runner systems use an additional plate located between the clamping plate
and the cavity retainer plate.
 A runner system typically 1 in or 25 mm in diameter is machine between this additional plate
and the cavity retainer plate.
 The insulated hot runner system is recommended for low temperature polymers that have a
wide melting range such as polyethylene, polystyrene, ABS and softer elastomers.
 It is not recommended for rigid and heat sensitive polymers such as polycarbonate, nylon,
acetyl and PVC. These polymers tend to freeze off or degrade.
 After the hot runner has been filled the polymer is injected through the insulated hot runner
to the part cavity.
 When the mold opens and the party's ejected, the runner remains within the mold.
 The outer plastic in the runner system cools and remains on the channel walls. Since there
are no heating elements this material acts as the insulator for the center material.
 The center material does not freeze off unless the cycle stops or if the cycle time is too long.
Processes using a cycle time of approximately 20 seconds or less are able to incorporate
these systems.
 If the insulated hot runner system does freeze or when material or color changes take place,
the runner system must be removed from the mold.
 To avoid complete disassembly of the mold, when removing the insulated runner system a
floating cavity retainer plate can be used.
 The floating cavity retainer plate is latched to the A side of the mold and houses the
insulated hot runner system.
 To remove the hot runner system, the floating plate is unlatched and can slide back.
 In many cases, a three plate mold based could be used for an insulated hot runner mold,
where the floating plate is used as the cavity retainer plate.
 Mold design series

 The advantages to the insulated hot runner system are

o No runner scrap is generated during production.
o The runner system is simple in design
o And the cost is similar to that of a cold runner system.
 The disadvantages to the insulated hot runner system are
o The runner freezes easily. There is no control over the hot runner temperature.
o It is not ideal for rigid materials
o And the runner system has to be removed from the mold during changes in material
or color.
 The insulated hot runner system is typically used for molding low tolerance parts such as
toys, flower pots, buckets and coat hangers.

Externally Heated Hot Runner System

 The externally heated hot runner system is the most common type of hot runner used.
 In an externally heated runner system, annular or round runner channels are machine
through the manifold, heater bands, heater cartridges or heating elements are used to heat
the manifold and thermo couples are used to measure the temperature of the manifold.
 A temperature controller receives the manifold temperature from the thermo couples and
then adjusts the power supply to the heating elements to maintain the correct manifold
temperature.
 The manifold is mounted in one of three ways.
o In the first method, a manifold is located between the clamping plate and the cavity
retainer plate. These plates are separated by rails on either side of the manifold.
o The second method uses a manifold that is directly mounted into the cavity retainer
plate. This is commonly used in large molds where rails can allow for excessive cavity
plate deflection.
o The third method uses a special mold plate mounted between the clamping plate
and the cavity retainer plate. This plate contains runner channels, heater cartridges
and thermo couples.
 Although this is a more expensive method, it is preferred since it reduces deflection and
simplifies the mold assembly process.
 Most externally heated hot runner systems use externally heated gate drops. These are
added to the manifold to transfer the polymer from the hot runner system to the part cavity
through an annular runner channel.
 Since the temperature controller maintains only the manifold temperature, the actual
polymer temperature is different than that of the manifold.
 During start-up and long cycle times, the plastic temperature is usually lower than the
manifold temperature.
 During production the plastic temperature is typically higher than the manifold temperature.
 Due to the sheer heating caused by the polymer passing through the manifold.
 Although the externally heated hot runner system does not control the actual polymer
temperature, it does provide superior process control compared to that of the insulated hot
runner system. Many of the newer externally heated hot runner systems use heating
 Mold design series

elements and thermal couples place near the runner channels to improve the temperature
control.
 Except for some heat sensitive materials such as PVC and acetyl, all materials can be
processed using an externally heated hot runner system.
 Externally heated hot runner systems are used for applications that require shut off gates.
These shut off gates use dramatically or hydraulically controlled rods that passed through
the gate to control the polymer flow.
 The advantages of the externally heated hot runner system over the insulated hot runner
system are
o Manifold temperature control,
o Annular flow,
o Better process consistency.
o More materials can be processed
o And the runner does not freeze off during slower cycles.
 The disadvantages to the externally heated hot runner system over the insulated hot runner
system are
o The system is more expensive
o Requires more design
o And is more complicated than the insulated hot runner system.
 Externally heated hot runner systems are ideal when the elimination of runner scrapped
justifies the added expense such as automotive, medical and consumer products.
 These hot runner systems are also useful when shut off valves are required, such as with
sequential gating and foaming applications.

Internally Heated Hot Runner System

 The internally heated hot runner system uses heating elements located in the center of the
Tubular Runner channel.
 The Tubular Runner channel produces more pressure loss than an annular runner channel,
therefore requiring more injection pressure to fill and pack the part.
 Both heater elements and thermal couples are inserted inside the runner channel to heat
and measure the polymer temperature directly.
 The internally heated runner system can be implemented in four different ways.
o In the first method, the runner system is machine behind the cavity retainer plate,
and an additional plate is placed between the clamping plate and the cavity retainer
plate.
o The second method uses a manifold located between the clamping plate and the
cavity retainer plate, which are separated by two rails.
o In the third method polls a recessed into the cavity retainer plate to house the
manifold.
o The fourth method uses a specialized mold plate also mounted between the
clamping plate and the cavity retainer plate.
 Mold design series

 This plate contains the runner channels, heater cartridges and thermal couples. Although
this is more expensive cavity retainer played, deflection is reduced and mold assembly is
simplified.
 The polymer is transferred from the runner system to the part cavity using two different
types of internally heated gate drops.
o The first type uses a conductive rod, which passes through the runner system and
the center of the gate drop. This heats the gate and measures the gate temperature
internally.
o The second type of internally heated gate drop uses a heating element and a thermo
couple unit mounted in the center of the gate. These systems are delicate but
provide the best control over the polymer melt since they can control the
temperature near the part cavity.
 More advanced gate drops, known as thermal valve gates have a second heating element,
which both heats and cools the tip of the gate rapidly. These allow the gate to be opened
and closed faster and are designed to be used with complex shut off in sequential valve
gating systems.
 Internally heated hot runner systems provide better melt temperature control than
externally heated hot runner systems. Since the heating element is in direct contact with the
temperature probe.
 The advantage to internally heated hot runner systems over externally heated hot runner
systems is
o Better control over the polymer melts
o And more consistent processing.
 The disadvantages to internally heated hot runner systems over externally heated hot
runner systems are
o They are more expensive
o More complex and are more delicate.
 Internally heated hot runner systems are ideal for hot runner applications that require high
process control. This system is typically used for processing high tolerance parts from
engineering and specialty materials.

Hybrid Hot Runner Systems

 Hybrid hot runner systems are commercially available to mold makers to want to match a
hot runner system to their application, or to reduce the cost of a hot runner system.
 These hot runner systems are made from a combination of hot runner technologies.
 Heated drops can be added to an insulated hot runner mold to improve process control and
to decrease gate freeze off these are less expensive than externally heated hot runner
systems and can accommodate more materials and longer cycle times than the insulated hot
runner systems.
 Internally heated gate drops could be added to externally heated hot runner systems to
provide better control over the polymer melt as well as lowering the cost.
 In most hot runner systems, there are dead zones which are places where the polymer flow
stops. These zones cause highly heat sensitive materials such as PVC and acetyl to degrade.
 Mold design series

 Dead zones also retained colored materials causing streaking and discoloration during color
changes.
 Some hot runner systems are designed with highly polished runners and rounded corners to
reduce or eliminate dead zones.
 These runner systems are used for color changes and processing heat sensitive materials.

Parting line locks

 To properly align the parting line during mold, closing parting line locks are used parting line
locks help prevent damage to the party lines during injection and mold closing.
 The three most common parting line locks are the
o Round
o Rectangular
o And straight locks
 Round parting line locks are tapered mold inserts, which are placed into the core and cavity
halves of the mold.
 A conical insert locks with the tapered hole, which guides the two mold halves together at
least two round locks are needed to reduce twist in the mold half’s.
 Rectangular tapered locks are long inserts with precisely ground interlocking sides. A
combination of two tapered locks mounted perpendicular to each other provide more
support than the smaller round inserts.
 As the name implies, straight locks are designed to act as a straightening guide during the
closing of the mold. These utilize a male insert and a female insert to lock the two mold
halves together.
 When mounting straight locks perpendicular to each other. The locks not only ensure that
the parting lines are line when the mold closes, but also guides the mold as it closes.
 Straight parting line locks are ideal for molds that have delicate detail, which can damage
easily if the mold closest improperly.
 Unlike straight parting line locks, the round and rectangular locks align the half’s just as the
mold finishes closing.

Specialized Tooling

 As different forms of injection molding developed, specialized forms of tooling also arise.
 Consumer product industries have developed specialized tooling to withstand extremely
high quantities and speeds.
 These high cavity tools are equipped with custom hot runner systems designed to produce
millions of parts.
 These tools are constructed using hardened cores and cavities, which improved their
strength and durability.
 Many of these tools are also fitted with lubrication systems providing lubrication to all mold
components allows the mold to run for extended periods of time without interruptions for
basic mold maintenance.
 Mold design series

Stack Molds

 Many high production injection molders use stack molds having to parting lines to double
production.
 These multiple parting lines are injected from a central hot runner system.
 When parts are molded opposite each other in a stack mold, the injection pressures from
the two cavities cancelled each other out, therefore requiring the same clamping force as
one parting line.
 As the mold opens, the core remains with both the stationary and movable Platoon. The hot
runner system and mold cavities are mounted in a floating center section which remains in
the middle as the mold opens.
 To keep the cavity plates centered, a hydraulic cylinder is commonly used to push the cavity
away from the stationary Platoon.
 Other mechanical means such as a lever or gear can also be used.
 As the mold opens, the lever system holds the Center plate between the movable and
stationary Platoon using a series of linkages.
 A gear can also be placed on the Center plate with tooth draw odds attached to the two core
sides. The gear keeps the cavity plates centered as the mold opens and closes.

Co-Injection and Double Shot Molds

 Many consumer and automotive parts are molded using multiple materials and colors. This
is done using either co injection or double shot molding.
 These processes use machines equipped with two barrels to inject the different materials.
 Co-injection molds inject to materials into one mold simultaneously and are most commonly
used when the part requires two different colors.
 Unfortunately, the appearance and strength of the Weld line is typically poor.
 This process is typically used for low strength applications where the joining of the two
materials is not visible.
 Double shot molds inject two different materials in two separate stages.
 There are three different types of double shot tooling
o The shuttle mold,
o The rotary platinum mold
o And the retractable core mold.
 The shuttle mold contains a core that is inserted into a frame, which shuttles the core back
and forth.
 The shuttle passes under the first cavity closes, and the first material is injected.
 After the part cools, the mold opens and the core shuttles under the second cavity. The mold
then closes, and the second material is molded over the first.
 This system provides better strengthen appearance to the parts than the co injection
process and is commonly used for automotive applications.
 Rotary Platinum Old uses two identical cores and two different cavities.
 Mold design series

 One material is injected into the first cavity, while the second material is molded over the
initial part at the second cavity.
 When the mold opens, the parts from the second cavity are removed and the parts from the
first cavity are rotated.
 Unlike the shuttle mold, the rotary system essentially doubles production since both cavities
are molded at the same time, one producing a finished part and the other making the initial
part.
 The retractable core mold contains a movable core which is moved back and forth.
 After the first material is injected, the core retracts and leaving a space for the second
material to be injected.
 This is commonly used for cosmetic parts that require detailed to be molded into the part
such as lettering.

Electrical Connectors

 Since the field of electron IC’s is constantly upgrading. Connectors need to be manufactured
in a wide variety of sizes and configurations.
 To avoid the high cost of manufacturing a variety of injection molds.
 Connector molds are built with multiple inserts. Inserts could be added or removed to create
the desired length and style of the connector.
 These inserts can be rearranged quickly to reduce the change over time.
 Connector mold inserts are designed using hardened tool steels, which reduced damage
caused by changing inserts and during high production runs.

Compact Discs

 Molds used for compact disks must produce parts with the high surface finish at very fast
rates.
 A master containing the information to be molded on the 500 is mounted to the core side.
This master can be changed quickly since the center is held in place using a round insert and
the perimeter by vacuum force.
 The CD or DVD is gated using a circular disc gate, the machine nozzle is brought close to the
gate to reduce the spruce size and runner scrap.
 The mold bases round to reduce cooling variations and special circular cooling channels are
used on both sides to decrease cooling time.
 The CD Molds are designed to be used in specially configured CD molding machines. These
machines run at high speeds and use three tie bars close to the mold to reduce variations in
mold tonnage.
 These machines were made exclusively for making CDs and DVDs.

In-Mold Labeling
 Mold design series

 Most parts are decorated after molding using secondary operations such as stickers or
painting.
 In mold labeling, is a new process that molds the polymer directly over the label and
therefore does not require any secondary finishing operations.
 Automation is used to pick up the pre printed labels and to apply a static charge. The labels
are then placed directly into the cavity side of the mold while the finished part is ejected
simultaneously off the core side.
 The label is held into place for molding using static electricity. Ah, highly polished mold
surface helps keep the label flat for optimal appearance.

PET Forms

 PET pre forms are injection molded parts that are later sent to a reheat blow molding station
to produce plastic bottles.
 The molds used for the pre forms are high cavity molds designed to produce millions of
parts.
 Since PET has poor heat transfer characteristics the cores are typically made of hardened
H13 steel.
 A bubbler passes through the center of the core which improves heat transferred between
the polymer and the cooling lines.
 A cooling channel passes around the cavity block to provide consistent cooling to the cavity
insert.
 Side actions are mounted within the stripper plate to remove the threads from the part
before it is picked up by the robotics.
 Since PET cools slowly the parts must be ejected warm to reduce cycle time.
 The robotics equipped with cooling channels retained the warm pre-forms until cooling is
complete. This cooling method allows for cycle times to be a slow as 11 seconds.

