ADVANCE INJECTION MOULD DESIGN

CORPORATE TRAINING

01

SPLIT MOULD

CORPORATE TRAINING

02

SPLIT MOULD

It is required for components incorporates a recess or

projection right angle to the line of draw, to relieve the
undercut before the moulding is removed.

A moulding which has a recess or projection is termed as

undercut moulding.

The undercut may be external, internal, local part of the

component.

Two or more parts of the cavity closed together in a

chase bolster by using locking heels during injection.

CORPORATE TRAINING

03

Fig: 1.1

Fig: 1.2

CORPORATE TRAINING

04

VISIBLE LINE ON MOULDING

Parting line: The line formed on the molding
surface where the core and cavity closed together.
Joint Line: The line formed on the molding
surface where the splits (side cores) are closed
together.

CORPORATE TRAINING

05

SLIDING SPLITS

The splits are positioned in guides on a flat mould

plate are actuated by mechanical or hydraulic system
and those are held together by locking heels which
project on the other mould half.

The splits are possible to mount on either the moving

or fixed mould plate.

CORPORATE TRAINING

06

Fig: 1.3

Fig:
1.4
CORPORATE TRAINING

07

GUIDING AND RETENTION

OF SPLITS - SLIDING FIT

Fig: 1.5

Fig: 1.6
CORPORATE TRAINING

08

Fig: 1.7
CORPORATE TRAINING

Fig: 1.8

09

DESIGN CONSIDERATION
OF SPLIT MOULD
The side movement should ensure the split halves
always come together in the same plane.
In split mould all the parts should have enough
strength to withstand the force applied to the splits by
the operating system.
It should allow smooth movements of splits.

CORPORATE TRAINING

10

SPLIT DESIGN
CONSTRAINTS
Amount of splits movement and delay period required.
Ease with which the molding can be removed.
Whether a short or long production run is required.
Whether the available machines are programmed for
ancillary cylinder control.
Whether molding inserts are to be incorporated.

CORPORATE TRAINING

11

SPLIT MOULD
ACTUATION METHODS
1. Finger cam actuation method
2. Dog-leg cam actuation method
3. Cam track actuation method
4. Hydraulic actuation method
5. Angled-lift splits
6. Spring actuation system
CORPORATE TRAINING

12

1.FINGER CAM ACTUATION

Fig: 1.9

Fig: 1.10
CORPORATE TRAINING

13

FINGER CAM ACTUATION

MOULD FOR CAP COMPONENT

CORPORATE TRAINING

FINGER CAM MOULD FOR

LEDHOLDER

CORPORATE TRAINING

FINGER CAM PIN

Hardened, circular steel pins, termed finger cams are
mounted at an angle in the fixed mould plate.

Length and angle of the finger cam determine the

distance traversed by each split across the face of the
mould plate.

CORPORATE TRAINING

14

FINGER CAM PIN

Fig:
1.11

M = splits movement
= Angle of finger cam, 10-25
L = working length of finger cam
C = clearance (0.75mm)

CORPORATE TRAINING

15

CALCULATION
The finger cam movement can be computed by the
Formula
M = (L sin ) (C / cos )
If the required movement is known, the following formula
used to determine the finger cam length.
L = (M / sin ) + (2C / sin 2)
Where, M = splits movements,
= Angle of finger cam, 10-25
L = working length of finger cam
C = clearance (0.75mm)
Cam diameter is usually 13 mm.
CORPORATE TRAINING

16

2. DOG - LEG CAM ACTUATION

This actuation system is used where a more
splits delay time is required compare to finger cam
actuation method.

CORPORATE TRAINING

17

DOG-LEG CAM

Fig: 1.12
CORPORATE TRAINING

18

DOG-LEG CAM
ACTUATED MOULD

Fig: 1.13

Fig: 1.14
CORPORATE TRAINING

19

DOG LEG CAM ACTUATED

SPLIT MOULD

M = movement of each split,

La= angled length of cam,
Ls = straight length of cam,
= Cam angle, C = clearance, D = delay,
e = length of straight portion of the hole.

