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Dangel
Injection Moulds for Beginners
Rainer Dangel
Injection Moulds
for Beginners
Hanser Publishers, Munich Hanser Publications, Cincinnati

The Author:
Rainer Dangel, 73266 Bissingen/Teck, Germany, rainer@dangel.de
Distributed in the Americas by:

Hanser Publications
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Distributed in all other countries by:

Carl Hanser Verlag
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Fax: +49 (89) 98 48 09
www.hanser-fachbuch.de
The use of general descriptive names, trademarks, etc., in this publication, even if the former are not especially
identified, is not to be taken as a sign that such names, as understood by the Trade Marks and Merchandise Marks
Act, may accordingly be used freely by anyone. While the advice and information in this book are believed to be true
and accurate at the date of going to press, neither the authors nor the editors nor the publisher can accept any legal
responsibility for any errors or omissions that may be made. The publisher makes no warranty, express or implied,
with respect to the material contained herein.
The final determination of the suitability of any information for the use contemplated for a given application
remains the sole responsibility of the user.
Cataloging-in-Publication Data is on file with the Library of Congress
All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic
or mechanical, including photocopying or by any information storage and retrieval system, without permission in
writing from the publisher.
© Carl Hanser Verlag, Munich 2016

Editor: Mark Smith
Translation: Kristin Bylund Thurnher, Meusburger Georg GmbH & Co KG
First proofreader: Birgit Lins, Abteilungsleiterin Übersetzungsmanagement, Meusburger Georg GmbH & Co KG
Production Management: Jörg Strohbach
Coverconcept: Marc Müller-Bremer, www.rebranding.de, München
Coverdesign: Stephan Rönigk
Typesetting: Kösel Media GmbH, Krugzell
Printed and bound by Hubert & Co GmbH, Göttingen
Printed in Germany
ISBN: 978-1-56990-631-6
E-Book ISBN: 978-1-56990-632-3
Foreword
German die and mould making is a brand with global significance. The reasons for
this are diverse, but the industry’s secrets to success can certainly be attributed to
smart design with a great deal of know-how, top performance production engineer-
ing and quality related criteria. One major aim of this book is to disseminate this
philosophy to a wider, English-speaking readership.
Rapid implementation of innovations through close information exchange between
all parties is planned for the future. Injection moulds today already play a key role
in modern production engineering in the manufacturing industry. Visions of the
future such as the “smart factory” in the context of injection moulding now offer
the chance to raise the energy and resource efficiency of the production process to
a new level with intelligent management and network flexibility. But the basis for
this is a solid knowledge of the basics of engineering and manufacturing processes
in mould making. The above-mentioned topics can only be implemented based on
this knowledge and wealth of experience. And this is exactly where this technical
book from Rainer Dangel comes in. What is required for bringing a product into
shape?
In the book the author didactically as well as technically breaks new ground in the
field of technical literature for injection mould making. In a very clear way, he com-
bines theory with practice, always focussing on the following questions: “What is
this product relevant for? What needs to be solved technically for which product
specifications?” And, regarding the method of the manufacturing implementation:
“How and with what can I fulfil the product requirement within the scope of
the design and also the manufacturing process?” Through Mr. Dangel’s technical
expertise which he established and developed over many years, it quickly becomes
clear when studying the book that the practical implementation of the described
has great significance. Basic knowledge and solutions are holistically considered.
Advantages and disadvantages are presented and discussed. The wealth of 35 years
of experience, beginning with training as a tool maker to the master craftsman’s
diploma then to owning a private company flows through this technical book.
VI Foreword
“Injection Moulds for Beginners”, the title of this book, hits the bull’s eye and old
hands who think it is no challenge to them might be taught a lesson!
Prof. Dr.-Ing. Thomas Seul

Vice rector for Research and Transfer at the Schmalkalden University of Applied
Sciences and President of the Association of German Tool and Mold Makers (VDWF).
The Author
(Source: wortundform GmbH, Munich)
Rainer Dangel began his professional career in mould making with training as a
tool maker from 1976 to 1980. As a young skilled worker, he already realised the
possibilities of making a difference in this emerging technical profession. He laid
VIII The Author
the foundations for his career with the master craftsman’s diploma in mechanics at
the age of 23.
He segued into self employment in 1987. He began with a small CNC milling shop
for mould making components which within a few years developed into a modern,
technically high-quality specialist company for manufacturing injection moulds for
various requirements. He had already introduced and was using the first 3-D CAD
CAM system successfully in 1995.
All manufacturing options of modern mould making could now be offered. Rainer
Dangel made it his duty to actively continue to develop and perfect the manufac-
turing processes. In 2006, the company built their own injection mould making
shop in order to expand the process chain and be able to supply finished plastic
components. Through the certification in accordance with DIN EN ISO 9001:2008
in 2008, his company was able to supply a variety of industries. Among other
things plastic parts for the automotive industry could be VDA tested and approved
(VDA = Association of German Automobile Manufacturers, see https://www.vda.
de/en).
In the generally difficult economic year of 2009, the mould making company was
closed. After that, Rainer Dangel was the head of the technology centre at the
Heller brothers machining company in Nürtingen, where he was responsible for
the support of the customers in the area of die and mould making.
Now back in the mould making arena, Rainer Dangel is currently active in two
main branches: Firstly, project management for injection moulds, from part design
via tool design all the way to start of production. Included in this are the procure-
ment and support of injection moulds externally. The second branch is the educa-
tion and training of young people on the topic of injection moulds generally, but
especially in the considerably demanding area of milling in mould making.
Acknowledgement
I would like to express a heartfelt thank you to my colleagues at the Association of

German Tool and Mold Makers (VDFW) for the support during the development of
this book. Special thanks to Prof. Dr.-Ing. Thomas Seul, President of VDWF, for the
foreword.
Formenbau Schweiger GmbH & Co. KG, Uffing am Staffelsee, Germany, Anton
Schweiger (Vice President)
Formenbau Rapp GmbH, Löchgau, Germany, Markus Bay (Director of Training)
VDWF, Schwendi, Germany, Ralf Dürrwächter (Marketing)
bkl-Lasertechnik, Rödental, Germany, Bernd Klötzer
Cimatron GmbH, Ettlingen, Germany, Dirk Dombert
exeron GmbH, Oberndorf, Germany, Udo Baur
Gebr. Heller Maschinenfabrik GmbH, Nürtingen, Germany, Marcus Kurringer,
Jörg Bauknecht
GF Machining Solutions GmbH, Schorndorf, Germany, Gabriele Urhahn
Hans Knecht GmbH, Reutlingen, Germany, Hans Knecht
MAKINO Europe GmbH, Kirchheim-Teck, Germany, Andreas Walbert
Meusburger Georg GmbH & Co KG, Wolfurt, Austria, Andreas Sutter
PSG Plastic Service GmbH, Mannheim, Germany, Andreas Kißler
Reichle GmbH, Gravier- und Laserschweißzentrum, Bissingen, Germany, Volker
Reichle, Marco Reichle
Werz Vakuum-Wärmebehandlung GmbH, Gammertingen-Harthausen, Germany,
Henry Werz
wortundform GmbH, Munich, Fabian Diehr
X Acknowledgement
The following are not association members, but were also on hand to help me. For
this a heartfelt thank you to:
Friedrich Heibel GmbH Formplast, Heuchlingen, Stefan Heibel
Carl Hanser Publishers, Munich, Ulrike Wittmann, Jörg Strohbach
Finally, I would like to thank the Translation Management department at Meus-
burger Georg GmbH & Co. KG, Wolfurt, Austria, in particular Kristin Bylund
Thurnher and Birgit Lins, for their expert translation of my German text into
English. Achieving a high-quality translation of a specialist technical book is no
trivial task, and for this the professional support of Meusburger is most warmly
acknowledged.
Contents
Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
The Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII
Acknowledgement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IX
How to Use This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVII
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 Mould Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1 Simple Open/Close Mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.1.1 Classic Structure of an Open/Close Mould . . . . . . . . . . . . . . . . . . . 6
2.1.2 Guiding Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.3 Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Moulds with Moving Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.1 Undercut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.2 Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.2.3 Slide Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.2.4 Latch, Clip Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2.5 Inclined Ejector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2.6 Forced Demoulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.2.7 Mould Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.3 Mould for Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.3.1 External Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.3.2 Internal Threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
2.3.3 Drive Types for De-spindling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3.3.1 Hydraulic Unscrewing Unit . . . . . . . . . . . . . . . . . . . . . . . . 23
2.3.3.2 Gear Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.3.3.3 High-Helix Lead Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.3.3.4 Multi-cavity Moulds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
XII Contents
2.4 Multi-component Injection Moulds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.4.1 Material Pairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.4.2 Mould Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.2.1 Shifting Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4.2.2 Rotary Table Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.4.2.3 Sealing Slide Technology . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.4.2.4 Further Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.5 Stack Mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
2.5.1 Material Combinations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5.2 Hot Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.5.3 Opening and Closing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.5.4 Toggle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.5.5 Ejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
2.5.6 General Information on the Stack Mould . . . . . . . . . . . . . . . . . . . . 41
2.6 Further Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.1 CAD System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
3.2 Data Transfer, Procedure, and Processing . . . . . . . . . . . . . . . . . . . . . . . . . 44
3.2.1 Data Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2.2 Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2.2.1 IGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.2.2.2 STEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2.2.3 STL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.2.3 Data Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.4 Shrinkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.4.1 Material Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3.2.4.2 Shrinkage (Physical Process) . . . . . . . . . . . . . . . . . . . . . . . 49
3.2.4.3 Influencing Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
3.2.5 Calculation and Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.2.5.1 Free Shrinkage, Constrained Shrinkage . . . . . . . . . . . . . . 53
3.2.5.2 Warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
3.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.1 Location of the Component inside the Injection Mould . . . . . . . . 59
3.3.1.1 Demoulding Direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
3.3.2 Number of Cavities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.3.3 Arrangement of Cavities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
3.4 Material Selection for Injection Moulds . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
3.5 Mould Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Contents XIII
3.6 Plate Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