Shuttle Molding

 Not to be confused with the double shot process. Shuttle molding is used when inserts must
be manually loaded or when manual part removal is required.
 Shuttle molding machines are usually vertical machines that open the mold using the cavity
side and inject the polymer at the parting line.
 The core side of the molding machine shuttles two identical cores back and forth.
 At the end of each cycle, the cores are shuttled allowing the operated to remove the molded
part from one core, while the other core is being molded.
 This process increases productivity when manual, part removal or manual insert loading is
needed.
 When machining these molds, it is important to ensure that the core dimension Zahra's
close to each other as possible to reduce part variation.

MuCell Process
 Mold design series

 The MuCell process is a new injection molding technology licensed by Trexel. This
incorporates either nitrogen or carbon dioxide into the polymer before injection.
 This significantly reduces the viscosity of the polymer, allowing for lower temperatures and
lower injection pressures to be used and therefore decreasing the overall cycle time.
 During injection the gas creates a micro cellular structure in the part that reduces part
weight.
 When designing tooling for the MuCell Process. Large number events should be used to
accommodate for high injection speeds.
 All mold components must be made to high tolerances and shallow vents should be used to
prevent flash.
 To take advantage of the low material viscosity, significantly smaller gates and runners
should be used to reduce runner scrap.
 When using hot runner molds Mechanical valve gates are required to prevent the gas filled
polymer from drooling while the mold is opened.
 The part must be properly cool to prevent cell growth after ejection.
 To control the cell growth, heat must be transferred from the part to the mold as quickly as
possible during cooling.
 Metals such as beryllium, copper and aluminium help increase the thermal conductivity as
well as reduce the cooling time.
 The MuCell processes becoming more common since a number of machine manufacturers
are offering this technology with their newer machines.

Injection Compression

 Injection compression uses a movable core to reduce stresses in the part.

 Before injection, the core is retracted to increase the cavity thickness. This reduces injection
pressure, which places less stress in the part.
 During packing, the core is forced forward. This compresses the polymer and provides um or
uniformed pressure.
 Mold using the injection compression technique typically use a cam driven by a hydraulic
motor to control the movement of the core.
 These systems are typically used for thin wall and optical applications, since they're more
susceptible to part warpage and distortion.

Conclusion

Upon completing this program, you should have an understanding of the three most common types
of injection molds used in the different types of hot runner systems and specialized tooling used in
the injection molding industry.

You should now participate in the next program entitled Mold Basis, Tool Steels and Heat Treating.

Mold Basis, Tool Steels and Heat Treating

 Mold design series

 Mold bases, tool steels and heat treating is the fifth program in the mold design and mold
making Series.
 Before beginning, you should have already participated in the first four programs the last
entitled 2 plate, 3 plate and hot runner molds.
 Mold bases, tool steels and he treating provides participants with an understanding of
common mold bases and different materials used for injection mold construction.
 The topics covered in this program are
o Quantitative and qualitative material properties for tool steels.
o Heat treating
o Surface treating
o Surface coatings
o Low and high hardness
o Tool steels
o And alternative tooling materials
o Also discussed our common mold bases and interchangeable mold systems.

Material properties

 Since there are literally thousands of mold based tool steel and he treating combinations,
we've narrowed this program down to the most commonly used materials and processes.
 The materials used for injection mold construction could be evaluated using both
quantitative and qualitative properties
 Quantitative material properties are those that can be measured and easily compared such
as hardness and strength.
 These properties are represented by a numerical value obtained through testing. For
example, AISI P-20 steel may have a hardness of 34 Rockwell C and a tensile strength of
200,000 PSI material. Properties such as materials, chemical resistance or its ability to be
machined or polish cannot be assigned a numeric value.
 These are considered qualitative properties and represented in relative terms. For example,
the tool Steel AISI 10-30 could be easily machined yet has poor chemical resistance and
cannot be polished to a mirror finish.
 In the next sections we discuss the more common criteria used in tool steels selection. More
specific material properties can be obtained through your supplier.

Quantitative properties

 Quantitative properties for injection mold tool steels consists of a

o Material's hardness
o Strength
o And thermal conductivity.
 These properties are represented as numeric values based on the results of various industry
standard tests.
 Mold design series

 The hardness of materials used in injection mold construction are expressed using either the
Brinell or Rockwell C scales.
 Softer metals such as aluminium or beryllium copper are measured using the Brinell
hardness scale.
 This test consists of penetrating ah hardened steel ball under a specified load into the
material and measuring the resulting indentation.
 The heart of the material being tested the higher the value, the Brinell scale produces values
up to 300.
 Harder materials, which cannot be measured using the Brinell scale, require the use of the
Rockwell C hardness scale.
 The Rockwell test uses a diamond point held under a specified load to pierce the material.
 As with the Brinell hardness test, a higher numeric value represents ah harder material. A
measurement of 30 Rockwell C is roughly equivalent to a 300 Brinell result.
 Another quantitative property of a tool steel is its strength. The most commonly used
measurement is tensile strength and is a measure of a steals resistance to stretching under a
specified load. This is expressed in PSI or MPa. Higher strength indicates a higher resistance
to deflection.
 A materials ability to transfer heat is known as thermal conductivity. Materials that arm or
efficient in transferring heat have a higher thermal conductivity value. This is generally
expressed as BTU/(hr*ft*Fo) or Cal/(s*cm*Co).

Qualitative Properties

 Some common qualitative properties of tool steels include corrosion and wear resistance
and its ability to be machined or polished.
 These properties are expressed in a straight forward manner, for example, AISI 420 Stainless
steel has high corrosion resistance and could be polished to a high service finish.
 During the processing of certain polymers and additives such as PVC, acetyl and flame
retardants. Harsh chemicals are produced.
 A materials corrosion resistance is its ability to protect itself against such harsh chemicals.
 Another qualitative property is the materials wear resistance. Harder materials generally
provide optimal wear resistance. Yet some softer materials, such as copper and brass, have
exceptional wear resistance.
 As a general guideline, materials softer than 30 Rockwell C could be easily machine using
standard milling and turning procedures.
 Harder materials are usually softened before machining, thus reducing where on machining
equipment as well as machining.
 Time hardened steel requires milling machines that are equipped with high speed spindles.
Harden steals can also be purchased containing sulphur, which allows them to be machined
using standard equipment when polishing, the result in possible surface finish varies with
each material. For example, materials such as ANSI 10-40-06 cannot be polished to a mirror
finish while ANSI 420 steel and aluminium can.
 Mold design series

Heat Treating

 Heat treating is the act of heating and cooling the steel at predetermined temperatures and
times to adjust its hardness and strength.
 Some old makers perform he treating in house, though we recommend sending the steel to
an outside vendor. Steal consists of 0.4% carbon or more can be heat treated.
 During the heat treating process, the chemical structure and dimensions of the steel are
changed.
 As the steel is hardened, it typically increases in size and may cause distortion.
 More distortion is likely to take place when working with larger steel blocks or when a
dramatic change in hardness is desired.
 The amount of dimensional changes is case dependent. For example, an increase in hardness
of 20 Rockwell C during heat treatment results in more severe changes than an increase of
10.
 When he did, the steel reaches a specified hardening temperature, which transforms it to an
Austenite state. In the Austenite state, the carbon is dispersed within the steel and then
must be cooled.
 When cooled slowly or any yield the steel has changed into soften state called perlite.
 Annealing involves placing the steel into a medium such as hot oil, warm air or salt. This
process is used to soften the steel before machining or to significantly reduce the stresses
within the steel after machining.
 When the steel is cooled quickly from the austenite state, it changes to a very hard yet
brittle state called Martensite. Hardening is performed in a medium such as cold oil, air or
water, which quickly removes the heat from the steel.
 After the steel has been hardened, it should be tempered multiple times before being used
for high production runs.
 Tempering involves heating the steel to a temperatures slightly below the hardening
temperature.
 The steel is then slowly cooled to reduce hardness and to increase Durability.
 Normalizing the steal from the heated Austenite state is often done through air cooling.
 Normalizing cools the steel faster than the A kneeling process and produces a composition
of both Perlite and Martin site, which is harder than a kneeled steel.
 After machining normalized steel to near final dimensions, the steel should be stress
relieved. As with tempering, stress relieving involves heating to a temperature slightly below
the hardening temperature and then slowly cooling the steel. This reduces stresses within
the steel before hardening to help reduce distortion.
 Stress relieving is performed after a large amount of steel is removed or after welding.

Surface Treating

 Mold components could be surface treated to increase their hardness or their chemical
resistance.
 Surface hardening heats the surface of the steel to above the hardening temperature
through the use of lasers or electron beams.
 Mold design series

 The surface cools quickly and ah, hardened layer of steel is formed.
 As with heat treating this procedure can be performed on steals having a carbon content
equal to or greater than 0.4%.
 Steals that cannot be surface hardened can be carburised. This process heats to steal in the
presence of a high carbon medium, such as leather or charcoal. The carbon rich surface is
then cooled quickly and hardened.
 When processing corrosive materials such as PVC and acetyl.
 Mold components should be nitrated. This involves heating the steel in an ammonia rich
environment to incorporate nitrogen into the surface.
 Boariding is done to avoid heat treating mold components having simple geometry.
 Boariding involves surrounding the steel with boron rich metal plates. The boron migrates to
the surface of the steel being treated and creates a thin hard layer of iron bow ride. This
process cannot be used for components having complex geometry, since the steel must
come in contact with the boron rich plates.

Surface coatings

 This section discusses some of the more common surface coatings that are used references
such as the Coatings Guide published by Injection Molding magazine, can be used as a
helpful reference in selecting that surface coating that is appropriate for your application.
 Coatings provide an additional layer of metal to a service. Coatings are used to increase the
hardness or chemical resistance of steel as well as to reduce surface friction.
 Surface coatings are commonly used in place of nitrating or carburising. Since they do not
alter the chemical composition of steals or subject them to high temperatures.
 All machining and finishing operations must be complete before sending out mold
components to be coated.
 To increase the surface hardness of steel, a layer of titanium carbide or titanium nitride can
be added.
 Titanium carbide is among the hardest coatings available and is applied to prolong the life of
high production cores and cavities.
 Titanium carbide or titanium nitrides are commonly used with abrasive additives such as
glass fibbers, talc and Mica.
 Nickel or Nickel Teflon plating is used to improve the chemical resistance and to reduce the
surface friction of the steel.
 Adding a layer of chrome to the surface increases both its hardness and its chemical
resistance.
 Chrome plating is usually reserved for treating highly polished core and cavity surfaces or for
use with polymers, which create residue such as ABS, PVC or polyethylene.

Low-Hardness

 The following sections discuss the most common steel types used in mold construction.
 Steals having Rockwell C values of 40 and lower are considered to be low hardness steals.
 These steals could be machined using conventional milling and turning techniques.
 Low hardness steals generally have strengths lower than 200,000 PSI or 1400 MPa.
 Mold design series

 These steels have thermal conductivity values between 22 to 29 BTU/(hr*ft*F o) or 0.09 to

0.12/( s*cm*Co).
 The softer steals have poor corrosion, oxidation and wear resistance properties.
 Since most low hardness steals cannot be polished to a high surface finish, their mostly used
as mold plates, rails, support pillars and locating rings.
 When used as core and cavity blocks. This steals are reserved for low production and
prototype molds.
 AISI 10-20, 10-30 and 10-40 steals are low strength tool steels that range of hardness from
100 to slightly over 200 Brinell.
 These steels are generally used for low stress mold components or as mold plates in low
production molds.
 AISI 41-30 and 41-40 are tool steels that range from 25 to 30 Rockwell C Hardness. The
hardness of these steels makes them suitable to be used as mold plates in high production
molds.
 AISI P-20 is a 41-40 steel that has increased hardness as well as improved chemical and
corrosion resistance. This steel has ah hardness of 28 to 32 Rockwell C and is often used in
corrosive and human environments for high production mold plates.
 PX-5 and NAK-55 tool steels have Rockwell C hardness values of 33/40 respectively.
 Both steals are sulphur added, which allows them to be machined easier. These steels could
be polished to a high service finish and are ideal for use with core and cavity blocks in low
production molds.
 In some cases, PX-5 and NAK-55 can be used for large cores and cavities in high production
molds.

High-Hardness

 Steels that are hardened to over 40 Rockwell C are very difficult to mill or turn.
 Therefore, these high hardness steals are generally purchased and machine in the annealed
or normalized state and then hardened.
 High hardness steals generally have strengths higher than 200,000 PSI or 1400 MPa.
 Most of these steels have thermal conductivity values between 18 to 24 BTU/(hr*ft*F o) or
0.07 to 0.10/( s*cm*Co).
 AISI 420 stainless D2 and M2 tool steels have significantly lower thermal conductivity. This
increases cooling time, making them a poor choice for core and cavity blocks in high speed
processes.
 Most high hardness steals a relatively easy to machine in soften state can be polished to a
high surface finish and show little distortion during heat treatment.
 High hardness steals are used as core and cavity blocks, slides, stripper rings and lifters for
high production molds.
 ANSI 420 stainless is corrosion resistant steel that could be hardened up to 52 Rockwell C
and polished to a mirror finish.
 420 Stainless is best suited for molds used in corrosive or human environments.
 AISI H-13 steel can be hardened up to 51 Rockwell C. This steel has a high resistance to
thermal shock, which allows it to withstand large changes in temperature during production.
 Mold design series

 AISI H-13 is an excellent tool steel for use as core and cavity inserts, especially for processing
high temperature materials.
 AISI D-2 steal can be hardened up to 59 Rockwell C.
 D-2 steal is difficult to polish, difficult to grind, cannot achieve a high surface finish and has
poor thermal conductivity.
 This deal does have excellent wear properties and is often used for wear plates and high
wear components.
 AISI S-7 tool steel can be hardened up to 58 Rockwell C. This deal has excellent resistance to
mechanical shock, making it ideal for high stress applications.
 S-7 is typically used for core and cavity inserts and for components in high speed tooling and
stripper plate molds.
 AISI 01, 02 & 06 tool steels are capable of being hardened up to 60 Rockwell C.
 All three of these steels have poor corrosion resistance and low resistance to thermal and
mechanical shock.
 Although these steels have good wear resistance, they should not be used for applications
where the steel is subjected to high stresses and high temperatures.
 AISI A2 & A10 can be hardened up to 62 Rockwell C have good corrosion resistance and
excellent wear qualities.
 Since these steels are difficult to polish their best suited for high wear mold components
such as lifters and slide blocks A2 & A10 steals are often used for core and cavity blocks if
extensive polishing is not required.
 AISI M2 is commonly referred to as high speed steel. This deal can achieve a Rockwell C
hardness of up to 63 but is very difficult to machine even in the softened state.
 M 2 is generally used for pre-made mold components such as ejector pins and ejector
sleeves.