Fig: TRAINING
CORPORATE

20

CALCULATION
Formula for calculating the opening movement, the
length of cam, and the delay period
M = La tan - C
La = (M + C)/ tan
D = (Ls e) + (C/tan )
Where M = movement of each split,
La= angled length of cam,
Ls = straight length of cam,
= Cam angle, C = clearance,
D = delay,
e = length of straight portion of the hole.
CORPORATE TRAINING

21

3. CAM TRACK ACTUATION

This type of actuation system is used for components
having under cut which requires more delay period
Due to external fitment of cam track the mold actuation
system becomes simpler and mold cost is reduced.
The cam track is machined into a steel plate attached to
the fixed mould half.
A boss fitted to both sides of the split runs in this cam
track.
The movement of the splits accurately controlled by
specific cam track design .
CORPORATE TRAINING

22

CAM TRACK PLATE

Fig: 1.16

Fig: 1.17
CORPORATE TRAINING

23

SLIDING SPLIT MOLD

(CAM TRACK PLATE
ACTUATED)

Fig: 1.18
CORPORATE TRAINING

24

ASSEMBLY OF CAM TRACK

ACTUATION MOLD IN CLOSED
POSITION

Fig: 1.19
CORPORATE TRAINING

25

CAM TRACK

M = movement of each split,

La= angled length of cam track,
= cam track angle,
C = clearance,
D = delay,
R = radius of boss

Fig: 1.20

CORPORATE TRAINING

26

CALCULATION
M = La tan - C
La = (M + C) / tan
D = Ls + C/ tan + r ( 1/tan - 1/sin )
M = movement of each split,
La= angled length of cam track,
= cam track angle,
C = clearance,
D = delay,
R = radius of boss

CORPORATE TRAINING

27

4. HYDRAULIC ACTUATION
The splits are actuated by hydraulic system. It
is independently opening movement of the mould.
The splits can be operated automatically at any
specific time by the operating program of the machine
ADVANTAGES
Cycle time less
Large delay movements and large split movements
can be achieved
CORPORATE TRAINING

28

DISADVANTAGES
The mould is more bulky as compared with the
other designs
Mould setting more difficult and the hydraulic system
has to be connected each time the mould is set up.

CORPORATE TRAINING

29

HYDRAULIC ACTUATION
OF SPLITS

Fig: 1.21
CORPORATE TRAINING

30

ANGLED-LIFT SPLITS
In this method the splits are mounted in a chasebolster, which forms part of the moving half of the mould.
The splits are moving outward with an angular
motion which relieve the undercut portion of the
molding and retraction of the split alignment is
controlled by using spring actuation or cam track
actuation

CORPORATE TRAINING

31

ANGLED LIFT
SPLITS DIAGRAM

Fig: 1.22

Fig: 1.23
CORPORATE TRAINING

32

TYPES OF ANGLED LIFT SYSTEMS

Angled guide dowel actuating system

Cam track actuating system
Spring actuation.

CORPORATE TRAINING

33

ANGLED GUIDE
DOWEL ACTUATING
SYSTEM
The Guide dowels are fitted at an angle to the
underside of each split which passes through holes
machined at an angle in the chase-bolster.
When the ejector system is actuated, the relative
movement between the ejector plate and the chasebolster causes the guide dowels to move forward at
an angle corresponding to the splits which opens.

CORPORATE TRAINING

34

ANGLED
GUIDE DOWEL ACTUATION

Fig:
CORPORATE
TRAINING
1.24

35

 = Guide dowel angle.

Fig:
1.25
CORPORATE TRAINING

36

The convenient angle for the guide dowel is 10

it may be increased if large opening movement is
required. The actual opening movement of each split
calculated by the following formula.
M = E tan
E = effective ejector plate movement,
= Guide dowel angle.

CORPORATE TRAINING

37

CAM TRACK
ACTUATING SYSTEM
In this method the opening movement of the splits
are controlled by a cam track. When the splits are
actuated, studs fitted to each end of the split slide
along this cam track.
Actuation of the splits is by means of pin ejector
system. The splits are fitted into an open channel type
chase-bolster, which have wear plates.
Studs, screwed into the splits, protrude into the cam
track machined in the cam track plate which is
attached to the bolster.
CORPORATE TRAINING

38

CAM TRACK ACTUATION

Fig:
CORPORATE
TRAINING
1.26

39

CALCULATION

The opening movement of each split

calculating by
M = E tan
E = effective ejector plate movement,
= Cam track angle, usually 15

CORPORATE TRAINING

40

SPRING ACTUATION
The opening movement of the split depends on
the slot provided in the chase bolster and the spring
effective expansion length.
This ejection method is suitable for shallow
undercut components.
The ejector pin actuates the split, the spring exerts
the a force to vertical direction, which maintains
contact between the split and the angled wall of the
chase-bolster and gives angled movement to the
splits. Thus the splits get open.

