Injection Mold Tooling Standards Manual2019

Summit Polymers, Inc.
INJECTION MOLD TOOLING

STANDARDS MANUAL
Revised: August 1, 2019

SECTION 00.01
INDEX
01. MOLD BUILD PROGRAM EXPECTATIONS
SECTION TITLE REV. LEVEL / DATE
01.01 Mold Build Timing & Expectations L / 05-31-17
01.02 SPI Global Molding Machine Specifications 06-11-18
01.03 SPI Data Management H / 07-13-18
01.04 List of Drawings / Tables 08-01-19
02. MOLD BUILD PRODUCTION SET UP REQUIREMENTS
02.01 Side Loaded, <280T Press Size G / 08-01-19
02.02 Top Loaded, >280T Press Size D / 06-11-18
02.03 Cavity Thickness Under Part Rel / 09-30-18
02.04 Core Thickness Under Part Rel / 09-30-18
03. MOLD BUILD STANDARDS
03.01 Material / Tolerances F / 08-26-16
03.02 Mold Components (General) F / 08-01-19
03.03 Air Poppets C / 08-01-19
03.04 Cavity Pressure Transducers Slot & Pin Plate Recess B / 07-31-19
03.05 Clamp Plates / Spacer Rails M / 08-01-19
03.06 Eye Bolts F / 01-19-15
03.07 Safety Straps B / 01-09-15
03.08 Gating D / 05-31-17
03.09 Cold Runners / Cold Sprues G / 05-31-17
03.10 Hot Manifolds / Hot Sprues / Sequential Valve Gating I / 08-01-19
03.11 Mold Temperature - Cooling M / 08-01-19
03.12 Cavity Venting F / 08-26-16
03.13 Ejection / Reverse / Accelerated Ejection J / 08-01-19
03.14 Slides F / 08-01-19
03.15 Lifters / Retractors D / 08-26-16
03.16 Hydraulics - Core Pulls and Reverse Ejection C / 08-01-19
03.17 Mold Identification - External and Internal E / 08-01-19
03.18 SPI Functional Practices E / 08-01-19
03.19 Robot Interface C / 05-31-17
03.20 2-Shot Tool Requirements D / 06-11-18
03.21 Coatings A / 08-26-16
03.22 Mold Shipping Standards A / 06-11-18
03.23 Grain / Texture A / 08-01-19
03.24 Gas Assist Rel / 05-31-17
03.25 In Mold Decorating A / 08-01-19
03.26 OEM Specific Requirements Rel / 06-11-18
03.27 Applique Specific Requirements Rel / 08-01-19
03.28 High Gloss Painted Part Specific Requirements Rel / 08-01-19
Page 1 of 221
SECTION 00.02
REVISION HISTORY
06-24-09 Initial Release
08-14-09 Rev. A
Section 01.02 Section 03.10
06-15-10 Rev. B
Section 03.08
09-29-11 Rev. C
Section 02.02
09-28-12 Rev. D
Section 03.08
03-11-13 Rev. E
Section 01.02 – Updated and added new press information
Section 01.04 – Updated revision levels of changes
Section 02.01 – Added stop block area to drawing
Section 03.05 – Removed bullet point about 2-shot clamp plates
Removed alignment mark requirement
Section 03.08 – Added specific cashew gate / runner combinations
Section 03.09 – Changed dovetail sprue puller to “Z” puller
Added runner shut-off requirement
Section 03.10 – Added 6” minimum requirement for position
Section 03.11 – Changed braided hose supplier and part number
Added maximum number of baffle requirement
Changed GPM requirement
Corrected spacer rail matrix for China presses
Section 03.12 – Added ejector pins to atmosphere
Added blueing off of tool after F1 requirement
Section 03.13 – Added stripper plate requirement bullet points
Section 03.19 – Removed vacuum flag requirement
Page 2 of 221
SECTION 00.02
REVISION HISTORY
04-12-13 Rev. F
Section 01.01 – Added requirement of photos to items 18 & 19
Section 03.17 – Revised external ID requirement
07-01-13 Rev. G
Section 01.01 – Added SPI sample expectations to item 1
Changed Sample Data Sheet to steel dimensional
certification in item 10
Added payment requirements to item 18 & 19
Changed F1 points in item 22
Section 02.01 – Added note to clarify stop block area for Op Side
Added chamfer to bottom of clamp plate
Section 03.05 – Added 250T Haitian 2-Shot clamp plate information
Removed 2-Shot bullet point and moved to
Section 03.20.
Section 03.09 – Added TPE ejection requirement for runners
Section 03.10 – Added support behind hot manifold drops
Section 03.11 – Added insulator board placement requirement
Section 03.13 – Added TPE ejection pin size/straight lifter req.
Added stripper plate no suicide condition bullet pt.
Section 03.20 – Added 2-Shot section to manual
03-07-14 Rev. H
Section 01.01 – Changed PR payment approval drawing req’ment
Section 01.03 – Added PDR & FDR requirement to data transfer
Section 01.04 – Added 03.20.02C and changed name to 03.20.02D
Section 03.01 – Added CENA 1
Section 03.02 – Added requirement for spare parts
Section 03.05 – Fixed 1000T clamp plate thickness typo
Section 03.08 – Added bullet nose design
Changed length of runner pin for subgate designs
Section 03.10 – Added Synventive supplier contact information
Added valve gate couplers to BOM
Added Staubli supplier contact information
Added preference for valve gate/manifold suppliers
Added fitting orientation for valve gate connection
Section 03.15 – Added lifter car (foot) length to height requirement
Section 03.18 – Added welding notification requirement
Section 03.20 – Added holder for K.O. extensions
Added ½” quick disconnects for water B side
Section 03.21 – Added Coatings section (Initial Release)
Page 3 of 221
SECTION 00.02
REVISION HISTORY
05-14-14 Rev. I
Section 01.01 – Updated drawing requirement on CD for payment
Section 01.03 – Added PR and Tool Number to zip file name
Section 01.04 – Updated revision level for 03.10.02
Section 03.10 – Updated 03.10.02 to show clearance for connector
Removed note on bottom of 03.10.02
Section 03.22 – Added Crating section (Initial Release)
07-18-14 Rev. J
Section 01.01 – Updated F1 to FR lead time
Section 03.10 – Updated Staubli connector port numbering
Section 03.11 – Updated gpm requirement for side load tools
Specified Parker as only brand for BH8-60 & 61
½” ID for water hoses
01-09-15 Rev. K
Section 01.01 – Clarification on CD Requirements for PR
Section 01.03 – Added DropBox and email PE and TE
Section 03.01 – Added hardness for Lamina/O1 & BOM Req.
Section 03.02 – Added “unless specified by SPI TE”
Section 03.05 – Added 1125T clamp plate. Corrected Haitian
2-shot clamp plate size. Added 170T to 0.875”
category
Section 03.06 – Added color code for eyebolts. Added 2” & 2 ½”
eyebolt information
Section 03.07 – Added shear strength table to BOM
Section 03.08 – Added applique tool gating requirements
Section 03.09 – Added runner volume requirement for hot sprue
Section 03.10 – Added mini water manifold for valve gates. Added
socket tool to BOM. Updated Staubli contact info
Section 03.12 – Added crush pads for ≥500T tools
Section 03.13 – Updated BOM to new thin switch design. Added
all tools to have thin switches
Section 03.17 – Clarified customer part number for ext. engraving
Section 03.20 – Updated water manifold orientation for Hiatian
01-19-15 Rev. L
Section 03.06 – Corrected document to match Section 03.06.04
Page 4 of 221
SECTION 00.02
REVISION HISTORY
04-30-15 Rev. M
Section 01.01 – Updated items 8, 9, 17 and 18 for requirements
Section 01.02 – Added Max. Distance Below Platen to press specs
Section 03.09 – Corrected runner volume vs. shot volume
Section 03.13 – Added distance between early return pins for robot
Added ≤170T sgl. safety swch. at discretion of TE
10-16-15 Rev. N
Section 01.04 – Added Zero Parting Line drawing, adjustable water
manifold, jump gate, mold mx inserts for slider
knobs, sleeve ejectors for links and strip retainers,
over flow channel for nylon vanes, grommet tuning
for slider knobs, polypropylene gating for rear
vanes and honeycomb lifter/pin design
Section 03.05 – Added no through pocket requirement
Section 03.08 – Added jump gate
Section 03.11 – Added adjustable water manifold for 170T
Section 03.12 – Added ring venting
Section 03.13 – Added Omron and McMaster-Carr for thin switch
manufacturers
Section 03.14 – Added Zero Parting Line requirement & >70 lbs
slides opposing gravity need hydraulic cylinder
Section 03.20 – Added 5x13 puck slots to clamp plate KM 2-shot to
allow plant to run single shot tools in press
08-26-16 Rev. O
Section 01.02 – Updated, added, reformatted press information
Section 01.04 – Added transducer, latch lock, vent design and lifter
safety switch design drawings
Section 03.01 – Added Ampocoloy 944 to materials list
Section 03.04 – Resurrected section Cavity Tranducers
Section 03.05 – Corrected clamp plates to match press information
Section 03.06 – Updated crane matrix
Section 03.08 – Updated venting depths for PBT & “Toyobo” mat’ls.
Section 03.09 – Added runner choke inserts
Section 03.10 – Added cooling bushing and hot manifold carrot
requirement
Section 03.11 – Updated water fittings
Section 03.12 – Clarified when to use ring venting
Section 03.13 – Changed spring and set screw in BOM, added
latch locks
Section 03.15 – Added crush pad requirement & geometric grain
requirement
Section 03.19 – Added alignment holes for EOAT
Section 03.21 – Added Tribocoat for TPE (req’d) and PP (rec’d)
Page 5 of 221
SECTION 00.02
REVISION HISTORY
05-31-17 Rev. P
Section 01.01 – Added Mold Kick Off Date info, expectations of
Mold Suppliers designs and changed Final CAD
Data to Kick Off Data Transfer under expectations
Section 01.02 – Updated, added, reformatted press information
Section 01.03 – Updated file preference and naming preferences
Section 01.04 – Updated drawing revision levels
Section 03.05 – Corrected and reformatted clamp plates
Section 03.08 – Added balance with gates unacceptable
Section 03.09 – Added balance with runner segments
Section 03.10 – Updated mini water manifold info for valve gates
Section 03.11 – Added minimum distance for water channel / part
Section 03.13 – Added safety ejector switch jumped with A side ej.
Section 03.18 – Added welding signoff, balance using runners
Section 03.19 – Added EOAT docking hole pictures
Section 03.23 – Added Grain/Texture section (Initial Release)
Section 03.24 – Added Gas Assist section (Initial Release)
07-13-18 Rev. Q
Section 00.01 – Updated index
Section 00.02 – Revision history
Section 01.02 – Updated, added press information
Section 01.03 – Updated to match new document control procedure
Section 03.03 – Add requirement for all TPE parts
Section 03.10 – Added thermocouple/power pins to bill of materials
Section 03.11 – Added supply and return to water fittings, note
about side load tools and hose diameter.
Section 03.14 – Added dowels to gibs for location of slide
Section 03.16 – Added notes to Limit Switch item
Section 03.18 – Added core out requirement for gating on 2nd shot
Section 03.20 – KM water fitting callout removed
Section 03.22 – Renamed section. Added ship req’s for all loc’s.
Section 03.25 – Added IMD section (Initial Release)
Section 03.26 – Added OEM Specific Req. (Initial Release)
08-01-19 Rev. R
Section 00.01 – Updated index
Section 00.02 – Revision history
Section 01.03 – Removed parasolid labeled folder requirement
Section 03.02 – Update leader pin bushing requirement. Clarified
when spare ejector pins/sleeves are required
Section 03.03 – Correct logic for both versions
Section 03.04 – Transducer slots for TPE and Shoot Ship tools and
component tables for RJG & non-RJG
Page 6 of 221
SECTION 00.02
08-01-19 Rev. R (Cont.)
Section 03.05 – Added 500 KM CX, 530 2-shot Hiatian and 651 KM
GX and updated multiple clamp plate sizes.
Section 03.10 – Updated carrot length requirement
Section 03.11 – Fixed typo on 03.11.05B and added water line dia.
for water channels
Section 03.13 – Updated switches for new safety switch design,
added tool shop responsibility for ejecting part,
added parts/runners present to EOA to match FR
checklist, added rect./sq. ejector bars, added guide
bushing oversize reference
Section 03.14 – Added detentes for hydraulically driven slides
opposing gravity
Section 03.16 – Changed type of hydraulic cylinder, added fittings
and electrical connectors for up to 4 hyd. core
pulls, corrected which fittings for ejector forward
and retract
Section 03.17 – Added date wheel requirement, added engraving
area to cavity/core block for textures and coatings
Section 03.18 – Added scribe line requirement, flat guides, 3
degree angle for cavity/core inserts and using gas
springs for transfer molding, added parting line
mismatch requirement
Section 03.23 – Updated Tennibac/Mold Tech - Standex Engraving
Section 03.25 – Ejector pins and inserts used for eject must be
Coated for IMD tools
Section 03.27 – Added Applique section (Initial Release)
Section 03.28 – Added High Gloss Paint section (Initial Release)
Page 7 of 221
S SUMMIT POLYMERS, INC.
P
I
Molded & Decorated Plastic Systems _____________________________________________________
SECTION 01.01 REV. LEVEL: L
REV. DATE: 05-31-17

MOLD BUILD TIMING & EXPECTATIONS
ISSUE: 06-24-09
PAGE: 1 of 6
1) All quotations for Summit Polymers, Inc. (SPI) must be based on the “SPI
Injection Mold Tooling Standards Manual” and SPI mold validation
expectations.
o V1 Sample – Tool suppliers initial shots into mold (30 minutes)
[Suppliers only sample]
o F1 Sample – scoring event for mold (2 hours)
o F2, F3, F4+ Sample(s) – closure of issue(s) identified on mold
critique sheet(s) [As Needed]
o FR Sample – sign off of all open issues identified (4 hours)
2) All quotations must be based on the lead time for the F1 Sample event. Do
not quote solely to a V1 date. Okay to quote V1 target and F1 target dates.
3) The Mold Kick Off date is the date the Mold Supplier receives the Purchase
Order and Kick Off Data Transfer for each respective project.
4) SPI will issue one Purchase Order for the mold build. Any costs that
arise during the mold build become the responsibility of the Mold
Supplier. Engineering Changes will be treated as new business and
quotations will be required. P.O.’s for the EC’s will be issued.
5) Mold Suppliers are expected to coordinate all design review events and
sample events with the appropriate SPI personnel to assure the
availability of the specific members of the Product Development Team
(PDT). Domestic Mold Suppliers must coordinate the participation of the
Tooling Engineers (TE) and the Tooling Engineer, Process (TE,P) by
contacting the Tooling Group Engineering Coordinator, to set up the
event schedule.
6) Approved Mold Preliminary Designs are the Mold Supplier’s
authorization to purchase mold materials.
7) Preliminary mold designs should feature the concept and detail of the
mold (actions), but not the bill of materials. Informal concept reviews will
be conducted by SPI by request prior to the preliminary mold design
review.
8) Approved Mold Final Designs are the Mold Supplier’s authorization to
start machining the mold materials.
Page 8 of 221
REV. DATE: 05-31-17

ISSUE: 06-24-09
PAGE: 2 of 6
9) The Mold Supplier’s mold designs are expected to be as compact as

possible, without sacrificing robustness, tool longevity, or sacrifice SPI
standards intent and fit in the smallest press size.
10) Mold Timing Expectations:

o Design For Manufacturing (DFM), if applicable, is expected 2-3
days from project Kick Off or sooner if Mold Supplier was
brought in ahead of formal Kick Off.
o Preliminary mold design reviews should occur within one week
of receipt of Kick Off Data Transfer.
o Final mold design reviews should occur within two weeks of
receipt of Kick Off Data Transfer.
o Domestic mold build lead-times start with the receipt of Kick Off
Data Transfer
o Off-Shore mold designs start with the receipt of Kick Off Data
Transfer. Off-shore mold build lead-time starts with the receipt
of the final mold design approval.
o Functional Ready Approval expected to be ≤ 20 days after F1
Sample but not to exceed 60 days after F1 Sample. Under
normal mold construction and validation conditions, any F1+60
days will trigger an automatic “OK To Ship” status. The
remaining issue(s) documented at this milestone will be closed
at “home” destination and all associated costs will be debited
back to the mold supplier.
11) Dimensions and Tolerances:
o Critical dimensions and tolerances are called out on KBPD
04.06.01 “Sample Data Sheet.”
o KBPD 04.06.01 must be completed and submitted to the SPI
TE on or before the F1 sample event.
o On non-critical dimensions the tolerances default to +25% of
the nominal part print tolerance shown on the part drawing.
12) Asian Mold Suppliers must submit their steel certification paperwork with
their steel dimensional certification paperwork on or before the F1
sample event. Steel certs should include but not be limited to: cavity set
material, cavity set heat treatment, cavity set hardness, insert steel
material, insert steel heat treatment, insert steel hardness, component
steel material, component steel heat treatments, component steel
Page 9 of 221
REV. DATE: 05-31-17

ISSUE: 06-24-09
PAGE: 3 of 6
hardness, etc. Tooling will not be approved for final payment if the steel
certification package is not received. PR sign-off cannot be achieved
without the receipt of the steel certification package.
13) Mold Suppliers are responsible for all subcontracted work quality and
delivery; i.e. wire EDM, gun drilling, cavity set roughing, heat-treating,
fitting, texture, etc. Subcontracting of entire molds is not permitted
without prior authorization.
14) Mold Supplier is responsible for all sample costs through validation,
functionally ready (PR) and process capable (PC) sign-off.
15) Mold Supplier validation sample (V1) is expected at least one week prior
to scheduled delivery of tool (F1 sample).
16) SPI first shots are recognized as parts produced from the 1st functional
delivery sample, F1. All correspondence related to first shots must be
qualified by the person distributing the correspondence. Special
arrangements must be made if SPI Engineering requires parts from the
Mold Supplier Validation Sample, V1, for gage qualification or customer
pre-production demands. In all cases, the SPI first shot sample is F1.
17) The Mold Supplier should be present at the samples. Functional and
process concerns will be noted on the SPI Mold Critique Sheet. SPI
expects 24/7 Mold Supplier attention to Open Issue closure for all
functional, process and EC issues.
18) SPI expects Mold Suppliers to schedule sufficient capacity for mold build
corrective action and EC requirements.
19) Domestic mold build payment terms are (1) 70% with Functional Ready
approval and (2) 30% with the SPI part dimensional approval and the
corresponding customer’s visual approval. A modified 70/30 plan can
be negotiated if the customer’s visual approval is planned >4 months
after the PR sign-off date. Off-Shore mold build payment terms are (1)
40% down, (2) 45% with Function Ready approval and (3) 15% at OK
To Ship Approval.
20) Off-Shore Suppliers: To receive payments:
o FR Payment Approval (45%)
o Functional Ready Tooling / Process Capable Checklist & Plant
Ready Sign-Off has been signed off by TE, TE,P and Project
Engineer (PE). All issues identified on Mold Critique Sheet must be
closed. PE has received a copy of the steel certification package.
o OK To Ship Payment Approval (Final 15%)
Page 10 of 221
REV. DATE: 05-31-17

ISSUE: 06-24-09
PAGE: 4 of 6
o Submit an electronic version of the Final Design to the Summit

Polymers ftp site or DropBox and send a CD to SPI TE USA. The
CD must include the following:
 Bill Of Material showing all items of mold (excel format)
 3D Data (current design / revision level)
 Parasolid (.x_t format)
• Parts and Runner
• A Side Inserts
• B Side Inserts
• A Side Components
• B Side Components
 Native data (UG, CATIA, etc.)
 2D Data (current design / revision level) [high resolution pdf]
 Hot manifold including bill of material
 Mold assembly with call-out bubbles for each item
 6 views of tool
 Steel measurements on Summit Polymers Sample
Data Sheet [SDS]
 Material certification (pdf)
 Heat treatment certification (pdf)
 Photographs of completed mold and external mold
identification
 Mold in closed position
 Entire mold cavity side
 Entire mold core side
 Full view of side of mold with etched identification
 Close up of OEM identification requirement
21) Domestic Suppliers: To receive payments:

o FR Payment Approval (70%)
o Functional Ready Tooling / Process Capable Checklist & Plant
Ready Sign-Off has been signed off by TE, TE,P and Project
Engineer (PE). All issues identified on Mold Critique Sheet must be
closed. PE has received a copy of the steel dimensional
certification.
o PR Payment Approval (Final 30%)
o Submit an electronic version of the Final Design to the Summit
Polymers ftp site or DropBox and send a CD to SPI TE USA. The
CD must include the following:
Page 11 of 221
REV. DATE: 05-31-17