Tooling Materials

 Although steel is the most common material used in mold construction. There are other
material options. These materials include
o Beryllium
o Copper
o Aluminum,
o Kirksite
o Bronze
o And photopolymers
 Beryllium copper and similar alloys can reach a hardness of up to 40 Rockwell C.
 These alloys have high thermal conductivity values, reaching up to 100 BTU/(hr*ft*F o) or
0.37 Cal/( s*cm*Co).
 Beryllium copper must be machined and welded in an enclosed nitrogen rich environment,
since toxic and carcinogenic gases are produced.
 Due to health and safety concerns, the use of beryllium copper is reserved for molds that
require extensive cooling, such as low pressure or high speed processes.
 Aluminum alloys are extremely low strength metals having hardness is that do not exceed
150 Brinell.
 Mold design series

 Aluminum can be easily machined and has excellent heat transfer characteristics similar to
beryllium copper.
 Aluminum alloys are commonly used for prototype and low production molds. This steel
could be used in some high production molding applications when used for parts requiring
low injection pressure.
 Kirksite has ah hardness of only 100 Brinell with similar thermal conductivity to aluminum
and beryllium copper. This metal is cast around a prototype part and then machined and
ground to make the final core in cavity blocks for prototype tooling.
 Bronze and bronze alloy boys are soft metals that could be easily machined and have
excellent wear resistance. These metals are typically used for wear components such as
bushings, wear plates and guide blocks.
 Photopolymers are used for prototyping tooling using a stereo lithography machine. The
stereo lithography process is used to manufacture prototype parts, using a pair of computer
guided lasers that cure a photo polymer in layers.
 The result in tool is only useful for producing a few 100 prototype parts before deteriorating.

Common Mold Bases

 There are five common mold based configurations used in the industry. Most mold based
manufacturers including DME National Tool and Superior Die Set, refer to these mold bases
as the
o A-Series
o B-Series
o AX-Series
o T-Series
o And X-Series
 These mold bases used the AISI 10-30 steel or a steel of similar grade for the ejector plates,
clamping plate and ejector housing.
 The support core retainer cavity, retainer and stripper plates are available in a variety of
steals including AISI 10-30, 41-40 and P-20.

A and B Series

 The A and B Series of mold bases are used for two plate mold applications.
 The cavity side of the A Series mold base contains the clamp plate cavity, retainer plate
locating ring screw bushing and leader pins.
 The core side of the A Series contains the support plate core retainer plate leader, pin
bushings, ejector plates, screw puller and return pins.
 The clamp plate rails and buttons are combined to form the ejector housing.
 The cavity side of the B Series differs from the A Series by using a single cavity side plate in
place of both the clamping and cavity retainer plates.
 A single core plate is used in the B Series in place of the support and core retainer plates
used in the A. Series.
 Mold design series

 The A Series mold base should be used when core and cavity blocks are present and the B
Series is ideal when the core and cavity detail is machine directly into the mold base.

AX and T Series

 Three played mold applications use the AX and T Series mold basis.
 The AX Series is a Series style mold base that has an additional floating Center plate.
 This mold base does not provide a method of ejecting the runner system from the mold and
therefore requires manual or robotic removal.
 The T Series mold base is capable of ejecting the runner system through the use of a second
floating plate located on the cavity side of the mold.
 Mold designers typically use small pins mounted in the clamping plate, which passed
through the floating plate.
 These pins are used to hold the runner to the cavity site of the mold before it is ejected.
 The T Series mold base is more frequently used in the AX mold base due to its ejecting
capabilities.

AX and T Series

 The X Series mold bases designed for mold applications that use a stripper plate. This design
comes is both 5 & 6 plate assemblies.
 Both X Series mold bases use a clamping plate and core retainer plate on the cavity side of
the mold.
 In this configuration, the leader pin bushings are placed into the cavity retainer plate, and
the leader pins are mounted into the core retainer plate. A floating Center plate is also used
in both bases for party ejection.
 The six plate mold base uses both a core retainer plate and a support plate on the core half
of the mold. This design is ideal for stripper plate mold basis that use core block inserts.
 The five played mold base uses a single core plate in place of the core retainer and support
plates. It is used when the core detail is machine directly into the mold base.

Stripper Plate Bushings

 Choosing the appropriate bushings for a stripper plate is critical in determining the
performance and longevity of the mold and its components.
 There are four common bushing styles used by mold makers.
 The most common style of stripper plate bushings known as standard are made of steel or
platted with brass. These bushings are commonly used with low production molds.
 Specialized bushings that are designed for high production molds include graphite
impregnated bushings, linear ball bearing bushings and preloaded bushings.
 Graphite impregnated steel has improved wear characteristics when compared to brass and
can be used in place of standard bushings without making any modifications to the mold
design.
 Linear ball bearing bushings use rows of ball bearings and require a larger whole than the
standard bushings for mounting purposes.
 Preloaded bushings are the superior style of bushings, yet require additional design and tool
modifications to accommodate its larger size.
 Mold design series

 These bushings use many ball bearings, which are mounted within a retainer.
 The retainer slides between the leader pin and a sleeve mounted within the stripper plate.
 The sleeve is typically large considering it must accommodate the length of the bearing
retainer plus half the distance of travel of the stripper plate.
 These were not conducive for molds having long cores, since the stripper plate would need
to be much larger.

Interchangeable Mold Systems

 The mold bases that we have mentioned in this program are all standard sizes.
 Most suppliers could manufacture mold bases in custom sizes and materials to fit your mold.
 Interchangeable mold systems use a common mold base designed to accept different cores
and cavities. This concept eliminates the cost of purchasing a separate mold base for each
application and significantly simplifies the mold change process.
 Tool shops often designed their own interchangeable mold systems.
 These systems can range from entire core and cavity inserts to smaller adjustable inserts.
 Two of the more common interchangeable mold systems available are the master unit die
and roundmate systems.
 The Master Unit Die or mud system offers different size mold bases. That except rectangular
core in cavity inserts.
 The mold inserts slide into the mold base and are held in place using Allen screws.
 A variety of inserts are available to fit each mold base, thus allowing a wide variety of parts
to be molded using the same old base.
 Cooling line fittings could be purchased to further simplify the mold change process, these
connect the water lines directly to the insert as it is placed into the frame.
 The round mate system is used for round core and cavity inserts.
 Cooling channels are machine into the mold base and provide water to the perimeter
cooling channels machine around the core and cavity inserts.
 M aster Unit Die and Round mate mold basis have the ability to house multiple core in
cavity inserts, which could be used as high production or family molds.

Conclusion

 Upon completion of this program, you should have an understanding of quantitative and
qualitative material properties for
o Tool steels
o Heat treating
o Surface treating
o Surface coatings
o As well as classifications of low and high hardness tool steels.
 Also discussed
o Alternative tooling materials
o Common mold bases
o And interchangeable mold systems
 Mold design series

 The next program entitled External and Internal Actions, discusses methods of removing
undercuts from apart before ejection.

External and Internal Actions

 External and internal actions are the sixth program in the mold design and mold making
Series.
 Before beginning this program, you should have already completed the first five programs.

Introduction

 External and internal actions provide participants with an understanding of how different
mold components are used to remove undercuts from an injection molded part.
 These components include slides, core pins, lifters, expandable cores, collapsible cores and
unscrewing cores.
 This program also covers material considerations pre-load and sell offs.
 Undercuts are features in the part that interfere with mold opening and part ejection. Some
common undercuts include threads, slots, holes, clips and lettering.
 To remove undercuts from the mold, external or internal actions must be added to the
mold.

Slides

 External actions are mold components used to remove undercuts from the outside of the
molded part.
 The four most frequently used external actions are slides, core pins, lifters and expandable
cores.
 The most common external action is the slide. Slides move into place before mold filling and
then retract to remove the undercut detail before or during ejection.
 A typical slide assembly contains a slide block guide, blocks where plates, a slide retainer, an
actuator and slide blocks.
 A slide block is made of hardened tool steel and contains the cavity detail for molding the
undercut.
 When using larger slides or molds with intricate detail a hardened insert should be added to
the front of the slide block slide block inserts are used for high wear applications that
require frequent replacement.
 The slide block and insert should be interlocked, preventing any unwanted movement during
injection and packing.
 Mold design series

 Unfortunately, when using slides small witness lines are formed where the slide block in the
core block meat.
 One way to improve witness line appearance is to use an angled shut off on the sides of the
slide block
 Using metals with similar thermal conductivity for both the slide block and core block can
also improve witness line appearance by promoting even cooling.
 Adding surface texture is another way to disguise witness lines.
 If the slide block and mold cavity are textured together, the witness lines are far less evident.
 As the slide block moves back and forth. Guide blocks or Gibbs are used to direct the
movement.
 Guide blocks are bolted to the mold and our precision ground to interlock with the sides of
the slide block.
 Guide blocks are typically made of softer, wear resistant materials such as bronze, bronze
plated steel or graphite impregnated medals.
 These materials are intended to wear before the slide block, where plates are also added to
the mold and are positioned underneath the slide block.
 Like guide blocks where plates are also made of softer materials and are designed to help
reduce slide wear.
 Slide retainers are used to keep the slide in position during part ejection.
 Springs, clamps and spring loaded slide retainers are the three most common types used.
 A spring between the slide and the core block holds the slide in the back position while the
mold is open.
 One drawback associated with the spring slide is that a constant force is applied to the slide
and the actuator. These springs also have a tendency to break during long production runs.
 Clamp slide retainers use a small spring loaded clamp, which interlocks with a post mounted
on the slide block. This clamp has enough strength to keep the slide from floating, but
releases the slide when the actuator starts to push it forward.
 Spring loaded slide retainers use it in dent on the slide block, which locks with a spring
loaded ball or bar mounted underneath the slide. As with clamps slide retainers, these apply
minimal force to the actuator.

Actuators

 Actuators move the slide into position before injection and pull the slide back before part
removal.
 The three forms of actuators used are the mechanical, pneumatic and hydraulic.
 The mechanical actuator is the most common and uses actuator pins, also known as horn or
angle pins.
 Actuator pins are made of hardened steel and are mounted opposite the slide block in the
cavity plate at an angle to simplify construction and installation.
 Many actuator pins can be equipped with angled or rounded heads during mold, closing the
actuator pins, engage with holes machine into the slide block and force it forward as the
mold opens.
 Mold design series

 The actuator pins remain with the slide block until it is in the back position. The length of
engagement equals the amount of distance. The actuator pin travels within the slide block.
 The length of engagement and the angle of the actuator pin determine the amount of
movement and force applied to the mechanically actuated slide.
 Calculating
 Slides length of travel = Length of engagement x Sin (Actuator pin angle)
 This dimension must be greater than the depth of the undercut being removed in order for
the slide to work properly.
 Increasing the angle of the actuator pin increases the length of travel. Yet more wear is
induced on slide components.
 With this in mind, high production molds typically use actuator pin angles of 10 degrees or
less.
 Mechanical actuators can also be utilized in a two stage ejection system. The first stage
actuates the slide and the second stage ejects the part.
 The slides length of travel = (Ejector plate’s length of travel) x tan (Actuator pin angle)
 Pneumatic actuators use an air powered cylinder to move the slide back and forth.
 To control the pneumatic cylinder an auxiliary function on the machine or a pneumatic
pump linked with the machine is required.
 These systems can actuate the slide faster than the mechanical method and induce less wear
on the slide assembly.
 Pneumatic actuators are ideal for high speed applications in which the slide has little detail
and can be easily pulled from the part.
 Hydraulic actuators also require an auxiliary hydraulic pump or auxiliary functions such as
core pole to control the movement of the slide.
 Hydraulic actuators apply a greater force to the slide than pneumatic actuators.
 When hydraulic or pneumatic cylinders are used, it is the respective pressures that hold the
slide in place during ejection.
 A proximity sensor is located on the cylinder, is used to signal the molding machine when
the slide is in place.
 A slide lock holds the slide in place during injection. Ah, he'll block applies pressure to the
slide block when the mold is clamped.
 Due to the force is applied to the hell block a small wear plate can be used to ease
replacement when wear is evident.
 The angle ground onto the back of the slide block corresponds with the angle on the face of
the heel block. This angle is typically 10 to 20 degrees and locks after the slide has been put
in place by the actuator.
 If actuator pins are used to push the slide forward, the angle of the slide lock should be
approximately 5o higher than the angle of the actuator pins.
 This is done to minimize the force applied to the pins.

Pre-load

 Freeload can be incorporated into mold components other than actions, support pillars can
use positive pre load to provide additional support.
 Adding pre load to core and cavity blocks ensures that the clamping pressure is directed to
the parting line and not the mold base.
 Mold design series

 Injection molding pressures could exceed 45,000 PSI or 3000 bar. These high pressures can
cause internal or external actions to move during filling and packing, resulting in flash.
 Varying amounts of pre-load are used to counter act these extreme pressures.
 Pre-load is the measure of interference between two components in a closed mold without
clamp force being applied, such as when a mold is closed on a bench.
 In respect to external and internal actions, pre load is the interference between the action
and the feature holding it closed.
 A positive pre-load exist when interference prevents the mold from completely closing.
 In the case of a slide, a positive pre load is the interference between the heel block and the
slide block.
 When the mold is clamped, this interference creates additional force holding the slide block
in the forward position.
 When using an action with a positive pre-load where plates should be used on mating
surfaces to protect the action.
 To reduce successive mold wear, the pre-load should not exceed 0.002 in or 0.05 mm.
 Positive pre-load is ideal for molds using materials that flash easily or for molds that require
high injection pressures.
 Positive pre load is commonly used with large actions to counter act the high forces during
injection.
 When an action has no pre load, there is no interference between the action and the feature
holding it closed without clamp force.
 In the case of a slide, the hell block and slide block are flush.
 Even without pre load. The high forces incurred during clamping compressed the mold steel
and create enough force toe hold the action forward during injection and packing.
 Actions with no pre-load are commonly used in cases when the action requires a moderate
amount of venting and the material is not likely to flash.
 This is also ideal for many high production applications in which, where maybe an issue.
 If inaction has a negative pre load, there is a space between the action and the feature
holding it closed when clamp forces not applied.
 In the case of a slide, the hell block and the slide block would not be touching.
 Actions with a negative pre load are held in place with little or no force, which greatly
reduces component wear.
 Negative pre load is ideal for low pressure molding applications, when the action contains
delicate detail or a venting around the action is necessary.