CORPORATE TRAINING

41

SPRING
ACTUATION METHOD

Fig:
1.27
CORPORATE TRAINING

42

SPRING ACTUATION SYSTEM

This actuation system is suitable for small straight and
angled undercut components.
In this method the compression springs are used to
force the splits apart and utilizes the angled faces of the
chase bolster to close them. The opening of split
movement should be limited so that they will allow to reenter the chase bolster when the mould is closed.
The splits are mounted on the mould plate and retained
by guide strips. Studs project from the base of the splits
into a slot machined in the mould plate. The length of this
slot therefore controls the opening movement of each
split.
A compression spring is fitted between the studs in a
link-shaped pocket situated in the lower mould plate. The
splits are held closed by the chase bolster.
43
CORPORATE TRAINING

SPRING ACTUATION

Fig:
CORPORATE
1.28 TRAINING

44

SEQUENCE OF OPERATION
The chase bolster holds the splits during the injection
phase.
The compression springs exerts a force to split halves
immediately when the mould starts to open.
The stud reaching the end of the slot in the mould plate
stops the split movement.
Continued movement of the moving mould half
operated the ejector system to release the molding .

CORPORATE TRAINING

45

CALCULATION
The formula for calculating the splits opening movement is
M = H tan
Where M = movement of each split, Approximately
H = height of locking heel
= angle of locking heel
Suitable angle for the locking heel is 20 to 25.

CORPORATE TRAINING

46

SIDE CORES

It is a local core mounted at an angle to the

mould axis for forming a hole or recess inside
the molding.
This side core prevents the in-line removal
of the molding hence, side core must be
withdrawn prior to ejection .

CORPORATE TRAINING

47

TYPES OF SIDE CORE

Internal Side Core Assembly
The dog-leg cam actuation method
The spring-loaded system
External Side Core Assembly
Side cores on the parting surface
Side cores below the parting surface
Angled withdrawal Curved side core
CORPORATE TRAINING

48

INTERNAL SIDE
CORE ASSEMBLY
In this method the side core is T-shaped is mounted
in guides, which are securely attached to the moving
mould plate.
The retaining plate to the carriage secures the side
core element.The actuation of the carriage is by
means of a finger cam/dog leg cam method
The carriage is locked in the forward position by the
locking heel

CORPORATE TRAINING

49

DOG-LEG CAM
METHOD OF ACTUATION

Fig: 1.29
CORPORATE TRAINING

50

THE SPRING-LOADED SYSTEM

The spring-loaded system is an operating
method confined to those moldings that have very
shallow undercuts or projections.

CORPORATE TRAINING

51

Fig: 1.30
CORPORATE TRAINING

52

EXTERNAL SIDE
CORE ASSEMBLY
In this design, the side core is fixed to an
extremely mounted carriage which is actuated by
hydraulic or
pneumatic means.

CORPORATE TRAINING

53

Fig: 1.31
CORPORATE TRAINING

54

CURVED SIDE CORE

The core is withdrawing from the mould along the
arc of a circle.
It is suitable for components requires smooth curved
internal hole
Example: telephone hand set and pipe fittings.
In this type of component the side core can be
mounted on the parting surface of the mould.

CORPORATE TRAINING

55

MOULDS FOR
INTERNAL
UNDERCUT
COMPNENTS
0

INTERNAL UNDERCUT

An internal undercut is the internal protrusion or recess

formed in the molding by using matching core or cavity.
It is prevents a moulding from being extracted from the
core in line of draw.

059

EXAMPLES OF INTERNAL
UNDERCUT COMPONENTS

Fig: 2.2

Fig: 2.1
CORPORATE TRAINING

060

FORM PIN

A component, which has a local undercut portion, can

be successfully moulded in the conventional mould
by incorporating the undercut form on a pin.

CORPORATE TRAINING

061

UNDERCUT COMPONENTS
WHICH NEED FORM PINS
ACTUATION

Fig: 2.3
CORPORATE TRAINING

062

TYPES OF FORM PIN

EJECTION

Form Pin : Straight action

Form pin : angled action

CORPORATE TRAINING

063

FORM PIN:STRAIGHT
ACTION

This design is normally used for components, which

incorporate an undercut on one internal wall only.