ISSUE: 06-24-09
PAGE: 5 of 6
 Bill Of Material showing all items of mold (excel format)

 3D Data (current design / revision level)
 Parasolid (.x_t format)
• Parts and Runner
• A Side Inserts
• B Side Inserts
• A Side Components
• B Side Components
 Native data (UG, CATIA, etc.)
 2D Data (current design / revision level) [high res. pdf, dwg or

dxf]
 Hot manifold including bill of material
 Mold assembly with call-out bubbles for each item
 6 views of tool
 Steel measurements on Summit Polymers Sample
Data Sheet [SDS]
 Material certification (pdf)
 Heat treatment certification (pdf)
 Photographs of completed mold and external mold
identification
 Mold in closed position
 Entire mold cavity side
 Entire mold core side
 Full view of side of mold with etched identification
 Close up of OEM identification requirement
o Parts must meet SPI’s customer’s full submission needs.
22) Mold Supplier is expected to warrant the tool for 12 months from the
start of production.
23) SPI Engineering Department Manager, Tooling Group, is responsible for
Supplier Development, Supplier Performance Tracking, Supplier
Performance Reporting, Internal SPI Supplier Performance Summaries,
and Internal SPI Supplier Commodity & Preferred Supplier Lists.
24) Domestic and Off-Shore Mold Supplier Performance will be documented
and evaluated annually. Mold Suppliers that exceed performance
expectations will become SPI Preferred Mold Suppliers. SPI maintains
five performance measurables: (1) Open Issues at the Final Mold
Design Review, <1.5 issues, (2) F1 quality determined on the FR
Checklist, <15 points, (3) Days from kick-off to OK to Cut ≤ 28 days,
(4) F1 actual date vs. quoted date ≤ 0, (5) Lead-time F1 to FR days ≤
20.
Page 12 of 221
REV. DATE: 05-31-17

ISSUE: 06-24-09
PAGE: 6 of 6
25) Mold Supplier Executive Management is required to submit prompt

corrective plans when requested by the SPI Engineering Department
Manager, Tooling Group, for poor performance resulting from monthly
reviews or semi-annual performance reports.
26) Supplier Executive Management will review performance annually and
take immediate corrective action, as appropriate, to meet or exceed SPI
expectations.
27) If parts are dimensionally approved, the engineer will give direction to
the mold source for final graining or functional needs. If rejected, the
mold source will be responsible to verify tool steel dimensions. The
mold source will correct and re-certify as needed. Any deviations must
be reviewed and approved by SPI Engineering.
28) If the parts meet all physical, functional, dimensional, and appearance
requirements, they will be submitted to SPI’s customer. The customer
will then fully approve the parts. Final instructions will be given to the
mold source by the SPI Engineer to close the program.
Revision Record
Rev. A – Added line # 16 and re-numbered subsequent numbers thereafter.
Rev. B – Section 9, added second bullet point. Added new Section 10 and re-numbered
subsequent Sections thereafter.
Rev. C – Sections 9 and 10, change “Part Data Sheet” to “Sample Data Sheet”.
Rev. C – Section 22, changed “Final Mold Design Review, <3” to “<1.5” and changed “FR
days <21 days” to “<6 days”.
Rev. D – Section 10 and 12, change “FR” to “PR”. Section 17 change “FR” to “PR” and
payment terms for Shenzhen, China.
Rev. E – Added 2nd bullet points under items 18 & 19 requiring photographs.
Rev. F – Added mold validation expectation bullet points under item 1 and changed item 22
F1 quality points from 36 to 15. Added payment requirements to items 18 & 19.
Changed Sample Data Sheets to steel dimensional certification in item 10.
Rev. G – Changed items 18 & 19 requirements for PR payment.
Rev. H – Added drawing requirements on CD for payment.
Rev. I – Changed Lead Time F1 to FR to 20 days under item 22.
Rev. J – Added CD requirements for PR approval. Added F1 goal to item 22. Changed
semi-annual to annually on performance reviews.
Page 13 of 221
REV. DATE: 05-31-17

ISSUE: 06-24-09
PAGE: 7 of 6
Rev. K – Updated item 8 to include FR Approval. Changed item 9 from PE to TE. Updated
item 17 & 18 for Offshore payment requirements.
Rev. L – Added Mold Kick Off Date, added DFM, changed final CAD data to Kick Off Data
Transfer and added note about smallest/robust tool size.
Page 14 of 221
(in.)
Locate Ring Dia.
Max Mold # # # #
Tonnage Ejector Pattern Max Weight on Fixed # Moving Integrated Integrated Integrated
Asset ID#
Open Clamp
Units (H X V) Tie Bar Day Light Platen Size Ejector Max Stack Min Stack Max Mold Moving Centerline Platen Hyd Platen Valve Gate Valve Gate Hot
Tonnage (the largest pattern on Daylight Stroke
Press (listed on the
(MT or Tonnage Barrel machine)
Ejector Hole in Mold (H x V) (H X V) Max Max Stroke Height Height Weight Platen of Platen to Core Hyd Core Circuits Inj Circuits Inj Manifold
Location machine) UST) Brand Model (UST) Ounces (in.) (in.) (in.) (in.) (in.) (in.) (in.) (in.) (in.) (lbs) (lbs) cross bar Circuits Circuits Unit 1 Unit 2 Ctrl Circuits
Note - do not build molds for 35 / 40 / 85 Ton machines without plant GM approval. There are very few machines in the company, and typically produce only clips and bumpers
Plant 3 2503 35 UST VD ET 35 2.9 4 0 x 7 vertical 1 11 x 11 16.1 x 16.1 20.9 13.8 3.9 Calculate 7.10 530 331 0 1 0 n/a 0
Plant 8 3489 85 UST VD HT 85 5 4 0x7 1.25 16 x 13.6 22.8 x 20.4 24.0 12 3 11.73 0.00 660 505 na - 0 1 0 n/a 0
Plant 8 4440 85 UST VD HT 85 3 4 0x7 1.25 16 x 13.6 22.8 x 20.4 25.2 12 3 12.99 1.24 800 575 na - 0 1 0 n/a 0
Note - do not build molds for 35 / 40 / 85 Ton machines without plant GM approval. There are very few machines in the company, and typically produce only clips and bumpers
Plant 18 4007 120 UST VD HT 120 6 4 0 x 7/7 x 0 1.25 17.1 x 17.1 25.2 x 25.2 27.1 14 3 12.84 3.09 1,068 759 na - 0 1 0 n/a 0
Plant 6 TBD 120 UST VD HT 120 8 4 0 x 7/7 x 0 1.25 17.1 x 17.1 25.2 x 25.2 27.2 14 3 12.99 3.24 1,130 790 na - 0 1 0 n/a 0
1st - 8.2 na -
Plant 6 3683 200-2 UST Engel TB 200-2 4 4 x 16/16 x 4 1.25 Tie Barless 27.9 x 22.1 36.8 22.65 5.9 Calculate 5.67 1,160 930
2nd - 6.2 sideload 0 1 0 0 0
Plant 9 4090 170 UST VD HT 170 8 4 4 x 16/16 x 4 1.25 20.1 x 20.1 29.1 x 29.1 31.4 17 4 14.13 2.38 1,700 1,200 na - 0 1 0 n/a 0
Plant 1 4541 170 UST VD HT 170 14 4 4 x 16/16 x 4 1.25 20.1 x 20.1 29.1 x 29.1 32.2 17 4.5 14.99 3.24 1,750 1,225 na - 0 1 0 n/a 0
1238
na -
Plant 15 or 170 UST VD HT 170 8 4 4 x 16/16 x 4 1.25 20.1 x 20.1 29.1 x 29.1 30.7 17 4 13.42 1.67 1,660 1,180
sideload
1133 0 1 0 n/a 0
1238
na -
Plant 15 or 170 UST VD HT 170 8 4 4 x 16/16 x 4 1.25 20.1 x 20.1 29.1 x 29.1 32.2 17 4 14.99 3.24 1,750 1,225
sideload
1133 0 1 0 n/a 0
Plant 15 6640 160 MT KM CX 180 9.39 4 4 x 16/16 x 4 1.18 22.44x20.47 34.25x33.27 44.3 25.59 5.91 Calculate 18.74 3,589 n/a 1 0 0 n/a 12
Plant 18 3542 230 UST VD HT 230 14.7 4 4 x 16/16 x 4 1.25 22 x 22 32.3 x 32.3 39.1 20 4.5 18.84 4.09 2,800 1,950 na - 0 1 0 n/a 0
Plant 17 5822, 230 UST VD HT 230 14.7 4 4 x 16/16 x 4 1.25 22 x 22 32.3 x 32.3 37.7 20 4.5 17.50 2.75 2,530 1,815 na - 0 1 0 n/a 0
Plant 6 4359 230 UST VD HT 230 20 4 4 x 16/16 x 4 1.25 22 x 22 32.3 x 32.3 39.2 20 4.5 18.99 4.24 2,860 1,980 na - 0 1 0 n/a 0
Page 15 of 221
(in.)
Locate Ring Dia.
Max Mold # # # #
Asset ID#
Open Clamp
Plant 8 4011 230 UST Demag HT 230 14.7 4 4 x 16/16 x 4 1.25 22 x 22 32.3 x 32.3 39.2 20 4.5 18.99 4.24 2,860 1,980 na - 0 1 0 n/a 0
Plant 18 263 200 MT KM CX 225 15 4 4 x 16/16 x 4 1.25 22 x 22 36.02 x 36.02 41.7 27.5 7.87 Calculate 14.11 4,529 n/a na - 0 1 0 n/a 0
Plant 18 3967 300 UST VD HT 300 30 4 4 x 16/16 x 4 1.25 25 x 25 36.9 x 36.9 45.4 24 6 21.13 4.38 3,740 2,670 24" 0 1 0 n/a 0
Plant 8 4723 300 UST Demag HT 300 48 4 4 x 16/16 x 4 1.25 25 x 25 36.9 x 36.9 46.2 24 6 21.99 5.24 4,100 2,850 24"
0 1 0 n/a 0
2.25 = 6x28 or larger
Plant 15 1263 300 MT KM CX 337 29.63 4 6 x 28/28 x 6 27.97 x 24.84 42.36 x 41.37 46.8 32.28 7.87 Calculate 14.57 6,502 4,385 61.7"
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
Plant 15 1264 350 MT KM CX 393 65 4 6 x 28/28 x 6 27.95 x 27.95 41.76 x 43.14 52.8 36.22 9.84 Calculate 16.54 9,478 6,320 61.7"
1.25 = 4x16 or smaller 0 1 4 n/a 4
Plant 15 1268 350 MT KM CX 393 65 4 6 x 28/28 x 6 27.95 x 27.95 41.76 x 43.14 52.8 36.22 9.84 Calculate 16.54 9,478 6,320 61.7"
1.25 = 4x16 or smaller 0 1 0 n/a 4
Plant 15 1269 350 MT KM CX 393 65 4 6 x 28/28 x 6 2.25 = 6x28 or larger 27.95 x 27.95 41.76 x 43.14 52.8 36.22 9.84 Calculate 16.54 9,478 6,320 61.7" 0 1 0 n/a 4
Plant 17 5828 350 MT KM CX 393 39.7 4 6 x 28/28 x 6 2.25 = 6x28 or larger 31.5 x 27.95 45.26 x 43.14 54.2 36.22 9.84 Calculate 17.96 9,738 6,450 61.7" 1 1 4 n/a 12
Plant 15 TBD 400 UST VD HT 400 60 4 4 x 16/16 x 4 1.25 28.1 x 28.1 42 x 42.8 50.4 26 6 24.13 4.38 5,320 3,760 27" 0 1 0 n/a 0
Plant 18 4370 400 UST VD HT 400 40 4 4 x 16/16 x 4 1.25 28.1 x 28.1 42 x 42.8 50.4 26 6 24.13 4.38 5,320 3,760 27" 0 1 0 n/a 0
6429
or
1244
Plant 15 400 UST VD HT 400 48 4 4 x 16/16 x 4 1.25 28.1 x 28.1 42 x 42.8 50.0 26 6 23.73 3.98 5,100 3,650 27"
or
1289
or ? 0 1 0 n/a 0
Plant 8 1988 400 UST VD HT 400 48 4 4 x 16/16 x 4 1.25 28.1 x 28.1 42 x 42.8 50.4 26 6 24.13 4.38 5,320 3,760 27"
0 1 0 n/a 0
Plant 8 4925 400 UST Demag HT 400 40.3 4 4 x 16/16 x 4 1.25 28.1 x 28.1 42 x 42.8 50.0 26 6 23.73 3.98 5,100 3,650 27" 0 1 0 n/a 0
4 33 x 33
1st- 27.53 30.654 x 4
Plant 6 938 450-2 UST Engel ES 450-2 1.25 Note: Minimum mold 47 x 47 61.6 23.125 9.45 Calculate 11.81 4,949 3,366
2nd- 7.0 28.654 x 0 0 2 0 0 0
2 B side width must be 32" for
Page 16 of 221
(in.)
Locate Ring Dia.
Max Mold # # # #
Asset ID#
Open Clamp
Plant 1 905 450 UST Engel ES 450 38 4 4 x 16/16 x 4 1.25 33 x 33 47 x 47 57.2 27.56 9.45 26.17 5.42 8,132 5,788
2 1 0 n/a 0
Plant 3 3402 450 UST Engel ES 450 38 4 6 x 28/28 x 6 33 x 33 47 x 47 40.0 27.6 6 23.50 3.75 8,132 5,788
1.25 = 4x16 or smaller 0 1 0 n/a 0
Plant 18 3772 500 UST VD HT 500 60 4 6 x 28/28 x 6 32.5 x 32.5 47.8 x 47.8 55.4 30 6 25.13 6.38 7,800 5,450 30"
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1198 2.25 = 6x28 or larger
Plant 15 500 UST VD HT 500 60 4 6 x 28/28 x 6 32.5 x 32.5 47.8 x 47.8 56.7 30 6 26.42 5.67 7,500 5,300 30"
or 1.25 = 4x16 or smaller 0 1 0 n/a 0
1198 2.25 = 6x28 or larger
or 1.25 = 4x16 or smaller 0 1 0 n/a 0
1198 2.25 = 6x28 or larger
or 1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0

1.25 = 4x16 or smaller
0 1 0 n/a 0
Plant 17 TBD 420-2 MT KM CX.2 472
29.6 1st 15.74 x 15.74 square, 35.43 x 31.50 53.98 x 47.28
Plant 17 5810 420-2 MT KM CX.2 472 4 1.5 56.4 40.16 9.84 Calculate 21.18 13,161 8,945
8.1 2nd 10 x 20, 6 x 28, 4 x 16 2 shot mold from press Rotary table 42.91 1 1 8 0 24
29.6 1st 15.74 x 15.74 square, 35.43 x 31.50 53.98 x 47.28
Plant 8 5468 420-2 MT KM CX.2 472 4 1.5 56.2 40.16 9.84 Calculate 20.98 13,161 8,945
8.1 2nd 10 x 20, 6 x 28, 4 x 16 2 shot mold from press Rotary table 42.91 1 0 0 0 12
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 1 1 8 n/a 12
1.25 = 4x16 or smaller 1 1 6 n/a 16
1.25 = 4x16 or smaller 1 1 0 n/a 12
1.25 = 4x16 or smaller 1 1 4 n/a 12
1.25 = 4x16 or smaller 0 1 6 n/a 0
1.25 = 4x16 or smaller 1 1 6 n/a 12
6712 420 MT KM CX 472 65.36 4 6 x 28/28 x 6 35.43 x 31.50 53.98 x 47.28 56.1 40.16 9.84 Calculate 15.99 13,211 8,970 65.7"
Plant 17 1.25 = 4x16 or smaller 1 1 8 n/a 12
5900 420 MT KM CX 472 65.36 6 x 28/28 x 6 35.43 x 31.50 53.98 x 47.28 56.1 40.16 9.84 Calculate 15.99 13,211 8,970 65.7"
Plant 17 4 1.25 = 4x16 or smaller 1 1 4 n/a 12
1.25 = 4x16 or smaller 1 1 8 n/a 24
6028 420 MT KM CX 472 65.36 4 6 x 28/28 x 6 35.43 x 31.50 53.98 x 47.28 56.1 40.16 9.84 Calculate 15.99 13,211 8,970 65.7"
Plant 17 5805 500 UST VD HP Wide 500 90 4 6 x 28/28 x 6 36.5 x 32.5 51 x 47 64.4 40 6 Calculate 8.38 11,300 7,750
1.25 = 4x16 or smaller 0 1 0 n/a 0
Plant 18 4052 650 UST VD HT 650 60 4 6 x 28/28 x 6 36 x 36 53 x 53 65.9 35.5 8 30.13 8.38 10,900 7,700 31.5"
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
Plant 1 4420 650 UST VD HT 650 139 4 6 x 28/28 x 6 2.25 = 6x28 or larger 36 x 36 53 x 53 65.9 35.5 8 30.13 8.38 10,900 7,700 31.5" 0 1 0 n/a 0
Page 17 of 221
(in.)
Locate Ring Dia.
Max Mold # # # #
Asset ID#
Open Clamp
Plant 8 2211 650 UST VD HT 650 89.6 4 6 x 28/28 x 6 2.25 = 6x28 or larger 36 x 36 53 x 53 65.2 35.5 8 29.50 7.75 10,400 7,450 31.5" 0 1 0 n/a 0
Plant 18 4617 700 UST VD HP 700 90 4 10 x 40/40 x 10 2.25 = 6x28 or larger 36.5 x 36.5 53.5 x 53.5 55.6 44 6 Calculate 13.09 17,800 12,200 0 1 0 n/a 0
Plant 17 6374 500 MT KM CX 562 73.51 4 10 x 40/40 x 10 39.37 x 31.5 53.94 x 47.24 62.0 46.06 9.84 Calculate 16.09 15,847 n/a 27.95
Plant 18 2491 730 UST VD Caliber 730 103.7 4 10 x 40/40 x 10 42.3 x 42.3 57 X 57 67.2 52.2 6 37.54 10.79 18,150 12,375 42.5"
1.25 = 4x16 or smaller 0 1 0 n/a 0
Plant 1 112 730 UST Demag Caliber 730 89.6 4 10 x 40/40 x 10 42.3 x 42.3 57 X 57 67.2 57 9.8 36.83 10.08 17,800 12,200 42.5"
1.25 = 4x16 or smaller 1 1 0 n/a 0
Plant 9 4069 730 UST VD Spectra 730 63.5 4 10 x 40/40 x 10 2.25 42.3 x 39.4 59.8 x 56.9 67.3 52.2 7.9 Calculate 15.07 18,171 12,386 32.5"
0 1 0 n/a 0
Plant 1 4310 730 UST VD Spectra 730 103.7 4 10 x 40/40 x 10 2.25 42.3 x 39.4 59.8 x 56.9 65.8 52.2 7.9 Calculate 13.57 16,870 11,735 32.5"
1 1 0 n/a 0
Plant 15 1283 730 UST VD HP 730 139 4 10 x 40/40 x 10 2.25 42.3 x 39.4 59.8 x 56.9 65.8 52.2 7.9 Calculate 13.57 16,870 11,735 32.5"
0 2 0 n/a 0
(Spectra)
Plant 3 4036 730 UST VD 730 59.2 4 10 x 40/40 x 10 2.25 42.3 x 39.4 59.8 x 56.9 67.3 52.2 7.9 Calculate 15.07 18,171 12,386 32.5"
HP 0 1 0 n/a 0
Plant 6 3631 700 UST VD HP Wide 700 80 4 10 x 40/40 x 10 45 x 36.5 62 x 53.5 54.2 44 6 Calculate 10.25 16,870 11,735 50"
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0