Core-Pin

 As an external action, core pins can either remove and undercut on the side of the part
cavity or create a through hole in the part.
 Core pins tunnel through the core or cavity block into the part cavity.
 Core pins that do not pass through the part require a lock to hold it in place during injection
and packing.
 Core pins that passed through the part do not require a lock.
 When used as an action, A Core-pin requires an actuator to move it into place before
injection and to remove it before rejection.
 Mechanically actuated core pins are actuated in the same manner as the mechanical slide.
 Mold design series

 The Core-pin is mounted in the front of the slide block and is moved by an actuator pin.
 Pre-load can be applied to the Core-pin using a slide lock.
 A pneumatic or hydraulic cylinder can also be used to actuate core pins. As with slides,
Pneumatic Lee Actuated core-pins provide less force than both hydraulically and
mechanically actuated core pins.
 Pneumatic and Hydraulic core-pins assemblies operate in one of three ways.
o The first method uses two additional plates, typically mounted on the outside of the
mold to house the core-pin heads. Cylinders are mounted to these plates to move
them back and forth.
o The second method connects the cylinder directly to the core pin. This assembly is
typically used when only one Core-pin is required. These two methods do not allow
for any sort of lock to be applied to the core pins and therefore should only be used
for through core pins. Materials that flash easily, such as nylon and polypropylene,
should not be used with these assemblies.
o The third method mounts a core-pin within the slide assembly, which has pushed
back and forth by either the pneumatic or hydraulic cylinder. If additional forces
required pre load could be applied using a slide lock both through hole and non
through whole core pins are designed and machine to correspond with the
application in which it is being used.
 When using a Core-pin to create a through hole, the Core-pin could be machined in one of
two ways.
o One method is to grind the Core-pin so it's flush with the opposing wall. Although
easy to machine, this method promotes core-pin deflection. This can cause flash to
occur, as well as damage to the core-pin, core-pin hole or the molded part. This
method can also cause the Corp in to be pushed back if pre-load is not used. Having
the Core-pin flush with the opposing wall is only recommended for low production
molds or for materials that are not likely to flash.
o The second method mates the core-pin with the opposing wall using a tapered hole.
This reduces the amount of Corp in deflection during injection and packing.
 When the Corp in is not used as a through hole. The core-pin assembly is also manufactured
in one of two ways.
o In the first method, the Corp in is inserted into a straight hole. This is the simplest
method, but the core-pin can deflects easily. This method should not be used for
smaller diameter pins or in high production molds.
o The second method uses a larger core pinhole that tapers down just before the part
cavity. When pre-load is used, the core-pin locks into place, reducing both Corp in
deflection and whole damage. This method is recommended for smaller core pins
and high production tooling. Since, it provides additional strength and support to the
core-pin.
 When designing a through hole for a core pin, an angled shut off should be machined into
the opposing wall. This will reduce flash as well as Corp in deflection.

Lifters

 Lifters can be used as either internal or external actions.

 Mold design series

 As an external action the lifter passes through the mold at an angle and moves outward to
clear the lifters can be used as either internal or external actions.
 As an external action, the lifter passes through the mold at an angle and moves outward to
clear the undercut as the part is being ejected. These lifters consist of a lifter body and a
slider.
 The lifter body contains the mold cavity detail, passes through the core block and support
plate, and is mounted in the ejector plate assembly.
 The simplest design has the cavity detail machine into a pin, which is used as the lifter body.
 More complex lifters use an attached insert containing the cavity detail. An angle should be
added to the lifter below the cavity detail to improve alignment and shut off.
 The lifter is moved by a slider, which is mounted between the ejector plates.
 Slots are machined within the pin retainer plate hold the slider and allow it to slide back and
forth as the lifter is pushed forward.
 Wear plates and guide blocks can be added to the slider to reduce component wear for
larger lifters in high production molds.
 Standard lifter assemblies can be purchased containing a lifter, a slider and guide block.
 The guide block mounts into the ejector plate. The slider fits in the guide block and the lifter
body mounts to the slider.
 An insert is typically added to the lifter body so that the same standard assembly can be
used for a wide range of lifter angles and designs.
 The ejector played travel and the angle of the lifter determined the lifter movement. To
calculate the size of undercut, the lifter can clear multiply the length of ejector play travel by
the tangent function of the lifter angle.
 The forces involved in moving the lifter causes wear to both the lifter and the core.
 Lifted guides can be placed behind the core retainer plate or the support plate. These guides
are precision ground from softer materials and are designed to guide the lifters movement
as well as to reduce wear.
 Adding pre-load to the lifter can be done in one of two ways.
o The first uses a lifter that extends beyond the mold cavity and is pushed in place by
the cavity side of the mold. In this case, pre load is the interference between the
cavity side of the mold and the lifter.
o The second type uses a shortened lifter and a positive ejection return. In this case,
the tension of the lifter acts as the pre load. It is important to properly secure the
lifter to the slider when using this method, since the tension can cause the lifter
components to separate.

Expandable Cores

 Another external action is the expandable core. These cores are manufactured from
hardened A to steal and contain the undercut detail.
 The expandable core is held in a restrained position during injection and packing, and then
expands before the part is ejected.
 There are two types of expandable. Core is commonly used.
o One type attach is the core to a two stage ejection system. The core is tapered at the
top and is mounted into a tapered sleeve before injection. The expandable core is
 Mold design series

retracted in the sleeve. During the initial stage of ejection, the expandable core is
pushed out of the sleeve and the undercuts are removed.
o The second type of expandable core also acts as the core block. In this case, the
expandable core has an angle around the outside, which corresponds with an angle
disk on the cavity side of the mold.
 When the mold is closed, the disk restrains the expandable core for injection and packing,
using the mold to actuate the expandable core.
 When the mold opens, the core expands, removing the undercuts and allowing for the part
to be easily ejected.
 It is not recommended to add pre load to the expandable core, since they have purchased in
a pre assembled state having very high tolerances.

Lifters

 Internal actions are required to move undercuts from the inside of the molded part.
 Common internal actions include lifters, unscrewing cores, collapsible cores, inserts and
dissolvable cores.
 As an internal action lifters move inward to remove internal undercuts.
 When designing internal lifters, it is important to consider underside part features that may
interfere with the movement of the lifter.
 For example, contoured parts may have to be reoriented in the mold to prevent the lifter
from digging into the part. Other features, such as ribs or clips, may need to be relocated to
allow room for lifter movement.

Unscrewing cores

 Unscrewing cores are used to remove threads from the inside of molded parts.
 Unscrewing cores are designed to retract from the molded part as they unscrew.
 These cores contain two sets of threads, one for the molded part and one to retract the
core.
 The pitch of these threads is identical. There are two types of unscrewing cores commonly
used in the first type of unscrewing core, the whole core is supported by the threads as it
rotates.
 These threads can wear prematurely if used with larger cores or high injection pressures.
 The movement of the core is controlled by an attached gear. Since the entire core rotates,
cooling channels cannot be used and only circular detail could be added.
 The second type of unscrewing core remained stationary, while Aguirre unscrewed the collar
around the core. Since the whole core does not rotate, the core can be cooled and non
concentric features can be added.
 This design reduces where, since the threads on lee support the collar and not the whole
core.
 This system is ideal for large unscrewing cores. Both types of unscrewing cores use a gear
mechanism to rotate the core or collar.
 The gears are driven using one of two methods. The more common of the two uses either an
electric or hydraulic motor. The other uses a tooth rod, which is actuated by a hydraulic
cylinder. Both of these mechanisms are controlled by the molding machine.
 Mold design series

 When constructing unscrewing cores, it is important to heat treat the steel before machining
final dimensions.
 After the final dimensions have been machined, the unscrewing core is then nitrated.
 Nitrating increases both the surface hardness and the wear resistance of the core.

Collapsible Cores

 Expandable and collapsible cores are typically the fastest and most efficient method of
undercut removal for round parts. These actions should be used whenever the budget
permits.
 Collapsible cores removed undercuts from the inside of round cores. The collapsible core is
machine from ah hardened eight to tool steel cylinder and contains divisions that allow it to
collapse prior to the injection and packing phases the core is retracted over a center pin
made from hardened D6 tool steel.
 During ejection, the collapsible core is pushed forward, allowing the court to collapse and
clear the undercuts.
 To operate the collapsible core, a two stage ejection system is required.
 The initial stage pushes the collapsible core from the center pin mounted in the clamping
plate.
 The next stage pushes the part from the collapsed core. One drawback associated with
collapsible cores is that it is difficult to incorporate cooling.

Inserts

 Inserts can be used as both internal and external actions. The use of inserts is time
consuming, since the insert must be placed into the mold before each cycle so that the
polymer can be molded over the insert.
 The part and the insert are removed from the mold together and must be separated either
manually or by automation.
 Inserts are commonly used when molding low production prototype molds or when it's too
difficulty or expensive to manufacture automated internal actions.

Dissolvable Core Process

 The dissolvable core also known as the lost core process, involves molding a polymer over a
dissolvable metal core. This is used when the internal detail cannot be mechanically
removed by an internal action.
 The core is precision cast from a low melting temperature metal such as tin bismuth. This
core is placed into the mold and the polymer is injected around the core.
 The polymer has a higher melting temperature than the core insert.
 During injection, the polymer cools before the dissolvable core reaches its melting point,
keeping the core intact.
 The part and core are then ejected together and placed into a heated saline solution, which
melts away the metal insert without damaging the molded part. This process allows for
complex internal shapes, contours and undercuts to be molded within the part.
 Unfortunately, this process is expensive, requires extensive engineering and requires long
lead times to manufacture the tooling for both molding and casting.
 Mold design series

 This rare processes used in applications where traditional undercut removal cannot be used,
such as the molding of are in take, manifolds, bicycle wheels and tennis rackets.

Seal Off’s

 Since all internal and external action is involved, movement components must seal against
the mold cavity or core. Seal offs keep material from flowing around actions to prevent flash.
 The simplest form of seal is the butt seal. This seal uses to flat surfaces which meet
perpendicular to the direction of closure. When used on an action the but seal allows the
action to shift easily, causing premature wear.
 This can result in flash or damage to the action.
 Angled seals are the preferred method of seal when designing internal and external actions.
 When used on an action, the angled service guides the action into position and prevent the
slide from shifting.

Material Considerations

Choosing the appropriate materials from old components is critical to increasing component life and
reducing wear.

When constructing external and internal components, the portion touching the mold cavity is
typically made from hardened tool steel.

Galling occurs when mold materials of similar hardness where together through contact.

Different from regular wear galling results in the two mating services balling up creating large
grooves.

To prevent galling mating materials must have a difference of a least 6 Rockwell C hardness

To reduce wear on actions, wear plates made of softer materials should be used whenever possible.
These should be checked frequently and replaced when excessive wear is detected.

Brass is commonly used for wear components since it is easy to machine and wears before harder
steel components.

Brass plated steel components are even more effective having the wear characteristics of brass with
increased strength.

Although expensive graphite impregnated materials should be used whenever possible. These
materials contained graphite inserts embedded into the metal, which lubricate the surface and
provide superior wear resistance.

As stated previously galling, can be avoided by using a different Rockwell C hardness for components
that come into contact with each other.

When using steals for mating surfaces, be sure that the softest steel is used for the component that's
easier to replace.

Conclusion
 Mold design series

 Upon completion of this program, you should have an understanding of

o The available methods for removing undercuts from both the outside and inside of
an injection molded part.
o These include slides, core pins, lifters, expandable cores, collapsible cores and
unscrewing cores.
o This program has also covered material considerations, pre load and sell offs.
 You should now participate in the seventh program in the mold design and mold, making
Series entitled part ejection, venting and cooling.

Introduction

 Part ejection, Venting and cooling is the seventh program in the mold design and mold
making Series.
 Before beginning this program, you should have already completed the first six programs,
the last entitled External and Internal Actions.
 This program covers part ejection methods and concepts, including ejector pins, ejector
sleeves, ejector blades, lifters, stripper plates, air poppet valves to stage ejection and
positive ejection return.
 This program also covers different methods for venting and cooling injection molds.

Part Ejection

 Ejecting the part is one of the four major functions and mold must perform.
 A uniformity section force must be applied to the part in order to avoid warpage and
deformation.
 Additional force may be required in areas having small draft angles, long ribs, rough surface
texture, sharp corners or deep part walls.
 The ejection system must overcome the friction forces between the part and the core, as
well as the vacuum forces that are created by the lack of air underneath the part.
 These forces can be reduced by adding draft vents, are poppet valves or by polishing the
core.
 The ejection methods covered in this program are ejector pins, ejector blades, ejector
sleeves, lifters, stripper plates and are poppet valves.