3.7 Demoulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.7.1 Basic Principle of Demoulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.7.2 Draft Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.7.2.1 Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
3.7.2.2 Effect on the Opening of the Mould . . . . . . . . . . . . . . . . . . 80
3.7.2.3 Draft Angle in the Split Line Face . . . . . . . . . . . . . . . . . . . 81
3.7.2.4 Demoulding Problems and Solutions . . . . . . . . . . . . . . . . . 83
3.8 Split Line Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.8.1 Plain Split Line Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
3.8.2 Contour-Forming Split Line Face . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.8.3 Jumping Split Line Face . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.8.4 Wear Plates in the Split . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.8.5 Visible Split Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.9 Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.9.1 Injection and Feed Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.9.2 Simulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.9.3 Sprue System, Sprue Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.9.3.1 Cold Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3.9.3.2 Hot Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
3.9.4 Runner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.9.5 Sprue on the Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.9.6 Tunnel Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
3.9.7 Film Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3.9.8 Diaphragm Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.9.9 Hot Runner Single Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.9.10 Hot Runner Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
3.9.11 Hot Runner Distribution System with Needle Valve . . . . . . . . . . . 118
3.9.11.1 Integral Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.9.12 Three-Plate Mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.9.13 Tunnel Gate Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.10 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
3.10.1 General Information about Ventilation . . . . . . . . . . . . . . . . . . . . . . 127
3.10.2 Ventilation via Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.10.3 Geometric Design of Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
XIV Contents
4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.1 Mould Inserts/Mould Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.1.1 Mould Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
4.1.2 Mould Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.2 Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.2.1 Application Areas of Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
4.2.2 Design of a Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
4.2.2.1 Mould Contour . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.2.2.2 Split Line on Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
4.2.2.3 Slide Body and Guiding . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4.2.2.4 Operation of Slides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
4.2.2.5 Locking in the End Position . . . . . . . . . . . . . . . . . . . . . . . . 157
4.2.2.6 Cooling in Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.2.3 Further Slide Concepts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4.2.3.1 Slide in Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.2.3.2 “Backpack” Slide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.3 Ejectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
4.3.1 Types of Ejectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.3.2 Ejectors as Auxiliary Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
4.3.3 Inclined Ejectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
4.3.4 Stripper Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
4.3.5 Two-Stage Ejectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
4.3.6 Collapsible Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
4.3.7 Forced Demoulding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.4 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
4.4.1 Cooling Type and Auxiliary Equipment . . . . . . . . . . . . . . . . . . . . . 186
4.4.1.1 Drilled Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
4.4.1.2 Redirection of Cooling Circuits . . . . . . . . . . . . . . . . . . . . . 190
4.4.1.3 Copper Cores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.4.1.4 Heating Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.4.1.5 Connection of circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.4.2 Connection and Sealing of Cooling Holes . . . . . . . . . . . . . . . . . . . . 198
4.5 Components and Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
4.6 Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
4.6.1 Rough Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.6.2 EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
4.6.3 Graining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
4.6.4 Laser Texturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
4.6.5 Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Contents XV
4.7 Systematic Design Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

4.7.1 Strategy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.7.2 Standard Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
4.7.3 Manufactured Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.1 Systematic Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
5.2 Spotting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
5.3 Connection of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
5.4 Check the Cooling for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
6 Further Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

6.1 Process Chain in Mould Making . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
6.2 Quality Assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
6.3 Fits and Play in the Mould: What Must Fit? . . . . . . . . . . . . . . . . . . . . . . . 235
6.4 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
6.4.1 Annealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
6.4.2 Hardening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241
6.4.3 Nitriding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
6.5 Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
6.6 Changes: What Is to Be Considered? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
7 The Finished Mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

7.1 Mould Validation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
7.1.1 Clamping and Connecting the Media . . . . . . . . . . . . . . . . . . . . . . . 249
7.1.2 Filling of the Mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
7.1.2.1 Balancing Cavities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254
7.1.2.2 Optimising the Parameters . . . . . . . . . . . . . . . . . . . . . . . . . 256
7.1.2.3 Influence on the Injection Process . . . . . . . . . . . . . . . . . . . 257
7.1.3 Parameters during Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
7.1.4 Forces Acting in the Mould during the Injection Process . . . . . . . 258
7.1.5 Initial Sample Inspection Report . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
7.2 Labels on the Mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
XVI Contents
8 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

8.1 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
8.2 Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
8.2.1 Tungsten Inert Gas Welding (TIG) . . . . . . . . . . . . . . . . . . . . . . . . . . 264
8.2.2 Laser Beam Welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
8.3 Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
9 Manufacturing Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

9.1 Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
9.1.1 3-Axis Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
9.1.2 4- and 5-Axis Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
9.1.2.1 4-Axis Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
9.1.2.2 5-Axis Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
9.1.2.3 3+2-Axis Milling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
9.1.2.4 Simultaneous 5-Axis Milling . . . . . . . . . . . . . . . . . . . . . . . 276
9.1.3 CAM Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
9.2 EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
9.2.1 Sinker EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
9.2.2 Wire EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
9.3 Grinding/Profile Grinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
9.4 Drilling/Deep Hole Drilling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287
9.5 Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
9.6 New Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
9.6.1 LaserCUSING®/Laser Sintering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
9.6.2 Vacuum Soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
9.7 Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
10 Practical Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

10.1 Design Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
10.2 Design Colour Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
10.3 Sequential Function Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
10.4 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
10.5 Formulas and Calculations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
How to Use This Book
In this book the planning, designing, and construction of injection moulds is

explained and described. It deals exclusively with injection moulds for thermo
plastics processing.
To simplify matters, the term “injection mould” is also referred to as mould, but
has the same meaning. The term mould established itself in the specialist world
and is predominantly used there. Note also that the spelling “mold” is used in U. S.
English, but again the meaning is the same.
Everything is explained and described concretely and understandably. A plastic
container with a cover is the basis for almost all explanations. The drawings and
designs of both of these plastic parts were especially made for this book. The
dimensions of the designed moulds and the technical details are real, so the injec-
tion moulds can be actually built. On the basis of both or one of these parts, as
much as possible is shown and explained.
There are sample calculations for the planning and dimensioning of injection
moulds. Different functions and elements relevant for the design are explained in
detail. With the increasing demands on technology in the mould, the two parts
become ever more complex so there is always a reference to the previous topics. If
the part and/or the mould becomes more complex, the reason for it is therefore
comprehensible.
Figure 1 Container with cover

XVIII How to Use This Book
Figure 2 Container
Figure 3 Cover
There are further chapters in which the existing designs of actually manufactured
injection moulds are the basis for the explanations.
1 Introduction
“Where do all these plastic parts actually come from? Who makes them and how
are these plastic components even manufactured?” These are questions that hardly
anyone asks. “What are those little curls on or in the plastic part, what are they
for? Then there is a small spot that looks as if something was cut or torn.” These
are all characteristics that are visible on each part and arise in the manufacturing
of plastic parts. For this manufacturing technique, besides an injection moulding
machine and plastic granulates, an injection mould is needed.
Review your day and think about how many plastic parts you held in your hand,
and then you can imagine that firstly there is an incredible number of injection
moulds and secondly the diversity of injection moulds there must be in a variety of
industries, applications, or life situations.
For each plastic part which is manufactured there is the corresponding

injection mould. There are at least as many injection moulds as different
plastic parts, worldwide. Nevertheless every injection mould is unique
and there is an unimaginable number which increases every day.