0 2 0 n/a 0

0 1 0 n/a 0
Plant 3 1986 700 UST VD HP Wide 700 80 4 10 x 40/40 x 10 45 x 36.5 62 x 53.5 54.9 42.5 6 Calculate 12.38 17,300 11,950 50"
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
1.25 = 4x16 or smaller 0 1 0 n/a 0
Plant 17 6713 651 MT KM GX 732 90.76 4 10 x 40/40 x 10 47.2 x 40.2 65.4 x 60.2 79.1 57.09 11.8 43.37 21.97 27,800 18,960
1.25 = 4x16 or smaller 1 2 8 n/a 24
Plant 17 6714 651 MT KM GX 732 90.76 4 10 x 40/40 x 10 47.2 x 40.2 65.4 x 60.2 79.1 57.09 11.8 43.37 21.97 27,800 18,960
1.25 = 4x16 or smaller 1 2 8 n/a 24
1st - 65.36 2.25 = 6x28 or larger 65.35 x 60.25
Plant 18 5716 651-2 MT KM GX.2 732 4 10x40/40x10 47.24 x 40.19 81.2 64.96 11.81 45.54 16.26 27,865 18,960
2nd - 10.19 1.25 = 4x16 or smaller rotary table 59.06 dia 1 2 6 6 24
1st - 65.36 2.25 = 6x28 or larger 65.35 x 60.25
Plant 15 6639 651-2 MT KM GX.2 732 4 10x40/40x10 47.24 x 40.19 81.2 64.96 11.81 45.54 16.26 27,865 18,960
1st - 65.36 2.25 = 6x28 or larger 65.35 x 60.25
Plant 15 6641 651-2 MT KM GX.2 732 4 10x40/40x10 47.24 x 40.19 81.2 64.96 11.81 45.54 16.26 27,865 18,960
1.25 = 4x16 or smaller 1 1 8 n/a 12
1.25 = 4x16 or smaller 1 1 6 n/a 16
Plant 15 1211 850 MT KM MX 955 132 4 16 x 52/52 x 16 2.25 44.92 x 44.92 63.04 x 63.04 86.2 63 11.81 50.53 23.23 22,576 15,840 1 1 0 n/a 0
Plant 9 3914 1000 UST VD HP 1000 125 5 16 x 52/52 x 16 2.25 44 x 44 65 x 65 71.0 50 8 Calculate 9.01 25,692 17,496 1 1 0 n/a 0
Plant 18 3690 1000 UST VD HP Wide 1000 125 5 16 x 52/52 x 16 2.25 52 x 44 73 x 65 67.5 50 8 Calculate 7.75 24,435 16,868 35" unless 0 1 0 n/a 0
Page 18 of 221
(in.)
Locate Ring Dia.
Max Mold # # # #
Asset ID#
Open Clamp
35" unless
mold
narrower
than 46" -
Plant 8 1982 1000 UST VD HP Wide 1000 125 5 16 x 52/52 x 16 2.25 52 x 44 73 x 65 71.0 50 8 Calculate 21.01 28,192 19,196
where
clearance
becomes
54" 0 1 0 n/a 0
35" unless
mold
narrower
than 46" -
where
clearance
becomes
54" 0 1 0 n/a 0
35" unless
mold
narrower
than 46" -
where
clearance
becomes
54" 0 1 0 n/a 0
Plant 18 4595 1100 UST VD Caliber 1100 139 5 16 x 52/52 x 16 2.25 55 x 45 69 x 59 90.2 74.8 10.8 46.70 15.45 26,534 18,367 0 1 0 n/a 0
Plant 1 300 1000 MT KM MX 1124 86.53 5 16 x 52/52 x 16 2.25 55.91 x 46.06 77.17 x 67.32 98.7 74.8 11.81 51.25 23.93 40,340 26,440 43" 1 1 6 n/a 12
Plant 3 5443 1000 MT KM MX 1124 108 5 16 x 52/52 x 16 2.25 55.91 x 46.06 77.17 x 67.32 90.2 74.8 11.81 42.66 15.37 39,560 26,050 43" 2 1 10 n/a 0
Plant 3 5564 1000 MT KM MX 1124 108 5 16 x 52/52 x 16 2.25 55.91 x 46.06 77.17 x 67.32 98.7 74.8 11.81 51.25 23.93 40,340 26,440 43" 2 1 10 n/a 16
Plant 8 5715 1000 MT KM MX 1124 132.03 5 16 x 52/52 x 16 2.25 55.91 x 46.06 77.17 x 67.32 99.4 74.8 11.81 51.96 24.64 40,660 26,600 43"
1 1 6 n/a 12
5715 1000 51.96 24.64

Plant 18 MT KM MX 1124 132.03 5 16 x 52/52 x 16 2.25 55.91 x 46.06 77.17 x 67.32 99.4 74.8 11.81 40660 26600 54" 1 1 8 n/a 24
TBD 1000
Plant 17 MT KM MX 1124
Plant 15 TBD 1000 MT KM MX 1124 132.03 5 16 x 52/52 x 16 2.25 55.91 x 46.06 77.17 x 67.32 99.4 74.8 11.81 51.96 24.64 40660 26600 extra low 1 2 8 n/a 24
6422 1000 51.96 24.64
Plant 18 MT KM MX 1124 132.03 5 16 x 52/52 x 16 2.25 55.91 x 46.06 77.17 x 67.32 99.4 74.8 11.81 40660 26600 54" 1 1 8 n/a 24
Plant 3 5927 1300 MT KM MX 1461 145.93 5 16 x 64/64 x 16 2.25 61.81 x 50 87.01 x 75.2 121.1 92.52 13.78 55.90 28.59 58,800 39,300 46.5"
2 2 8 n/a 24
Plant 3 5990 1300 MT KM MX 1461 145.93 5 16 x 64/64 x 16 2.25 61.81 x 50 87.01 x 75.2 121.1 92.52 13.78 55.90 28.59 58,800 39,300 46.5" 2 2 8 n/a 24
Plant 18 5714 1300 MT KM MX 1461 145.93 5 16 x 64/64 x 16 2.25 61.81 x 50 87.01 x 75.2 121.1 92.52 13.78 55.90 28.59 58,800 39,300 54" 1 2 6 n/a 24
Plant 18 6423 1300 MT KM MX 1461 145.93 5 16 x 64/64 x 16 2.25 61.81 x 50 87.01 x 75.2 121.1 92.52 13.78 55.90 28.59 58,800 39,300 54" 1 2 6 n/a 24
Plant 15 6638 1300 MT KM MX 1461
Plant 9 4540 1500 UST VD HP Wide 1500 165 5 16 x 64/64 x 16 2.25 72 x 52 96 x 76 82.7 60 10 Calculate 22.67 71,500 48,500 0 1 0 n/a 0
Plant 15 1210 1600 MT KM MX 1798 169.95 5 16 x 64/64 x 16 2.25 73.68 x 55.95 100.47 x 82.74 129.5 106.3 12 58.41 23.23 88,700 58,700 52.5" 2 2 6 n/a 0
Plant 18 5713 1600 MT KM MX 1798 218 5 16 x 64/64 x 16 2.25 73.68 x 55.91 100.47 x 82.74 137.8 106.3 13.77 63.77 28.59 89,200 58,950 52.5" 1 2 6 n/a 24
TBD 420 MT KM CX 472 65.36 4 6 x 28/28 x 6 35.43 x 31.50 53.98 x 47.28 56.1 40.16 9.84 Calculate 15.99 13,211 8,970 65.7"
Plant 17 TBD 651 MT KM GX 732 90.76 4 10 x 40/40 x 10 47.2 x 40.2 65.4 x 60.2 79.1 57.09 11.8 43.37 21.97 27,800 18,960
1.25 = 4x16 or smaller 1 1 8 n/a 24
1300 or
TBD
Plant 9 1600
TBD 1000 51.96 24.64
Plant 1 MT KM MX 1124 132.03 5 16 x 52/52 x 16 2.25 55.91 x 46.06 77.17 x 67.32 1 24
Plant 18 TBD 1300 MT KM MX 1461 145.93 5 16 x 64/64 x 16 2.25 61.81 x 50 87.01 x 75.2 121.1 92.52 13.78 55.90 28.59 58,800 39,300 54" 2 2 12 n/a 48
TBD 1300 121.1 55.90 28.59 58,800 39,300
Plant 8 MT KM MX 1461 145.93 5 16 x 64/64 x 16 2.25 61.81 x 50 87.01 x 75.2 92.52 13.78 54" 2 2 12 n/a 48
TBD 1300 121.1 55.90 28.59 58,800 39,300
Plant 8 MT KM MX 1461 145.93 5 16 x 64/64 x 16 2.25 61.81 x 50 87.01 x 75.2 92.52 13.78 54" 2 2 12 n/a 48
Page 19 of 221
(mm)
Locate Ring Dia.
Max Mold
Tonnage Ejector Tie Bar Day Max Weight on
Asset ID#
Ejector Pattern Open Clamp

Units Hole in Light Platen Size Daylight Stroke Ejector Max Stack Min Stack Max Mold Moving
Tonnage (H X V)
(MT or Tonnage Barrel (the largest pattern on machine)
Mold (H x V) (H X V) Max Max Stroke Height Height Weight Platen
Location machine) UST) Brand (UST) Ounces (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (lbs) (lbs)
P13 002162 120 MT Haitian 132 6.1 125 0 x 200/200 x 0 31.75 410 x 410 625 x 627 810 360 120 460.00 170.00 862 431
P13 002413 120 MT Haitian 132 6.1 125 0 x 200/200 x 0 31.75 410 x 410 625 x 627 810 360 120 460.00 170.00 862 431
P13 002660 120 MT Haitian 132 6.1 125 0 x 200/200 x 0 31.75 410 x 410 634 x 635 830 360 120 460.00 170.00 814 407
P13 002825 120 MT Haitian 132 4.26 125 0 x 200/200 x 0 31.75 410 x 410 634 x 635 830 360 120 460.00 170.00 814 407
P16 6097 120 MT Haitian 132 4.26 120 0 x 200/200 x 0 25 410 x 410 625 x 627 850 480 120 480.00 150.00 862 431
P16 6052 120 MT Haitian 132 6.1 125 0 x 200/200 x 0 31.75 410 x 410 625 x 627 810 360 120 460.00 170.00 862 431
P13 002112 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 705 x 705 950 430 140 520.00 180.00 1010 505
P13 002113 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 705 x 705 950 430 140 520.00 180.00 1010 505
P13 002163 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 705 x 705 950 430 140 520.00 180.00 1010 505
P13 002653 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 720 x 727 950 430 140 520.00 180.00 1227.6 613.8
P13 002658 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 720 x 727 950 430 140 520.00 180.00 1227.6 613.8
P13 002661 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 720 x 727 950 430 140 520.00 180.00 1227.6 613.8
P13 002826 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 720 x 727 950 430 140 520.00 180.00 1227.6 613.8
P13 003115 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 720 x 727 950 430 140 520.00 180.00 988 494
P13 003116 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 720 x 727 950 430 140 520.00 180.00 988 494
P16 3296 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 705 x 705 880 430 140 444.00 165.00 1280 640
P16 3311 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 705 x 705 880 430 140 444.00 165.00 1280 640
P16 0952 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 705 x 705 950 430 140 520.00 180.00 1050 525
P16 6059 160 MT Haitian 176 8.92 125 0 x 200/200 x 0 31.75 470 x 470 705 x 705 950 430 140 520.00 180.00 1010 505
4 Hole - 400x100
P13 001925 200 MT Haitian 220 11.78 160 38 530 x 530 791 x 791 1040 490 140 550.00 200.00 1190 595
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 002114 200 MT Haitian 220 11.78 160 38 530 x 530 791 x 791 1040 490 140 550.00 200.00 1190 595
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 002164 200 MT Haitian 220 11.78 160 38 530 x 530 791 x 791 1040 490 140 550.00 200.00 1190 595
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 002165 200 MT Haitian 220 11.78 160 38 530 x 530 791 x 791 1040 490 140 550.00 200.00 1190 595
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 002654 200 MT Haitian 220 11.78 160 38 530 x 530 810 x 800 1070 490 140 580.00 200.00 1513.6 756.8
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 002659 200 MT Haitian 220 11.78 160 38 530 x 530 810 x 800 1070 490 140 580.00 200.00 1513.6 756.8
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 002662 200 MT Haitian 220 14.53 160 38 530 x 530 810 x 800 1070 490 140 580.00 200.00 1513.6 756.8
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 002823 200 MT Haitian 220 11.78 160 38 530 x 530 810 x 800 1070 490 140 580.00 200.00 1513.6 756.8
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 002824 200 MT Haitian 220 11.78 160 38 530 x 530 810 x 800 1070 490 140 580.00 200.00 1513.6 756.8
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P13 003114 200 MT Haitian 220 11.78 160 38 530 x 530 810 x 800 1070 490 140 580.00 200.00 1274 637
2 Hole - 0 x 200/200 x 0
Page 20 of 221
Locate Ring Dia.
Max Mold
Asset ID#
Tonnage (H X V)
P13 002162 120 MT Haitian 132 6.1 125 0 x 200/200 x 0 31.75 410 x 410 625 x 627 810 360 120 460.00 170.00 862 431
4 Hole - 400x100
P13 003117 200 MT Haitian 220 11.78 160 38 530 x 530 810 x 800 1070 490 140 580.00 200.00 1274 637
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P16 3326 200 MT Haitian 220 11.78 160 38 530 x 530 791 x 791 970 490 140 600.00 165.00 1540 770
2 Hole - 0 x 200/200 x 0
P16 6504 200 MT Haitian 220 11.78 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1034 580 140 580.00 200.00 1274 637
4 Hole - 400x100
P16 6045 200 MT Haitian 220 11.78 160 38 530 x 530 791 x 791 970 490 140 580.00 200.00 1540 770
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P16 6068 200 MT Haitian 220 11.78 160 38 530 x 530 791 x 791 1040 490 140 550.00 200.00 1190 595
2 Hole - 0 x 200/200 x 0
4 Hole - 400x100
P16 1361 200 MT Haitian 220 11.78 160 38 530 x 530 810 x 800 1070 490 140 580.00 200.00 1513.6 756.8
2 Hole - 0 x 200/200 x 0
P16 6102 200 MT Haitian 220 14.53 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1034 580 140 580.00 200.00 1274 637
P16 6103 200 MT Haitian 220 11.78 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1034 580 140 580.00 200.00 1274 637
6.1
P16 6098 250-2 MT Haitian 276 120 200x200/500x500 28 910x570 1080x1140 980 520 110 520.00 200.00 3960 1980
2.3
P13 001926 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1220 590 150 630.00 350.00 2730 1365
P13 002166 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1220 590 150 630.00 350.00 2730 1365
P13 002414 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1220 590 150 650.00 350.00 3260 1630
P13 002475 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1220 590 150 630.00 350.00 2772 1386
P13 002476 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1220 590 150 630.00 350.00 2772 1386
P13 002655 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1220 590 150 650.00 350.00 3084.4 1542.2
P13 002656 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1220 590 150 650.00 350.00 3084.4 1542.2
P13 002816 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1220 590 150 650.00 350.00 3084.4 1542.2
P13 002817 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1220 590 150 650.00 350.00 3084.4 1542.2
P13 002818 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1220 590 150 650.00 350.00 3084.4 1542.2
P13 002819 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1220 590 150 650.00 350.00 3084.4 1542.2
P13 002820 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1220 590 150 650.00 350.00 3084.4 1542.2
P13 002821 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1220 590 150 650.00 350.00 3084.4 1542.2
P13 003113 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 930 x 930 1240 590 150 650.00 350.00 2769 1384.5
P16 3340 280 MT Haitian 309 21.80 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1240 590 150 662.00 398.00 3260 1630
P16 6099 280 MT Haitian 309 21.79 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1250 660 185 660.00 230.00 2772 1386
P16 6100 280 MT Haitian 309 21.79 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1250 660 185 660.00 230.00 2772 1386
P16 6101 280 MT Haitian 309 21.79 160 400 x 100/100 x 400 38 630 x 630 940 x 940 1250 660 185 660.00 230.00 2772 1386
P13 002663 380 MT Haitian 419 37.67 160 400 x 100/100 x 400 57.15 730 x 730 1036 x 1040 1350 700 180 730.00 350.00 5011.6 2505.8
P13 002665 380 MT Haitian 419 14.53 160 400 x 100/100 x 400 57.15 730 x 730 1036 x 1040 1350 700 180 650.00 350.00 5011.6 2505.8
P13 002814 380 MT Haitian 419 37.67 160 400 x 100/100 x 400 57.15 730 x 730 1036 x 1040 1350 700 180 730.00 350.00 5011.6 2505.8
Page 21 of 221
Locate Ring Dia.
Max Mold
Asset ID#
Tonnage (H X V)
P13 002162 120 MT Haitian 132 6.1 125 0 x 200/200 x 0 31.75 410 x 410 625 x 627 810 360 120 460.00 170.00 862 431
P13 006250 380 MT Haitian 419 37.67 160 400 x 100/100 x 400 57.15 730 x 730 1036 x 1040 1350 700 180 650.00 350.00 5011.6 2505.8
P13 006251 380 MT Haitian 419 37.67 160 400 x 100/100 x 400 57.15 730 x 730 1036 x 1040 1350 700 180 730.00 350.00 5011.6 2505.8
P13 006252 380 MT Haitian 419 37.67 160 400 x 100/100 x 400 57.15 730 x 730 1036 x 1040 1350 700 180 650.00 350.00 5011.6 2505.8
P13 006254 380 MT Haitian 419 37.67 160 400 x 100/100 x 400 57.15 730 x 730 1036 x 1040 1350 700 180 730.00 350.00 5011.6 2505.8
P16 6505 380 MT Haitian 419 36.10 160 400 x 100/100 x 400 38 730x730 1050x1050 1400 760 180 760.00 280.00 5011.6 2505.8
P16 6506 380 MT Haitian 419 36.10 160 400 x 100/100 x 400 38 730x730 1050x1050 1400 760 180 760.00 280.00 5011.6 2505.8
P16 6104 380 MT Haitian 419 16.61 160 400 x 100/100 x 400 38 730x730 1050x1050 1400 760 180 760.00 280.00 5011.6 2505.8
P16 6105 380 MT Haitian 419 36.10 160 400 x 100/100 x 400 38 730x730 1050x1050 1400 760 180 760.00 280.00 5011.6 2505.8
11.78
P16 6108 530-2 MT Haitian 580 160 200x200/500x0 35 700x1170 1600x1600 1300 670 150 670.00 250.00 7400 3700
4.3
P13 002657 600 MT Haitian 661 37.67 200 700 x 150/150 x 700 57.15 880 x 880 1300 x 1320 1670 900 240 770.00 400.00 8613.4 4306.7
P13 002815 600 MT Haitian 661 37.67 200 700 x 150/150 x 700 57.15 880 x 880 1300 x 1320 1670 900 240 770.00 400.00 8613.4 4306.7
P13 006253 600 MT Haitian 661 37.67 200 700 x 150/150 x 700 57.15 880 x 880 1300 x 1320 1670 900 240 770.00 400.00 8613.4 4306.7
P16 3360 600 MT Haitian 661 78.03 200 700 x 150/150 x 700 57.15 880 x 880 1300 x 1320 1670 900 240 872.00 520.00 8770 4385
P16 6503 600 MT Haitian 661 36.10 200 700x150/700x150 60 880x880 1300x1300 1650 910 240 910.00 380.00 8613.4 4306.7
P16 6106 600 MT Haitian 661 28.04 200 700x150/700x150 60 880x880 1300x1300 1730 910 240 910.00 380.00 8613.4 4306.7
P16 6107 600 MT Haitian 661 36.10 200 700x150/700x150 60 880x880 1300x1300 1650 910 240 910.00 380.00 8613.4 4306.7
P13 002664 900 MT Haitian 992 50.23 250 700 x 150/150 x 700 57.15 1080 x 1080 1580 x 1600 2070 1120 300 970.00 450.00 15048 7524
P16 6109 900 MT Haitian 992 50.22 250 700x150/700x150 60 1080x1080 1580x1580 2180 1110 300 1110.00 450.00 15048 7524
4.30 A Side:
P13 002974 250 - 2 MT Haitian 276 200 x 200/200 x 200 38 910 x 570 1250 x 1148 970 460 110 610.00 200.00 4840 2420
2.33 125
4.30 A Side:
P13 003009 250 - 2 MT Haitian 276 200 x 200/200 x 200 38 910 x 570 1250 x 1148 970 460 110 510.00 200.00 3960 1980
2.33 125
4.30 A Side:
P13 003010 250 - 2 MT Haitian 276 200 x 200/200 x 200 38 910 x 570 1250 x 1148 970 460 110 510.00 200.00 3960 1980
2.33 125
Page 22 of 221
P
I
Molded & Decorated Plastic Systems ___________________________________________________
SECTION 01.03 REV. LEVEL: I
REV. DATE: 08-01-19

SPI DATA MANAGEMENT
ISSUE: 06-24-09
PAGE: 1 of 3
DATA TRANSFER CAPABILITIES
 UNIX and WINDOWS
Engineering and Estimating Software

 Vis Mockup-utilized by Sales Dept, Engineering and Tooling. Please send .jt files for quoting
purposes making sure they are precise and monolithic. Second preferred format would be .stp
or .x_t.
Product Development and Design Software

 Ideas 10.1, 13
 CatiaV5 R25, R26 (changes with CatiaV5 upgrades)
 UG NX 11.x
 NX Nastran
 Mold Flow
 CF Design
Methods for Data Exchange Used

 Can accept native data or .x_t, .stp
 Direct access to Ford, Chrylser and GM via Team Center Engineering
 FTP site - http://station.summitpolymers.com/WebInterface/login.html
 Email: We can receive up to 8MB via email. If larger than 8MB, use ftp site or dropbox.
Email data to datamngt@summitpolymers.com
 CD Rom, DVD
 USB Device
 Rocket
 Toyota GR-BBS
 Direct data transfer methods in place with Delphi, Lear, JCI, Toyota, VW, Ford, GM and
Chrysler (FCA)
 Summit Drop Box (http://dropbox.summitpolymers.com)
 Nissan TCP2
 VW – HyperKVS
Page 23 of 221
REV. DATE: 08-01-19

SPI DATA MANAGEMENT
ISSUE: 06-24-09
PAGE: 2 of 3
_________________________________________________________________________
DATA TRANSFER CAPABLITIES FOR INCOMING DATA
 UNIX and WINDOWS
Engineering and Estimating Software

 Parasolids (x_t) utilized for Tooling. Please send .x_t files only.
Methods for Data Exchange Used

 Preferred file type is parasolid files (.x_t ), however .stp files are acceptable.
 When writing out a parasolid file for a mold design the following files must be written:
 Parts and Runner – includes just the parts and runner (ie: T18824_parts_and_runner.x_t)
 A Side Inserts – includes A side cavities and inserts (ie: T18824_a_inserts.x_t)
 B Side Inserts – includes B side cores and inserts (ie: T18824_b_inserts.x_t)
 A Side Components – includes everything A side not in the a inserts file (ie:
T18824_a_components.x_t)
 B Side Components – includes everything B side not in the b inserts file (ie:
T18824_b_components.x_t)
o Other descriptors, for each of the five layers, may be used as long as intent is satisfied.
o Additional layers are also acceptable provided the core 5 layers are satisfied first.
 This data must be zipped in the following format: Tool Shop sending data, Program, Tooling Data,
PDR/FDR or PR, Tool #, Date (ie: Summit_K2XX_Tooling_Data_PDR_T18824_20111214.zip). A
copy of the PDR and FDR must be sent in to Tooling Engineer prior/during design review event.
 Example of contents of the zip file:
 Only data for one (1) program/program# per zip file.