Ejector Pins

 The most common form of party ejection is the use of ejector pins.
 This is due to their simplicity and design, and they're relatively low cost.
 Since ejector pins use a relatively small surface area to remove the part, multiple ejector
pins are typically required.
 The head of each ejector pin is mounted into the ejector played assembly and passes
through the support plate and core retainer plate through the use of relief holes.
 Just before reaching the mold cavity. The ejector pin also passes through the land area.
 The land is a whole machine into the core block, which guides the ejector pin as well as
prevents flashing.
 Mold design series

 An improper depth or diameter of the land can damage the ejector pin or gall the ejector pin
hole surfaces.
 When specifying the land diameter, it is important to consider the material and injection
pressures being used when molding materials have a low viscosity or when high injection
pressures are needed a low tolerance between the diameter of the pin and the land is
required. These calls for the land to be finished using a wire EDM machine or a jig grinder.
 Materials with a high viscosity have a lower tendency to flash and therefore more clearance
could be used between the diameter of the ejector pin and the land. These diameters can be
machined using a drill and a reamer.
 This allows gas to vent around the ejector pin and reduces the amount of wear.
 Ejector pins up to 0.25 in or 6 mm in diameter should use the land depth equal to 2 times
the ejector pin diameter. Land = 2 x D
 Ejector pins larger than 0.25 in or 6 mm in diameter should use the land depth equal to 1.5
times the ejector pin diameter. Land = 1.5 x D
 Ejector pins could be purchased in almost any diameter in length, as either through
hardened or case hardened.
 Through hardened ejector pins have a Rockwell C hardness of 65-72, a recommended for
high production molds.
 Case hardened pins have a Rockwell C hardness of 60-65 on the perimeter but are not
hardened throughout, which makes them more susceptible to bending and breaking since
they're softer and less rigid.
 When ejector pins are used on contoured surfaces, flat needs to be ground on the ejector
pin head and a slot must be milled in the retainer plate.
 The ejector pin is mounted in the retainer plate and is held in place using a key. This metal
piece keeps the ejector pin from rotating during injection and ejection.
 When assisting in the removal of ribbing, it is recommended that ejector pins be placed at
rib intersections so that larger pins could be used.
 If ejector pins required pushing along a rib, ejector pads should be used.
 Ejector pads are thick sections added to the rib to create a larger surface area.
 Since thinner ejector pins have a tendency to break, ejector, pins can be purchased having
shoulders.
 Shoulders are thicker sections near the head of the pin that improved their strength and
performance.
 The advantage of ejector pins is they're inexpensive, easy to machine, available in virtually
all lengths and diameters, and require minimal engineering and design considerations.
 The disadvantages of ejector pins are multiple ejector pins are needed to provide a
uniformed ejection force.
 An ejector pin holes may interfere with cooling line placement ejector pins are used for
rejecting a wide range of parts and are commonly used in conjunction with other forms of
ejection.
 From a machining standpoint, ejector pins are the least complex ejection method. Be aware
that these should only be used as a loan form of ejection when the part geometry is simple.

Ejector Blades
 Mold design series

 Ejector blades are wide rectangular blades used to improve ejection force distribution along
thin walls and ribs. These are often used in place of ejector pins.
 Ejector blades are mounted in the ejector plates and passed through the support and cavity
retainer plates as well as the core blocks.
 As with ejector pins, ejector blades are controlled by the back and forth movement of the
ejector plates. These blades were used as both one piece and to peace assemblies.
 One piece ejector blades are available as both case hardened and through hardened and
have a transition from around head to a rectangular blade.
 One piece blades are the stronger of the two designs, but more expensive and are only
available in limited sizes.
 Two piece ejector blades consists of an ejector pin with a blade mounted to the top.
 This blade could be made from any material and custom sizes and is easy to replace.
 The easiest and most common method of machining and ejected Blade Hole is to grind or
mill a slot into the side of the core insert.
 When the core insert is placed into the mold, a rectangular hole is formed to house the
ejector blade.
 When this is not possible, the ejector blade hole must be wire EDM directly into the core.
 The inherent corners of the wire make it difficult to fit the ejector blade into the hole and
often require the corners of the blade to be ground.
 The ejector blade hole should have a clearance of the back with the land depth of
approximately twice the thickness of the blade.
 The advantages of ejector blades are
o They provide good force distribution for ejecting parts
o Within ribs and walls can fit into tight areas
o And custom two piece ejector blades are easy to make.
 The disadvantages of ejector blades are
o One piece ejector blades are only available in limited lengths and sizes.
o Ejector blade holes may interfere with cooling line placement
o And require additional design in machining time.
 Ejector blades are ideal for rejecting parts having thin walls or ribs, especially when they're
located on the edges of the core inserts.

Lifter

 A straight or angled lifter is used to distribute the ejection force over a large surface area.
 Straight lifters are mounted directly into the ejector plates and passed through the core
block. These lifters are used to help eject part features that may stick to the mold, such as
deep ribs and thin sections.
 Angled lifters are also mounted in the ejector plates, yet passed through the core at an
angle. These are used to remove internal or external undercuts from the mold. It can also
help eject the part from the mold to reduce where lifters are commonly made from shock
resistant S 7 or harden H 13 steel.
 If lifter cooling is needed, lifters can be made from materials having improved thermal
conductivity, such as beryllium, copper or cal tool. Another option is to add cooling lines to
the lifters, yet this is usually reserved for larger lifters.
 Mold design series

 Angled selloffs should be used at the bottom of lifters to significantly reduce the possibility
of flash.
 Lifter guide should be inserted either in the support plate or the clamping plate to keep the
lifter in the correct position during ejection.
 To reduce lifter wear, lifter guides are typically made out of bronze coated or graphite
impregnated materials.
 The advantages of using lifters are
o One lifter can remove large areas.
o Cooling could be applied to large lifters.
o They provide excellent force distribution
o And can be used to remove undercuts.
 The disadvantages of using lifters are
o They're expensive to manufacture
o Require additional engineering and design considerations
 Lifter components can increase the stack height of the mold and lift. The holes may interfere
with cooling line placement
 Lifters are often used to remove delicate detail that could be damaged by ejector pins or
blades when molding softer polymers.
 They're also used to remove larger part features such as rib sections and deep cores.

Stripper Plates

 Stripper plates are ejection systems that encircle the core and remove the part by pushing
on its outer edges. By doing so, a uniformed ejection force is applied along the perimeter of
the part.
 Since the stripper plate is an additional plate, it is the only ejection method not to interfere
with cooling line layout in the core.
 An angle is ground into the bottom of the stripper plate and seals with an angle at the base
of the core.
 These mating services should be made of hard, shock resistant materials such as S 7 or H 13
to reduce wear.
 leader pins and leader pin bushings guide the stripper plate as it moves back and forth
during ejection.
 Plastic inserts or springs can be placed between the stripper plate and the core retainer
plate to reduce the amount of stress and curd as the mold closes.
 Individual stripper rings can be used at each mold cavity these come in contact with the core
block and are mounted into a larger stripper plate for multi cavity molds.
 The stripper plate could be actuated using several different methods. One method is to
attach shoulder bolts to the cavity plate during mold opening the shoulder bolts pulled the
stripper plate away from the B half of the mold.
 As the mold closes, the stripper plate is returned into place by the core retainer plate. This
method decreases the overall stack height of the mold, since ejector plates are not required.
 Shoulder bolts are not recommended for high speed or high production tooling, since the
stresses incurred during mold, opening and closing cause excessive wear to the stripper
plate and bolts.
 Mold design series

 Mounting change to the stripper plate and the a half of the mold is also a form of actuating
the stripper plate. This is the simplest method of stripper plate actuations, but is only
recommended for use in prototype environments, since the chain assembly breaks easily.
 Another method of stripper plate actuation is to mount a latch system to both the A and B
halves of the mold, like the shoulder bolt assembly. The latch system also reduces the
overall stack height of the mold, yet its durability allows it to be used in virtually any stripper
plate assembly.
 Actuating the stripper plate can also be accomplished through the use of return or ejector
pins. These pins attached the ejector plate to the stripper plate and use the machines
ejection system to control the stripper plate movement. This method is durable, easy to
implement and allows for other forms of ejection to be added when needed.
 The final method mentioned uses auxiliary cylinders to actuate the stripper plate. These
cylinders can be hydraulic or pneumatic and do not require the use of the machines ejection
system. These systems can also eject from the stationary side of the mold.
 The advantages of stripper plates are
o They provide an even forced distribution across the perimeter of the part.
o The mold stack height may be reduced.
o They do not interfere with cooling line placement
o And allow form or uniformed cooling.
 The disadvantages of stripper plates are
o They require special engineering
o And design considerations and are expensive to manufacture.
 Stripper plate should be used whatever possible. Since an even force distribution is
provided.

Air Poppet Valves

 Air poppet valves supplies are to the top of the core. Since are poppet valves provide less
ejection force than other methods, these can only be used as a sole form of ejection for
lightweight and thin walled parts.
 Air poppet valves, arm or commonly used with other forms of rejection. by reducing the
vacuum forces under the part.
 Air poppet valves use a spring loaded valve mounted in the core block. This valve remains in
a seated position during injection and is then forced forward by air during ejection when
using air poppet valves.
 A clean, consistent are supply must be used to prevent inconsistent ejection and surface
contamination.
 The advantages of air poppet valves are there simple and design reduce vacuum forces and
could remove lightweight parts from the mold without contact.
 The disadvantages of are poppet valves are they supply less ejection force than other forms
of ejection and an external are supply is required.
 Air poppet valves are typically used for ejecting light, thin walled parts such as food
containers and cups. They're also used to aid in ejection for parts with deep cores by
reducing vacuum forces.

Two-Stage Ejection
 Mold design series

 When a single stage ejection system is inadequate for rejecting complex parts, a two stage
ejection system can be used.
 Two stage Ejection is commonly used to remove parts from other ejection components such
as expandable cores, collapsible cores and lifters.
 Two stage Ejection can also be used to angle parts to ease sorting for family molds or to
provide additional ejector stroke.
 The molding machines ejection system is responsible for the initial ejection stage, and
hydraulic or mechanical actuator is responsible for the second.
 Hydraulic actuators use cylinders to move the second set of ejector plates and auxiliary
hydraulic pump controls.
 The movement of these cylinders mechanicals to stage ejection systems use accelerators to
actuate a second set of ejector plates.
 The simplest mechanical accelerator uses a pivoting block which is attached to the primary
ejector played assembly.
 As the primary ejector plate moves forward, a post pushes on the pivoting block and the
second stage of ejection is then actuated.
 Mounting a rack and pinion insert to the primary ejector plates is another form of
mechanical acceleration. The rack and pinion insert, also contact supposed to initiate the
second stage of ejection.
 This system can also be used to directly actuate additional ejector pins. The rack and pinion
assembly exhibits less wear than the pivoting block assembly.
 Therefore, is better suited for high production in high speed applications.
 The advantages of using to stage ejection are parts could be removed from other ejection
components. Ejector stroke can be increased and parts can be angled.
 The disadvantages of using to stage ejection are additional engineering and design
considerations are required as well as additional maintenance.

Positive Ejection Return

 If you're using Tide ejection, we recommend making a standard set of knockout rods that are
specific to the machine that is being used.
 To significantly reduce set up time. A custom set of spacers should be connected to the
knockout rods. Thes spacers should be made for all tied injection molds.
 Positive ejection return ensures that the ejection system is fully retracted before the mold
closes. This prevents damage from occurring to the ejection system and is superior
compared to the use of return pins.
 There are five common methods of positive ejection return used in the industry today.
 The simplest method uses springs located between the ejector plates and the support plate.
These springs pushed the ejected plates back when part ejection is complete.
 Another method uses springs located behind the return pins, which advanced them forward
as the mold closes. The return pins pushed the ejector, played back the springs, then
compress and allow the mold to continue closing.
 Connecting the molds ejector plates to the molding machines. Ejection system using
knockout rods is also a form of positive ejection return. This is commonly referred to as tied
ejection.
 Mold design series

 When the machines ejection system is retracted, the attached knockout rods pull the ejector
plates back.
 A fourth method uses leader pins to push on an expandable bushing mounted in the core
plate. As the mold closes, the bushing forces the ejected plates back. The bushing then
expands, allowing the mold to continue closing after the ejector plates have been returned.
 The final positive ejection returned system mentioned is the DME toggle lock system. A lever
is mounted to the A side of the mold, while the toggle assembly is mounted to the B side of
the mold. The lever actuated the toggle mechanism and pushes the ejected plate into the
back position before the mold is completely closed.
 Many mold makers at electrical proximity switches to signal the molding machine that the
ejection system has been fully retracted. This is another safety measure to eliminate mold
damage during closing.
 The advantages of positive ejection return are the ejection system is completely returned
before the mold is closed and the ejection system damage is prevented.
 The disadvantages of positive ejection return are additional design considerations are
required and the cost of the ejection system is increased.
 Ejection system should be simplified whenever possible. The use of standard ejection
components, such as lifters and ejector blades is encouraged and will reduce the cost of
both the mold and replacement parts.

Venting

 Keep in mind that you can never over vents an injection mold. Therefore, vents should be
placed wherever possible.
 Venting at the screw or runner system will reduce stress is in the part and improve process
consistency.
 During injection unreleased are creates gas traps in the mold. These gas traps apply
additional stresses to the part and can cause short shots flash burning or severe weld lines to
occur.
 Proper venting can significantly reduce warpage and distortion, as well as improved part
appearance and process consistency.
 When designing vents, it is important to consider both the process and the material being
used.
 The most common placed event is at the parting line. Parting line vents are ground or
machine onto the edge of the mold cavity.
 These vents are very efficient and could be easily cleaned while the mold is opened.
 Multiple parting line vents should be used within the runner system, especially at the cold
wells. This helps remove some of the gas from the mold before it reaches the mold cavities.
 A side from venting at the parting line, additional vents should be placed where the polymer
flow ends or where the two flow fronts meet. These could be added to both stationary and
movable mold components.
 Static vents are used with stationary mold components such as core pins, cavity inserts and
vent pins. These vents are the clearance between the component and the core, or cavity
block or grooves directly machined onto mold components.
 Static vents should not be used with volatile materials, since the vented component must be
removed from the mold to be cleaned. This often requires partial disassembly of the mold.
 Mold design series

 Vince can also be added to moving components such as ejector pins, lifters and slides. These
vents are self cleaning, since the movement of the component breaks up any volatile build-
up.
 Ejector components could be vented by using additional clearance in the land area or by
machining grooves along the sides. Ejector pins and sleeves are available with a helical
groove pre machine around the component for venting.
 Slides, Lifters and core pins could be vented using negative pre load or through grooves
machined onto the side or bottom of the component.
 One of the most effective forms of venting is the use of porous metals. These allow gas to
vent through the metal and are available in both poorest steel and aluminum.
 To prevent volatile build-up, Pressurized air should be forced through the poorest metal
between each cycle.
 Porous medals must be machined using either wire EDM or die sinking EDM machines. Other
machining methods, such as milling and grinding, damaged the service by covering the
pores.
 Since poorest medals are expensive, they're commonly reserved for small mold cavities or
used as inserts vent drops required behind each vent. These drops are deep grooves, which
channel the gas from the vent to the outside of the mold.
 Vacuum systems can also be used to improve mold venting. These systems use a parting line
sealed with rings and a vacuum line attached to the vent drop.
 As the mold closes, the vacuum pressure is applied and the gas is are pulled across the vent
during injection. This greatly reduces gas traps from occurring in the mold.