Or to put it in a different way, imagine yourself in the kitchen, bathroom, office, or

sitting in the car. Now imagine all of the plastic parts gone. What remains? Not
much is left that is not made of plastic.
In concrete terms: Let’s start early in the morning. Before even getting up you
hit the alarm button. You already have had the first contact with a plastic part. It
continues when you brush your teeth. Today’s toothbrushes are, although this is not
easily recognisable, manufactured with very complex and complicated injection
moulds. The conventional toothbrushes with automatically inserted brushes are the
simpler version. However, for manufacturing an electrical toothbrush, two different
plastics are injected one after another in the injection mould in a very complicated
procedure in order to make the rotating brushes in the small brush enclosure.
Hair dryers, coffee machines, tea kettles, refrigerators, stoves, and ovens are just
a few consumer goods used in daily life. Opening the door of your car, you again
2 1 Introduction
have contact with plastic parts. Without injection moulds, the interior of a car is
unimaginable. Seats, steering wheel, switches, buttons, handles, levers, blinds,
instruments, covering, trays and so on, a countless number of injection moulds are
used for the manufacturing of a vehicle.
Plastics surround us in the immediate vicinity of our workplace, whether it is in
the workshop, in the office or in school. It doesn’t matter what you hold in your
hand or use, again it’s plastic parts. A computer, a keyboard, whether it is on the
machine or on the desk. Everywhere there are things made of plastic, in different
colours, contours, shapes, and degrees of hardness—from hard and stable printer
housings to the soft and flexible protective covers for the mobile phone.
Last but not least, a child’s room! Almost all children’s toy boxes are full of toys
made from plastic: toy blocks, board game figurines, racetracks, puppets, game
consoles, etc. Plastic parts, no matter what we do or where we are, accompany us
the whole day. Plastic parts are everywhere, and without them a normal life would
be inconceivable.
The list goes on and on. Everyone goes through their day, consciously or uncon-
sciously in contact with plastic parts, but no one thinks about their origin, even
though there is a huge worldwide industry behind them. Not only are there manu-
facturers of injection moulds all over the world but also large corporations that
manufacture the machines for the production of the plastic parts and very large
chemical companies that constantly develop and produce new plastics for different
applications. Millions of people are at home in this inconspicuous world.
Through the constant development of ever improving high-quality plastics the
application possibilities continue to increase. Sheet metal parts made of steel or
aluminium are gradually replaced by plastic parts. Brackets made of metal used for
fixing cables, fuel lines, containers, or the like in a car’s engine compartment are
replaced today by high-strength plastic parts.
Further evidence that this development will certainly continue is the progress in
the production of bioplastics. To put it simply, for bioplastics, the petroleum used
normally as raw material is replaced by biologically derived material. These oils
are extracted from renewable raw materials and are also biodegradable. So far
there have only been a few applications that were often only explored by scientific
facilities. The whole thing is still in the stages of development. However, if only
from the sustainability point of view, bioplastic is predicted to have a bright and
important future.
The most significant advantage of plastic parts is that after manufacturing or the
injection process a ready-to-use piece comes out of the injection moulding machine.
The manufacturing time for such a component is only a few seconds. This also has
an impact on the much lower cost per piece. But now we come back to the contents
of this book—the success of this whole process depends on a high-quality injection
mould.
2 Mould Types
2.1 Simple Open/Close Mould

The open/close mould got its name from its easy movement and function when the
injection mould for machining of the plastic parts is clamped onto an injection
moulding machine. The injection mould or the injection moulding machine opens
and closes without any further necessary movement taking place in the injection
mould.
The entire motion sequence is called an injection cycle or just cycle. It begins with
a closing of the injection mould. When it is closed, a liquid, hot plastic mass is
injected into the injection mould under pressure. Now a certain amount of time
must pass before the liquid plastic has cooled and solidified and the plastic part in
the injection mould reaches a certain stability. The injection mould opens and the
finished, still-warm plastic parts are ejected from the injection mould. When all of
the movements are finished, the process starts again. For the outside observer, the
machine opens and closes again and again.
The direction in which the injection mould or the injection moulding machine
opens and closes is called the main demoulding direction. All movements of
the injection moulding machine, the injection moulds and the moving parts in the
injection mould run in this axial direction. Depending on the component there can
be additional demoulding directions. This is described in Section 2.2.
The open/close mould is the simplest of all injection moulds. As a result it is often
the cheapest. Already in the planning and designing of plastic parts, efforts are
made so that the plastic piece can be produced with this type of injection mould.
Figure 2.1 shows the demoulding direction of a simple open/close mould. Both
upper part (fixed half) and lower part (moving half) open and close in an axial
direction. The plastic part has been designed for being produced with this specific
mould in such a way that when opening the mould on the injection moulding
machine it is not damaged or destroyed.
4 2 Mould Types
upper part
(fixed half)
demoulding direction
of an
open/close mould
lower part
(moving half)
Figure 2.1 Demoulding direction
The plastic parts which are to be produced with such an injection mould have no
structural elements which deviate from the main demoulding direction. Cup-
shaped or flat parts, for example, are manufactured with this type of mould.
A plastic part can have elements such as side openings, latches and clips, later-
ally protruding edges or pipes. For the demoulding of these elements, moving
components—called slides or inserts—are designed for the mould. In a secondary
demoulding direction, these elements called undercuts can be removed from the
mould without damage. More on this in Section 2.2.
The previously mentioned “expanding” parts container and cover is shown in Fig-
ure 2.2 to illustrate how such plastic parts produced in an open/close mould can
look.
Here already is the first addition to container and cover. To connect the two and be
able to close the container, a sleeve is introduced in every corner of the container
and, aligning to the sleeve, a stepped bore is introduced in the cover. Now you can
screw down the cover on the container with four screws.
Both the size of the injection mould as well as the open and close technique do not
change despite these additions to the plastic parts. The additional elements are
also in the demoulding direction.
2.1 Simple Open/Close Mould 5
cover
container
both components have no elements

which deviate from the
Figure 2.2 Parts for an open/close mould
In Figure 2.3, the additional sleeves in the container and the stepped bores in the
cover are shown. The demoulding direction remains the same.
container
cover
both the sleeves in the container

as well as the holes in the
cover are in demoulding direction
Figure 2.3 Parts for the open/close mould with additional elements
6 2 Mould Types
2.1.1 Classic Structure of an Open/Close Mould
The upper part (fixed half) and the lower part (moving half) are made up of several
plates and risers. Via the integrated guides, that is, bolts in the fixed half and the
bushes in the moving half, the mould closes precisely.
The fixed half consists of the clamping plate and the cavity plate. The guide bolts
are installed in the cavity plate. The guide bolts are provided at the back end with
a collar, which is embedded in the cavity plate. Against the slip out of the guide
bolts the clamping plate is screwed tightly with the cavity plate. The cavity plate is
fixed to the mould plate via another fitting diameter at the guide bolt.
The moving half of a classic open/close mould is made up of the mould plate,
possibly a backing plate, the risers and the lower cavity plate. The ejector set is
between the risers. The guide bushes are also provided with a collar here and
mounted in the cavity plate. They are secured in the moving half through the
risers, which are attached, like the fixed half, via the back fitting diameter of the
guide bush. The risers are again installed with the clamping plate and with the
additional guide sleeves. Everything is screwed tightly together with long screws
from the clamping plate through to the mould plate. This guarantees that all com-
ponents are aligned and tightly connected. Ejectors are the moving parts in the
injection mould that eject or expel the plastic part after opening the mould. Ejec-
tors are usually round pins which are installed in the ejector set. The small rings
mentioned at the beginning which are usually visible on the plastic part are the
imprints of these ejectors.
In Figure 2.4 several longitudinal and cross sections through an injection mould
are represented so that the classic structure of an open/close mould can be seen.
The accuracy of fit in a mould is extremely important. Without precise

guiding and fixing of both mould halves they can move radially.

Longitudinal Section Cross Section
FH clamping plate
guide bolt FH screws

with fitting collar FH cavity plate
guide bush
with fitting collar MH cavity plate
backing plate
risers
guide bush MH screws
ejector set
MH clamping plate
FH = fixed half
MH = moving half
Figure 2.4 Section through a mould structure
2.1.2 Guiding Elements
The guiding elements in an injection mould are very important. They ensure that
both mould halves are already centred while closing against each other. Except in
special solutions, guide bolts are built into the fixed half and guide bushes are built
into the moving half. The tolerances between the cavity plates and the guide bolts
and bushes are so small that they are installed with a light press fit.
The fixed half with the guiding bolts fits exactly, free of play, into the guide bushes
of the moving half. Only in this way is it guaranteed that both sides fit together on
top of each other precisely and repeatedly. If this were not the case, the mould
halves could move radially, which among other things can lead to different wall
thicknesses in the plastic parts. This is also called mould offset.
Figure 2.5 shows what can happen when the guiding elements of an injection
mould are not exactly aligned.
8 2 Mould Types
fixed half
moving half
demoulding direction If the fixed half and the moving half are not exactly aligned
and positively locked on top of each other this can lead to
different wall thicknesses on the plastic part.
Figure 2.5 Mould offset through insufficient guiding
Here are a few comparisons to get an idea of how important the accuracy of
the guiding is. The tolerances between the bolt and the plate have to be so
accurate that some light strikes are required when installing the bolt in the
plate. If the bolt is just 0.006 mm too thick, it will be very difficult to install.
The tolerance between the guiding bolt and the guiding bush is even smaller.
The difference between free of play movement and getting jammed is a
maximum of 0.004 mm in diameter.
If the centre distance between the guiding elements of the plates in the
upper part and the lower part differs by more than 0.02 mm it is difficult for
the mould to close.