CORPORATE TRAINING

064

Fig: 2.4

Fig: 2.5
CORPORATE TRAINING

065

FORM PIN: ANGLED ACTION

The basic feature of this design is that the working face
of the form pin is caused to move inwards relative to the
core during ejection, thereby relieving the undercut.
It can be used for components, which incorporate internal
undercuts on one or more walls.

CORPORATE TRAINING

066

Fig: 2.6

CORPORATE TRAINING

67

CALCULATION
The amount of withdrawal is calculated by the following
relationship:
M = E tan
Where,

M = the withdrawing movement

E = ejection movement.
= fitting angle of the form pin.

CORPORATE TRAINING

68

SPLIT CORE ACTUATION

This split core may be moved forward either in a
straight plane or an angled plane.

CORPORATE TRAINING

69

SPLIT CORES-STRAIGHT
ACTION
This design is used for components, which
incorporate an external undercut on one wall only.
The moulding can be removed at right angles to the
mould axis.

CORPORATE TRAINING

70

Fig:
CORPORATE
2.7 TRAINING

71

SPLIT CORE ANGLED

ACTION
In this design the split core is caused to move
inwards during the ejection stroke, thereby withdrawing
the restriction and allowing the moulding to be extracted
in the line of draw.
The advantages of this method is that the
withdrawing action automatic and the moulding does not
have to be removed at right angles to the moulds axis.
This design can therefore be used for components
with undercuts on opposing faces in addition to being
used for components with an undercut on one wall only.

CORPORATE TRAINING

72

Fig: 2.8
CORPORATE TRAINING

73

STRIPPING INTERNAL
UNDERCUT
Suitability:

The shape of the undercut,

The elasticity of the material, and
Whether the external form permits expansion during
ejection.

CORPORATE TRAINING

74

Fig: 2.9
CORPORATE TRAINING

75

CURVED SIDE CORE

Fig:
1.32
CORPORATE
TRAINING

56

MOULDS FOR
THREAD
COMPONENTS
CORPORATE TRAINING

MOULDS FOR
THREADED COMPONENTS

The threaded components are usually prepare for where

the repeated disassembly or where the strength of
assembly is required. The threads can be formed in by
three methods:
Cored or drilled holes with either thread cutting or thread
forming using self-tapping type screws.
Molded with local inserts.
Molded thread formed by using unscrewing threaded
inserts.
CORPORATE TRAINING

TYPES OF THREADS

External thread.

Internal thread.

According to thread shape subdivided into continues

and discontinuous thread.

CORPORATE TRAINING

Fig: 3.1

Fig: 3.2
CORPORATE TRAINING

COMPONENTS
INCORPORATING THREADS

Fig: 3.3

Fig: 3.4
CORPORATE TRAINING

MOULDS FOR INTERNAL

THREADED COMPONENTS
The internal thread is an internal undercut in that the
thread forms a restriction, which prevents the straight
draw removal of the moulding from the core. The types of
mould design for withdrawing the moulding, as follows:

Stripping (jumping-off) thread design

Fixed threaded core design
Loose threaded core design
Collapsible core design
Unscrewing mould designs

CORPORATE TRAINING

STRIPPING (JUMPING)
INTERNAL THREADS
1. The moulding must be free to expand during
ejection to permit the moulded undercut to ride
over the restriction on the core.
2. The outside form of the component to be formed
in a cavity, which is fully contained in one half of
the mould.
3. The internally threaded component may be
stripped (Jumped) from the core using the
stripper plate design providing a roll thread and
the plastic material has sufficient elasticity during
the ejection phase.
4. This method is recommended for polyethylene
(PE), polypropylene (PP) material.
CORPORATE TRAINING

STRIPPING INTERNALLY
THREADED COMPONENTS

Fig: 3.5

CORPORATE TRAINING

FIXED THREADED CORE

DESIGN
In this method, the thread form is incorporated on a
non-rotating core fixed to the moving mould plate. An
integer type cavity forms the external shape of the
moulding.
In operation, when the mould is opened, the moulding
remains on the core and is afterwards unscrewed by the
operator by hand or using release devices.

CORPORATE TRAINING

FIXED THREADED CORE

DESIGN

Fig: 3.6
CORPORATE TRAINING

ADVAMTAGES
Mould cost is cheaper than the unscrewing mould design
because of its require ejector mechanism
Maintenance cost is minimum as there are no moving
parts within the mould.
DISADVANTAGES
This design particularly used for multi-impression moulds
where the individual moldings to be unscrewed manually.
Increases the moulding cycle time.