 Put zip file into Summit’s DropBox or FTP site. Preference is to use the ftp site.
 Those who have their own folder on Summit’s FTP site please put the zip file in their incoming folder.
 Email: Send an e-mail to datamngt@summitpolymers.com, PE and TE including program, tool # and
zip file name in the subject line. (ie: K2XX Tooling Data for T12345
Summit_K2XX_Tooling_Data_PDR_ T112345_20111214.zip). In the body of the e-mail please list
person(s) tool data is intended for.
Page 24 of 221
REV. DATE: 08-01-19

SPI DATA MANAGEMENT
ISSUE: 06-24-09
PAGE: 3 of 3
_________________________________________________________________________
DATA TRANSFER TECH AT SUMMIT POLYMERS INC.
Naomi Chavez (Ext. 50424)

Email Address: datamngt@summitpolymers.com
Phone: (269) 324-9330 Fax: (269) 324-9311
Revision Record
Rev. A – No record of changes.

Rev. B – Changed title from “Data Transfer Capabilities”. Added everything below
“Incoming Data” title. Added revision record.
Rev. C – Added PDR and FDR to zip file format.
Rev. D – Added Tool Number to zip file format.
Rev. E – Added Summit DropBox and emails to PE and TE. Updated file format pic.
Rev. F – Changed preference of incoming data and naming convention.
Rev. G – Changed ftp site address. Removed duplicate information about iges/zip files
and removed login and password for ftp site along with CD requirement.
Updated extention for Naomi and added Shayne McPeake information.
Rev. H – Changed .igs to .x_t for engineering and estimating software, removed 11.2
for Ideas, Catia V5 changed to R25 and R26, changed UG NX to only 11.x,
removed .iges from acceptable data exchange, added TCP2 for Nissan and
added Ford, GM and Chrysler (FCA) to direct data transfer methods.
Rev. I – Removed Parasolid folder naming
Page 25 of 221
SECTION 01.04
LIST OF DRAWINGS / TABLES

Rev. Date: 08-01-19
Document Title Rev. Level/Date

02.01 Complete Drawing of Connections ≤280T (Side Load) G / 08-01-19
02.02 Complete Drawing of Connections >280T (Top Load) D / 06-11-18
02.03 Cavity Thickness Under Part Rel / 09-30-16
02.04 Core Thickness Under Part Rel / 09-30-16
03.02.01 Stand Off Legs – Guidelines for Safe/Robust Designs Rel / 06-15-10
03.03.01 Air Poppet Fitting Location ≤280T & >280T A / 08-14-09
03.03.02 Air Poppet Pneumatic Logic Diagram A / 08-01-19
03.04.01 Transducer Selection Table Rel / 09-30-16
03.04.02 Slot For Pressure Transducer / Actuator Pin (RJG) B / 08-01-16
03.04.03 Slot For Pressure Transducer / Actuator Pin (DME) Rel / 08-01-19
03.05.01 Clamp Plate 120 MT/160 MT/200 MT Rel / 09-28-12
03.05.02 Clamp Plate 280 MT/380 MT Rel / 09-28-12
03.05.03 Clamp Plate 600 MT/900 MT Rel / 09-28-12
03.05.04 Clamp Plate 35T / 40T / 85T A / 09-28-12
03.05.05 Clamp Plate 120T/170T B / 09-28-12
03.05.06 Location Scheme 230T/337T/350T/200T 2S F / 08-01-19
03.05.07 Location Scheme 393T/400T/450T 2-S/500T C / 08-01-19
03.05.08 Location Scheme 650T/700T/730T/731T/1000T/1100T/1125T/1500T/1763T C / 08-01-19
03.05.10 Spacer Rails for Side Load Molds ≤200T D / 09-28-12
03.05.11 Spacer Rails for Side Load Molds ≤200T E / 03-11-13
03.05.12 >200T Clearance for Standard Clamping Rel / 06-15-10
03.05.13 Example of Improperly Cleared Mold Base Rel / 06-15-10
03.06.01 Standard Lifting Eyebolt Holes A / 01-09-15
03.06.02 Eye Bolts Handling Holes A / 06-15-10
03.06.03 Cutting Steel Forged Shoulder Pattern Eyebolts Shanks to Meet Maximum Rated A / 01-09-15
Lifting Capacity
03.06.04 Lifting Eyebolt Hole Color Codes Rel / 01-09-15
03.06.05 Crane Matrix D / 06-11-18
03.07.01 Safety Strap B / 09-28-12
03.08.01 Subgate into Split Pin D / 01-09-15
03.08.02 Subgate into Part E / 01-09-15
03.08.03 Subgate into Sleeved Split Pin E / 01-09-15
03.08.04 Ball End Subgate into Part E / 01-09-15
03.08.05A Curved Subgate (Cashew) B / 08-01-19
03.08.05B Curved Subgate (Cashew) Pin Placement Rel / 03-11-13
03.08.05C Curved Subgate (Cashew) Pin Placement Rel / 03-11-13
03.08.05D Curved Subgate (Cashew) Pin Placement Rel / 03-11-13
03.08.06 Chiseled Edge Gate A / 09-28-12
03.08.07 Diamond Vane Gate B / 01-09-15
03.08.07A Polypropylene Gating For Rear Vane Rel / 10-16-15
03.08.08 Jump Gate Rel / 09-10-15
03.08.09 Designs for Runner Pins Presentation to Robot A / 01-09-15
03.08.10 Runner and Gate Size Guidelines C / 09-30-16
03.09.01 Cold Sprue Bushing & Locating Ring D / 01-09-15
03.09.02 Sprue Pullers C / 08-01-19
03.09.03 Runner Shut-Off Guideline A / 09-28-12
03.09.04 Runner Choke Insert Rel / 09-30-16
03.09.05 Runner Flags B / 09-28-12
Page 26 of 221
SECTION 01.04
03.10.01 Hot Manifold/Hot Sprue Electrical Connection Location B / 03-11-13
03.10.02 Valve Gate Sequencing Component Connection Locations >280T D / 01-09-15
03.10.03 Valve Gate Staubli Quick Coupler Orientation A / 07-18-14
03.10.04 Mini Water Manifold for Valve Gate Systems Rel / 05-31-17
03.11.01 Cooling Manifold C / 09-29-11
03.11.02 Countersunk Cooling Fittings A / 09-30-16
03.11.03 Brass Plug Baffle Rel / 06-24-09
03.11.04A <280T Connection Location for Cooling Manifolds F / 09-30-16
03.11.04B <280T Connection Location for Cooling Manifolds C / 06-15-10
03.11.05A Side Load Cooling Manifold Jumper D / 01-09-15
03.11.05B Side Load Cooling Manifold Jumper D / 08-01-19
03.11.06 170T Adjustable Water Manifold Bracket Rel / 10-16-15
03.11.07 >280T Connection Location for Cooling Manifolds D / 09-30-16
03.11.08 >280T Connection Location for Cooling Manifolds B / 09-30-16
03.11.09 <280T Connection Location for Hot Oil C / 03-11-13
03.11.10 Low Profile Water Jumper Fittings/Hose Rel / 06-15-10
03.11.11 Water Line Reynolds Number Table For GPM Rel / 08-01-19
03.12.01 Venting for Cartridge Vanes C / 08-01-19
03.12.02 Vent Design Rel / 09-30-16
03.13.01A 7/8” Press Knock Out Extensions <350T A / 06-15-10
03.13.01B 2” Press Knock Out Extensions >400T Rel / 06-15-10
03.13.02 Keyed Ejector Pins Rel / 06-24-09
03.13.03 Hydraulic Reverse Ejection (Preferred Mounting) Rel / 06-24-09
03.13.04 Hydraulic Reverse Ejection (Optional Mounting) Rel / 06-24-09
03.13.05 Hydraulic Reverse Ejection Coupler Rel / 06-24-09
03.13.06 Ejector Safety Electrical Outlet Connection Location (<280T & >280T) A / 08-14-09
03.13.07 Ejector Box Cover for >200T Molds Rel / 06-15-10
03.13.08 Early Return Pin Retention Assembly Rel / 09-28-12
03.13.09A Accelerated Ejectors Rel / 09-28-12
03.13.09B Accelerated Ejectors Rel / 09-28-12
03.13.09C Accelerated Knock Out Rel / 09-28-12
03.13.10 “B” Side Stripper Plate Switch Placement Rel / 03-11-13
03.13.11 Safety Ejector Switch Design B / 08-01-19
03.13.12A Latch Locks (DME – Internal) Rel / 09-30-16
03.13.12B Latch Locks (DME – External) Rel / 09-30-16
03.13.12C Latch Locks (Progressive) Rel / 09-30-16
03.13.12D Latch Locks (Misumi) Rel / 09-30-16
03.13.12E Latch Locks (Baffle Bar) Rel / 09-30-16
03.13.13 Guide Bushing Reference Rel / 08-01-19
03.14.01 Slides – Height to Length Ratio of 1 to 1.5 A / 09-28-12
03.14.02 Slides – Zero Degree Parting Line Rel / 10-16-15
03.15.01 Lifter Safety Switch Design Rel / 09-30-16
03.16.01 Hydraulic Connection Location <280T (Side Load) Rel / 06-24-09
03.16.02 Hydraulic Connection Location >280T (Top Load) Rel / 06-24-09
03.16.03A Hydraulic Core Pull Connectors A / 08-01-19
03.16.03B Hydraulic Core Pull Connectors Rel / 08-01-19
03.18.01 Floating Insert to Form Cruciforms Too Small to Eject Rel / 06-24-09
03.18.02 Steel Proud Pullers for Elastomer Mats Rel / 06-24-09
03.18.03 Cup Holder Retention Rings Rel / 09-28-12
03.18.04 B-Side High Heat Transfer Cooling Insert Design – Dual C/Hs and Center Housing Rel / 06-15-10
03.18.05 Spring Washers Under Core Pins for Strip Retainers Rel / 03-07-14
Page 27 of 221
SECTION 01.04
03.18.06 Mold Max Inserts Forming Inside Of Slider Knob Rel / 10-16-15
03.18.07 Sleeve Ejectors For Links Rel / 10-16-15
03.18.08 Sleeve Ejectors For Strip Retainers Rel / 10-16-15
03.18.09 Over Flow Channel For Nylon Vanes Rel / 10-16-15
03.18.10 Grommet Tuning For Slider Knobs Rel / 10-16-15
03.18.11 Honeycomb Lifter/Pin Design Rel / 10-16-15
03.18.12 Core Out For 2-shot Gating Over Substrate Rel / 06-11-18
03.18.13 Mold Insert Pocket Angle Requirement Rel / 08-01-19
03.18.14 Gas Spring For Transfer Molding Rel / 08-01-19
03.19.01 Mold Open Clearance for EOAT B / 03-07-14
03.19.02 EOAT Vacuum Flag Standard C / 03-11-13
03.19.03A Gating Considerations for Molding Automation Rel / 06-15-10
03.19.03B Gating Considerations for Molding Automation Rel / 06-15-10
03.19.03C Gating Considerations for Molding Automation Rel / 06-15-10
03.19.04A EOAT Docking Hole Orientation - Horizontal Rel / 05-31-17
03.19.04B EOAT Docking Hole Orientation - Vertical Rel / 05-31-17
03.19.04C EOAT Docking Hole Orientation - Diagonal Rel / 05-31-17
03.20.01A Clamp Plates – Engel 2-Shot (450T Rotary) Rel / 07-01-13
03.20.01B Clamp Plates – Haitian 2-Shot (250T Rotary) A / 01-09-15
03.20.01C Clamp Plates – Krauss Maffei 2-Shot (420T Rotary) A / 10-16-15
03.20.01D Clamp Plates – Krauss Maffei 2-Shot (651T Rotary) Rel / 06-11-18
03.20.02A Peripheral Item Locations – Engel 2-Shot (450T Rotary) Rel / 07-01-13
03.20.02B Peripheral Item Locations – Haitian 2-Shot (250T Rotary) A / 01-09-15
03.20.02C Peripheral Item Locations – Haitian 2-Shot (250T Rotary) Rel / 03-07-14
03.20.02D Peripheral Item Locations – Krauss Maffei 2-Shot (420T Rotary) A / 06-11-18
03.20.02E Peripheral Item Locations – Krauss Maffei 2-Shot (651T Rotary) Rel / 06-11-18
03.21.01A Coatings Matrix A / 08-01-19
03.21.01B Coatings Matrix Rel. / 08-01-19
03.26.01 FORD Engraving Plaque Rel / 06-11-18
03.26.02 GM Engraving Plaque Rel / 06-11-18
Page 28 of 221
Page 29 of 221
Page 30 of 221
Page 31 of 221
Page 32 of 221
P
I
SECTION 03.01 REV. LEVEL: F
REV. DATE: 08-26-16

MATERIALS / TOLERANCES
ISSUE: 06-24-09
PAGE: 1 of 3
Mold Component Bill of Materials

Typical
Hardness
Tool Material Typical Application Notes
Range
(Rc)
P20 (HH) 34-38 1. Cores & Cavities “cut in solid” USA
2. Cavity Sets/Inserts
3. Lifter Heads (Nitrided for P20
core/cavity)
4. Slide Bodies/Lock Block
5. Slide Faces (Nitrided for P20
cores/cavity)
P20 (HH) (GS 738 HH or 34-38 1. Cores & Cavities “cut in solid” China
Finkl) 2. Cavity Sets/Inserts
core/cavity)
4. Slide Bodies/Lock Blocks
cores/cavity)
H13 48-50 1. Cavity Sets/Inserts USA
core/cavity)
cores/cavity)
5. Inserts
6. Gate inserts for high abrasion
material
H13 48-50 1. Cavity Sets/Inserts China
(GS 2344 ESR) 2. Lifter Heads (Nitrided for P20
core/cavity)
cores/cavity)
5. Inserts
6. Gate inserts for high abrasion
material
Page 33 of 221
REV. DATE: 08-26-16

ISSUE: 06-24-09
PAGE: 2 of 3
Typical
Hardness
Tool Material Typical Application Notes
Range
(Rc)
S7 50-52 1. Cavity Sets/Inserts USA
2. Lifter Heads
4. Slide Faces
5. Inserts
S7 50-52 1. Cavity Sets/Inserts China
(Finkl or Unimax) 2. Lifter Heads
4. Slide Faces
5. Inserts
420 Stainless Steel 46-48 1. Cavity Sets/Inserts USA
2. Corrosion protection for
acetal parts
420 Stainless Steel 46-48 1. Cavity Sets/Inserts China
(GS 136 ESR) 2. Corrosion protection for
acetal parts
Assab Uddeholm Unimax 54-56 1. Lifter Heads China
3. Slide Faces
4. Inserts
DME #2 33 1. Mold Base USA
2. All plates/rails
3. Support pillars
4. External early return systems
(case hardened)
LKM 1050 33 1. Mold Base China
2. All plates/rails
3. Support pillars
4. External early return systems
(case hardened)
Steel (Cold rolled tubing) 1. Cooling manifolds China/USA
Porcerax 35-40 1. Inserts for venting China/USA
Mold Max XL / Mold Star / 28-32 1. Areas of poor cooling China/USA
Ampcoloy 944
Ampcoloy 18-20 1. Laminated cooling plates China/USA
CENA 1 38-42 1. Molded In Color cavity block USA
Hardened O1/Lamina 56-58 1. Gibs China/USA
2. Wear plates
Page 34 of 221
REV. DATE: 08-26-16

ISSUE: 06-24-09
PAGE: 3 of 3
• All materials must be called out on the Mold Design Bill of Materials
• Mold Design Bill of Materials to include:

o Balloon Number for component(s)
o Description of component(s)
o OEM Supplier
o Quantity
o Material Type
o Hardness
o Standard / Custom
• Mating parts must be dissimilar materials and hardness.
Revision Record
Rev. A – No record of changes

Rev. B – Changed China P20 HH, H13, S7 and 420 Stainless steels brand names.
Added revision record.
Rev. C – Added CENA 1 information and added XL / Mold Star to Moldmax line for
beryllium free materials.
Rev. D – Corrected hardness for MoldMax XL / Mold Star.
Rev. E – Added hardness for O1/Lamina. Added BOM requirements.
Rev. F – Added Ampcoloy 944
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REV. DATE: 08-01-19

MOLD COMPONENTS
ISSUE: 06-24-09
PAGE: 1 of 4
Preface
• It is not our intention to cause deviation from best mold build practices.
• Any requirement challenging a best practice should be brought to the
attention of the SPI Engineering Department Manager, Tool Group.
• It is the expectation of SPI to have Mold Supplier part design concerns
identified and discussed at the mold pre-design / mold kick-off meeting or
the preliminary tool design review.
• Ideas for improvements should be stressed at every opportunity. Examples
of part design challenges impacting tooling feasibility and performance
integrity are; feature sink, sharp corners were a feature is formed on the
main wall section, weld lines in functional locations, radius post ends, lead in
for assembly, poor draft to grain relationships, etc.
• All molds must be built with DME or equivalent purchased (available off the
shelf in USA) leader pins, guide pins, ejector pins, guide bushings, ejector
sleeves, core pins, etc.
• All wear surfaces must have grease grooves, no graphite impregnated wear
surfaces unless otherwise approved by SPI TE.
• Leader pins must engage before horn pins or standing core.
• All leader pin bushings must be made of bronze (must have grease grooves)
and be mechanically retained.
• Leader pin vents must be cut into the support rails on a 45°, and be large
enough for the leader pin to purge solid resin debris without obstruction.
• Zero corner leader pin & zero corner return pin must be offset.
• Special features ≥0.625” deep (cruciforms, clip towers, etc.) and ribs >0.500
deep will be inserted.
Page 36 of 221
REV. DATE: 08-01-19