Anti-rotation Protection
Today nearly all injection moulds are rectangular. For this reason normally four
guiding elements are installed, one in every corner. To prevent a false (rotated) as-
sembly of the fixed half and the moving half, one of the guides is smaller or bigger
than the other three.
In Figure 2.6 the fixed half of a mould is displayed: three guide bolts with diameter
(Ø) 18 mm and one guide bolt with Ø 20 mm. This should prevent a false (rotated)
assembly of the fixed half on the moving half.
Fixed Half
guide bolt Ø 20 mm anti-rotation protection

through different diameters
of the guiding elements
guide bolts Ø 18 mm
Figure 2.6 Anti-rotation protection in mould making
The following is important for the length selection of the guide bolts: Before the
mould contours of the two halves approach, the guides must already fit into one
another. If the guides are too short, the mould contour could be damaged during
the closing action of the mould halves.
In Figure 2.7 it is clearly visible that the guides are already sliding into one an-
other before both sides can have contact.
Length of the Guiding Elements

The guide bolts are already The fixed half and the moving half
inside the guide bushes. still have no contact at the shortest
distance.
Figure 2.7 Length selection of guiding elements

10 2 Mould Types
2.1.3 Backing Plate
These are not used very often in a very simple injection mould. They are installed
when a complex cooling, a core pin or additional components that have no space in
the cavity plate or pass through the cavity plate and should be held by the backing
plate, are required in an injection mould.
In Figure 2.8 a core pin is shown which is installed in the cavity plate and is held
by the backing plate.
The use of a backing plate has more functions and advantages here. One of the
advantages is that the backing plate is installed under the cavity plate and is level.
Therefore all the components which are attached to the backing plate are geomet-
rically determined and on the same level. A further advantage is the manufactur-
ing costs. To achieve a similar fixing of such a core pin, an additional installation of
another cover from below would be necessary. A possibility here is a small built-in
cover plate or a set screw which fixes the core pin.
Moving Half
cavity plate
backing plate
demoulding direction The core pin is held by the backing plate.
Figure 2.8 The backing plate fixes and holds the core pin
Both alternatives cause higher production costs. If they are used several times in a
mould, it makes sense to install a backing plate.
In Figure 2.9 two possible alternatives for the fixing of core pins are shown.
Further additional and basic designs, functions, elements and components of an
injection mould are discussed individually in the following sections of this book.
2.2 Moulds with Moving Elements 11
Moving Half
cavity plate
screwed cover plate core pin additional set screw
Figure 2.9 Alternatives for fixing
2.2 Moulds with Moving Elements

Almost everything that makes an injection mould complicated and expensive orig-
inates from the geometry of the subsequent plastic parts. Therefore attention
should already be paid in the planning and design of this plastic part that everything
that should later contain the plastic part is also to be realised in the injection mould.
This is often a big challenge in the development, that is, the d esign of plastic parts.
When design and technology meet, sometimes one has to compromise.
2.2.1 Undercut
The next level of difficulty in plastic parts is elements which cannot be demoulded
in the main demoulding direction like in an open/close mould. These elements,
which are troublesome during demoulding, are called undercuts. They need to be
released or demoulded in an additional demoulding direction. For this purpose
moveable components, such as slides, core pins, ejectors for inclined ejection units
or inserts, are used in the injection mould. They support the plastic piece so that it
can be better demoulded and ejected.
In Figure 2.10 two possible elements, a side bore hole and a side pipe, are seen on
our component. Both elements are an undercut on the plastic part and must be
released via the second demoulding direction. Only this way can the plastic parts
be ejected from the mould without damage. For these two examples slides are used
to do this.
12 2 Mould Types
main demoulding direction
second
demoulding second
side opening example demoulding
direction
side pipe example direction
Figure 2.10 Additional demoulding directions
2.2.2 Slide
When implementing these side openings the open/close mould becomes a mould
with slides. Slides are moving components inside the injection mould. One or more
parts of the mould contour are incorporated into these slides. The slide itself moves
away from the plastic part during or after the opening of the mould in an additional
demoulding direction. Through this movement the undercuts are released before
the plastic part is ejected from the injection mould. The required path is calculated
and defined in advance. It must be large enough so that the plastic piece drops out
of or can be removed from the injection mould without damage after the ejection.
In Figure 2.11 the slide for demoulding the side opening on our container is shown.
In the front area of the slide a part of the mould contour of the plastic part is incor-
porated. The round surface in front has contact with the fixed insert when the
mould is closed and is injected. During injection, this contact prevents that the
plastic covers this spot and thus forms the bore holes in the plastic part. In techni-
cal language, this contact point is also called an aperture.
Slide without Plastic Part
slide mould contour
contact to the insert

for the aperture
Slide with Plastic Part
Figure 2.11 Slide with and without plastic part
2.2.3 Slide Operation
To move this slide there are two possibilities. The first possibility is that the slide
is connected with a hydraulic cylinder which is in turn screwed tightly to the injec-
tion mould. The slide is moved via this cylinder. For this solution the cylinder
covers a clearly defined distance. It is bought and installed as a standard part. Find
out more in Section 4.2. The second option is the forced control through an inclined
pin. The pin is installed with a defined inclination on the fixed half of the injection
mould. The front part of the inclined pin submerges in the moving slide. When the
mould opens in the main demoulding direction, through the resulting movement
this inclined pin moves the slide in an additional demoulding direction. There are
additional details in Section 4.2.
Figure 2.12 displays the closed mould on the left and the slightly open mould on
the right. On the slightly open mould the inclined pin has moved the slide in an
additional demoulding direction to the end position.
14 2 Mould Types
slightly open mould

main demoulding direction
closed mould
additional
slide
Figure 2.12 Closed and slightly open mould
2.2.4 Latch, Clip Lock
Even a very small and harmless looking clip or catch can have a major impact on
the design and on the cost of an injection mould.
The simplest application is a clip for snapping the cover onto the container. Clips
or catches are also used to connect several plastic parts or to fix them together in
an entire assembly group. The assembly of plastic parts has to be done very fast
today and if possible be automated. The use of such clip connections on plastic
parts has, among others, the advantage that they can be quickly and easily in-
stalled without further hand tools.
For the size, type, complexity and also for the costs of an injection mould, it can be
very important if the clip is attached outside or inside of the plastic part. This
should be considered during the planning of the plastic part. If the clip or latch is
outside of the component, it is in the demoulding direction and thus there is no
undercut. Consequently, it is demouldable without further action.
Figure 2.13 shows both variations of a latch, inside and outside. The outer latch is
open above, thus enabling a problem-free demoulding. The inner latch is not open
in the demoulding direction. It will be damaged or even torn away during ejection.
Consequently, one must think of how to prevent this.
latch outside latch inside
Figure 2.13 Outside and inside latch
2.2.5 Inclined Ejector
As previously described, the latches usually lie outside of the plastic part, in the
demoulding direction. They can therefore be demoulded without further action. The
situation is different when the latch is inside of the plastic part. Slides are used for
the demoulding of outside undercuts. In contrast, the latch which is located inside
of the part is demoulded with an inclined ejector. The round ejectors were already
mentioned in Section 2.1. They are pushed to the front together with the ejector set
to eject the plastic parts in the demoulding direction. The inclined ejector is also
installed in the ejector set. In contrast to the round ejector the inclined ejector is not
fixed. The inclined ejector is held in the ejector set in a kind of shoe, but can move
radially with the shoe. Like for the slide, this comes from a movement resulting
from the forward movement of the ejector. Therefore a diagonal guiding is incorpo-
rated in the insert. This guiding has a defined angle for the demoulding situation.
The ejector moves forward in this diagonal guiding. The further the ejector moves
forward, the more it releases the latch on the plastic part. In the end position there
is no more undercut and the plastic part can fall unhindered from the mould.
Figure 2.14 presents two situations: on the left, the ejector after the opening of
the injection mould, before it is ejected; on the right, when the ejector set with the
inclined ejector has moved to the front end position. The latch is released and the
plastic part falls from the mould.
16 2 Mould Types
the moving half moves

in this direction plastic part
view without plastic part
insert
inclined ejector in
moving shoe
t
emen
l mov
radia
ejector set
Figure 2.14 Three-dimensional view of an inclined ejector
Figure 2.15 shows again the exact situation in the plastic part; left, again the initial
position before the ejection; right the latch released through the diagonal move-
ment of the ejector. More about this in Section 4.3.3.
Before the Ejection After the Ejection
plastic part
after the
before the ejection
ejection
insert
inclined ejector
Figure 2.15 Situation of the inclined ejector

2.2.6 Forced Demoulding
A possible alternative is to change the latch geometry or design so it can be for

example forced demoulded. This variant is selected for moulds that are required
for the production of only a few sample parts or when the cost of the mould should
be kept low. Then no additional element is needed in the mould.
Forced demoulding means that during ejection from the injection mould the plas-
tic part is elastically deformed without damage. After the ejection it springs back
to its original state. Note that for forced demoulding the force for ejection is slightly
higher.
The difference between both latches is:
Latch 1 is has a level top surface. During demoulding, it is sure to be torn away,
and the plastic piece will break.
Latch 2 has an inclined top surface. During demoulding of the plastic part, the
wall of the container presses so far away, that the piece is indeed slightly de-
formed but after the demoulding it springs back again to the original state.
In Figure 2.16 both variants are presented.
latch 1 latch 2
Figure 2.16 Latch for forced demoulding

18 2 Mould Types
Exemplary for a functioning variant of the forced demoulding in serial operation

are the plastic screw caps for drink bottles. They are force demoulded during ejec-
tion. The screw caps are especially designed for this type of demoulding. There are
several good reasons for that: they are produced in millions, consequently time
plays an essential role. The production of the plastic part is extremely fast with
this type of mould. The mould does not need additional slides or cores, it is also
smaller. Fewer components in the injection mould also mean less maintenance
costs for the mould.
2.2.7 Mould Size
Such additional elements can strongly influence the size and therefore the effort
and the costs for an injection mould. This has already been mentioned above. This
influence on the size can be clearly shown in our two examples. Our plastic piece,
the container does not change in the basic dimensions. Only the side opening has
been added, which we can demould via the slide from the outside, and the inside
clip, which generates an undercut that can be released through the inclined ejector.
In Figure 2.17 the difference in the mould size is clearly seen. The edge length in
the direction shown is the same for both moulds. But the width of a mould with
slide is clearly larger.
Different Mould Sizes

with the Same
mould with Component Size mould with
slide from the inclined ejector
outside inside
h t
ng
le
h
ge
t
ng
ed
le
e
ge
m
ed
sa
e
m
sa
Figure 2.17 Different mould sizes