Part Cooling

 Another major function of an injection mold is to cool the part before ejection.
 The objective is to cool the part as quickly and as evenly as possible.
 Uneven cooling can create internal stresses, which can contribute to part warpage and
distortion.
 The cooling fluid used consists of either water or oil, and is circulated throughout
strategically placed cooling lines within the mold.
 Increasing the flow of the coolant, as well as the number of cooling lines in the mold can
significantly decrease cooling time, Productivity and economic efficiency hinge directly on
the cooling layout. Since most of the overall cycle time is consumed by cooling.
 Cooling is most effective when the coolant flow is turbulent within the mold.
 A turbulent cooling flow results when the flow passes through the cooling line fast enough
to disrupt the laminar flow. This increases the heat transfer from the mold to the coolant.
 Cooling lines should be kept as short as possible to maintain process consistency and to
minimize pressure loss.
 Longer cooling lines and lines used in series can cause the coolant temperature to rise,
creating hotspots in the mold.
 Using lines in parallel reduces cooling line length, since each of these lines uses their own
special coolant flow.
 Although cooling varies from old to mold their design guidelines that should be followed
when designing the cooling line layout.
 Mold design series

 The diameter of the cooling line represented by D should be less than the diameter of the
pipe or hose that provides the coolant flow.
 The pitch of the cooling lines represented by P is the distance between the centers of the
adjacent cooling lines. This should be between three and five times the diameter of the
cooling line.
 The pitch could be adjusted to increase or decrease the amount of cooling in designated
areas.
 The depth of the cooling line represented by H is the distance between the mold cavity
service and the center of the cooling line. This distance should be twice the diameter of the
cooling line.
 Using a larger number of cooling lines having smaller diameters will cool the part more
consistently than a smaller number of larger diameter cooling lines.

Cooling Examples

 Evenly spaced cooling lines are ideal for parts having simple geometry with a constant wall
thickness.
 Parts having uneven geometry or parts with varying thickness require a complex cooling line
layout.
 As stated previously, part ejection can often interfere with a cooling line layout.
Consequently, the most appropriate cooling system is a balance between even cooling and
ejection force distribution.
 This face plate, for example, has too thick clips, ribbing on the underside and a thick section
of decorative trim on the top.
 To maintain proper appearance and clip performance, warpage must be kept to a minimum.
 During design reviews, It was determined that ejector blades should be used to remove the
clips, and the rib intersections should be equipped with bosses to accommodate ejector
sleeves.
 The simplest cooling line layout for the core would use cooling lines on each side of the clips
and evenly spaced cooling lines across the top of the part. Since the center of the part is not
sufficiently cooled, this layout is inadequate.
 Improve core cooling could be achieved using cooling lines passing lengthwise along the part
through the center as well as on either side of the part.
 To decrease cycle time is well as to improve the cooling of the clips. Additional cooling lines
can be placed next to the clips.
 The thick section on the top of the part may cause the part toe warp due to differential
shrinkage.
 This could be improved by placing the cooling lines lengthwise along the part in the cavity
side with closely spaced cooling lines in the thick section.
 To further improve cooling heat, conductive materials such as aluminum or cal tool can be
placed in the cavity block at the thick section.

Core and Cavity Cooling

 Coors and cavities can be cooled using alternative methods such as angled cooling lines,
perimeter cooling and cooling inserts.
 Mold design series

 When machining angled cooling lines, intersecting holes were drilled to enable the coolant
to turn corners. This method brings the cooling lines closer to the mold cavity.
 If the holes do reach the mold cavity, they must be welded and then smooth to seal the
hole. This leaves a surface blemish on the part and may weaken the cavity surface.
 Perimeter cooling channels can be machined around circular core and cavity blocks. O rings
are used to seal these cooling lines.
 Perimeter cooling cannot cool the center of larger core and cavity blocks. This should only be
used for smaller mold cavities, typically less than 4 in or 100 mm in diameter.
 Another method is to mount an insert equipped with cooling channels behind the core
block. This insert follows the same contours as the core so that uniformed cooling could be
achieved and must be sealed with O rings.
 The cooler is channelled to the core or cavity block, using one of three methods.
o The first method uses pipes, which are threaded directly into the core and cavity
block.
o The second method uses cooling lines that pass from the core and cavity retainer
plates to the side of the core and cavity blocks. O rings on the side of the blocks keep
the coolant lines from leaking. When using this method, the old rings can be easily
sheared when the block is inserted.
o The third method uses cooling lines that passed to the back of the core, or cavity
blocks. In this case, a seal is created by placing the block directly on the O ring,
assuring that it won't be sheared.

Complex Cooling

 Since cooling lines cannot reach all parts of the mold that need cooling, alternative ways of
cooling must be incorporated. Baffles, bumblers and thermal pins are three methods, which
can be used.
 Straight baffles passed through the cooling line into a drilled hole in the mold. These divert
the coolant flow, causing the water to travel up and over the baffle.
 As cooler fluid passes up one side of the baffle, it is heated by the core and the warmer fluid
passes down the other side. This results in an uneven form of cooling. Twisted baffles
circulate both the warm and cool fluid around the baffle, and therefore improve cooling.
 Another way to cool parts of the mold away from the cooling lines is the use of bumblers.
These are mounted in the core retainer plate and consists of a tube that passes fluid up into
the core block bumblers are more efficient than baffles, since the cooler fluid is not heated
as it travels the length of the bubbler.
 Since bumblers tend to deflect small spaces can be welded to the sites to promote more
consistent flow down the tube.
 To further reduce inconsistencies, helical grooves could be added to the outside of the
bubbler. The spiral flow provides more efficient cooling than both the straight bubbler and
the twisted baffle.
 Thermal pins are another method of transferring heat from the core to the waterline. These
pins contain an evaporator end inserted into the core and a condenser end that contacts the
cooling lines in the mold.
 Mold design series

 Fluid within the thermal pin vaporize is in the evaporator end and passes back to the
condenser end, where the heat is then transferred to the coolant.
 These pins are most effective when mounted vertically in the mold and are kept in direct
contact with the cooling line.
 Although less effective, the condenser end can transfer heat to a cooler section of the mold
without contacting the water line.
 Placing the condenser and outside the mold can also cool thermal pins. Thermal pins are not
as efficient as baffles or bumblers, but are ideal for cooling components that are difficult to
place cooling lines in. These include lifters, slides and thin cores.

Pulse Cooling

 Mold filling software can help you evaluate the efficiency of your cooling line layouts. The
most prevalent program is mold flow. Mold flow can also analyze aspects such as filling and
packing.
 Even a sufficient cooling line, layout cannot compensate for the many variations incurred
during processing during production. The melted polymer heats the mold and it's platinum’s,
creating variations in mold surface temperature.
 The temperature of the mold surface is also affected by ambient temperature changes
alterations to the process or interruptions.
 Pulse cooling systems are used to establish and hold a consistent bold surface temperature.
These systems use mold temperature sensors located near the cavity surface as well as in
the cooling system, which relay temperature data to a common controller.
 During production, pulse cooling systems open and close valves within the cooling system to
maintain the programmed mold temperature. This is only effective once the mold has cycled
enough to reach the desired mold Surface temperature.
 More advanced pulse cooling systems can also apply heat to the mold using either heating
elements or a heating fluid. This is done during start-up or when the mold is idle and
therefore can reach and maintain the desired mold surface temperature much more
effectively.
 Pulse cooling is ideal for highly sensitive applications in which fluctuations and mold
temperature can affect both dimensional and process consistency.

Conclusion

 Upon completing this program, you have been introduced to part ejection methods and
concepts, including ejector pins, ejector sleeves, ejector blades, lifters, stripper plates, are
poppet valves to stage ejection and positive ejection return. Also discussed were venting
part cooling and pulse cooling.
 You should next participate in the eighth program of the mold design and mold making
Series.
 Mold design series

Gating Methods

Introduction

 Gating Methods is the eighth program in the mold design and mold making Series.
 Before beginning this program, you should have already completed the first seven programs.
 The last entitled Part Ejection, Venting and Cooling.
 Gating Methods introduces participants to many of the available cold and hot runner gate
types. This program also covers gate location considerations.

Gate Types

 Selecting a gate type in its location will dictate the parts orientation, shrinkage and
appearance.
 More detailed information on these topics can be found in our park design series.
 Choosing the appropriate gate type and location is crucial to the mold design process,
although there are general guidelines to follow gate dimensions are often application
specific.
 Material design guides are available from material suppliers and provide specific design
information for the polymers you intend to use.
 All major material suppliers have technical representatives with experience in the processing
of their materials to help answer questions or solve problems.
 Technical service bulletins are also available and consists of technical support and research
data.
 These should be checked on a regular basis since they may pertain to your application.
 Mold designs using cold runner systems incorporate either manually de-gating or self de-
gating gates.
 During the day gating process, vestiges left behind on the part. The amount of vestiges is
dependent on the gate and the polymer being used.
 Manual de-gating gates must be removed from the part by an operator or through the use
of auxiliary equipment.
 These gates include the Sprue Gate, Edge Gate, Fan Gate, Flash Gate, Disc gate, spoke Gate,
Ring Gate and the tangential Gate.

Sprue Gates

 The sprue gate is the simplest gate and fills directly from the nozzle. Therefore, these gates
can only be used with single cavity molds.
 Mold design series

 Since it is the widest gate available, the screw gate is used to fill large parts when molding
parts having contoured surfaces. The screw bushing must contain the same contour as the
cavity surface.
 To prevent the sprue from turning during production, Dowel pins are used to secure the
sprue bushing.
 Due to their size, sprue gates leave a large amount of vestige and are difficult to separate
from the part.
 Separating the gate from the part often requires large gate cutters.
 To remove the vestige, Parts often require a secondary operation such as machining or filing.
 The advantages of using screw gates are they allow a large amount of material to pass and
non contoured gates are easy to machine.
 The disadvantages of using screw gates are they're difficult to separate from the part, Leave
a large amount of gate vestige and can only be used for single cavity molds.

Edge Gates

 Edge gates of the most common gate and are typically used on molds having thin or small
cavities. These gates are easy to machine and are normally milled using an end mill.
 An edge gate should be approximately one third of the part thickness at the mold cavity.
 To optimize by easing removal and promoting a better flow, a tapered edge gate can be
produced using a die sinker EDM machine.
 Edge gates, as well as other smaller gates, create high shear rates by restricting the polymer
flow.
 When these gates are located at large open areas, jetting may occur.
 Jetting is a defect caused by material entering the cavity in a stream or spray.
 To create a smooth laminar flow, Front edge gates should flow directly into a wall or part
feature.
 The advantages of using edge gates are they're easy to machine, easy to remove from the
part and use little material.
 The disadvantages of using edge gates are. They leave a moderate amount of gate vestige,
promote jetting and allow only a small amount of material to pass.

Fan Gates

 Fan gates are used to fill large, high tolerance parts, these gates use a large amount of
material, yet promote a smooth polymer flow across the part and decrease warpage.
 This gate widens as it approaches the mold cavity and tapers down to approximately one
quarter of the part thickness.
 The fan gate is difficult to mill because of its geometry and typically requires the use of an
electrode in a die sinker EDM machine.
 Since the fan gate contacts the part over a large area, it is difficult to remove and a large
amount of vestiges is left behind.
 As with the screw gate, a secondary operation is typically required.
 The advantages of using fan gates are they allow a large amount of material to flow through
the gate, promote a smooth laminar flow and minimize part warpage.
 Mold design series

 The disadvantages of using fan gates are they're difficult to remove from the part difficult to
machine, leave a large amount of gate vestige and generate a large amount of runner scrap.

Flash gates

 Flash gates are similar in design to edge gates, but passed the material from the site of the
runner to the mold cavity using a larger contact area.
 These gates could be machine using either a milling machine or a dye sinker EDM machine.
 The flash gate tapers to approximately one quarter of the part thickness of the mold cavity.
 Like fan gates, flash gates promote a smooth flow along the part, are difficult to separate
and leave behind a large amount of vestige.
 Flash gates are recommended from multiple cavity molds that demand a large gate to fill the
part, or in family molds, where multiple parts are filled from a main runner.
 The advantages of using flash gates are they allow a large amount of material to flow
through the gate and promote a smooth laminar flow.
 The disadvantages of using flash gates are they're difficult to remove from the part. Leave a
large amount of gate vestige and generate a large amount of runners scrap.

Disc Gates

 Disc gates around tapered gates that Phil from the center of the part and promote a large
and even polymer flow. These gates are ideal for round and concentric parts, such as
compact discs and cylindrical housings.
 Since disc gates originate from the screw, they could only be used to fill single cavity molds.
 Disc gates taper down to less than one quarter of the par thickness at the mold cavity. These
complex gates can either be machine into the mold using a CNC milling machine or a die
sinker EDM machine.
 Since the disc gate contacts the part over a large area, it is difficult to remove and a
moderate amount of vestiges left behind.
 Disc gates often required to stage ejection or a secondary operation to remove the gate
from the part.
 The advantages of using disk gates are they allow a large amount of material to flow through
the gate and promote a smooth laminar flow for round parts.
 The disadvantages of using disk gates are they're difficult to remove from. The part can only
be used for a single cavity. Molds typically leave a moderate amount of gate vestige and are
difficult to machine.

Spoke Gate

 A spoke gate consists of a series of edge gates projecting outward from a central screw and
is used to fill single cavity molds. These gates allow a large amount of material to reach the
cavity quickly, since several gates are used.
 Unfortunately spoke Gates inherently create weld lines and promote jetting.
 Spoke gates or simple in design, and could be easily machine by milling or die sinking EDM.
 The cross section of each gate can be modified to control the flow across the part.
 Spoke gates are ideal for large parts containing ah, hole in the middle of the part.
 Mold design series

 Since multiple gates are used for a single part removal often requires gate cutters and a large
amount of vestiges left behind.
 The advantages of using spoke gates are they allow a large amount of material to flow
through the gate and are easy to machine.
 The disadvantages of using spoke gates are they're difficult to remove from. The part can
only be used for single cavity molds. Promote jetting, create well lines and leave a moderate
amount of gate vestige.