MOLD COMPONENTS
ISSUE: 06-24-09
PAGE: 2 of 4
• All pivot posts, pivot holes and pivot omega features, must be inserted for
tuning. SPI expects two tunes to be included in the quotation for all pivot
posts, pivot holes, and pivot omegas for USA/Canadian Mold Suppliers.
Components include, but not limited to, vanes, housings, shut off doors,
bins, bin covers, etc.
• Snap features must be inserted when applicable. Two snap feature tunes
are expected for, but not limited to, snap arm barbs and mating component
barbs for USA/Canadian Mold Suppliers.
• Tooling built in China must be within steel dimensional tolerance. Tooling
must be documented and confirmed to be within specifications. Any tuning
requirements will be treated as SPI EC’s.
• Coring steel must be inserted. Use hardened inserted pins. Core pins
should be oversized, a minimum of one standard diameter, then machined
to the final dimension.
• Break all parting line edges of mold (excluding part). Radius all inside and
outside mold component corners.
• All molds shall have sufficient pre-loaded support pillars to prevent mold
base deflection during normal molding cycle.
• Support pillars and rails to be secured to back clamp plate.
• Tooling in a solid block will be heat-treated for stress relief between rough
and finish cut.
• Pry-bar slots must be cut into all four corners, on a 45° angle to the base, 1”
into the corner (if 1” is not available, deviation must be reviewed and
approved by SPI Engineering), and result in a clearance between the plates
of ¼”.
• Top Load Molds Only: All clamp slots must continue through the end of the
tool, leader pins may become exposed. See Section 03.05.10, >200T
Clearance for Standard Clamping. Cooling/electrical fittings/connectors
must not obstruct the clamping zones.
• Top Load Molds Only: All molds must have legs installed where hydraulic
cylinders, limit switches, electrical boxes, etc. protrude beyond the bottom
edge of mold. When possible use rail type legs to support halves
separately. See Section 03.02.01, Stand Off Legs – Guidelines for
Safe/Robust Designs, for cylindrical stand off legs.
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REV. DATE: 08-01-19

MOLD COMPONENTS
ISSUE: 06-24-09
PAGE: 3 of 4
• Tooling support rails will be doweled to the core side support plate and the
clamp plate, solid or tube dowels can be utilized.
• Details EDM’d into ejector pins, per Initial RFQ or as requested by the
assigned TE no later than final design approval, must have a spare made at
the time of mold construction and shipped with the completed tool.
• Custom sleeve ejectors must have a spare set (ie 4 custom locations equals
4 spares) made at the time of the mold construction and shipped with the
completed tool.
Page 38 of 221
REV. DATE: 08-01-19

MOLD COMPONENTS
ISSUE: 06-24-09
PAGE: 4 of 4
Revision Record
Rev. A - Added the following bullet points, “All pivot posts, pivot holes and pivot
omega features, must be inserted for tuning. SPI expects two tunes to be
included in the quotation for all pivot posts, pivot holes and pivot omegas.
Components include, but not limited to, vanes, housings, shut off doors,
Bins, bin covers, etc. Snap features must be inserted when applicable.
Two snap feature tunes are expected, but not limited to, snap arm barbs
and mating component barbs.
Rev. B – Bullet point 12 and 13 added “for USA/Canadian Mold Suppliers”. Added
new bullet point 14. Bullet point 21 added “See Section 03.05.10, >200T
clearance for standard clamping. Cooling/electrical fittings/connectors
must not obstruct the clamping zones.” Bullet point 22 added “See Section
03.02.01, Stand Off Legs – Guidelines for Safe/Robust Designs, for
Cylindrical stand off legs”
Rev. C – Bullet point 7 removed “guide” and “at a minimum, ½” longer than longest”.
Added “engage before.”
Rev. D – Added last bullet point about details EDM’d into ejector pins.
Rev. E – Added “unless otherwise approved by SPI TE” on bullet point 6.
Rev. F – Added “made of bronze (must have grease grooves) and be” to the leader
pin bushing bullet point. Added “per initial RFQ” for details EDM. Added
spares for custom sleeves.
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SECTION 03.03 REV. LEVEL: C
REV. DATE: 08-01-19

AIR POPPETS
ISSUE: 06-24-09
PAGE: 1 of 1
Bill of Material
Component Acceptable Part Number Notes
Manufacturer/
Distributor*
Air Timer MSC 06930770 1-11 sec.
(Mead KLC-110) Use on timer style
Air Timer MSC 04086864 10-60 sec

(Mead KLC-260) (special order part
– must call in)
Use on timer style
3 Way Valve MSC 87823720 Use on both styles
Aluminum Manifold McMaster Carr 5469K101 1/4" NPT Inlet X

1/8" NPT Outlet
Use on both styles
Mechanical This bar should be fabricated. Use on
Actuation Bar mechanical style
Poppet system must be plumbed with push lock connectors and associated tubing.
• All TPE mats, gap hider, etc. must have air poppet system for allowing part not to
stick to A side of tool and/or helping eject part from B side of tool.
Revision Record
Rev. A – Changed grammar of sentence below BOM.

Rev. B – Added air poppets for all TPE tools
Rev. C – Corrected logic for both versions
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SECTION 03.04 REV. LEVEL: B
REV. DATE: 08-01-19

CAVITY PRESSURE TRANSDUCERS SLOT &
PIN PLATE RECESS ISSUE: 06-24-09
PAGE: 1 of 2
Bill Of Materials
RJG TABLE (EFFORT GENERATION)
Manufacturer/
Distributor
Pressure RJG Inc. LS-B-127-x-y x = denotes the anticipated injection
Transducer pressure the sensor will see at the
selected pin location (Reference
03.04.01)
y = denotes the length of cable
needed (3” – 48” in 1/8” increments)
Junction Box RJG Inc. J-LX5-CE One (1) required per 2-4 transducers
Cable RJG Inc. CE-LX5-1M One (1) required per transducer

when the tool has 2 or more
transducers
Bill Of Materials
NON RJG TABLE (TYPICALLY TPE AND SHOOT & SHIP TOOLS)
Manufacturer/
Distributor
Pressure DME BS412C Use the DME Catalog online to order
Transducer pressure and lead length.
Amphenol Plug Allied 70143472
(Male) Electronics
Amphenol Plug Allied 70143474
(Female) Electronics
• For all TPE and shoot and ship tools, a transducer slot must be put in the tool for the
end of fill pin (pin nearest end of fill) for each cavity.
• Cavity pressure transducers may be required for other select molds. Reference Tool
Layout Sheet at time of quoting for style, quantity and locations. Quotes and mold
builds must include any and all necessary cabling and junction boxes.
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REV. DATE: 08-01-19

CAVITY PRESSURE TRANSDUCERS SLOT &
PIN PLATE RECESS ISSUE: 06-24-09
PAGE: 2 of 2
• Transducer slot and actuator pin tolerances/clearances must be to SPI standards.
Revision Record
Rev. A – Resurrected section.

Rev. B – Added transducer slot for all TPE and shoot ship tools and Non RJG table.
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SECTION 03.05 REV. LEVEL: M
REV. DATE: 08-01-19

CLAMP PLATES / SPACER RAILS
ISSUE: 06-24-09
PAGE: 1 of 5
SPI Mold Clamp Plate - China

PRESS TIE BAR TIE BAR PLATEN CLAMP PLATE SIZE
RANGE DAYLIGHT DIAMETER SIZE H x V H x V x Thick (mm)
(Tons) (mm) (mm) (mm)
120 Haitian 410 x 410 70 634 x 635 620 x 400 x 34.925*

160 Haitian 470 x 470 80 720 x 727 700 x 444.5 x 34.925*
200 Haitian 530 x 530 90 810 x 800 800 x 495.3 x 34.925*
250 Haitian
910 x 570 105 1250 x 1148 890 x 600 x 34.925
2-Shot
280 Haitian 630 x 630 105 903 x 930 850.9 x 622.3 x 34.925
380 Haitian 730 x 730 115 1046 x 1046 1016 x 698.5 x 34.925
530 Haitian 1117.6 x 863.6 x
700 x 1170 145 1600 x 1600
2-Shot 34.925
1219.2 x 812.8 x
600 Haitian 880 x 880 145 1300 x 1320 34.925
1524 x 1066.8 x
900 Haitian 1080 x 1080 180 1580 x 1600 34.925
* = Denotes that the clamp plate can go to 22.225 mm if a max. stack height issue
SPI Mold Clamp Plate - North America Side Load
PRESS TIE BAR TIE BAR PLATEN CLAMP PLATE SIZE
RANGE DAYLIGHT DIAMETER SIZE H x V H x V x Thick (")
(Tons) (") (") (")
85 16 x 13.6 2.375 22.8 x 20.4 20 x 13.5 x 1.375*

120 17.1 x 17.1 2.75 25.2 x 25.2 22.5 x 16.5 x 1.375*
160 KM 22.44 x 20.47 4.72 37.80 x 36.22 26.5 x 19.5 x 1.375*
170 20.1 x 20.1 3.25 29.1 x 29.1 26.5 x 19.5 x 1.375*
200 2-Shot Tie Barless N/A 27.9 x 22.1 25 x 17.5 x 1.375

230 22 x 22 3.625 32.3 x 32.3 29.25 x 21.5 x 1.375
200 KM 22 x 22 4.92 36.02 x 36.02 29.25 x 21.5 x 1.375
* = Denotes that the clamp plate can go to 0.875" if a max. stack height issue
Page 49 of 221
REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 2 of 5
SPI Mold Clamp Plate - North America Top Load

Press Description
Clamp Plate Clamp Plate
Max Width ** Thickness Tonnage UST or
Brand Model
(on machine) MT
35 UST VD ET
10.5" 0.875"
40 UST Demag Extra
24.5" 1.375" 300 UST VD HT
300 MT KM CX
27.5" 1.375" 350 MT KM CX
400 UST VD HT
31" 1.375" 350 MT KM CX Wide
500 UST VD HT
32" 1.375"
450 UST Engel ES
32" *
1.375" 450-2 UST Engel ES
(47.2" dia)
34.5" *
1.375" 420-2 MT KM CX.2
(42.9" dia)
34.5" 1.375" 420 MT KM CX
650 UST VD HT
35.5” 1.375" 500 UST VD HP Wide
700 UST VD HP
38.5” 1.375” 500 MT KM CX
730 UST VD / Demag Caliber
41.5" 1.375"
730 UST VD Spectra / HP
1000 UST VD HP
43.5" 1.50"
850 MT KM MX
44.5" 1.375" 700 UST VD HP Wide
46.5" *
1.375" 651-2 MT KM GX.2
(59" dia)
650 MT KM CX
46.5" 1.375"
651 MT KM GX
51.5" 1.50" 1000 UST VD HP Wide
54.5" 1.50" 1100 UST VD Caliber
55" 1.50" 1000 MT KM MX
61" 1.50" 1300 MT KM MX
71.5" 1.50" 1500 UST VD HP Wide
73" 1.50" 1600 MT KM MX
* Rotary Press - Consider platen diameter and water/oil/air connection locations
** The widths noted are not intended to be "standard" widths but maximum widths for targeting
"smallest/robust' molds
Page 50 of 221
REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 3 of 5
• All molds for <280T molding machines will be designed and built to the SPI Side
Load Standards. All molds for >280T molding machines will be designed and
built to the SPI Top Load Standards.
• All molds for <280T molding machines must include compliance to the standard
location scheme for the A-side clamp plate.
• Clamp slots must be unobstructed for 100% of the length of the slot. See
Section 03.05.12 for additional clearance requirements for “Top Loaded” mold
set ups.
• All A-side clamp plates will be machined for standard locating rings. The locating
ring will be required for all pre-production samples.
• Clamp plates must include “self storing” locating ring pockets. The stored
locating ring needs to be flush/sub-flush with the clamp plate. A-clamp plates will
require the locating ring to be rotated 180° and stored in the original position.
Locating rings will be placed in the storage pocket while the tool is in production.
• Hot sprues and hot manifold sprue bushings must be flush/sub-flush with the
clamp plate and mechanically held in place without the use of the locating ring.
• Molds will be designed for the best/smallest robust mold base. < 280T Molds will
be fitted with the best-sized clamp plate that meets standard. Spacer rails will be
required for production flexibility to move up side load press sizes. >280T molds
will be fitted with clamp plate based on smallest /robust mold base. Reference
Clamp Plate to Mold Base Relationship on page 4 of this section.
• The SPI PDT will determine what size spacer rail will be constructed with the
mold. Spacer rails will be required for all side load molds, <200T.
• All molds built in the 400T-500T range will require both applicable location
schemes in the A-side clamp plate.
• All molds built ≥400T will require the 2” press knock out extensions. See Section
03.13.01B.
• Spacer rails must be stamped with press size and the next press size the spacer
rail will be used in (i.e. 85T – 120T)
• All clamp plates must have a minimum 0.800” steel thickness under any pockets
cut into clamp plates to allow sensors on magnetic platens to functions properly.
Through pocket cut-outs are not allowed on “A” side clamp plates.
Page 51 of 221
REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 4 of 5
TOP LOAD MOLDS

Clamping Surface/Clamp Slots Dimensions
Machine Tonnage Min Depth Width
300-500 1.000” 1.000”
650-1500 1.000” 1.500”
• Clamp Plate to Mold Base Relationship

1. All mold connectors and plumbing must be contained within the plane created by
the clamp plates on the operator and non-operator sides of top load molds (to fit
between tie bars) and on all sides except the operator side of side load molds.
Typically 1” is required between the mold base and the edge of the clamp plate.
See Section 03.11 for use of low profile cooling fittings on the backside of the side
load mold base.
2. If clamp plate cannot exceed edge of mold base by 1” (or required distance to
package all connections and plumbing), then recess all mold connectors and
plumbing so that they will be within the plane created by the clamp plate as
specified above.
3. If recessing connectors and plumbing is not feasible, clamp plate will need to be
sized to protect all connectors and plumbing.
4. If the mold base and the clamp plate for side loaded tools have the same
horizontal dimension, the lower operator and non-operator edges of the mold
base must be cleared for the cooling lines. The mold stop plate on the Mold
Docking Stations must not damage cooling lines. Refer to Section 03.05.13,
Example of Improperly Cleared Mold Base.
Clamp Plate Dimensional Tolerance
1. Plate thickness tolerance - + 0.005”(0.13mm)

2. Parallel tolerance - + 0.001”(0.025MM) total indicator reading
3. Flatness tolerance - + 0.001”(0.025mm) total indicator reading
Page 52 of 221
REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 5 of 5
Revision Record
Rev. A – Added “Clamp Plate Dimensional Tolerance” section.

Rev. B – Added last sentence to 3rd bullet point. Added last bullet point in the
instruction.
Rev. C – Significant changes, too numerous to list.
Rev. D – Separated clamp plate table into USA & China tables. Bullet point 10 on page
3 added ≥ and removed “in the” & “500T range”. Added bullet point 12
stamping spacer rails.
Rev. E – Removed bullet point about 2-shot clamp plates.
Rev. F – Added 250T Haitian 2-Shot clamp plate size. Removed bullet point for 2-shot
mold requirements.
Rev. G – Fixed typo on clamp plate thickness for 1000T clamp plates.
Rev. H – Added 1125 T clamp plate data and correct Haitian 2-shot clamp plate size.
Added 170T clamp plate to 0.875” category for stack height issues.
Rev. I – Added minimum 0.800” thickness for any pockets in clamp plate.
Rev. J – Error fixed for 731T clamp plates. All 731T are wide body platens/tie bars.
Rev. K – Corrected error on 500 T for tie bar spacing and clamp plate size.
Rev. L – Updated clamp plate sizes to have clearance of ½” per side and updated
clamp plate to mold base relationship 1-4. Change format of SPI North
America Clamp Plate information. Added 160 KM and 200 KM information in
the Side Load Clamp Plate table.
Rev. M – Added clamp plate sizes for 500 CX KM, 530 2-Shot Hiatian and 651 GX KM
information to Top Load Clamp Plate table. Multiple changes to clamp plate
widths for top load tools.
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REV. DATE: 01-19-15

EYE BOLT
ISSUE: 06-24-09
PAGE: 1 of 3
Bill Of Material
Lifting Capacity @ Various Lifting Angles
(lbs)
Component Manufacturers/ Part Thread Single 0° - 45° Lift 45° - 60° Lift
Distributors Number Lift
Forged Steel Eyebolt PPE - USA 3062 5/8" 4,000 1,000
3075 3/4" 5,000 1,250
(Use these if mold 3100 1" 9,000 2,250 DO NOT USE
needs 1 eyebolt for 3125 1-1/4" 15,000 3,750 OVER 45°
lifting to hang level) 3150 1-1/2" 21,000 5,250
3200 2" 38,000 9,500
McMaster Carr 3014T52 5/8" 4,000 1,000
3014T531 3/4" 5,000 1,250
3014T55 1" 9,000 2,250 DO NOT USE
3014T57 1-1/4" 15,000 3,750 OVER 45°
3014T58 1-1/2" 21,000 5,250
3014T61 2" 38,000 9,500
Swivel Eyebolt (*) FD Lake 42854 5/8" 4,620 3,300
(Pink Starpoint) 42856 3/4" 7,098 5,070
42860 1" 9,870 7,050
(Use these if mold 42862 1-1/4" 13,888 9,920
needs 2 eyebolts for 42864 1-1/2" 21,620 15,430
lifting to hang level) 42868 2" 37,030 26,450
McMaster Carr 3059T72 5/8" 4,620 3,300
3059T73 3/4" 7,098 5,070
3059T74 1" 9,870 7,050
3059T75 1-1/4" 13,888 9,920
3059T76 1-1/2" 21,620 15,430
3059T77 2" 37,030 26,450
Hoist Ring PPE - USA P23438 2-1/2" 50,000 35,710
(Use these if mold

McMaster Carr 3052T75 2-1/2" 50,000 35,710
needs >2" eyebolts)
Page 66 of 221
REV. DATE: 01-19-15

EYE BOLT
ISSUE: 06-24-09
PAGE: 2 of 3
* The swivel eyebolts are manufactured by RUD. Cannot buy direct.

F.D. Lake
3313 Lousma Drive SE
Grand Rapids, MI 49548
Contact Name: Brian Finkbeiner
Phone: 616-241-5639
To purchase McMaster Carr parts in China:

WuXi AMDA M&E Co.,Ltd.
TEL 86-510-85737116 /510-82917798 FAX 86-510-85730629
H P : 86-13771519966
E-mail: zhangjun@amdachina.cn / zhang_zj_jun@yahoo.com.cn
Website: http://www.amdachina.cn
Address: 99-3,Nanyangxincun,Wuxi,Jiangsu
ZIP : 214023
• Single lifting eyebolt hole on top of mold must be located so the mold hangs
level for all molds and labeled with the text “Lifting Hole”
• If one lifting eyebolt can not be located on top of mold to hang the mold level,
then two must be used and labeled with the text “Lifting Hole”
• Suppliers are required to quote and install SPI Standard Eyebolt(s) for the top of
mold lifting eyebolt holes labeled “Lifting Hole”
• Area around “Lifting Hole” to be painted (Refer to Section 03.06.04):
• ≤ 1” – 2”x2” Green square
• 1 ¼” – 1 ½” – 3”x3” Red square
• ≥ 2” – 6”x6” Orange square
• Single lifting eyebolt holes must be located on all four sides of each half of the
mold base.
• If the mold requires two eye bolts to hang level, each eye bolt must be rated for
the mass weight of the mold and sized based on the thread of the forged eye
bolt.
• All molds must be delivered for F1 sample with eyebolt(s) installed in the hole(s)
labeled “Lifting Hole” on top of mold.
• Eyebolt(s) must be installed to the shoulder with maximum standard thread
engagement. Refer to Section 03.06.03.
Page 67 of 221
REV. DATE: 01-19-15

EYE BOLT
ISSUE: 06-24-09
PAGE: 3 of 3
• Eyebolt lifting holes in all corners (vertical holes through the thickness of the clamp
plates):
• ≤ 280 A side only
• >280 A & B sides
Revision Record
Rev. A – In the Bill of Material changed “RUD” to “FD Lake” along with the
corresponding part numbers. Pg. 2 changed “RUD Startpoint Swivel Eyebolt
Suppler” to “*The swivel eyebolts are manufactured by RUD. Cannot buy
direct”.
Rev. B – Added “(*)” after “Eyebolt” in the Bill of Material section.
Rev. C – Added 5th bullet point to instruction.
Rev. D – Bullet point 5 added “and sized based on the thread of the forged eye bolt.”
Rev. E – Added 2” and 2-1/2” eyebolt information and lifting capacity for all eyebolts.
Added color coding for eyebolt area.
Rev. F – Removed the color blue 8”x8” square to match Section 03.06.04.
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REV. DATE: 01-09-15

SAFETY STRAP
ISSUE: 06-24-09
PAGE: 1 of 2
Bill Of Material
Shear Strength (lbs)
Component Manufacturers/ Part Notes Grade Grade 8 N/A
Distributors Number 2
1-1/4" T-Handle
Detent Pin 3/8" McMaster Carr 93750A497 N/A N/A 20,000
w/ Lanyard
Drill Bushing 3/8" ID McMaster Carr 8492A234 1/2" long N/A N/A N/A
2" T-Handle w/
Detent Pin 3/4" McMaster Carr 93750A896 N/A N/A 82,500
Lanyard
Drill Bushing 3/4" ID McMaster Carr 8492A304 1" long N/A N/A N/A
3/8" Socket Head

McMaster Carr 91251A633 2-1/4" long 4,903 9,939 N/A
Cap Screw
3/4" Socket Head

McMaster Carr 91251A845 2-1/2" long 19,615 39,790 N/A
Cap Screw
To purchase in China:
TEL 86-510-85737116 /510-82917798 FAX 86-510-85730629
H P : 86-13771519966
ZIP : 214023
Page 74 of 221
REV. DATE: 01-09-15

SAFETY STRAP
ISSUE: 06-24-09
PAGE: 2 of 2
Revision Record
Rev. A – Changed part number for the Detent Pin 3/8” from 9375A497 to 93750A497.
Changed part number for the Detent Pin ¾” from 937550A986 to 93750A896.
Rev. B – Added shear strength table to BOM.
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SECTION 03.08 REV. LEVEL: D
REV. DATE: 05-31-17

GATING
ISSUE: 06-24-09
PAGE: 1 of 1
• Gates should be shown 4x blown up view for a better understanding. The gate
details must include runner diameters and the dimensions of the actual gate
sizes.
• Sub-gates should be used whenever applicable.