2.3 Mould for Threads 19
The slide which comes from the outside has a certain size itself. It also needs a
guide in which it can move. This makes a broader tool necessary.
The inclined ejector, like the slide, is associated with more hours of work, but in
this case has no effect on the mould size. The mould with the inclined ejector is
incidentally the same size as the open/close mould in Section 2.1.
2.3 Mould for Threads

Threads are important additional elements on plastic parts. There are external
threads (screws) and internal threads (nuts). Just as different as the threads are, is
also their production and the injection mould. Plugs, nipples (external threads),
screw caps and screw-on points for holders (internal threads) are typical uses for a
thread on a plastic part.
On our cover in Figure 2.18 an external and an internal thread were designed. In
this example, the external thread offers the possibility to close the opening on the
cover with a screw cap. The internal thread in the second cover can for example be
the screw connection for screwing in a screw coupling for a hose or pipe.
Cover with Internal Thread Cover with External Thread
Figure 2.18 Cover with internal and external thread

20 2 Mould Types
2.3.1 External Threads
Plugs or nipples are plastic parts which consist mainly of only a thread. They are
used for example for sealing an opening or as an adapter for a hose.
In Figure 2.19 more plugs can be seen which are screwed into a fixture plate. The
plugs have an external thread and are screwed into the internal threads of the
fixture plate. In this case, they serve as protection for the screw holes from the
ingress of chips, water, and dirt. The plug itself is seen in the top left of the figure.
plugs as protection
for the threads
Figure 2.19 T hreaded plugs for protection of the screw holes

[Source: Meusburger GmbH, Wolfurt]
The injection mould for the external thread belongs to the category moulds with
moving elements. In our example, the contour of the thread is also an undercut.
What is special about this is that the whole of the thread is an undercut and there-
fore it must be fully incorporated in both slides. Both slides go exactly to the mid-
dle of the thread. With the thread halves, the entire contour of the cover which is
in the demoulding direction of the thread is incorporated in the slides. The thread
itself is round and therefore it does not matter in which direction the slide moves.
In such a case, the shortest distance for the slide to move inside the injection
mould is chosen.
In Figure 2.20 the injection mould for the cover with external thread is shown. The
slides are open and are force-controlled by means of inclined pins. The overall
contour is incorporated in the slide. The distance covered by every slide is half the
width of the plastic part plus a few millimetres safety margin. Note also the size of
the injection mould in relation to the size of the plastic part.
moving half fixed half
tion
ing direc
demould
Figure 2.20 Mould for cover with external thread
In Figure 2.21 the slide with all functional surfaces is displayed. Right in the front
there is the split line surface in the middle of the injection mould, where both
slides and the mould contour—where the thread geometry belongs—meet. In
addition, the inclined hole is shown in which the inclined pin for moving the slide
is immersed. On the sides the slide guides, in which the slides are embedded and
are driven in the demoulding direction, are displayed.
Only exception: the contour of the thread lies in the mould and is right in the main
demoulding direction. The threaded plug in the top left corner of Figure 2.19 is
such a plastic part. It is produced with an open/close mould.
22 2 Mould Types
split line face in the middle
slide guide
mould contour with

thread contour
hole for the movement

with inclined pin
Figure 2.21 Slide for the cover with external thread
2.3.2 Internal Threads
The injection mould for the internal thread also belongs to the category moulds
with moving elements but is a completely different mould concept. The thread itself
is also an undercut for this injection mould, but this time it cannot be demoulded
with slides.
There are two significant options for the demoulding of these internal threads:
Option 1 is the collapsible core. This is explained in detail later in Section 4.3.6.
Option 2 is the unscrewing of the thread. Specialists call this de-spindling. Here
the mould core, where the thread is incorporated on the front, unscrews from the
plastic part before it is ejected.
The difficulty when demoulding the internal thread is that there is no room to
move the slide inwardly with a linear movement such as with external thread. The
question is, how do you release the thread or undercut? The solution is to unscrew
the core from the mould contour using the thread.
Previously, all movements that were important for demoulding were linear move-
ments in either the main demoulding direction of the machine or the secondary
demoulding direction through a moving slide. But for unscrewing, a circular or
screwing movement is required.
The screwing movement for a core can be produced in different ways. The three
common types of operating a mould core are: the unscrewing unit, the drive via a
gear with gear rack or a gear with a high-helix lead screw.
For all types of de-spindling, it must be ensured that the plastic part does
not rotate during de-spindling with the turning of the mould core. Often the
parts that have an internal thread are round parts. Through serrations on
the outer surface or a polygon or small catches on the bottom edge, the
twisting can be prevented. This is not a problem for our rectangular cover.

In Figure 2.22 the plastic part is shown with the mould core which is injection
moulded with the thread.
part, cover
mould core
direction of rotation
for de-spindling
Figure 2.22 Plastic part with mould core
2.3.3 Drive Types for De-spindling
2.3.3.1 Hydraulic Unscrewing Unit

The hydraulic unscrewing unit is an additional device that either is screwed onto
the injection mould or to the machine. It is connected to the injection moulding
machine and driven and regulated from this. It can either be electrically or hydrau-
lically operated. These unscrewing units are highly flexible in their handling. They
can be used for demoulding threads which are on the fixed half or the moving half
or on the split line face. The unscrewing unit produces the screwing movement
and drives either a small gear or the mould core directly. Unscrewing units can be
obtained in different types and options from the manufacturers of standard mould
components or manufacturers of injection moulding machines.
24 2 Mould Types
The mould core has the thread as mould contour in front, which is later
reproduced in the plastic part. On the back side there is a thread with the
same pitch for the guiding of a guide nut. The diameter of the back thread is
irrelevant; only the pitch must be the same in front and back. Keep in mind
that both threads must be provided with the predetermined shrinkage!

In Figure 2.23 the mould core with insert, guiding above and guide nut below is
represented.
part, cover
insert
guiding mould core
demoulding direction guide nut
for de-spindling
Figure 2.23 Mould core with guiding and guide nut
2.3.3.2 Gear Rack

For this type of demoulding a hydraulically operated gear rack actuates a gear
which is connected with the mould core. For this type of demoulding the linear
movement of the gear rack is converted to a rotating movement of a gear wheel. In
this case, the screwing movement comes from the mould core. On the back side,
the mould core has a guide thread with the same pitch as the thread in the plastic
part. The big gear wheel turns through the movement of the gear rack. This in turn
actuates the mould core which is screwed into the guide nut. Through the rota-
tional movement of the mould core in the guide nut it unscrews from the plastic
piece. The insert has an integrated guiding on which the core moves and which it
is mounted on.
In Figure 2.24 the moving half with the complete drive unit is pictured. The gear
rack is drawn out of the mould. The large gear wheel turns counter-clockwise and
actuates the mould core. This turns clockwise and unscrews via the guide nut from
the plastic piece.
The cavity plate of the moving half is not represented in the large picture. The
hydraulic cylinder for operating the gear rack is screwed in on the left of the mould
and tightly connected to the gear rack.
part, cover direction of rotation

of drive
of mould core direction
r d e -s pindling
fo
of large gear wheel complete moving half
Figure 2.24 Complete drive unit with gear rack
Both drives, both the unscrewing unit as well as the drive with the gear rack, are
suitable for threads on the fixed half as well as on the moving half. It is also possi-
ble for both drives to operate within a closed or open mould. This can be an impor-
tant or even decisive criterion for the selection of the drive.
2.3.3.3 High-Helix Lead Screw

In contrast to the hydraulic unscrewing unit, or the gear rack, the high-helix lead
screw needs no additional drive—it is the drive. The high-helix lead screw is perma-
nently installed in the fixed half. Through the opening and closing of the machine,
the high-helix lead screw—similar to the gear rack—actuates the big gear wheel and
thus the mould core. The further procedure is identical.
26 2 Mould Types
An important note: in an open mould the high-helix lead screw must be

approx. ⅓ engaged in the high-helix thread nut.