CORPORATE TRAINING

LOOSE THREADED
CORES

This method is suitable for a large component

incorporates a local internally threaded hole or has
several internally threaded holes in close proximity to
each other.
Prevents automatic unscrewing thereby considerably
reducing the cost of the mould.
Where a number of holes are closely spaced,
automatic unscrewing becomes impracticable.
Because it require space for gear arrangement in
automatic unscrewing operation.

CORPORATE TRAINING

LOOSE THREADED CORES

Fig: 3.7
CORPORATE TRAINING

COLLAPSIBLE CORE

This design is suitable for components having internal

thread and internal undercut.

The important advantage of this method over the

rotating threaded core designs is that it eliminates the
need for complex unscrewing mechanism.

CORPORATE TRAINING

COLLAPSIBLE CORE

Fig: 3.8
CORPORATE TRAINING

EJECTOR PLATE ASSEMBLY

OPERATED USING
COLLAPSIBLE CORE

Fig: 3.9
CORPORATE TRAINING

UNSCREWING
MOULDS

High labour costs and other modern production

requirements demand the maximum use of automatic
operation.
In an unscrewing type mould either the cores or the
cavities are rotated to automatically unscrew the
moldings from the mould.
To provide the required rotary motion an unscrewing
unit is fitted behind the moving mould plate in place
of the conventional ejector unit

CORPORATE TRAINING

Manually powered fixed rotating core design

CORPORATE TRAINING

Manually powered fixed rotating core with gear transmission

CORPORATE TRAINING

POINTS CONSIDERED

In the axially fixed core design, the threaded core is merely

rotated to remove the moulding.
In the extractor plate design, the extractor plate is actuated
at the same time as the threaded core is rotated to remove
the moulding.
In the withdrawing rotating core design, the threaded core is
rotated by sun & planet gear mechanism and withdraws
the moulding from the core plate.

CORPORATE TRAINING

IMPRESSION LAYOUTS
1. The pitch circle diameter .
2. The In-line layout.

CORPORATE TRAINING

MACHINE POWERED
IN-LINE UNSCREW SYSTEM

Fig: 3.12 TRAINING

CORPORATE

THE PITCH CIRCLE

DIAMETER LAY-OUT

Fig:
3.13 TRAINING
CORPORATE

CORPORATE TRAINING

MULTIDAYLIGHT
MOULD

CORPORATE TRAINING

01

MULTIDAYLIGHT MOULD
It is a complex mould having more than one-daylight
when the mould is opened.
It consists of three main parts:
Fixed mould plate or feed plate,
Floating cavity plate or stripper plate,
Moving mould plate.

CORPORATE TRAINING

0102

TYPES OF MULTI DAY LIGHT

MOULDS
1. Double day light, stripper plate mould
2. Double day light, under feed mould
3. Triple day light, underfeed and stripper
Plate mould.

CORPORATE TRAINING

0103

DOUBLE DAYLIGHT,
STRIPPER PLATE MOULD
Suitability : The circular box-type moulding, which have thin
wall section.
Stripper plate:
The stripper plate is a rectangular plate, has aperture to sliding
on the core for ejection.
It is mounted between the cavity plate and the core plate.
These types of ejection will not leave any depression on the
molding.
CORPORATE TRAINING

0104

The moulding and feed system are removed in the

first day light between the stripper plate and the fixed
mould plate from the cavity plate.

Second daylight between the core plate and stripper

plate for ejection.

CORPORATE TRAINING

0105

STRIPPER PLATE EJECTION

Fig: 4.1

Fig: 4.2

CORPORATE TRAINING

Fig: 4.3

0106

DOUBLE DAYLIGHT
STRIPPER PLATE MOULD

Fig: 4.4

Fig: 4.6

Fig: 4.5

Fig: 4.7

Double Day Light With Underfeed Mould

CORPORATE TRAINING

0107

DOUBLE DAY LIGHT WITH

UNDER FEED MOULD
An Underfeed mould is one in which the feed system is
arranged to feed into the underside of the component.
In this mould the extra plate is added behind the cavity
plate to allow a runner system to be incorporated below the
cavity or cavities.
It consists of three main parts
1. Feed plate.
2. Floating cavity plate.
3. Moving mould plate.