Ring Gates

 Ring gates are large gates designed to fill the mold cavity from the perimeter.
 During injection, the ring is filled and then a smooth laminar flow is released into the part.
These complex gates are difficulty and time consuming to machine and usually require a CNC
milling machine or a die sinker EDM machine.
 This gate design uses a ring of approximately the same thickness as the part and tapers
down to less than one quarter of the part thickness.
 Ring gates are only used for round parts having high tolerances, these gates typically end up
using just us much material for the gate, as they do for the part.
 Ring gates are difficult to separate from the part, since the entire perimeter of the part
comes in contact with the gate, leaving gate vestige all around the part.
 The advantages of ring gates are they allow a large amount of material to flow through the
gate and promote a laminar flow around the circumference of the part.
 The disadvantages of ring gates are. They're difficult to remove from the part difficulty
machine. Leave a large amount of gate vestige and generate as much runner scrap as the
amount of material used to fill the part.

Tangential Gates

 Tangential gates flow around the part and spiral inward towards the edge of the mold cavity.
 These gates could be machine using a ball end mill in a helical cutting path or in a die sinking
EDM machine.
 The spiral gate begins at the runner and tapers down to one third of the part thickness.
 Tangential gates are used only to fill round or cylindrical parts and to promote a circular
flow.
 Although the number of weld lines increase as more gates are used, the strength and
durability of the part is significantly increased.
 Compared to ring gates, tangential gates are easier to remove from the part and generate
less runner scrap.
 The advantages of using tangential gates are they increase weld line strength and are easy to
separate from the part.
 The disadvantages of using tangential gates are they're difficult to machine, leave a
moderate amount of gate vestige and generate a moderate amount of runner scrap.

Pin Gates

 Self de- gating gates separate the part from the gate during mold opening or as the party
ejects.
 Mold design series

 Pin gates are a form of self dig aiding gates and passed the material from the runner to the
part using a single narrow gate.
 This pin gate breaks off during ejection. Yet a two stage ejection system could be added to
help facilitate part sorting.
 Pin gates are commonly machine to 1/8 of the part thickness, using a conventional or CNC
milling machine. Pin gates only allow a small amount of material to pass. It should only be
used for small, thin parts that require short filling and packing times, such as caps and
needles.
 Due to their size, these gates leave little vestige on the part and produce minimal runner
scrap.
 The advantages of using pin gates are they are easy to machine, leave a small amount of
vestige and generate a small amount of runner scrap.
 The disadvantages of using pin gates is that only a small amount of material can flow
through the gate.

Pinpoint Gate

 Another type of self de-gating gate is the pinpoint Gate.

 Pinpoint Gates are used in multi cavity three plate molds and passed through the floating
Center plate to the mold cavity.
 Pinpoint gates taper down to a diameter of approximately 1/3 of the part thickness.
 As they approach the cavity, these tapered gates separate from the part as the mold opens.
 Unfortunately, a moderate amount of vestige is left behind on the part.
 Pinpoint gates are difficult to machine since they passed through the cavity block into the
mold cavity.
 Die sinking EDM and CNC Milling are the recommended methods for machining pinpoint
gates because of their inherent accuracy.
 The pinpoint gate is used for round, concentric and symmetrical parts, which can be gated
on the cavity side.
 Larger parts call for multiple gates to be used. Yet as the number of gates increase, so does
the amount of runner scrap.
 The advantages of using pinpoint gates are they can gate on the cavity surface and multiple
gates allow a large amount of material to pass.
 The disadvantages of using pinpoint gates are they're difficult to machine, leave a moderate
amount of gate vestige and generate a large amount of runners scrap.

Submarine Gates

 Submarine gates also known as tunnel gates, are self de-gating gates that transfer the
polymer from the runner to the mold cavity by channelling underneath the parting line.
 During ejection, the submarine gate is sheared from the part and the moderate amount of
vestiges left behind.
 Like pinpoint gates, multiple submarine gates are needed to fill large parts, yet the amount
of runner scrap increases with the number of gates used.
 The submarine gate diameter at the mold cavity should be approximately one third of the
par thickness.
 Mold design series

 This gate should have a least a five degree taper per side, so it could be removed without
complications.
 When using softer, low strength materials such as polyethylene or polypropylene, the
submarine gate could be angled up to 45 degrees.
 More rigid materials such as polycarbonate and nylon require angles over 45 degrees to
keep the gate from breaking apart during ejection.
 The angle gate is difficult to cut in the milling machine and typically requires a die sinker
EDM machine.
 Submarine gates must tunnel under the parting line and the core side of the mold before
filling the cavity.
 When molding flat parts, a stepped parting line is required to gate on the side of the part.
This is often done using a core insert on the parting line, which contains the submarine gate
detail.
 Submarine gates are used for parts that must be gated below the parting line in order to
avoid gating on cosmetic services at the cavity or at the parting line.
 The advantages of using submarine gates are they allow a moderate amount of material to
flow through the gate and gated part features below the parting line.
 The disadvantages of using submarine gates are they're difficult machine leave a moderate
amount of gate vestige and generate a moderate amount of runner scrap.

Cashew Gates

 Curved tunnel gates are referred to as cashew gates or banana gates and tunnel under the
parting line to gate on the underside of the part.
 During ejection, a moderate amount of vestiges left behind since these self negating gates
must pull from the part and curl out of the mold.
 Therefore, only softer materials such as polyethylene and elastomers can be used with
cashew gates.
 These gates are difficulty machine. Since they cannot be machine directly into the core, the
runner has to be machined into a pair of core inserts, each containing half of the cashew
gate detail. This is done using a CNC milling machine or a die sinker EDM machine.
 The diameter of the cashew gate tapers to approximately 1/3 of the part thickness. These
gates allow a moderate amount of material to pass, yet multiple gates are required to fill
large parts.
 Cashew gates are ideal for flat parts that require gating from the underside.
 The advantage of using cashew gates are they allow a moderate amount of material to flow
through the gate and gate to the underside of the part.
 The disadvantages of using cashew gates are. They're difficult to machine, can only be used
with limited materials, leave a moderate amount of gate vestige and generate a moderate
amount of runner scrap.

Insulated Hot Runner Gates

 Gates used with hot runner systems are self to gating and do not generate runner scrapped
during production, these gates include the insulated, externally heated and internally
heated.
 Mold design series

 Insulated gates are used with the insulated hot runner system and are located where the
runner rounds off of the mold cavities. This gate opens into a mold cavity at a diameter that
is typically 1/3 of the part thickness.
 The depth of the round must be consistent to ensure proper gate diameter at each mold
cavity. Therefore insulated hot runner gates or machined using a CNC milling machine for a
die sinker EDM machine.
 Since insulated hot runner systems like any type of temperature control, they should not be
used when molding high tolerance parts. Large parts should also be avoided.
 As the mold opens, the cooler material at the gate remains, with the part leaving a large
amount of gate vestige.
 The advantage of using insulated hot runner gates is they are inexpensive.
 The disadvantages of using insulated hot runner gates are. They can restrict the amount of
polymer flow into the mold, have no control over the melt temperature and leave a large
amount of gate vestige.

Externally Heated Hot Runner Gates

 Unlike the insulated gate, externally heated gates control the temperature of the polymer
and are the most common hot runner gate used. These gates provide improved process
control and leave a small amount of gate vestige on the part.
 Externally heated gates channel the polymer from an externally or internally heated hot
runner system to the mold cavity.
 The body of the gate is typically made of heat conductive steel and is heated in one of two
ways.
 Heater bands either encircle the gate body or a cast directly into the steel.
 Heat conductive rods are used to evenly distribute heat from the heater bands throughout
the gate body. These rods are cast directly into the gate body.
 The tip of the externally heated gate is machine directly into the mold base or attached to
the gate drop.
 Gate tips machine directly into the cavity block must match the diameter of the gate drop.
 This prevents the material from flowing back around the gate and manifold externally.
Heated gates are typically machine having an insulated section.
 This section channels a small amount of polymer around the head of the gate drop when
gating on contoured or textured services. The gate tips should be machine directly into the
cavity block.
 Externally, heated gate tips attached to the gate drop passed through the cavity block to the
mold cavity surface, leaving a witness line on the part at the perimeter of the gate tip.
 Externally, heated gate tips come in a variety of styles. Many gate tips contain a raised
section, which creates a recess in the part to help disguise gate vestige. Others have multiple
openings that allow a large amount of material to flow through one gate.
 It is recommended to use standard gate tips provided by the runner manufacturer whenever
possible. Since custom gate tips are difficult to machine.
 The advantages of using externally heated hot runner gates are. They can allow a large
amount of material to flow through the gate, leave a small amount of gate vestige and have
moderate control over the melt temperature.
 Mold design series

 The disadvantages of using externally heated hot runner gates are the gate tip leaves.
Witness lines on the part and custom gate tips are difficult to machine.

Internally Heated Hot Runner Gates

 Internally heated gates provide the most control over the melt temperature at the gate. For
this reason, they're the most expensive hot runner gate and are usually reserved for molding
high tolerance parts.
 AISI 420 Stainless steel is typically used for the body of the internally heated gate.
 This poorly conductive steel helps retain the heat within the gate.
 The internally heated gate uses either a rod or an element to heat the polymer from within.
 The heating rod is mounted in the clamping plate or at the top of the gate drop and passes
through the tip of the gate.
 The heating rod provides a smooth polymer flow throughout the gate and can be easily
replaced.
 If a rod is not used, a heating element is mounted at the tip of the gate, using small brackets
for support. This element provides the best temperature control, and since it is located
within the gate tip, the amount of gate vestige is greatly reduced.
 One drawback associated with using this element is that the brackets can produce dead
zones.
 As with the externally heated gate tip, the internally heated gate tip can be either machine
directly into the cavity block or connected to the gate body.
 The advantages of using internally heated hot runner gates are they can allow a large
amount of material to flow through the gate, leave a small amount of gate vestige and have
the best control over the melt temperature.
 The disadvantages of using internally heated hot runner gates are they're the most
expensive hot runner gate. The gate tips leave witness lines on the part and custom gate tips
are difficult to machine.

Valve Gates

 Valve gates area form of hot runner gates. They're used to prevent drooling to improve gate
appearance or to enhance the control of the polymer flow through the gate. Both
mechanical valve gates and thermal valve gates are available.
 The mechanical valve gate uses it externally heated gate trough, which is sealed using an
actuated shut off pin.
 The spring actuated mechanical valve gate opens when injection and packing pressure is
applied. When packing is complete, the spring closes the gate.
 The spring actuated mechanical valve gate is used to eliminate gate vestige and to prevent
drooling during part removal.
 The pneumatically and hydraulically activated mechanical valve gate can be used to open
and close the gate at any stage during the injection and packing process. These gates are
also used to eliminate gate vestige and drooling and are ideal for sequential valve gating.
 Some hydraulically actuated valves. Gate systems can adjust the size of the gate opening by
accurately controlling the position of the shut off pin.
 These gates are used to control the injection speed of the polymer at the gate opening.
 Mold design series

 The thermal valve gate uses an internally heated gate with an additional heating element
located at the gate tip. This heating element is capable of heating and cooling the gate
rapidly, thus opening and closing the gate.
 These gates are most often used to eliminate drooling, though the more responsive thermal
Valve gates can also be used in sequential Valve gating systems.

Gate Location

 Many injection molds fail due to improper gate design. Always incorporate a processing
engineer, a technician or a tech service representative if you're unsure of the gate design to
use.
 This section covers some general guidelines used indeterminate gate location as well as the
number of gates to be used.
 Getting into thick sections is preferred over thin sections, since thin walls can freeze off
before the mold cavity has been completely filled and packed.
 When getting into thick sections using smaller gates such as edge and pin gates, it is
important not to get directly into an open area. Getting into open areas often promotes
jetting.
 Gating on decorative services should be avoided, since most gates leave behind vestige.
 Before the final gate size is determined. Preliminary shear rate and pressure drop
calculations should be performed.
 If the apparent shear rate is more than 50% of the materials limits, the gate should be
enlarged or multiple gates should be used.
 Shear rate limits for materials can be obtained from most material suppliers.
 High pressure drops indicate excessive stress on the polymer and may also exceed the
molding machines limitations.
 Using additional gates or larger diameter, runners and gates can often reduce the overall
pressure required to fill the injection mold.
 A single gate should be used whenever possible. This reduces the amount of weld lines and
gas traps and makes it easier to determine polymer orientation.
 Gates that may need adjustment should be machined steel safe. This allows the gate size to
be increased later, since it is easier to remove steel than added later.

Conclusion

 Upon completion of this program, you should have an understanding of Cold Runner Gates,
hot runner Gates as well as gate location considerations.
 The next program, entitled Runners Filling Software and Mold Design Process, is the ninth
and final program of the mold design and mold making Series.
 Mold design series

Runners Filling Software and The Mold Design Process

 Runners Filling software and the mold design process is the ninth and final program of the
mold design and mold making Series.
 Before beginning this program, you should have already completed the first eight programs.
 The last entitled Gating Methods Runners Filling software and the mold designed process
discusses
o Cold runner systems
o Runner temperature profiles
o Runner cross sections
o Parting line location
o Part orientation
o Mold design process
o And mold filling software is also covered.