In Figure 2.25 a complete drive unit with high-helix lead screw, high-helix thread
nut which is installed permanently in the large gear wheel, and the mould core
with guide nut and guiding is displayed.
of mould core
high-helix lead screw

part, cover
high-helix thread nut
guiding
mould core
large gear wheel
guide nut
of large gear wheel
direction of drive demoulding direction

for de-spindling
Figure 2.25 Complete lead-screw drive
In Figure 2.26 the entire assembly of the injection mould with high-helix lead
screw drive is presented. As you can see, a certain assembly space is necessary for
all drives, which makes the injection mould larger.
Entire Mould, Cross-Section Entire Mould, Transparent
Figure 2.26 Entire mould in section and transparent
2.3.3.4 Multi-cavity Moulds

The two moulds with unscrewing unit and gear rack are only suitable for the
multi-cavity moulds when the cavities are linearly arranged. You can buy the
unscrewing unit with the number of cavities. For moulds with gear racks a com-
plete drive is needed for each cavity. Only the gear rack which drives everything is
built in just once.
The mould with high-helix lead screw is more flexible. By arranging the cavities in
a circle around the big gear wheel in the centre, different numbers of cavities can
be realised.
In Figure 2.27 4-cavity and 6-cavity drives, respectively, are presented.
28 2 Mould Types
4-cavity mould
6-cavity mould
Figure 2.27 High-helix lead screw with 4-cavity and 6-cavity drives
2.4 Multi-component Injection Moulds

The term “multi-component” here refers to the several different plastics which are
injected into the injection mould. For a two-component injection mould, which spe-
cialists refer to as a 2-C mould, this means that two different plastics are injected
one after another into the injection mould.
This method is becoming more and more important. The demand for getting a
ready-to-use piece from an injection mould is steadily increasing. More and more
companies are upgrading their injection mould technology as well as machining
techniques. The areas of application for plastic parts are multiplying through this
method.
2.4.1 Material Pairings
The plastic parts that are used for this method have different characteristics.
For example they can be hard or soft. For a housing made of hard plastic, a soft
rubber sealing is injected in the second process step. For this pairing the hard and
the soft plastic must permanently bond.
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Das in Weiß gehaltene Zimmer ist an der Türe, den
Fensterleibungen und den Wänden mit überaus zierlichen, technisch
meisterhaft und mit feiner Formenempfindung ausgeführten
vergoldeten Schnitzereien ausgestattet. Die Stickereien in den 24
Panneaux und den 2 Sopraporten sind Kopien nach eigenhändigen
Arbeiten der Kaiserin Maria Theresia.
RAUM XX.
SITZUNGSSAAL.
Der Sitzungssaal ist von der Firma F. O. Schmidt nach dem
Originale im Schlosse Eszterháza bei Ödenburg im Stile Louis XV.
dekoriert. An der rechten Seitenwand eine Marmorbüste Seiner
Majestät des Kaisers, von Otto König, an der linken Seitenwand ein
lebensgroßes Porträt des Erzherzogs Rainer, gemalt von Siegmund
L’Allemand.
RAUM XXI.
ORIENTALISCHES ZIMMER.
Das orientalische Zimmer, rechts neben der Eingangstür zur
Bibliothek gelegen, soll die Ausstattung eines Wohnraumes im
Oriente zur Anschauung bringen. In die Wände sind Holzschränke
mit geschnitzten Füllungen eingesetzt und zwei mit Holzgittern
verschlossene Fenster eingebrochen. Unter dem Fenster eine
maurische Wandétagère. Die Bänke in den Fensternischen sind mit
Daghestan-Teppichen und tambourierten Seidenpolstern belegt, der
Fußboden mit einem Smyrna-Teppiche, in dessen Mitte ein Taburett
mit Kaffeeservice. Von der Stalaktitendecke hängt eine messingene
Moschee-Ampel aus Damaskus herab.
Unter den oberen Arkaden, oberhalb der Stiege, befindet sich
das Denkmal für den Gründer und ersten Direktor des Museums, R.
v. Eitelberger († 1885), entworfen von H. Klotz, in Erzguß ausgeführt
von der Metallwarenfabrik Artur Krupp in Berndorf; im Stiegenhause
die Marmorbüste des Erbauers des Museums, H. Freiherrn von
Ferstel ( † 1883), von V. Tilgner, die Marmorbüste des Industriellen
Ed. v. Haas ( † 1880) und ein Medaillonbild des Professors der
Kunstgewerbeschule, Ferd. Laufberger ( † 1881), entworfen von A.
Kühne und J. Storck.
BIBLIOTHEK.
Die Bibliothek des Österreichischen Museums enthält als
Fachbibliothek solche Werke, welche sowohl durch Abbildungen als
durch historische, künstlerische oder wissenschaftliche
Erläuterungen die Zwecke des Museums zu fördern geeignet sind.
Sie besteht aus zwei Abteilungen, aus der eigentlichen
Büchersammlung und aus der Sammlung von Kunstblättern.
Die letztere umfaßt eine reichhaltige Sammlung von
Ornamentstichen aus der Zeit vom XV. bis XVIII. Jahrhundert[26] und
eine Vorbildersammlung, bestehend aus Einzelabbildungen von
vorzugsweise kunstgewerblichen Arbeiten aller Art in
Originalzeichnungen, Kupferstichen, Holzschnitten, Lithographien
und photomechanischen Druckverfahren.
Eine spezielle Erwähnung verdient die stattliche Anzahl von
Fachzeitschriften, welche in einem eigenen Zeitschriftenlesesaale
(dem ehemaligen Vorlesesaale) dem Publikum auf die bequemste
Art zugänglich sind, ferner die bedeutende Sammlung von
kunsttheoretischen und kunsttechnischen Schriften, von Schreib-
und Zeichenbüchern aus dem XVI. bis XVIII. Jahrhundert, von
Kostümwerken und die kostbare Kollektion von Original-Stick- und
Spitzenmusterbüchern aus dem XVI. und XVII. Jahrhundert. Weiters
enthält die Büchersammlung eine große Zahl von Abbildungswerken
aus den Gebieten der Architektur, Skulptur und Malerei und eine
lange Reihe der besten Vorlagenwerke für sämtliche Zweige des
Kunstgewerbes.
Den Grundstock der Kunstblättersammlung bildet die im August
1863 erworbene Kollektion von Ornamentstichen aus dem Besitze
des Kunsthändlers W. Drugulin in Leipzig, bestehend aus 5000
Blättern nebst 87 Kunstbüchern aus dem XVI. bis XVIII. Jahrhundert.
Ornament von Aldegrever
Ornament von H. S. Beham
Ornament von B. Beham

(aus der Ornamentstichsammlung)
Ornamente von Virgil Solis
Diese Sammlung wurde seither durch Einzelankäufe auf mehr als
das Dreifache vermehrt und ist gegenwärtig in zwölf Gruppen
angeordnet, deren erste das Ornament im allgemeinen umfaßt und
dessen Stilwandlungen vom Ende des XV. Jahrhunderts bis zur Zeit
Ludwigs XVI. vor Augen führt; daran schließen sich in Gruppe II
Stick- und Spitzenmuster und Kostümdarstellungen und weiters in
den Gruppen III bis XII verschiedene mustergültige Vorbilder für die
einzelnen Zweige des Kunstgewerbes, als: Mobilien, Schmiede- und
Schlosserarbeiten, Waffen, Uhren, Goldschmiedearbeiten, Gefäße
und Geräte, Heraldik u. s. f.
Goldschmiedornamente von Johannes Hanias
Niellierte Goldschmiedverzierung von Jean Vovert
Goldschmiedornamente von Abraham de Bruyn
Besonders reich ist die Sammlung an Blättern der sogenannten

Kleinmeister in der Gruppe der allgemeinen Ornamente, dann an
Entwürfen für in Email oder Niello auszuführende
Goldschmiedeverzierungen, an Vorbildern für getriebene Gefäße, an
Entwürfen für Juweliere und an heraldischen Musterblättern, zu
welchen auch eine im Jahre 1878 angelegte Kollektion von
verzierten Buchhändler- und Buchdrucker-Signeten zu rechnen ist.
Hierzu kommt noch eine schöne Sammlung von etwa 14.000
Blättern Initialen aus deutschen, französischen, italienischen und
niederländischen Druckwerken des XV. bis XVIII. Jahrhunderts. Der
größte Teil dieser Sammlung. 12.631 Blätter, wurde im September
1867 aus dem Besitze des Glasmalers H. von Holtorp in London
erworben.
Der übrige Teil der Kunstblättersammlung besteht aus
Originalzeichnungen und Abbildungen von Kunst- und
kunstgewerblichen Objekten in Photographie, Lithographie etc. und
ist nach Gegenständen geordnet. Die größte und wertvollste
Bereicherung erhielt dieser Teil der Museumsbibliothek im Jahre
1866 durch die Überweisung der Fachbibliothek der aufgelassenen
k. k. Porzellanmanufaktur. In der hierdurch in den Besitz des
Museums gelangten, 5757 Blätter zählenden Mustersammlung der
Fabrik waren auch 1438 Blätter Originalzeichnungen, Entwürfe zu
Tassen, Tellern und verschiedenen andern Gefäßen sowie für deren
Verzierung enthalten.
Einen sehr wertvollen Bestandteil der Kunstblättersammlung
bildet eine Kollektion von Originalaufnahmen, Federzeichnungen
und Aquarellen, welche die Direktion des Museums im Laufe der
Jahre nach Kunstwerken, welche dem Institut zur leihweisen
Ausstellung überlassen wurden, mit Zustimmung der Besitzer
anfertigen ließ.
Der gesamte Bestand der Bibliothek betrug am Jahresschlusse
1913:
Büchersammlung zirka 41.000 Bände
Kunstblättersammlung, und zwar:
Ornamentstiche 15.873 Blätter
Initialen 14.000 „
Originalzeichnungen, Photographien etc. 45.670 „
Zusammen 75.543 Blätter
BENÜTZUNG DER BIBLIOTHEK.