• Needle designed sub-gates are unacceptable; all sub-gates will be a D-style or
ball end design.
• All elastomer component sub gates must be a ball end design.

• Gating will be inserted for high abrasive resins with H13 inserts, 48-50 Rc.
Glass-filled and mineral filled resins will require hardened H13 gate inserts.
Deviation from this standard will require a waiver from the Tool Group, SPI
Technical Leader/Manager, and the Plant Launch Champion.
• All vane gates must be of a “diamond” edge gate design except on PP rear
vanes (Reference Section 03.08.07 and 03.08.07A).
• Applique tools must use a hardened gate insert or a sleeved split pin for gating.
• Use of gates to balance multiple cavity tool(s) is unacceptable.
Revision Record
Rev. A – Revised 5th bullet point.

Rev. B – Added applique gating requirement.
Rev. C – Added PP rear vanes to 6th bullet point and reference section numbers.
Rev. D – Use of gates unacceptable for balancing.
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SECTION 03.09 REV. LEVEL: G
REV. DATE: 05-31-17

COLD RUNNERS / COLD SPRUES
ISSUE: 06-24-09
PAGE: 1 of 1
• Use a hot sprue if the cold sprue length and bushing recess standard cannot be
met (2” recess maximum, 4” sprue length maximum) or runner volume is > 30%
of shot volume.
• Runner system will be free of burrs and tooling marks. Runner system will be
polished to SPI #3 finish.
• Radius all runner system intersections, including the sprue.
• All runner systems must be balanced for even part fill. Add runner choke inserts
unless waived by TE. Refer to Section 03.09.04.
• Vented cold slug wells will be designed at the end of each runner segment.
• Sprue bushing must be securely mounted to the mold base without the locating
ring.
• Locating ring must be reversible 180° and be flush/sub-flush with the clamp plate
and be self-storing when not in use.
• Locating ring must not allow a gap for material to occupy in either orientation.
• Runner shut-offs are required when multiple cavities are not common (family
molds). Refer to Section 03.09.03 for guidelines.
• All TPE molds must have ejection under all runner transitions.
• Use runner segments to balance multiple cavity tools.
Revision Record
Rev. A – Bullet point 1 added 2” recess, 4” sprue length. Added bullet points 6
through 9.
Rev. B – Removed vacuum flag requirement. Reworded last bullet point.
Rev. C – Added bullet point for TPE runner ejection.
Rev. D – Added runner volume requirement to first bullet point.
Rev. E – Corrected runner volume vs. shot volume
Rev. F – Added runner choke inserts unless waived by TE
Rev. G – Use runner segments to balance tools
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REV. DATE: 08-01-19

HOT MANIFOLDS / HOT SPRUES / SEQUENTIAL
VALVE GATING ISSUE: 06-24-09
PAGE: 1 of 5
Bill of Material – Hot Manifold Connection

Component Acceptable Part Number
Manufacturer /
Power Thermocouple
Distributor*
1 Zone DME CKPTIC-1
12 Zone DME PIC-12-G MTC-12-G
Terminal Box** PPE PTC12TB

(12 zone)
Male Contact Pin PPE 0915-0006101
Female Contact PPE 0915-0006102

Pin
Crimp Tool PPE 0999-000-0021
* Or equivalent purchased component

** These terminal boxes require modification to meet location standard (reference
drawing). Terminal boxes are not required if connector can be mounted flush in the
mold.
Supplier Contact Information:

Synventive Parts and Service, tel: 800.367.5662. Press 2 for Parts, Press 4 for
Service. Must have system number when calling. techsupport@synventive.com
Yudo SIT Connectors and Cables for SIT 500: spareparts@yudousa.com
Page 98 of 221
REV. DATE: 08-01-19

PAGE: 2 of 5
Bill of Materials – Sequential Valve Gate Coupler

Manufacturer /
Distributor
Valve Gate Quick Staubli Corporation K32082513 1 or 2 Valve Gates

Coupler (Mold) K32082413 3 Valve Gates
K32082313 4 Valve Gates
Valve Gate Quick Staubli Corporation K32082613 Purchased By The

Coupler (Press) Plant.
Docking Plate Staubli Corporation K32082713 Good For All Tool

(Machine) Configurations As
Stated Above.
Plug (Mold) Staubli Corporation SPC 05.5414

IA/JV/MD
Plug Tool Staubli Corporation R 135 911 00
Socket (Press) Staubli Corporation SPC 05.2000

IA/JV/RD
Socket Tool Staubli Corporation R 235 901 01
Manifold Design and machine to mold specific

Staubli Corporation Customer Service, tel: 864.486.5455.
email: customerservice.connectusa@staubli.com
Page 99 of 221
REV. DATE: 08-01-19

PAGE: 3 of 5
• Hot manifold systems must be engineered for the tool and the resin etc., not a
collection of off the shelf items.
• Synventive Molding Solutions is the preferred source for all valve gate and hot
manifold systems. Yudo Hot Manifolds are only acceptable for single and 2 drop
(maximum) hot manifold systems.
• All valve gate systems must be a single unitized, drop-in system pre-wired and
pre-plumbed for the standard Staubli coupler(s) unless requested and/or
approved by SPI personnel.
• All valve gate systems must be hydraulically actuated.

• Any valve gate system that runs materials requiring ≥ 140° F must have a mini
water manifold for the valve gate system. Use 300 series fittings for IN and
OUT. The mini manifold is to be hooked up directly to tower water not the main
water manifold. Reference 03.10.04.
• Hot drops and hot sprues must not make contact with the opposite mold half. A
0.015” resin disc is required to assure contact is not made. Hot manifold drops
should have the drop number stamped into the disc area for drop location
identification.
• Hot manifolds must be engineered with minimum pressure loss, but enough
backpressure for quick color changes (3-5 shots).
• Hot manifolds must have support discs to back up drops to prevent deflection at
parting line.
• All hot manifolds systems will require a 12-zone male receptacle connector,
power and thermocouple.
• All hot sprue systems will require a 1-zone male receptacle connector.
• All wiring must be contained within protected wire channels unless approved by
SPI TE.
• All wires must be continuous; spliced wires are not acceptable.
• Wire channels will be machined from the manifold to the junction box.
• All heater leads are to have fiberglass insulation from the heater to the junction
box.
• Wiring schematic plaques illustrating manifold wiring will be mounted on the
operator side of tool, and will show complete detail to specific plug pin.
Page 100 of 221

REV. DATE: 08-01-19

PAGE: 4 of 5
• Refer to Section 03.17 for schematic plaque location and identification

requirements.
• Wiring order: 1st: Nozzles
2nd: Manifolds
• All heaters are to be 240 volt.
• Amperage per zone should not exceed 15 amps.
• All hot manifold / hot sprue thermocouples must be “J” type.

• Hot manifold / hot sprues must be securely mounted to the mold base without
the use of the locating ring.
• Locating ring must be reversible 180° and be flush/sub-flush with the clamp plate
and be self-storing when not in use.
• Locating ring must not allow a gap for material to occupy in either orientation.
• All hot manifold systems with multiple cavities of the same part must be
balanced with the manifold system and not by temperature of the drops.
• Valve gate open/closed on the Staubli quick connect coupler for both mold and
press. O – Valve gate open, I – Valve gate closed. (Reference 03.10.03).
• Cooling bushings should be evaluated for use to get adequate cooling at the hot
manifold tip area(s) and/or to prevent thin steel conditions using conventional
water line location(s).
• Non-Valve gated hot manifold and hot sprue systems, when gated into a runner,
will require a carrot length of at a minimum of 15mm and ≤ 30mm with a
minimum of 3° draft per side (5° - 8° draft is desired) and should have a 0.5 mm
radius at the base. The carrot should be draw polished.
Page 101 of 221

REV. DATE: 08-01-19

PAGE: 5 of 5
Revision Record
Rev. A – Pg. 3 added bullet points 3, 5 and 6.

Rev. B – Added Parts Manager Rick Kilburn to contact information. Bullet point 3
change “should” to “must”. Bullet point 12 removed “3rd : Back Up Manifold”
Added bullet points 15 - 18.
Rev. C – Added bullet point about supporting drops of manifold.
Rev. D – Added Staubli connectors to BOM. Added Synventive contact information.
Changed bullet point 2 for manifold preference. Added “for the standard
Staubli coupler(s)” to bullet point 3. Added last bullet point.
Rev. E – Changed Staubli contact information. Added socket tool to BOM. Added mini
manifold for valve gate system.
Rev. F – Added cooling bushing and sprue carrot length and draft.
Rev. G – Updated mini water manifold for valve gate systems.
Rev. H – Added Plug Tool to part list for Staubli items. Added “unless approved by SPI
TE” for wiring channels. Added male and female pins and crimp tool for power
and thermocouple adaptors.
Rev. I – Made the sprue carrot a range from 15mm to 30mm.
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REV. DATE: 08-01-19

MOLD TEMPERATURE – COOLING
ISSUE: 06-24-09
PAGE: 1 of 6
Bill of Materials
Manufacturer
Male Manifold Parker BST-N6-M 3/4” NPT Open
Connection** Fitting – Supply
Female Manifold Parker BST-6-M 3/4” NPT Open

Connection** Fitting – Return
Low Profile Water Progressive 300 series; WJ300-50 WJH50 (1/2”) hose
Jumper Fitting/Hose Components* 500 series; WJ500-50
(DongGuan
Changan
Shuanghe Die
Accessories
Line)
Hose Parker* 801-8-BLU-Length 1/2” ID, <185°F
(Shanghai Blue Supply
EORERO (oil resistant)
Machinery Co.,
Ltd)
Hose Parker* 801-8-RED-Length 1/2” ID, <185°F
(Shanghai Red Return
EORERO (oil resistant)
Machinery Co.,
Ltd)
Hose, Hot water Parker* 7212-501-BL-Length 1/2” ID, >185°F
Blue Supply
(oil resistant)
Hose, Hot water Parker* 7212-501-RD-Length 1/2” ID, >185°F
Red Return
(oil resistant)
Quick Connect Parker* PC318-BP (90) 1/2” Body/1/2”
(w/ Hose Barbs) PC328-BP (45) (Hose) ID
PC308-BP (Straight) Return (300 Series)
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REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 2 of 6
Quick Connect Parker* PC514-BP (90) 1/2” Body/1/2”

(w/ Hose Barbs) PC524-BP (45) (Hose) ID
PC504-BP (Straight) Return (500 Series)
Brass Plug Baffle DME* BB-60 1 piece
specify length
Cooling Manifold Fabricate* NA Reference
03.11.01 for
Hi Tech (USA) fabrication details.
Must be color
coded steel. (Blue
for supply; Red for
return)
Brass 90° Street Parker* 2202P-4-4 Low profile with ¼”
Elbows for std. pipe threads
cooling manifolds Brave Industrial 63812-S (short)
Drybreak Quick R.M. Wright Co., 71-3C8-8F (Coupler) Hot Oil Molds
Couplings Inc. “USA” 71-3N8-8F (Nipple) ½” steel
(Snap-tite Series 71)
WuXi AMDA Female 00469064 From WuXi AMDA
M&E Co.,Ltd, (Return) allow ±4 weeks for
(China) Male 00469072 delivery
(Supply)
Hose Plastics Process 919-5 >185°F Water for
Equipment, Inc.* tools built in China
& Hot Oil Molds
450°F max temp
Fittings Plastic Process 20190-4-5 >185°F Water for
Equipment, Inc.* tools built in China
& Hot Oil Molds
450°F max temp
* Or equivalent purchased.
** These components must be from this supplier.
*** It is the TE’s discretion on small side load tools whether to use smaller ID water
hose and necessary barbs on the water fittings for packaging issues.
Page 108 of 221

REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 3 of 6
USA Source for Brass 90° Street Elbows for Cooling Manifolds <185°F (85°C) -
Brave Industrial Fasteners
Otsego, MI, USA
1-800-334-1228
USA Source for Parker Fittings -

Depatie Fluid Power
6256 American Ave.
Portage, MI 49002
269-324-2850
Hi-Tech Tig Welding Inc.

814 East Buck Street
Three Rivers, MI 49093
269-278-5101
China source for Low Profile fittings:

DONGGUAN CHANGAN SHUANGHE DIE ACCESSORIES LINE
Jinghai Middle Road 12,
Changan town, DongGuan City
Tel: 86-0769-85079860 / 13527988125 Contact person: Yi Qing Shuang
Fax: 86- 0769-85370440
China source for Parker Hose:

Shanghai EORERO Machinery Co.,Ltd
Shanghai headquarters -
Room504,No.2000,Shangcheng Road, Shanghai
Suzhou Branch -
No. 169,Zhong Jie Road,
Ping Jiang District, Suzhou
Tel: 86- 0512-67706227 Contact person: Wang Hua Cheng
Fax: 86-0512-67298629
China source for Drybreak Quick Couplings (allow 4 weeks for delivery):
TEL 86-510-85737116 /510-82917798 FAX 86-510-85730629
H P : 86-13771519966
ZIP : 214023
Page 109 of 221

REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 4 of 6
• Cooling line area should be a minimum of 60% of the projected area of the part
on both hold halves. Do not include the area of mold cooling outside the part.
• Water connections will not be in clamp slots.

• Any molds requiring water or hot oil on top of mold need liquid drain slot
channels. Side load 200T/230T Non-Operator side tools require liquid drain slot
channels for upsizing to top loaded presses.
• Cooling lines will be machined in lifters and slides as applicable.

• No O-Rings without SPI Tooling Engineer and plant Launch Champion approval.
If authorized, mating surfaces to be corrosion protected.
• Cooling fittings should be one piece.
• Cooling line circuits must be a uniform distance from the surface of the part.
• All cooling circuits must be capable of maintaining a minimum of 90 PSI without
loss of pressure. Mold source will test all circuits prior to shipment of tool. Costs
related to initial failures may be charged back to the mold source.
• All circuits must be plumbed to achieve >1gpm. Reference Section 03.11.11.
• No more than 4 baffles per cooling circuit without approval from SPI Tooling
Engineer. Refer to Sections 03.11.01 and 03.11.05B for detail.
• Unless otherwise specified, the “A” and “B” plates will have a minimum thickness
of 1.5”. Additional plates with water lines will have a minimum thickness of 2”.
• All pipe joints must be sealed with Teflon tape.

• MoldMax must be used for difficult to cool areas. See Section 03.18.05 for
Center Housing and Dual Cup Holder Insert cooling insert mold component
design.
• Sufficient cooling for runners, runner bars, cold sprues, hot drops is required
• All cooling lines must be clamped to the mold base and must be contained within
the plane created by the clamp plates. Channels or chamfers/radii in mold base
may be required to achieve. Jumpers on the non-operator side for side-loaded
tools can extend to a maximum dimension of 2” beyond the clamp plates. Low
profile elbows should be used to help achieve this dimension. See Section
03.11.09.
Page 110 of 221

REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 5 of 6
• All temperature control circuits must be plumbed with hoses that are rated for
the operating temperature the resin requires in production. Special
consideration is required for mold temperatures required to be ≥185°F(85°C).
• Molds built in China will require stainless steel braided reinforced high
temperature hose rated at least for 150°C for applications of ≥185°F(85°C).
• All tools required to run hot oil must be painted to distinguish from tools that run
water. In North America – Orange. In China – Yellow.
• All tools requiring insulator boards must be placed between “A” cavity plate and
clamp plate. In the case of reverse injection, insulator board to be placed
between “B” cavity plate and clamp plate.
• Any valve gate system that runs materials requiring ≥ 140° F must have a mini
water manifold for the valve gate system. Use 300 series fittings for IN and
OUT. The mini manifold is to be hooked up directly to tower water not the main
water manifold. Reference 03.10.04.
• The recommended minimum distance from a part feature to the water line
channel shall be 0.394” (approx. 10 mm). TE approval needed for any part
feature to water line channels less than 0.394” (10 mm).
• The diameters of the cooling channels are to be made Ø12 mm or 0.437 inches
(minimum) unless approved by the TE.
Revision Record
Rev. A – Significant revisions, too numerous to list.
Rev. B – In the bill of material section changed “Water Manifold” to “Cooling
Manifold”, added new component “Brass 90° Street Elbows for std. cooling
manifolds” and removed component “Hose”. Added USA Source for
Brass 90° and USA source for Parker fittings. In 1st bullet point added
“include” between “not” and “the” and changed “for the” to “of mold”. In 3rd
bullet point added “and the Operator Side of 200T, 230T, or 280T molds.
Rev. C – Changes significant, too numerous to list.
Rev. D – Modified “Cooling Manifold” section. Added Hi-Tech Tig Welding source.
Rev. E – Changed bullet point 3 to Non-operator. Changed hot oil fitting supplier for
USA. Changed bullet point 15 removed “requires for”. Changed bullet
point 15 & 16 added “≥”. Added bullet point 17.
Page 111 of 221

REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 6 of 6
Rev. F – Changed hot oil hose and fittings. Reworded bullet point 3. Added “Plant
Launch Champion” to bullet point 5. Add baffle requirement in bullet
point 9.
Rev. G – Added last bullet point about insulator board placement.
Rev. H – Added asterisks to components that can be purchased as equivalent.
Added double asterisk to components that must be from that supplier.
Rev. I – Added last bullet point referring to valve gates and mini-manifold.
Rev. J – Updated BOM to eliminate 200 series fittings, added 500 series fittings,
changed hose ID to 1/2” and changed main water fittings to OPEN instead
of check valve.
Rev. K – Added minimum distance from part feature to water line channels.
Rev. L – Added “Supply” and “Return” to notes of the water fittings. Corrected quick
connect part numbers for 1/2” hose ID. Added Reference 03.11.11 to
show required gpm for specific water line sizes.
Rev. M – Added water channel diameter.
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REV. DATE: 08-26-16

CAVITY VENTING
ISSUE: 06-24-09
PAGE: 1 of 2
• Mold base parting line should be relieved .015” to .020” to allow venting and
assure clamp pressure on the cavity shut-off. Corner pads, pin push back area,
and runner area should be flush, with sufficient area to support the clamp
pressure of the press.
• Parting line crush pads must be added to ≥ 500T tools to protect parting line and
help maintain venting. Crush pads must be hardened and located on the A side
and B side opposing each other.
• Blind ribs, bosses, pockets or other potential gas trap areas will have vent pins
or other venting methods to eliminate gas.
• Periphery of the parting line must be vented at uniform intervals. Vents up to 0.5”
wide, 0.060”-0.080” land area relieved for resin selected; then relieved 0.020” to
atmosphere. Additional venting may be required at the end of fill based on the
validation sample results. Vents for low viscosity resins may have to be wider
than 0.5”, i.e. nylons, santoprenes.
• Parting lines and/or the cavities of small cartridge component parts (vanes, shut
off doors, etc.) must be adequately vented with a self-cleaning method to
eliminate gas trapping/dieseling.
• Porcerax or equivalent porous material should be quoted for hard to vent areas.
Porcerax installation guide is available from the SPI Tool Engineer.
• Porcerax venting surfaces must be machined by EDM not cutting.
• All vents must be relieved to atmosphere, not to a blind pocket.