CORPORATE TRAINING

0108

USE OF UNDERFEED TYPE

OF MOULD
1. Multi-point feeding can be accomplished on singleimpression moulds and on multi-impression mould.
2. Off-centre feeding can be achieved for both single
and multi-impression moulds.

CORPORATE TRAINING

0109

TRIPLE DAY LIGHT WITH

UNDERFEED AND STRIPPER
PLATE MOULD
A three-plate mold or triple daylight mould differs from a
two plate in that it has two parting planes and the mold
splits into three sections, every time the part is ejected.
Since the mold has two parting planes, the runner
system can be located on one, and the part on the other.
Three plate molds are used because of their flexibility in
gating location.
A part can be gated virtually anywhere along its
surface.

CORPORATE TRAINING

110

TRIPLE-DATLIGHT,
UNDERFEED-STRIPPER
PLATE MOULD

Fig: 4.8

Fig: 4.9

CORPORATE TRAINING

111

A THREE PLATE MOULD

ASSEMBLY

Fig: 4.10
CORPORATE TRAINING

112

THREE PLATE MOULD

This mould is mostly prepared for multi

impression circular cap components.

It is the combination of stripper plate and

under-feed system.

CORPORATE TRAINING

113

STRIPPER PLATE
MOVEMENT

Fig: 4.11

Fig: 4.12

CORPORATE TRAINING

114

SECONDARY SPRUE BUSH

Multi daylight moulds are having two sprue bushes.
Primary sprue bush is mounted at fixed plate backside.
Secondary sprue bush is mounted in the floating cavity
plate.

CORPORATE TRAINING

115

SECONDARY SPRUE BUSH

Fig: 4.13
CORPORATE TRAINING

116

 It is the simplest form of feed system.

It is not practicable for all types of components. The shape
of the component affects the design of the floating cavity
plate, which in turn determines the type of feed system can
be adopted and it requires the extra operation for removal of
runner from the moulding.

CORPORATE TRAINING

117

REVERSE TAPER
SECONDARY SPRUE
REVERSE TAPER SPRUE

Fig: 4.14
CORPORATE TRAINING

118

REVERSE TAPER
SECONDARY SPRUE
Standard type of pin point gate is used.
The main use of this sprue is to release the component
with automatic de-gating in three-plate mould.
Drawback of this method: the feed system is not free to fall
when the mould is opened because the secondary sprues
are retained within the floating cavity plate.
The feed system is removed by hand if the basic underfeed
mould design is used.
CORPORATE TRAINING

119

UNDERCUT RUNNER
SYSTEM SECTION VIEW

Fig: 4.15

Fig: 4.16
CORPORATE TRAINING

120

Fig: 4.17
CORPORATE TRAINING

121

DESIGN CONSIDERATION
The float period must be sufficient to permit the floating
cavity plate to clear the reverse-tapered sprues before the
puller pulls the sprue.
Considerable runner deflection is necessary to ensure that
the secondary sprues are not pulled back into their holes
when the puller is actuated.
To ensure that the puller is pushed back to its moulding
position when the mould is closed, the diameter of the
puller must exceed the width of the runner.

CORPORATE TRAINING

122

RUNNER STRIPPER PLATE

The fixed secondary puller is fitted directly below each
secondary sprue.
To release the feed system from this fixed secondary puller a
runner stripper plate is introduced between the feed plate and
the floating cavity plate.

CORPORATE TRAINING

123

UNDERFEED MOULD
SECTION VIEW

Fig: 4.18
CORPORATE TRAINING

124

UNDERFEED MOULD

Fig: 4.19

Fig: 4.21

Fig: 4.20

Fig: 4.22
CORPORATE TRAINING

125

STACK MOULD

When two injection moulds are operated in tendem in the

same molding machine it is called stack mould.

Used for molding shallow, small parts in large quantities

like tape cassettes.

The cavities are located in two planes corresponding to

two parting lines and are filled.

The clamping force required is 15% higher than a

standard mould.
CORPORATE TRAINING

126

 It is a simplest mould design, from a runner point of view

is a single-cavity, single-face mold arranged in back to back
configuration of same impression or different impressions.
The machine nozzle injects plastic directly into the mould
cavity. The single-face mould can also be extended to a
multi-cavity layout.
The machine nozzle injects the melt into a runner system
that feeds each individual cavity.
It is suitable of which has the thin-wall injection molding
with hot runner designs.
CORPORATE TRAINING

127

STACK MOULD IN IMM

Fig: 4.23

CORPORATE TRAINING

128

Fig: 4.24

CORPORATE TRAINING

129

TYPES OF STACK MOULD

1.