Die Benützung der Bibliothek ist jedermann gestattet und der
Eintritt in dieselbe an allen Besuchstagen frei. Die Bibliothek ist vom
21. März bis 20. Oktober an Wochentagen, mit Ausnahme des
Montags, von 9 bis 2 Uhr, an Sonn- und Feiertagen von 9 bis 1 Uhr
geöffnet. Vom 21. Oktober bis 20. März sind die Besuchsstunden an
Wochentagen, mit Ausnahme des Montags, von 9 bis 1 Uhr und von
6 bis 8½ Uhr, an Sonn- und Feiertagen von 9 bis 1 Uhr.
Das Ausleihen der Bücher erfolgt nur gegen Empfangsschein.
Dieser hat den Titel und die Signatur des entlehnten Werkes, Namen
und Wohnung des Entlehners und das Datum zu enthalten. Für
jedes Werk ist eine besondere Empfangsbestätigung auszustellen.
Als ausgeliehen ist jedes Werk zu betrachten, das mit Zustimmung
des Bibliotheksvorstandes aus dem Bibliothekslokal entfernt wird.
Das Weiterleihen in dritte Hand ist nicht gestattet. Der Entlehner
haftet für jede Beschädigung. Auf Verlangen des
Bibliotheksvorstandes ist jedes entlehnte Werk sofort
zurückzustellen.
Bücher und Blätter der Ornamentstichsammlung,
Originalzeichnungen und wertvolle, im Buchhandel vergriffene
Werke der Bibliothek dürfen nur im Bibliothekssaale benützt werden.
Im großen Bibliothekssaale liegen gedruckte Kataloge der
Bücher- und der Ornamentstichsammlung, im Zeitschriftenlesesaale
gedruckte Verzeichnisse der in den Journalständen enthaltenen
Zeitschriften auf. Die neuesten Erwerbungen werden durch Anschlag
beim Eingange in den Bibliothekssaal und überdies durch gedruckte
Nachtragsverzeichnisse regelmäßig bekannt gemacht.
[26] Schestag, Fr., Illustrierter Katalog der

Ornamentstichsammlung des k. k. Österr. Museums. 1871. Mit
Initialen und 20 Illustrationen.
Ritter, Fr., Illustrierter Katalog der Ornamentstichsammlung des
k. k. Österr. Museums. Erwerbungen seit dem Jahre 1871. Mit
130 Illustrationen. 1889.
C. ZWEITES STOCKWERK.
OSTASIATISCHE SAMMLUNG.
Kollektion ostasiatischer kunstgewerblicher Arbeiten. Die

Hauptstücke sind in den Spezialsammlungen des Museums
aufgestellt.
RAUM XXII.
In diesem Raume ist eine Anzahl von japanischen Wandbildern
(Kakemonos) teils religiösen, teils weltlichen Inhaltes aufgehängt.
RAUM XXIII.
An den Wänden die Türen eines altjapanischen Tempels, die aus
Holz geschnitzt und vergoldet sind, ferner bemalte
Holzschnitzereien, die als Füllungen in diesem Tempel gedient
haben. Auf Postamenten chinesische und japanische Vasen, neben
ihnen an der Wand Teller und Schüsseln. In Vitrinen Keramik
chinesischer und japanischer Herkunft.
RAUM XXIV.
In den beiden großen Vitrinen Lackarbeiten in Schwarzlack und
Goldlack. An den Wänden in Vitrinen Figuren japanischer
Gottheiten, teils aus Holz geschnitzt und vergoldet, teils aus Lack,
und Objekte des täglichen Gebrauches aus verschiedenen
Materialien, wie kleine Hausaltärchen, Schalen, Schüsseln,
Kästchen etc.
Beim Fenster in einer Vitrine eine Kollektion von Netzhes
(Medizinbüchsen), Kämmen und Inros.
Bei den Fenstern je ein japanischer Reisekoffer.
RAUM XXV.
In diesem Raum ist an der Wand ein Behang in Webetechnik
ausgeführt und aus 11 Stücken zusammengesetzt chinesischer
Herkunft angebracht, davor eine buddhistische Gottheit und große
chinesische Fischbehälter mit Malerei aus Porzellan aufgestellt.
In der Vitrine beim Fenster chinesisches Porzellan.
RAUM XXVI.
In den Vitrinen an der Wand eine Kollektion teilweise alter
japanischer Waffen und chinesischer Porzellanfiguren. In der
Mittelvitrine Porzellane aus Satsuma.
Neben den Vitrinen japanische Lackkästchen.
XXVII. Porzellanzimmer. A. Keramische Sammlung. B.
Glassammlung. C. Vorlesesaal.
D. ZUBAU.
Der Verbindungsgang zum Zubau dient wechselnden

Ausstellungen.
RAUM XXVII.
ALT-WIENER PORZELLANZIMMER, so genannt wegen des
reichen Porzellandekors aus der frühen Zeit der Wiener
Porzellanfabrik.
Die Türen und Türfüllungen, die Fenster und Fensterleibungen,
der Kaminaufsatz und die Lambrien sind aus Eichenholz und belegt
mit zahlreichen Porzellanplättchen, die in ornamentalen vergoldeten
Rähmchen aus Vergoldermasse gefaßt sind und, strenge
symmetrisch gehalten, aus dem Ende der Regierungszeit Karls VI.
stammen. Die Möbel haben vergoldete Holzgestelle, sind mit reicher
Schnitzerei verziert und mit Porzellanplättchen mit bunten
chinesischen Blumen verziert. Sie zeigen schon den Rokokostil
ebenso wie die ornamentalen vergoldeten Holzschnitzereien an den
Wänden. Auch die Bilderrahmen sind in diesem Stile gehalten, und
später etwas verändert worden, vielleicht zur selben Zeit, in der die
reich geschnitzte Wanduhr ausgeführt wurde, wohl in den achtziger
Jahren des XVIII. Jahrhunderts.
Die Wände und Möbel sind mit altem goldgelbem Brokat
überzogen.
Über das Porzellan in diesem Zimmer vgl. Seite 172.
KERAMIK.
Die keramische Sammlung ist im neuen Museumszubau im
ersten Stock aufgestellt und gibt ein anschauliches Bild der
Entwicklung dieses Industriezweiges von der Antike bis in die
Gegenwart.
Der Töpferton, ein Verwitterungsprodukt tonerdehaltiger
Gesteine, ist teils seiner natürlichen Beschaffenheit nach, teils
infolge künstlicher Beimengungen ein Material von außerordentlich
mannigfaltigen Qualitäten, dessen Verwendung in die Frühzeit
menschlicher Kultur zurückreicht. Verschiedenheiten des
keramischen Produktes ergeben sich aus der Beschaffenheit und
Zusammensetzung des Tones, der Stärke des Brandes, sowie aus
der Art des Überzuges, der Glasur.
Die wichtigsten Etappen in der Entwicklung der europäischen
Keramik bilden die Erfindung der Töpferscheibe, die Anwendung der
Zinnglasur und damit die Herstellung der echten Fayence und die
Entdeckung des Kaolintones, wodurch die Herstellung keramischer
Erzeugnisse ermöglicht wurde, welche dem ostasiatischen Porzellan
in allen wesentlichen Eigenschaften gleich kommen.
Die Aufstellung beginnt links vom Haupteingange mit der
Sammlung antiker Vasen und Terrakotten.[27]
ANTIKE KERAMIK.
Die keramischen Erzeugnisse der alten Griechen wurden schon