• Cavity to be vented every 1.5” - 2” around the periphery and in all part openings.
Where feasible, all openings in the part will be venting to atmosphere via non-
functioning ejector pin(s) or a hole. Non-functional ejection pin(s) for vents
should be relieved for the full length of the pin to allow gas to escape to
atmosphere.
• All ejector pins must be vented when applique crosses parting line.
Page 126 of 221

REV. DATE: 08-26-16

CAVITY VENTING
ISSUE: 06-24-09
PAGE: 2 of 2
• When vented ejector pins are required, they should be ring vented. The ring
vent must be 0.040”-0.060” land around the entire diameter of the pin. Vent
depth determined by material (Reference Section 03.08.09). Vent depth to be
entire diameter of the pin.
• After 2 hour run (F1), tool shop will blue tool off while in press to check parting
line and venting.
Revision Record
Rev. A – Added 6th bullet point to instruction.

Rev. B – Removed 1st and 3rd sentence to bullet point 6. Added bullet point 9.
Rev. C – Added “atmosphere via” and “or a hole”. Added “blueing” the tool after F1.
Rev. D – Added 2nd bullet point about crush pads.
Rev. E – Added ring venting for ejector pins.

Rev. F – Added “when vented ejector pins are required” to 2nd to last bullet point.
Added “up to” after vents in 4th bullet point sentence 2.
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SECTION 03.13 REV. LEVEL: J
REV. DATE: 08-01-19

EJECTION / REVERSE / ACCELERATED EJECTION
ISSUE: 06-24-09
PAGE: 1 of 4
Bill of Material
Manufacturer(s)
Safety Allen Bradley 802B-CSADBSXC3
Switches
McMaster-Carr 7317K12
Electrical Hubbell HBL7467

Outlet
Connector
• Knock-out patterns and mold dimensions to be correlated with SPI Global

Molding Machine Specification Matrix.
• All molds with conventional ejection must have two safety ejector switches located
on symmetrically opposite ends of the ejector plate. It will be at the discretion of the
TE on any tools for ≤170T, if packaging space is limited, to only have a single safety
ejector switch.
• Molds with A side ejection must also have the electrical outlet connector (HBL7467)
mounted in the standard location with the terminals jumped.
• Stripper plate tools that pull ejection system off of safety ejector switches prior to
ejection must have secondary switches that show stripper plate positions.
These switches must all be in series. Reference Section 03.13.10.
• Ejector pins must be > 3/32”. Ejector blades must be ≥ 0.046” x 0.234”.
• Two diagonally opposite push back pins must be tapped for ease of assembly.
Page 130 of 221

REV. DATE: 08-01-19

EJECTION / REVERSE EJECTION
ISSUE: 06-24-09
PAGE: 2 of 4
• Early return systems are required on tools with suicide conditions. DME ER101
is preferred.
o If tooling is too large for the ER-101 system, external DME Toggle-Lok or
fabricated equivalent is required.
o If space limited, gas springs with limit switches can be reviewed with the
SPI Tooling Engineer.
o If an engineering change requires pin(s) under a slide, an early return
system is required
• Early return systems must not interfere with robot extraction of part(s)
[i.e. Horizontal Configuration]. Distance between early return pins must be 12”
minimum center to center.
• Early return driver pins must be removable from the back of the clamp plate and
held in with a retention strap similar to core pins. See 03.13.08.
• Contoured pins must be keyed in ejector plate to prevent rotation. See Section
03.13.02.
• All ejector pinholes will have a minimum of ¾” and a maximum 1 ½” bearing
surface.
• All ejector plates are to be spring loaded with 3/8” pre-load and designed for 35%
maximum spring deflection using a spring rated for up to 50% deflection. All springs
must have a pin through the center (minimum of four springs).
• All purchased components (i.e., blades, pins, sleeves, etc.) must be a standard
size and readily available in the USA.
• All ejector plates must have stop buttons, quantity to be determined at the tool
design review.
• All ejector housings for top load set-ups must be covered. See Section
03.13.07.
• All molds will have a guided ejector plate with replaceable bushings and grease
grooves. The end of the guide pin must telescope into the support plate.
• Pins are to be placed inside ejector plate return springs.
• All molds 400T-500T requires 4x16 and 6x28 (if possible).
• Runner pins must have bullet nose keepers for robot extraction.
• All tools must be built with proper knock out pattern and the knock out pattern for the
next available sized press.
Page 131 of 221

REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 3 of 4
• All tools built in North America that will run in China must have knock out holes and
extensions elongated to run in both North American and Chinese presses.
• Stripper plate tools cannot allow hot sprue to leave stripper plate while in forward
position.
• All TPE molds must have ≥0.500” pin size or straight lifter for ejection. If possible,
use “A” side inserts with air blow off.
• Support pillars must be located as near as possible to high molding pressure areas.
(ie. cam pockets, runners, cavities, etc.). All support pillars must be attached to the
clamp plate using a single socket head screw.
• Support pillar pre-load must not exceed 0.005” (typically 0.002”-0.003”).
• The tool shop is responsible to incorporate adequate ejection (pins, lifters, kickers,
etc.) on either A side or B side to de-mold the part without deformation.
• Parts and runners must present to the robot end of arm tooling per design intent
(nothing drops freely). Parts and runner sections produced by the mold are not
transferred onto or retained on the cavity side of the mold during ejection.
• The preferred method of ejection for deep draw features is rectangular or square
ejector bars versus round pins with contoured features in the round pin. Prefer to
eject under features instead of pulling features out of the mold. This also allows for
venting of the features.
• Ejector guide bushing holes in the ejector plate, ejector retainer plate and the guide
pin pilot holes should be 0.003”-0.005” oversize (Reference 03.13.13)
Page 132 of 221

REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 4 of 4
Revision Record
Rev. A – Added 11th bullet point to procedure.

Rev. B – Added 3rd bullet point under bullet point 2. Added bullet point 4 and 5. Added
ejector blades to bullet point 6. Added bullet points 17 & 18.
Rev. C – Revised bullet point 10 for spring compression. Added last bullet point.
Rev. D – Added ejection requirement for TPE molds and middle bullet point about
stripper plates.
Rev. E – Added “All molds must have” to bullet point 2. Removed bullet points that
stated when thin switches were NOT needed in specific cases. Updated BOM
to reflect new thin switch design.
Rev. F – Added minimum distance between early return pins. Added ≤170T single
safety ejector switch at discretion of TE. Changed thin to safety ejector.
Rev. G – Added Omron and McMaster-Carr to thin switch manufacturers.
Rev. H – Added support pillar requirements Changed spring and set screw in BOM.
Removed “largest possible pin size” and changed to ≥0.500”. Added 2nd
sentence to same bullet point.
Rev. I – Added “with conventional molds” to bullet point 2. Added bullet point 3 for
clarification of ejector safety switches and reverse ejection.
Rev. J – Changed Allen Bradley and McMaster-Carr switch numbers. Removed Omron
as they don’t make that type of switch. Removed spring, set screw and ejector
pin from old design. Added statement for Tool shop responsible for adequate
ejection to demold parts without deformation. Added parts and runners
presented to robot to match FR checklist item. Added rectangular/square
ejector bars for deep draw features. Added guide bushing oversize
requirement.
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REV. DATE: 08-01-19

SLIDES
ISSUE: 06-24-09
PAGE: 1 of 2
• Mold surfaces working against one another, will be constructed of dissimilar

materials, sufficient angles, and/or differential hardness to prevent galling.
• Ejector Pins will not be placed under slides, without being reviewed and
approved by SPI Tooling Engineering. An early return system must protect for
suicide conditions.
• Horn (angle) pins for slides will not exceed an angle of 30° from vertical.
• Mechanical angle pin drivers preferred for slide travel <3”.

• Hydraulic cylinder drivers required for slide travel >3” or any slide opposing
gravity that is >70 lbs slide weight. Any hydraulically driven slides opposing
gravity must also have détentes to prevent slide from drifting if air present in
hydraulic line.
• Slides driven with hydraulic cylinders must be held forward mechanically.

• Slides will be held open mechanically, except for large slides on the bottom of a
top loaded mold. Superior slide locks preferred, retraction springs secondary.
Slides opposing gravity require retraction springs and slide locks.
o All molds 200T – 280T (may be side loaded or top loaded): Must protect all
actions from gravity.
• Typically, slides must be removable from parting line.

• Slide gibs and wear plates must have grease grooves, no graphite impregnated
gibs or wear plates are acceptable.
• Whenever slide lock détentes are required, the bar style (Superior) will be used.
• If a slide face must shut off or interlock with a lifter/retractor, refer to Safety
Switch requirement in Section 03.15 Lifters/Retractors.
• Leader pins must engage before horn pins.
• Slides must be contained in the mold base when retracted.
• Forward slide stops to support and protect parting line shut-offs.
Page 154 of 221

REV. DATE: 08-01-19

SLIDES
ISSUE: 06-24-09
PAGE: 2 of 2
• All slide gibs must be doweled to ensure slide location.

• If a slide and cavity must have Zero Parting Line or 60 µ Parting Line
Specification (called out on the drawing), the slide(s) must be positively secured
in its home position to be textured. (Reference 03.14.02)
Revision Record
Rev. A – Added last bullet point in procedure.

Rev. B – In 3rd bullet point added “(angle)”. Added new 4th, 5th, and 6th bullet points.
Rev. C – Bullet point 2 added early return system sentence. Bullet point 3 changed
28° to 30° to match other paperwork. Added bullet points12-14.
Rev. D – Added Zero Parting Line bullet point and >70 lbs slide weight for hydraulic
cylinder.
Rev. E – Added doweling to gibs.
Rev. F – Added détentes for hydraulically driven slides opposing gravity.
Page 155 of 221

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REV. DATE: 08-26-16

LIFTERS AND RETRACTORS
ISSUE: 06-24-09
PAGE: 1 of 2
• Lifter rods will be guided with replaceable bushings and grease grooves. Graphite
impregnated lifter rod bushings are not acceptable.
• All lifter and retractor assembly sliding components will have a hardened steel to
bronze (or equivalent non-galling surface) contact with provisions for lubrication.
• All lifter bodies will be fastened to the lifter rod with a spring steel pin.
• Lifter and retractor assembly components will be stamped with identification
numbers.
• A clearance hole will be provided in the clamping plate to remove the screw
holding the lifter rod T-gib foot, so the lifter can be removed without dismantling
the mold.
• All lifter/retractor rod T-gib feet, L-gibs, and other integral action components
must be purchased not fabricated by the Supplier. Components must be regular
stocked items in the USA and China for ease and timing of replacement. Spare
parts will be required of the Supplier in their original quoted price if purchased
components are not readily accessible to SPI. SPI to rule on the need for spare
components at the mold design review events.
• Any tool with geometric grain and/or any actions requiring a slide to inter-
lock/shut off on a lifter/retractor must be engineered to avoid and detect
malfunction. Lifter/Retractor rods and bodies of one piece construction
preferred.
• Supplier may be asked to install special safety switches wired in series with the
ejector retraction safety switch to assure the lifter or retractor has not failed
mechanically. Suppliers should include safety switches in their quotation. If
deemed necessary by the SPI PDT, an additional SPI PO will not be issued.
• Lifters and retractors will not exceed a 15° angle from vertical; all exceptions
must be reviewed and approved by SPI Tooling Engineer.
• Retractor actions driven with hydraulic cylinders must be held forward
mechanically.
• All lifter cars (foot) must have length of 2x the height requirement.
Page 158 of 221

REV. DATE: 08-26-16

LIFTERS AND RETRACTORS
ISSUE: 06-24-09
PAGE: 2 of 2
• Crush pads must be put in tool when lifters/retractors cross parting line
regardless of tool size.
Revision Record
Rev. A – Added bullet points number 6 and 7.

Rev. B – In 4th bullet point removed the word “lifter” between “with” and identification”.
Added last bullet point to procedure.
Rev. C – Added lifter car requirement.
Rev. D – Added crush pad bullet point for lifters/retractors crossing parting line. Added
the risk to geometric grain for safeties behind lifters/retractors.
Page 159 of 221

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REV. DATE: 08-01-19

HYDRAULICS – CORE PULL AND REVERSE EJECTION
ISSUE: 06-24-09
PAGE: 1 of 2
Bill of Materials
Manufacturer*
Cylinder** Parker 2H Series or Bore & Stroke per
CHE/CHD Series application
3000 psi working
5000 psi burst
Male Fitting Parker H3-63 3/8”. Use if single
Female Fitting Parker H3-62 hydraulic circuit (core
or ejector) – 1st circuit
Male Fitting Parker H4-63 ½”. Use if two
Female Fitting Parker H4-62 hydraulic circuits are
required. (core uses
3/8”; ejector uses ½”)
– 2nd circuit
Male Fitting Parker 4010-3P 3/8”. Use if three
Female Fitting Parker 4050-3P hydraulic circuits are
required. – 3rd circuit
Male Fitting Parker 8010-4P ½”. Use if four
Female Fitting Parker 4050-4P hydraulic circuits are
required. – 4th circuit
Limit Switch Allen Bradley 802T-NP Top Push Roller
Spring Return
Male Electrical Hubbell HBL2415 Flange style. For
Connector single hydraulic
circuits.
Connector second hydraulic
circuit.
Male Electrical Hubbell HBL2815 Flange style. For third
Connector hydraulic circuit.
Connector fourth hydraulic
circuit.
Hose NA NA 3000 psi working
5000 psi burst
* Or purchased equivalent (USA NPT standards)
** Replacement parts & shaft seal kits must be readily available in the US.
Page 161 of 221

REV. DATE: 08-01-19

HYDRAULICS – CORE PULL AND REVERSE EJECTION
ISSUE: 06-24-09
PAGE: 2 of 2
• All hydraulic circuits will be balanced as applicable. Compensators may be

required to balance the hydraulic circuit.
• Hydraulic lines should be incorporated into mold rails and plates when possible.
• External plumbing for all hydraulic components should be as close to parallel as
possible with the mold surface.
• All hydraulic lines must be contained within the plane created by the clamp
plates. Channels or chamfers/radii in mold base may be required to achieve.
• Fittings for hydraulic connections to molding press will be:

1. Male for core set and ejector retract (Molding Position)
2. Female for core pull and ejector forward (De-Mold Position)
• All hydraulic slides and cores must be locked mechanically in molding position.
• The stroke of each hydraulic cylinder must be controlled by one double pole
switch.
• Switches for multiple hydraulic cylinders must be wired in series.
• Proximity switches for hydraulic cylinder position control are not permissible.
• Threaded adjustment is required for all switch actuation cams.
• All cylinders will be equipped with Viton Seals.

• Mount a red sequencing plaque on operator side of mold. Location as directed
by SPI tooling engineer.
Revision Record
Rev. A – Added PF Series to part number for cylinder.
Rev. B – Added notes to Limit Switch.

Rev. C – Added Hubbell connectors and Parker fittings for 3rd and 4th core pulls.
Corrected the ejector retract and forward for which fitting to match plants.
Added Molding and De-Molding Positions.
Page 162 of 221

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SECTION 03.17 REV. LEVEL: E
REV. DATE: 08-01-19

MOLD IDENTIFICATION – EXTERNAL & INTERNAL
ISSUE: 06-24-09
PAGE: 1 of 2
Bill of Materials
Manufacturer
Dual-Ring Mold DME MD 20 20__*__ (20 mm insert) The blanks are
Dating Insert MD 16 20__*__ (16 mm insert) the years
MD 10 20__*__ (10 mm insert) required from
MD 08 20__*__ (8 mm insert) start of program
MD 06 20__*__ (6 mm insert) plus 6 years (ie
2020*2026)
External
• Tools will require outside identification and part identification. This cost is to
be quoted in the original tool build cost.
• Outside identification etched into mold base (no tags allowed) to include:
1. Top of mold
2. Mold weight
3. Shrink factor
4. Number of cavities
5. SPI tool number, 0.75” high on the top and operator side.
6. Part name (s)
7. Customer part number (s) [Not Summit Polymer part numbers]
8. Made in ____________ (Country of origin: i.e., USA, Canada,
Portugal, China, Germany, other)
9. Customer ID requirements (information below must be kept together)
 Property of (OEM)
 Asset Number (To be supplied by SPI)
 Part Description
10. Mold Supplier’s name
11. Mold Supplier’s Internal Job Number
Page 167 of 221

REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 2 of 2
• Photographs of the information in items 1-11 above are required to obtain FR

sign off. Reference Section 01.01, items 18 & 19 for photograph specifics.
• All water circuits will be numbered and designated “IN” or “OUT”.
(i.e., 1 - IN and 1 - OUT, 2 - IN and 2 - OUT, etc.).
• All tools with hot manifolds and tips will have a schematic plaque showing
details of wiring, number of zones, wattage/amps, and voltage rating. Plaque
to be mounted on the operator topside of mold.
• Tooling with mechanical or hydraulic action will have a process sequence
plaque mounted on the operator side of the mold.
Internal
• All slides, inserts, cavity blocks, and components will be stamped in a
recessed pad for: steel type, Rockwell hardness, and location number in the
mold.
• Ejector and core pins and their correlating holes will be numbered to clearly
identify location.
• All cavities will be properly identified for particular customer specifications.
This information and location will be provided by SPI Engineering. It may
include (but not limited to):
• Cavity number
• Material code
• Customer part number
• SPI identification: SPI, tool number, part number.
• Customer ID requirements
• Date wheel inserts
• All Cavity Sets (inserted tools) or Cavity Plates (cut in solid) must comply
with Customer ID requirements (i.e., Property of Ford, G.M., etc.)
• Recess an area on either cavity block or core block (where applicable) to
engrave the following: (Tool shop to engrave) [required prior to shipment of
tool]
• Texture callout or name (ie VDI24 or Finlay)
• Coating (ie Tribocoat, Dynablue etc)
Page 168 of 221

REV. DATE: 08-01-19

ISSUE: 06-24-09
PAGE: 3 of 2
Revision Record
Rev. A – revised 2nd bullet point adding additional countries.

Rev. B – revised 2nd bullet point removing Ford/GM from number 9 and added asset to
number 9.
Rev. C – revised 2nd bullet point adding “etched into mold base (no tags allowed), added
3rd bullet point regarding photographs and added under item 9 “information
below must be kept together” as well as the bullet points under item 9.
Rev. D – added [Not Summit Polymer part numbers] to External bullet point 2.
Rev. E – Added date wheel inserts. Added recess area for texture and coating on cavity
or core block.
Page 169 of 221

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REV. DATE: 08-01-19

FUNCTIONAL PRACTICES
ISSUE: 06-24-09
PAGE: 1 of 1
• Inserts are preferred for cavities with ‘critical’ areas.

• Vane pivot posts and the shut off door pivot posts must be inserted with H13 tool
steel, 44-48 Rc, or formed with an action.
• Cavity and / or core inserts to modify part geometry by forming a second part
number must be designed for mistake proofing so the inserts cannot be installed
90°, 180°, or 270° out of alignment.
• A complex shut-off will be designed with the maximum tapered angle available,
7° minimum without review and approval by the SPI Engineering. Knife edges
will not be approved.
• When a vertical shut-off is required, PCS or Progressive parting line die locks, or
equivalent, will be installed to lock in four directions, unless natural lock occurs.
• Any area needing weld must be identified to the SPI Tooling Engineer and
Project Engineer for approval prior to the weld process being performed. Use
Weld Sign Off Sheet (KBPD 04.04.06) to identify area(s) of weld and to receive
TE approval for stated weld. Failure by the Mold Supplier for welding without TE
approval will result in the Mold Supplier being charged for all repairs for life of
the tool. The welded area(s) on textured and/or class A surfaces must be color
matched as part of the welding application. Color matching is not to be left to
the texture source. The texture source must also be informed, preferably with
visual representation, of the welded location(s).
• Finished molds must be treated with rust preventative before closing for delivery.
• Purge water out of molds before shipping.
• Balancing of multiple cavity tool(s) must be done with runner segments only.
• Scribe lines must be engraved onto the back side of the part to aid in the quick
measuring of the part. For long, skinny parts, one set of scribe lines are required in
the direction of flow. For large parts, two sets of scribe lines are required. One in
the direction of flow and the other in the cross flow direction. The distance between
the scribe lines must also be engraved. This distance is from the outside edge to
outside edge of the scribe lines. The depth of the scribe lines must be the same
depth as the engraving on the part. [Need greater than size EM-6 inches] as
requested prior to OK to Cut approval
Page 170 of 221

REV. DATE: 08-01-19
FUNCTIONAL PRACTICES ISSUE: 06-24-09
PAGE: 2 of 2
• For all 2-shot tools where the 2nd shot is gated over the substrate, the substrate
must be cored out so the 2nd shot material is not directly injected onto the substrate.
(Reference 03.18.12).
• Tools over 500 T, the leader pins can be replaced by sufficiently dimensioned flat
guides. The flat guides are generally installed in the middle of the 4 sides of the tool.
The minimum hardness of these parts is 55 HRC.
• Used primarily for floating plates and deep draw/angled parts.
• For tools with mold inserts (cavity and core blocks), two sides of the pocket model
are to be equipped with a 3° angle. (Reference Section 03.18.13).
• In transfer molding, gas springs to press the molded part into place must be used.
(Reference Section 03.18.14).
• The parting line mismatch must be less than 0.0023” (0.058 mm) unless otherwise
specified in the OEM specific requirement section or the SPI Design Input Tool
Layout Sheet (KBPD 02.02.07).
Revision Record
Rev. A – No record of changes.
Rev. B – Changed bullet point 6 about welding on tools.
Rev. C – Added KBPD 04.08.02 for sign off of welding. Added balancing bullet point.
Added failure to weld without signature will result in charges for life of tool.
Rev. D – Added core out for 2nd shot on 2-shot tools.
Rev. E – Added scribe lines requirement, added flat guides, added 3 degree angle for
inserted cavity/core and added gas springs for transfer molding. Added parting
line mismatch requirement.
Page 171 of 221

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REV. DATE: 05-31-17

ROBOT INTERFACE
ISSUE: 12-18-09
PAGE: 1 of 1
• All tooling shall be quoted, designed, and built for robot extraction.
• All tooling shall be quoted, designed, and built with robot suction cup vacuum
flags. The SPI PDT may choose to waive the vacuum flags during the kick off
or design review events.
• Refer to Section 03.19.01 for End of Arm Tooling (EOAT) stack height
requirements.
• Refer to Section 03.19.02 for Vacuum Flag requirements.