FOUR-FACE (FOUR-LEVEL) STACK MOLDS

2.

THREE-FACE (THREE-LEVEL) STACK MOLDS

CORPORATE TRAINING

130

1.FOUR-LEVEL STACK
MOULDS
Four-level stack molds quadruple output over single-face
molds, and are suited to very high production volumes of
shallow parts.
Quick Change molds switch from one product to another in
less than an hour in both single-face and two face stack mold
applications.
Two-cavity slack molds allow molding of large parts in a backto-back configuration, thus doubling the machine capacity.

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The four-face stack mold is two stack molds placed

back to back and it increases the mold shut height.
It operates in the same molding machine as a
conventional slack mold.
Cycle limes identical to those of a conventional mold.
Shot-to-shot changeover time of less than one hour
required for both mechanically and air ejected parts in
the stack mold.
Machine shut height remains the same from one
product to the next.

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2.THREE-LEVEL STACK
MOULDS
Three-level stack molds permit molding of deep-draw or
tall pans to maximize the productivity of machine shut
height.
It is the development of a proprietary melt transfer system
to pass the plastic across the mold parting line.
The system avoids drooling on mold opening due to the
self-decompression of the central hot-runner system.

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 The three-level stack mold uses triple valueless melt

transfer system (VMTS) crossover nozzles to provide
equal pressure and flow characteristics to the plastic melt
to each cavity.
This stack mold configuration fills in when a two-level
mold cannot produce enough pans and a four-level mold
is too large for the machine.
Three-level stacks is used to mold both shallow draw
(for example, packaging lids) and deep draw pans (such
as tall containers).
They can be combined with quick-change systems to
give added flexibility to high-production tooling.
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HOT RUNNER
MOULD

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TYPES OF INJECTION MOULD

1. COLD RUNNER
2. HOT RUNNER
A runner is the channel in the mold that
conveys the molten plastic material from the
barrel of the injection-molding machine to the
part.

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COLD RUNNER MOULD

The runner is cooled and ejected with the part.

Every cycle, a part and a runner are produced.
There are two major types of cold runner molds: Two
plate and Three-plate mould.

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ADVANTAGES OF COLD RUNNER

MOULD

Mold requires less maintenance.

The mold design is very simple and much
cheaper than a hot runner system.
Less skill to set up and operate.
Color changes are also very easy, since all of
the plastic in the mold is ejected with each cycle.

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DISADVANTAGES OF COLD
RUNNER MOULD

The waste plastic is generated.

The runners are either disposed of or reground and
reprocessed with the original material.
This adds a step in the manufacturing process.
Regrinding increases variation in the injection
molding process, and decreases the plastic's
mechanical properties.

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HOT RUNNER MOULD

The hot runner mould contains a heated runner manifold

block, insulated from the rest of the mould keeps the
runner permanently melt.

The hot runner mould replaces the conventional sprue

bushing with a hot sprue bushing or a heated nozzle.

The polymer material directed to the mould cavities

without heat loss and pressure loss.

Large moulding like automotive dash board, bumpers,

computer housing, multi colour moulding etc. are
produced in this process.
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HOT RUNNER MOULD

In a three-plate cold runner mold the runner system must
be reground and the material is reused.
It is possible to eliminate the runner system entirely by
keeping it fluid.
The material is kept plasticized by the hot runner manifold,
which is heated with heating element (like electric
cartridges).
The block is usually thermostatically controlled.
Heater bands, which are individually controlled, can be
mounted round the nozzle.
The plastic is kept fluid and the injection pressure is
transmitted through the hot runner manifold.

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Assembly of hot runner mould

Fig: 5.1
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Hot runner mould section view

Fig: 5.2
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TYPES OF HOT RUNNER

MOULD
A hot runner system is divided into two parts
The manifold
The drops .
The manifold has channels that convey the plastic on a
single plane, parallel to the parting line, to a point above the
cavity.
The drops, situated perpendicular to the manifold, convey
the plastic from the manifold to the part.

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HOT RUNNER WITH

EXTERNALLY HEATED
MANIFOLD AND DROPS

Fig: 5.3
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TYPES OF HOT RUNNER SYSTEM

Internally drops and manifolds.
Externally heated drops and manifolds.

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EXTERNALLY HEATED HOT

RUNNER

Externally heated hot runner channels have the lowest

pressure drop of any runner system (because there is no
heater obstructing flow and all the plastic is in molten
state).