zu Zeiten Homers, also um das Jahr 1000, auf der Drehscheibe
hergestellt. Sie sind uns zu Tausenden erhalten geblieben, da die
Gräber der Verstorbenen nach antiker Sitte mit typischen Objekten
aus dem Hausrate der Lebenden ausgestattet wurden. Ihre rote
Farbe verdanken diese Erzeugnisse einem künstlichen oder bereits
von Natur aus vorhandenen Zusatz von Eisenoxyd. Die meisten der
Gefäße zeigen entweder schwarze Malerei auf rotem Grunde oder
rot ausgesparte Darstellungen auf schwarzem Grunde. Die Malerei
erfolgte auf dem noch ungebrannten Gefäße mittels einer schwarzen
Farbe, die vermutlich aus Eisenoxyd und Mangan bestand.
Gelegentlich wurde die Einförmigkeit dieser Malweise durch
stellenweise aufgesetztes Weiß, Rot, Blau, Gold und so weiter
unterbrochen. Das fertig gemalte Gefäß wurde sodann einem
Brande ausgesetzt, der ihm entsprechende Härte und Glanz verlieh.
Die Sammlung antiker Vasen und Terrakotten im
Österreichischen Museum umfaßt zwar bloß gegen tausend
Nummern, übertrifft aber nicht nur in bezug auf Formenreichtum,
Repräsentation verschiedener Entwicklungsperioden und
Fabrikationsgebiete zahlreiche weit größere und ältere Kollektionen,
sondern enthält auch einzelne Objekte, die vermöge ihrer Schönheit
und Seltenheit in der Gesamtgeschichte der antiken Keramik einen
hervorragenden Platz einnehmen.
Die Objekte sind nach historisch-geographischen
Gesichtspunkten systematisch geordnet und aufgestellt. Nur in der
Aufstellung der Sammlung Blum-Blankenegg mußte, den
Schenkungsbedingungen zufolge, von der systematischen
Aufstellung abgegangen werden, so daß sie ein von dem übrigen
Bestande getrenntes Ganze bildet.
Im ersten Wandschrank rechts repräsentieren die Reihen 1 und 2
die ersten Entwicklungsstadien griechischer Keramik, aus freier
Hand ohne Benützung der Drehscheibe geformte Gefäße der
vorphönizischen Nekropolen von Cypern. Diese Arbeiten zeichnen
sich nicht allein durch primitive Einfachheit der Technik aus, sondern
zeigen auch, wie die Bildsamkeit des Tones die schöpferische
Phantasie bereits in den Anfangsstadien der Entwicklung einer
keramischen Industrie zu überraschendem Formenreichtum
verlockte. Die späteren Arbeiten dieser Gattung sind bereits unter
Anwendung der Drehscheibe entstanden. Arbeiten der zweiten
Periode der griechischen Keramik, des mykenischen Stiles, sind in
der Sammlung nicht vertreten. Der folgende Stil, der nach dem Tore
von Athen, in dessen Nähe die bedeutendsten Funde gemacht
wurden, Dipylonstil heißt, ist dagegen in mehreren Beispielen
repräsentiert. Die Arbeiten dieser Gattung setzen die geometrische
Verzierungsweise der ersten Periode fort, ohne die
Errungenschaften mykenischer Kunst, namentlich nach technischer
Richtung zu ignorieren. Die Formen sind weniger willkürlich, in der
Dekoration herrschen geradlinige Kombinationen vor: Mäander,
Hakenkreuz, Zickzack, Schachbrett- und Rautenmuster, durch
Tangenten verbundene Kreise etc. Daneben tritt die Sternrosette als
Füllungsornament auf. An die Stelle der maritimen Tiermotive des
mykenischen Stiles treten rohe, dem Geiste der Linienornamentik
sich nähernde Tier- und Menschenfiguren. Unter diesen Typen ist
namentlich der große Krug Nr. 30 charakteristisch, in dessen Dekor
sich liebevolle Sorgfalt mit schematischer Trockenheit gepaart
zeigen. Als gut erhaltene altapulische Arbeiten verdienen hier auch
die zwei buntbemalten Lampenständer, „Thymiaterien“, Nr. 40 und
41 hervorgehoben zu werden.
Im nächsten Schranke sehen wir Vasen des VII. Jahrhunderts,
bei denen der linearen Ornamentik im Dipylonstil das Auftreten
phantastischer und exotischer Tiergestalten im korinthischen Stile
folgt. Derselbe steht unter dem Einflusse der Euphratländer und
Ägyptens. Die Vasenmalerei ergeht sich in der Darstellung von
Greifen, Sphinxen, Sirenen, fischleibigen Dämonen, Löwen,
Panthern etc., oft in Streifen eintönig nebeneinander gereiht,
während das vegetabilische Ornament Lotosknospen und -blüten
sowie die ebenfalls aus Ägypten stammende Palmette verwendet.
Daneben tritt der Mensch auf. Typisch sind Kampfszenen,
Frauenreigen, später auch tanzende Männer in absichtlich grotesker
Zeichnung. Der Tongrund ist bei den älteren Stücken hellgelblich bis
ins Grünliche, bei den späteren rötlich. Hierher gehören die kleinen
kugelförmigen Ölgefäße der obersten Reihe, die schlauchförmigen
Tropfgefäße der dritten Reihe, verschiedene Formen der
Deckelbüchse, Reihe 4, Nr. 114 bis 120, die Trinknäpfe, Reihe 2, Nr.
89 bis 91, und die für die korinthische Kunstweise dieser Periode
überaus charakteristischen Krüge, mit umlaufenden Tierfriesen,
unterste Reihe, Nr. 125 und 128.
Im folgenden Schranke sind hauptsächlich schwarztonige
Gefäße etruskischer Herkunft (Bucchero, Vasen) ausgestellt, Näpfe,
Becher, Kannen und Amphoren, die durch Dämpfung eine schwarze
Färbung erhielten, in der folgenden Reihe Amphoren mit in Relief
verzierten Bandhenkeln, rechts Nr. 206 das interessanteste Stück,
ein mit sieben Sphinxen in Relief verzierter Krug der voll
entwickelten Bucchero-Technik. In der Mitte der dritten Reihe eine
kyrenäische Schale (Nr. 140), das einzige Stück dieser Art in der
Sammlung. Unter dem Schranke, freistehend, etruskische
Aschenurnen mit liegenden Figuren auf den Deckeln.
Die nun in chronologischer Folge anschließenden
schwarzfigurigen Gattungen sind in verschiedenen Schränken
untergebracht. Zum Eingang zurückkehrend finden wir im linken
Schranke in der Mitte der oberen Etage einen jonischen Deinos auf
hohem Untersatz Nr. 215, zu beiden Seiten die nach ihrem Fundorte,
dem etruskischen Caere benannten Caeretaner Vasen. Ihr
Fabrikationsort dürfte in einer der jonischen Kolonien Ägyptens zu
suchen sein, wo diese in Sammlungen nur selten vertretene Klasse
im VI. Jahrhundert den Abschluß der jonisch-kleinasiatischen
Vasenmalerei bildet. Die zwei Hydrien unserer Sammlung zählen zu
den bedeutendsten existierenden Stücken dieser Gattung; ein
besonders bemerkenswertes Objekt ist überdies der
danebenstehende vorzüglich erhaltene Dreifuß altattischen Stiles
aus Theben. In der darunter befindlichen Reihe finden wir Vasen (Nr.
220 und 221), die gleichsam ein Resumé der verschiedenen
vorangegangenen Kunstweisen bilden.
Zum vierten Wandschrank zurückkehrend, finden wir kleinere
attische schwarzfigurige Lekythen (Salbgefäße mit langem, engem
Hals und trichterförmiger Mündung (Nr. 241-271), worunter
namentlich Nr. 264 hervorzuheben ist) mit der ältesten Kopie der
berühmten Statuengruppe des Antenor, die Tyrannenmörder
Harmodios und Aristogeiton. Die größeren und bedeutenderen
attischen Vasen dieser Periode sind in den beiden
gegenüberliegenden freistehenden Schränken ausgestellt.
Die altattische Freude an reichem figuralen Schmuck, der alle
Teile des Gefäßes bedeckt, erfährt bereits merkliche
Einschränkungen, denn in der Keramik Athens machen sich im
Laufe des VI. Jahrhunderts zwei Richtungen geltend: eine, die auf
ausgiebige Verwendung der schwarzen Firnisdecke hinzielt und die
auf die spätere Keramik Korinths zurückzuführen ist, und eine
andere, die zugunsten eines ausgiebigen figuralen und

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Injection Moulds for Beginners - eBook

Hanser Publishers, Munich Hanser Publications, Cincinnati

Distributed in the Americas by:

Distributed in all other countries by:

Cataloging-in-Publication Data is on file with the Library of Congress

© Carl Hanser Verlag, Munich 2016

Prof. Dr.-Ing. Thomas Seul

(Source: wortundform GmbH, Munich)

I would like to express a heartfelt thank you to my colleagues at the Association of

The Author . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VII

How to Use This Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . XVII

2.4 Multi-component Injection Moulds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

3.6 Plate Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

4.7 Systematic Design Approach . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

6 Further Knowledge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

7 The Finished Mould . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

8 Maintenance and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

9 Manufacturing Technologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

10 Practical Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

In this book the planning, designing, and construction of injection moulds is

Figure 1 Container with cover

For each plastic part which is manufactured there is the corresponding

Or to put it in a different way, imagine yourself in the kitchen, bathroom, office, or

2.1 Simple Open/Close Mould

Figure 2.1 Demoulding direction

both components have no elements

Figure 2.2 Parts for an open/close mould

both the sleeves in the container

2.1.1 Classic Structure of an Open/Close Mould

The accuracy of fit in a mould is extremely important. Without precise

Longitudinal Section Cross Section

guide bolt FH screws

Figure 2.4 Section through a mould structure

2.1.2 Guiding Elements

Figure 2.5 Mould offset through insufficient guiding

guide bolt Ø 20 mm anti-rotation protection

Figure 2.6 Anti-rotation protection in mould making

Length of the Guiding Elements

Figure 2.7 Length selection of guiding elements

2.1.3 Backing Plate

demoulding direction The core pin is held by the backing plate.

screwed cover plate core pin additional set screw

Figure 2.9 Alternatives for fixing

2.2 Moulds with Moving Elements

main demoulding direction

Figure 2.10 Additional demoulding directions

Slide without Plastic Part

slide mould contour

contact to the insert

Slide with Plastic Part

Figure 2.11 Slide with and without plastic part

2.2.3 Slide Operation

slightly open mould

Figure 2.12 Closed and slightly open mould

2.2.4 Latch, Clip Lock

latch outside latch inside

Figure 2.13 Outside and inside latch

2.2.5 Inclined Ejector

the moving half moves

Figure 2.14 Three-dimensional view of an inclined ejector

Before the Ejection After the Ejection

Figure 2.15 Situation of the inclined ejector

2.2.6 Forced Demoulding

A possible alternative is to change the latch geometry or design so it can be for

2.1 Simple Open/Close Mould

2.2 Moulds with Moving Elements

2.3 Mould for Threads

Figure 2.19 T hreaded plugs for protection of the screw holes

2.4 Multi-component Injection Moulds