• EOAT docking holes must be located inside the tie bars (side load tools) or
inside the leader pins (top load tools). EOAT docking holes should be opposite
each other (ie. horizontally, vertically or diagonally). The EOAT docking holes
are 0.500” dia. x 0.750” deep with a 0.060” chamfer. The operator side docking
hole must be elongated by 0.125” in plane with the non-operator side docking
hole. Refer to Section 03.19.04A through 03.19.04C.
Revision Record
Rev. A – Bullet point 2 removed ≥ 4 cavities after tooling.
Rev. B – Added EOAT docking holes bullet point.
Rev. C – Corrected EOAT docking holes locations and added references for
locations.
Page 186 of 221

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REV. DATE: 06-11-18

2-SHOT TOOL REQUIREMENTS
ISSUE: 12-19-14
PAGE: 1 of 2
GENERAL
• All molds built for 2-Shot Molding Machines will require standard location slots
on the A side clamp plate and locating rings on the B side clamp plate.
o Reference Section 03.05 for location slots for A side clamp plates.
o Reference 03.20.01 for locating rings on B side clamp plates.
• Locating ring (A Side) must be reversible 180° and be flush/sub-flush with the
clamp plate and be self-storing when not in use.
• Locating ring (A Side) must not allow a gap for material to occupy in either
orientation.
• Reference Section 03.10.01 for hot manifold / hot sprue electrical connection
location.
ENGEL
• Ejector safety plug to be mounted in standard location.

• Knock outs extensions need to be 4.875” long from back of clamp plate.
Reference Section 03.20.02A.
HAITIAN
• General mold base construction will be a common base meaning substrate and
over-mold do not have separate molds on common clamp plate.
• No water manifolds on the moving/rotating side of molds. A single supply and
return line with quick disconnect couplers must be routed to center line of mold
to manifold mounted on rotary platen. Reference Section 03.20.02B.
• Separate water circuits for substrate half of tool and over-mold half of tool.
• Ejector safety plug to be mounted on top of mold as close as possible to the
operator side of the tool. Ejector switches to be wired in series for each section
of the tool.
Page 195 of 221

REV. DATE: 06-11-18

2-SHOT TOOL REQUIREMENTS
ISSUE: 12-19-14
PAGE: 2 of 2
• Use the same set of electrical connectors for each side of the tool.
• All molds built for 250T Haitian 2-Shot Molding Machines will require the clamp
plates (both A & B side clamp plates) to have through holes to match the
outside bolt pattern on the platens. Reference 03.20.02B for bolt hole locations.
• Knock outs extensions need to be 80mm longer from back of clamp plate.
Reference Section 03.20.02B.
• An integrated knock out extension holder to be located on top of B side of mold.

• Water manifold connections on “A” side to be 90 degrees facing up for ease of
connection. Reference Section 03.20.02B.
• Water manifold block on top of “B” side to have ½” quick disconnects.
Reference Section 03.20.02C.
KRAUSS MAFFEI
• Ejector safety plug to be mounted in standard location.
• Location slots for A side clamp plate need to include locations referenced in
Section 03.20.01C to allow plant to run single shot tools.
• Knock outs extensions need to be 6.375” long from back of clamp plate.
Reference Section 03.20.02C.
• Water manifolds on A side to be standard configuration and fittings. The B side
water manifolds will be female facing up and male facing down. Reference
Section 03.20.02D.
• The 2nd shot sprue bushing to be flush with clamp plate. Diameter to be
determined by manifold design. Reference Section 03.20.01C for 2nd nozzle
location.
Revision Record
Rev. A – Added extension holder to top of B side of mold for Haitian and Krauss Maffei
tools. Added B side water manifold requirement and reference 03.20.02C.
Rev. B – Changed Haitian water A side to face up.
Rev. C – Added location slots for other sizes in KM for single shot tool runs on clamp
plate.
Rev. D – Removed water fittings call out under Krauss Maffei bullet point 4.
Page 196 of 221

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SECTION 03.21 REV. LEVEL: A
REV. DATE: 08-26-16

COATINGS
ISSUE: 03-07-14
PAGE: 1 of 1
• A placard or engraving on tool that states coating was done on tool.

• All Bin Mat and Cupholder Inserts/Liners run out of TPE, TPV, etc material must
be Tribocoated.
• All Class A Polypropylene panels are recommended to be Tribocoated. Refer to
the tool layout.
Revision Record
Rev. A – Added Tribocoat requirement for TPE, TPV, etc and recommendation for PP
panels
Page 206 of 221

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REV. DATE: 06-11-18

MOLD SHIPPING STANDARDS
ISSUE: 05-14-14
PAGE: 1 of 1
• Shipping from China to USA, China to Mexico or USA to China, the tools must be
crated.
o All molds must be contained within a wooden or steel structure and the
weight evenly distributed.
• The wood should be heat treated or fumigated and stamped with the appropriate
designation shown below.
• The bottom of the crate shall be constructed to allow for fork lift truck access on a
minimum of two sides, preferred four sides.
• The corners must be reinforced and able to withstand stacking of other molds.
• Molds must be supported / fastened / restrained within the container to prevent
any shifting or movement during transport.
• Molds must have a rust preventative applied to all surfaces of the mold including
ejector box components. Use either LPS 3 or PPE Spray MSL-216.
• Molds must be vacuum sealed.
Page 209 of 221

REV. DATE: 06-11-18

MOLD SHIPPING STANDARDS
ISSUE: 05-14-14
PAGE: 2 of 2
• When shipping from USA to Mexico, molds ≤ 3000 lbs must be strapped down
onto a plastic or wooden skid and shrink wrapped. Molds > 3000 lbs should not
be on a skid and must ship on a flat bed truck.
Revision Record
Rev. A – Added shipping requirements for China to USA, USA to China and USA/China
to Mexico. Added how to ship based off of weight.
Page 210 of 221

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REV. DATE: 08-01-19

GRAIN / TEXTURE
ISSUE: 05-31-17
PAGE: 1 of 1
• Area(s) requiring grain must be accessible. Insert area(s) as needed.

• EDM grain must match VDI plaque.
• For all cavity seal off conditions, the use of scribe lines or steel surface files
(IGES or stp) are required.
• Scribe line location must match the marked up part from the customer.
Recommend 0.020” from parting line if there is no marked up part from the
customer or the texture area is undefined.
• In the instance(s) when the texture area is completely defined (parting line, step
or radius), a scribe line is not needed.
• The draft angle on the part must match the grain call out draft requirement. In
case(s) where it doesn’t match the draft angle, and with customer approval,
washing out of the grain may be needed.
• Any area needing weld must be identified to the SPI Tooling Engineer and
Project Engineer for approval prior to the weld process being performed. Use
Weld Sign Off Sheet (KBPD 04.04.06) to identify area(s) of weld and to receive
TE approval for stated weld. Failure by the Mold Supplier for welding without TE
approval will result in the Mold Supplier being charged for all repairs for life of the
tool. The welded area(s) on textured and/or class A surfaces must be color
matched as part of the welding application. Color matching is not to be left to the
texture source. The texture source must also be informed, preferably with visual
representation, of the welded location(s).
• The graining of the core side (B-side) of the tool may be needed for anti-squeak,
help release the part from the cavity side (A-side) of the tool or change the flow
of the plastic.
o T 1711, MT 11100 or MT 11040 grains for anti-squeak from Standex
Engraving
Revision Record
Rev. A – Updated Tenibac and Mold Tech anti-squeak grains into Standex Engraving
Page 211 of 221

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SECTION 03.24 REV. LEVEL: Release
REV. DATE: 05-31-17

GAS ASSIST
ISSUE: 05-31-17
PAGE: 1 of 2

Manufacturer
Plug Staubli RBE06.6251/HPG/3 – (RED) Tool
RBE06.6251/HPG/45 – (GREEN) Components
RBE06.6251/HPG/6 – (BLUE)
RBE06.6251/HPG/9 – (BLACK)
Dust Caps For Staubli RBE06.8550/BC
Plugs
Socket Staubli RBE06.1201/IA/3/VD/HPG/JV/PP – Gas Unit
(RED) Components
RBE06.1201/IA/45/VD/HPG/JV/PP –
(GREEN)
(BLUE)
(BLACK)
Gas Pin Maximator-AIM FN10/7 10MM High
Assembly Pressure
Assembly

Staubli Corporation Customer Service, tel: 864.486.5455
email: customerservice.connectusa@staubli.com
Maximator-AIM, tel: 734.449.8301
email: sales@maximator-aim.com
• All gas assist fittings must be on operator side of the tool.

• The gas pin must have a copper washer between pin assembly and cavity block
to make a good seal.
• The gas inlet pipe must be a straight thread. A copper washer must be between
the inlet pipe and cavity block to make a good seal.
Page 212 of 221

REV. DATE: 05-31-17

GAS ASSIST
ISSUE: 05-31-17
PAGE: 2 of 2
• Each fitting location will be labeled and color coded for each cavity.
Same Cavities In Tool Different Cavities In Tool Color Code
Cavity 1 RH RED
Cavity 2 LH GREEN
Cavity 3 RH BLUE
Cavity 4 LH BLACK
Revision Record
Page 213 of 221

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REV. DATE: 08-01-19

IN MOLD DECORATING (IMD)
ISSUE: 06-11-18
PAGE: 1 of 1
Bill Of Materials
Manufacturer
3/8” Push-Lock SMC or KQ2H11-02AS (Straight) ¼” NPT -
Air Fitting equivalent KQ2L11-02AS (90 degree elbow) Vacuum
Attachment
• Tools must be gated into split pins.
• Cavity surface to be a mirror finish (SPI A2).
• Vacuum attachment on the moving side of the tool.
• All IMD tools must have “A” side ejection using a core pull.
• Clamp frame to secure the film must be on the “B” side of the tool. The clamp
frame will be activated with the standard ejection of the press. The clamp frame
must move enough to allow the film to index.
• The cavity insert must have an “O” ring to ensure vacuum is sealed.
• The ejector pins and lifter rods must be coated with C-DLC (diamond-like
carbon).
• There will be NO grease used in the tool.
• All ejector pins and inserts which are used for ejection must be provided with a
coating to improve adhesive wear of the sliding components.
Revision History
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REV. DATE: 06-11-18

OEM SPECIFIC REQUIREMENTS
ISSUE: 06-11-18
PAGE: 1 of 3
Bill Of Materials
Manufacturer
CVe Monitor Progressive CVE-O-SUMMIT-xxxxx xxxxx – SPI Tool Number
USB Cable Progressive CVE-USB-6 6 ft long or 15 ft long USB

CVE-USB-15 2.0 to Type B Cable –
Purchased for download
capability only
• All Ford and FCA molds must have a CVe monitor attached to the mold. All other
OEM’s as specified by SPI Tooling Engineer.
• For all applications where the tool will run ≥ 190° F, insulator board must be used to
protect the monitor on all sides interfacing with the tool.
FCA Specific Requirements
• Safety straps must be painted yellow and stamped with the tool number.
• When using porcerax inserts, 2 inserts must be manufactured per insert location.
• Distance between return pins must not exceed 24”.
• All water lines must be checked for water flow. Water flow must be ≥3.5 gpm for
each water line or approved by SPI if ≤3.5 gpm.
• When using hydraulic cylinders on top of mold, a drain slot must be machined to
keep oil from getting into parting line.
• All single round rod lifters must have a flat on one side and a plate inserted into
the back of the core block for anti-rotation.
• External lubrication fittings must be used for all sliding components, except
ejector pins and lifter rod bushings. Grease fittings must be designed and
mounted sub-flush condition. Each fitting must supply lubricant to a single
location only.
• Grease grooves must be cut into components such as slide & lifter gibs and slide
& lifter wear plates.
Page 215 of 221

REV. DATE: 06-11-18

ISSUE: 06-11-18
PAGE: 2 of 3
FORD Specific Requirements
• Safety strap must be painted red or yellow, with preference being yellow.
• Each sub runner shall be stamped with cavity identification.
• Ejector stroke must be ½” longer than part height.
• Water lines must be lettered on the core and numbered on the cavity.
• Each and every water line will be checked for water flow.
• Each cavity of the mold shall have a date stamp that includes year, month and
day (if space available).
• Hot runner connector box recessed or protected by stand offs.
• Recessed plaque on both halves of the tool. Reference Section 03.26.01.
• Limit switches must have color coded covers. Green – Ejector Return/Core Pull.
Red – Ejector Forward/Core Set.
• Lifting holes for center of gravity for each half of the tool as well as lifting hole for
center of gravity for complete tool.
• 4 hoist rings to be supplied with tool.
GM Specific Requirements
• Safety strap must be painted red or yellow.

• Tools over 48” in overall length must have 6 return pins at a minimum.
• When using porcerax inserts, 2 inserts must be manufactured per insert location.
• All molds must have a mold cycle counter. Use CVe monitor.
• All buried slides (slides that cannot be greased) must use graphite impregnated
wear surfaces.
• One set of scribe lines for measuring shrinkage must be included in the tool
design on the largest flat vertical and horizontal sections of the part. Scribe lines
must not exceed 0.004” in depth.
• General tool identification tag plates are required to be installed on the tool
preferably on the operator side of the tool. Reference 03.26.02.
• All tools must have mold locks on all 4 directions.
• Spare thermocouples must be included for each zone of the hot runner system.
• A thermocouple must not control more than one zone on a hot runner system.
More than one heater can be controlled by a single zone as long as wired in
parallel.
Page 216 of 221

REV. DATE: 06-11-18

ISSUE: 06-11-18
PAGE: 3 of 3
• A tool over 48” in length must have eight additional machined seal off surfaces (4
leader pin corners and four center lines).
• For lifter angles >15°, guide rods may be used to prevent lifter bending. The
guide rods should be mounted to lifter body and anchored to the bottom of the
core block and clamp plate.
• Lifter pockets must be 3° larger than the lifter angle on all non-molding surfaces.
• Must have a baffle directly opposite any direct hot drop.
• For tools >500 T and using hydraulic ejections, 4 hydraulic cylinders must be
used (2 top and 2 bottom) to actuate ejection.
Revision History
Page 217 of 221

Page 218 of 221
Page 219 of 221
P
I
REV. DATE: 08-01-19

APPLIQUE SPECIFIC REQUIREMENTS
ISSUE: 08-01-19
PAGE: 1 of 1
• All applique parts must be gated from the back of the part to prevent blow-by on
the surface of the part.
• Gates should flow into the part at a 90° angle to prevent stretching in the local
area of the gate.
• The preferred method for gating is a sleeved split pin subgate.
• On parts where the applique does not cover the entire part, the plastic must
always flow from the appliqued surface to the non-appliqued surface to prevent
blow-by.
• If a part requires the applique to cross over parting line, vent pins or other means
of venting must be used.
• In order to properly hold and locate the applique in the cavity, the part/mold must
have at least a 3 mm ledge to rest the applique. Reference 03.27.01. When this
is not possible, there must be enough depth in the parts other features to
properly locate or locating tabs must be utilized to hold the applique in the mold.
• Ditching around backside features to prevent sink do not typically work with
applique parts.
• The cavity requires an A3 polished finish for applique tools.
• Cavity steel is to be made from HH-P20. Core steel is to be made of HH-P20.

The cavities must be inserted.
• Runner pins are required to be at a minimum of 5/16” even if runner is smaller

because of the pack pressure needed to pack out sink.
Revision History
Page 220 of 221

P
I
REV. DATE: 08-01-19

HIGH GLOSS PAINTED PART SPECIFIC
REQUIREMENTS ISSUE: 08-01-19
PAGE: 1 of 1
• The preferred method for gating is onto a “B” side feature or a sleeved split pin
subgate. Cashew gates are not allowed directly onto “A” surface.
• All high gloss painted tools should be valve gated if multiple gates per part.
• All “B” side features should be ditched to prevent sink.
• The cavity requires an A3 polished finish for high gloss painted parts.
• The parting line mismatch must be less than 0.0023” (0.058 mm) unless
otherwise specified in the OEM specific requirement section or the SPI Design
Input Tool Layout Sheet (KBPD 02.02.07).
• Periphery of the parting line must be vented at uniform intervals. Vents up to 0.5”
wide, 0.060”-0.080” land area relieved for resin selected; then relieved 0.020” to
atmosphere. Additional venting may be required at the end of fill based on the
validation sample results and knit line locations.
Revision History
Page 221 of 221

Injection Mold Tooling Standards Manual2019

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Injection Mold Tooling Standards Manual2019

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Summit Polymers, Inc.

INJECTION MOLD TOOLING

Revised: August 1, 2019

REV. DATE: 05-31-17

REV. DATE: 05-31-17

9) The Mold Supplier’s mold designs are expected to be as compact as

10) Mold Timing Expectations:

REV. DATE: 05-31-17

REV. DATE: 05-31-17

o Submit an electronic version of the Final Design to the Summit

21) Domestic Suppliers: To receive payments:

REV. DATE: 05-31-17

 Bill Of Material showing all items of mold (excel format)

 2D Data (current design / revision level) [high res. pdf, dwg or

REV. DATE: 05-31-17

25) Mold Supplier Executive Management is required to submit prompt

REV. DATE: 05-31-17

2.25 = 6x28 or larger

2.25 = 6x28 or larger

2.25 = 6x28 or larger

5715 1000 51.96 24.64

Ejector Pattern Open Clamp

REV. DATE: 08-01-19

DATA TRANSFER CAPABILITIES

 UNIX and WINDOWS

Engineering and Estimating Software

Product Development and Design Software

Methods for Data Exchange Used

REV. DATE: 08-01-19

DATA TRANSFER CAPABLITIES FOR INCOMING DATA

 UNIX and WINDOWS

Engineering and Estimating Software

Methods for Data Exchange Used

 Only data for one (1) program/program# per zip file.

REV. DATE: 08-01-19

DATA TRANSFER TECH AT SUMMIT POLYMERS INC.

Naomi Chavez (Ext. 50424)

Rev. A – No record of changes.

LIST OF DRAWINGS / TABLES

Document Title Rev. Level/Date

REV. DATE: 08-26-16

Mold Component Bill of Materials

REV. DATE: 08-26-16

REV. DATE: 08-26-16

• Mold Design Bill of Materials to include:

• Mating parts must be dissimilar materials and hardness.

Rev. A – No record of changes

REV. DATE: 08-01-19

REV. DATE: 08-01-19

REV. DATE: 08-01-19

REV. DATE: 08-01-19

REV. DATE: 08-01-19

Air Timer MSC 04086864 10-60 sec

Aluminum Manifold McMaster Carr 5469K101 1/4" NPT Inlet X

Rev. A – Changed grammar of sentence below BOM.

REV. DATE: 08-01-19

Cable RJG Inc. CE-LX5-1M One (1) required per transducer

REV. DATE: 08-01-19

• Transducer slot and actuator pin tolerances/clearances must be to SPI standards.

Rev. A – Resurrected section.

REV. DATE: 08-01-19

SPI Mold Clamp Plate - China

120 Haitian 410 x 410 70 634 x 635 620 x 400 x 34.925*

85 16 x 13.6 2.375 22.8 x 20.4 20 x 13.5 x 1.375*