Unbalanced Runner Systems

 We recommend using the smallest possible screw and runner cross section to reduce the
amount of runner scrap.
 Standard dimensions, such as 3/8 in or 10 mm, can be used to decrease the complexity of
the runner system.
 To transfer the plastic resin from the machine nozzle to the gate, a hot or cold runner
system is used.
 Cold runner systems are the more common due to their simplicity and low cost, and can be
used with both to plate and three plate molds.
 The three common types of cold runner systems used in the mold making industry are the
unbalanced, naturally balanced and the artificially balanced.
 Unbalanced runners are the least complex form of cold runner systems. Since, unequal
lengths and cross sections are used an uneven polymer flow, and pressure dropped to each
mold cavity is produced.
 These filling inconsistencies can cause over packing and flash to occur in the cavities closest
to the screw and short shots and sink marks in the cavities furthest from the screw.
 Unbalanced runner systems produce parts that vary in weight and dimensions, yet they
generate the least amount of Cold Runner scrapped because of the proximity between the
cavities and the runner.
 Mold design series

 The advantages of unbalanced runner systems are they're easy to design and manufacture
and produce a small amount of runner scrap.
 The disadvantages of unbalanced runner systems are uneven, filling of mold cavities,
unbalanced packing and variations in part weight and dimensions.
 Unbalanced runner systems are commonly used for high volume, low tolerance applications.

Naturally Balanced Runner Systems

 Naturally balanced runner systems use runners of equal length and cross sections. This
balance provides a consistent pressure drop throughout the runner system and ensures that
the material reaches each mold cavity at the same time.
 There are two variations of naturally balanced runner systems. One type consists of radial
runners projecting outward from the screw. This system provides the shortest path from the
screw to the gate and his ideal for molding round parts in 2,3 or 4 cavity molds.
 The use of radio runners is not recommended for molds having more than four cavities,
since the runner junction becomes extremely thick as the number of cavities increase.
 As the thickness of the runner junction increases, so does the cooling time. The other type of
naturally balanced runner system uses a branched runner system. This uses long yet equal
flow lengths to fill each mold cavity and can be used with molds having any number of
cavities.
 Since, branched runner systems use a large amount of material, it is recommended to use
thinner cross sections to reduce the amount of runner scrap.
 The advantages of naturally balanced runner systems are they promote even filling and
equal pressure drops to each mold cavity and are easy to design.
 The disadvantages of naturally balanced runner systems are a large amount of runner scrap
is generated naturally. Balanced runner systems can be used for virtually all injection molds.

Artificially Balanced Runner Systems

 Artificially balanced runner systems are used to help compensate for variations in flow
length. These systems use increased gate and runner diameters for cavities, having longer
flow lengths to equalize the pressure drop for each mold cavity.
 The following basic equations are used to calculate the pressure drops from each cavity
during filling.
 It is recommended to use mold filling software for complex applications that may require
additional process control.
 In order to determine the pressure drop within the runner and gates of a given mold, the
apparent shear rate must be calculated.
 The apparent shear rate is a measurement relative to the cross section of flow as well as the
polymer flow rate.
 The formula for calculating the apparent shear rate through a circular cross section is as
follows 4Q/R3π , For rectangular cross section 6Q/H2 W.
 After calculating the apparent she rate, the apparent viscosity can now be found using a
chart for the material being used.
 Viscosity charts show both the viscosity and sheer rate of the material and can be obtained
right off the websites of most material suppliers.
 Mold design series

 Now that the material viscosity has been determined using the apparent shear rate, the
pressure drop could be determined. The pressure dropped formula for a circular cross
section equals 8QɳL/R4π .
 The pressure drop equation for a rectangular cross section equals 12QɳL/WH 3 , to balance
the pressure dropped reach cavity runner and gate cross sections are altered to reduce the
pressure drop for given cavity or cavities, the runner and gate dimensions are increased.
 Decreasing the diameters will create a larger pressure drop for the desired cavities.
 When altering the runner and gate dimensions. Be aware that risks are involved/
 During packing, the smaller diameter gates freeze off before the larger diameter gates,
creating differential packing and the possibility of unacceptable parts.
 Increased schooling times There also a symptom of using unequal runner in gate diameters.
 As stated previously, mold filling software can help predict these problems and their severity
artificially balanced runner systems are ideal for balancing the flow within family molds.
 In such cases, the runner system could be used to restrict flow to smaller cavities and
increased flow to the larger cavities.
 The advantages of artificially balanced runner systems are minimal. Runner scrap is
generated and can be used to balance family molds.
 The disadvantages of artificially balanced runner systems are differential packing and
increase cooling times in the runner and gate can occur.
 The artificially balanced runner system is ideal for low tolerance applications and family
molds.

Temperature Profile

During filling the material at the front of the polymer melt, as well as the material along the runner
walls has a lower temperature than the center of the melt.

To improve process consistency, features can be added to the runner system to even out the runner
temperature profile.

Overflow wells are used to trap the cooler material at the front of the melt and allow the warmer
material to enter the mold cavity first.

Overflow wells are typically located at the bottom of the screw at runner intersections and just
before, where the polymer melt reaches the mold cavities.

At runner branches, the material on the inside of the corners, has ah higher temperature and
receives higher stresses than the material of the outside of the corners.

Therefore, the polymer has a tendency to fill the inter cavities before the outer cavities.

This creates an inconsistent fill in multi cavity molds, even when a naturally balanced runner system
is used.

Inconsistent filling can be reduced by using larger Radio I at corners and runner branches or through
the use of newer technologies such as the melt flipper.
 Mold design series

The melt flipper, licensed by Beaumont Runner Technology, uses inserts at each runner branch to
mix the polymer. This technology creates um, or consistent flow through each runner branch.

Shown here is how the melt flipper technology rotates the polymer melt and promotes or even
temperature profile throughout the cross section of each runner. This also provides more uniformed
filling to each cavity.

The melt flipper is one way of reducing the filling and packing inconsistencies inherent in branch
runner systems. We strongly suggest that you discuss your branch runner design with a specialist,
namely Beaumont Runner Technology.

Runner Cross Sections

 There are five cross sectional shapes commonly used for cold runner systems
o The rectangular
o Trapezoidal
o Semi circular
o Parabolic
o And Circular
 The rectangular runner system is machine into the mold using a square and mill.
 The vertical walls in this cross section can cause the runner to stick during ejection.
 The rectangular runner is an inefficient method of channelling the polymer melt. As the
polymer tends to flow in a circular cross section, leaving the four corners to freeze off.
 The trapezoidal runner system is machine using a tapered end mill. The inherent draft in this
runner provides better ejection than the rectangular runner, yet is inefficient in channelling
the polymer.
 A ball-end mill is used to machine a semi circular runner system. The shallow runner system
is easy to eject, yet provides the least effective polymer flow. Since, the sides freeze off
quickly and a great deal of polymer is wasted in the corners. Parabolic runner systems
require the use of two different end mills.
 A tapered end mill is used to cut the tapered sides and the ball end mill is used to machine
the semi circular bottom.
 The tapered sides of the trapezoidal runner system promote Easy runner ejection. This
system is also very effective in channelling the polymer melt, since only the top two sections
of the cross section are wasted.
 The circular runner system is the most difficult runner system to machine since a ball end
mill must be used to machine both halves of the mold.
 This runner system is easy to eject from the mold and provides the most efficient polymer
flow.

Parting Line Location

 Determining the location of the parting lines is one of the most important aspects of
designing a mold.
 As mentioned in previous programs seals having high angles or a small radii have a tendency
to flash and where quickly.
 Mold design series

 The most efficient seal is the butt seal and consists of two flat surfaces. Part orientation can
often help to simplify the mold construction.
 For example, the sharp angles on this cover would require a sharp angled parting line using
the depicted orientation. This could be improved by adjusting the orientation of the part,
which lowers the angle of the parting line.
 In the case of this mug, the current part orientation only uses one slide for undercut
removal.
 Unfortunately, the radius seal on the parting line provides a poor seal and can cause
premature wear on the slide by reorienting the part, a butt seal is established even though
two slides are now required this provides a better seal, which is easier to machine.

Mold Design Process

 Although each mold has its own unique requirements, there general procedures to follow
when designing an injection mold.
 The first step in designing a mold is to review the existing part design to avoid complications.
The part designer processing engineer and mold designers should all be involved.
 During this review the processing engineer is responsible for assuring that the mold could be
filled impact properly.
 The mold designer determines if any changes need to be made to simplify the mold. Also
discussed our gate location, part orientation and the ejection method are methods that will
be used.
 After the design review is complete. The dimensions of the steel are determined using the
polymers shrinkage values.
 The upper and lower shrinkage values must be calculated to determine whether the critical
dimensions can be obtained.
 All questionable dimensions should be thoroughly reviewed. If a change cannot be made to
a part dimension or its tolerance, the feature should be machined steel safe.
 The core and cavity blocks are designed after the steel dimensions are established.
 As a general rule, there should be more steel around the cavity than the depths of the part
and no less than 1 in or 25 mm. This helps prevent deflection from occurring during injection
and packing.
 If this is not possible, interlocks can be added between the core and cavity blocks. These
interlocks connect the blocks and provide additional support.
 If applicable actions are added to the core in cavity blocks when designing actions, it is best
to use standardized components since they simplify mold construction and are easy to
replace and maintain.
 Pre-load can be incorporated into the core and cavity blocks by creating interference with
the parting line. This improves the parting line seal by centralizing the clamp pressure on the
core and cavity blocks rather than the mold base. In this case, less than 0.005 in or 0.12 mm
of pre-load is added.
 Gates, Runners and vents are integrated into the mold design after the core and cavity
dimensions are finalized and the actions are designed.
 The cooling line layout and ejection methods are designed together since they often
interfere with each other.
 Mold design series

 Using standardized components for cooling will help simplify mold construction and
maintenance.
 After the cooling line layout is determined, the mold base should be selected. The mold
based supports the core and cavity blocks and houses all the mold components.
 A standard mold base should be selected whenever possible. After selecting the mold base,
support pillars should be added.
 The mold designer should use many support pillars if possible. All additional components to
the design, such as cycle counters, proximity switches, date stamps, mold straps, cooling line
connectors and parting line locks should be added after everything else is in place.

Mold Filling Software

[Please Note: Although newer Autodesk Moldflow software is available, the basic information
discussed in the following video is still relevant.]

 Although molds filling software packages can become very complex, these programs can be
used to optimize even the most simple mold design.
 Mold filling software is a valuable tool used to simulate the filling of an injection mold. This
software allows designers to optimize every aspect of the manufacturing process, starting
with part design and extending to part Processing.
 The industry leader of this software is mold flow and is the product that will be featured in
the following sections.
 Mold Flow offers three different applications designed to evaluate and enhance both part
and mold designs.
 Part adviser caters to part designers Mold adviser to mold designers and Insight is an
advanced program that gives in depth analysis on issues such as shrinkage and warpage,
fiber orientation and cooling line layout.
 These programs are sold in different combinations to accommodate both large and small
manufacturers in the industry.
 All of the applications support STL, STP, IGES and Para Solid file formats.
 Shown here is a small electrical casing containing features such as ribs, bosses and a thin
section in the base, which may be problematic during manufacturing.
 By running a quick analysis within part adviser, these concerns will be put to the test.
 Preparing a model for analysis requires selecting a material and specifying the gate or gate
locations.
 The material database contains approximately 7500 grades of polymer for this part ABS and
polycarbonate blend will be used.
 The gate location can be selected manually or through the aid of automatic gate location
analysis.
 Shown here, the results of the analysis Red areas indicate a poor choice, whereas blue areas
denote an acceptable gate location.
 After specifying a gate location, plastic flow analysis can be done on the part.
 The confidence of fill part uses traffic light colors to display which regions of the model will
fill properly. Red regions have a low confidence of fill in our potential manufacturability
problems like the thin area on the base of the part.
 Mold design series

 The reason for this is the temperature in this region has dropped below the specified limit. A
list of solutions is proposed to prevent the low confidence of fill, one of which suggests
altering the section to have a uniformed thickness.
 This change must take place within the CAD model and requires the user to re-import the
file.
 After altering the model, a problem free confidence of Phil is achieved. There are several
other plots that could be obtained using the plastic flow analysis.
 The fill time plot shows how the cavity is filling. Injection pressure and pressure drop plots
indicate the amount of pressure required for filling the mold and the amount of pressure
loss during injection, respectively.
 The flow front temperature displays the warmer and cooler areas of the part during filling.
To pinpoint areas where lack of quality may be an issue, the quality prediction plot can be
used.
 The sink mark index identifies sink mark locations and estimates how deep the sink will be. If
sink marks do exist and surface appearance is critical, then design changes may be needed.
 To obtain a basic understanding of the cooling aspects of a given part. The cooling quality
plot can be used.
 Areas that differ from the average cooling time, such as thick and thin sections are
highlighted in red.
 A part report could be generated that details all results obtained from the performed
analyses.
 This report includes data graphics as well as animation and can be viewed using any Web
browser.
 Mold Flows Mold adviser allows the mold designer to analyze and optimize runner systems
for single cavity, multi cavity and family molds.
 In the following example, a six cavity mold of the electrical casing model will be designed
and evaluated.
 After opening the file, the first step is to orient the part with respect to the mold opening
direction.
 Five additional cavities are then created and rotated so that all the gates are facing the
center of the mold.
 A parting line plane must then be defined and mold dimensions. Determined Mold adviser
automatically estimates the absolute minimum mold based dimensions. However, custom
dimensions can also be entered if necessary.
 Both to plate and three paint molds can be designed with the mold based set up. Now
complete the screw runner and gate dimensions are defined mold flow allows for both hot
and cold runner systems to be used in various cross sectional shapes.
 The mold is using six tunnel gates in it's Cold Runner. After creating the runner layout, this
mold can be analyzed.
 The unbalanced runner fills the center to cavities before the four outer cavities.
 To prevent over packing flash and short shots from occurring, this runner system must be
artificially balanced.
 This is done using the automatic runner balancing analysis, which resize is the runner
channels to balance Filling.
 This feature is especially helpful in sizing the runner systems to be used in family molds.
 Mold design series

 After the mold has been configured, Cost adviser could be used to estimate the overall part
cost.
 The part cost is estimated in four steps. Resin cost, mold cost, machine operating costs and
post molding costs.
 This is an excellent tool for preparing quotes. As with part adviser, a project report can be
generated from mold adviser, which details all of the results.
 Mold flow offers a more advanced application with enhanced modelling, filling, packing and
cooling analyses.
 Since this program is more technical, it is geared towards experienced users.
 As shown here, more detailed information can be obtained from the various filling analysis
plots, with the ability to model both the mold base and the cooling line layout.
 Mold manufacturers have the luxury of testing several different configurations before the
steel is cut.
 This advanced software can offer valuable insight in optimizing any injection mold.