They are better for colour changes none of the plastic in

the runner system freezes.

There are no places for material to hang up and degrade,

so externally heated systems are good for thermally
sensitive materials.
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INTERNALLY HEATED
RUNNER SYSTEM
Internally heated runner systems require higher molding
pressures, and color changes are very difficult.
There are many places for material to hang up and
degrade, so thermally sensitive materials should not be used.
Internally heated drops offer better gate tip control. It
separate runner heat from the mold because an insulating
frozen layer is formed against the steel wall on the inside of
the flow channel.

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INTERNALLY HEATED CORE

ROD SECONDARY NOZZLE

Fig: 5.4
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DESIGN CONSIDERATION
FOR HOT RUNNER MOULD
Insert plug close off manifold bores should be smooth.
Runner diameters should impart shear stress not more
than 1 percent of the resins tensile strength.
The pressure drop from sprue bushing to tip should not be
more than 25 percent of the maximum plastic fill pressure,
with the resulting temperature increase remaining as close
to the desired melt as possible.
A runner volume of 25 percent of the part volume, and a
shear rate of about 1000 sec-1, are good
Sufficient heating elements should be incorporated so that
the hot-runner unit heats quickly to the required moulding
temperature from cold.
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.
Sufficient heat energy must be supplied to the hot-runner
unit it replaces conduction, convection and radiation heat
losses.
To ensure that the temperature of the melt in the flowway is maintained without either hot or cold regions, careful
location of the heating elements is essential.
Considerable production time may be lost if a heater
fails. Thought must be given therefore to choice of heating
element; its location and the facilities for. removing it.

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 The layout of the wiring system should be

neat and easily traceable.
Heating element wires, which are subject to,
heat or abrasion attack should be protected.
Use manufacturers recommended
clearances when fitting heating elements of the
cartridge type.
Flat-type heating elements and induction
heating elements should be completely
enclosed within the unit for maximum efficiency.

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 The hot-runner unit must be insulated from

the rest of the mould structure.
For many materials, close control of the
temperature of the melt is vital. Hence Careful
consideration to be made for the location of
thermocouples.
To minimize degradation, color-changing and
material-changing problems the melt flow-way
must be as streamlined as possible, without
sharp corners, ledges or other stagnation points
which tend to hold back the polymer melt for
extended periods.
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APPLICATIONS OF HOT
RUNNER MOULD
It allows for the pin gating of mouldings on
multi-impression types of mould
It allows for multi-point gating on singleimpression and multi-impression mould
It allows for side or film gating of large
mouldings.
It permits the semi-runnerless design to be
adopted, where small groups of impressions
are fed from secondary sprues.

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THE MANIFOLD BLOCK

Rectangular Manifold Block

Circular manifold block

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Fig:5.6

Fig:5.5
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RECTANGULAR
MANIFOLD BLOCK

Fig:5.7
Fig:5.8

Fig:5.8
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Fig:5.9

23

THE MELT-FLOWWAY

Fig: 5.10
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RUNNER PLUG
It is made from stainless steel for plugs in the flow path of
hot runner system to direct the plasticized materials.
It has larger thermal expansion than the manifold
material. As the manifold is heated to operating
temperature, the stainless plugs will expand at a greater
rate making the possibility of leakage impossible.

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TYPES OF NOZZLES
1. Extended nozzle
2. Barb nozzle
3. Antechamber nozzle

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1.EXTENDED NOZZLE

On the extended nozzle a resistance type band heater is

provided which is controlled by means of thermocouple.
To minimize the transfer of heat from the heated nozzle to
the mould, a circumferential clearance of at least 7mm must be
provided between the two parts.
The main advantage of this nozzle is to minimize the
length of the sprue gate as short as possible.

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Fig:5.11

EXTENDED NOZZLE

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2.BARB NOZZLE

This type of nozzle is used to minimize the blemish on

the component at the gate point.
The plastic material flows through to the nozzle, sprue
and gate. After solidification, the sprue is pulled from the
sprue bush by the barb of the nozzle.

Fig:5.12
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3.ANTECHAMBER NOZZLE

It is termed as hot well design, a small mass of plastic

material is retained in the antechamber which insulates
the central core of plastic material.

The plastic material remains fluid to allow it to pass

intermittently through the antechamber into the
impression.

This type of nozzle is used for moulding thin-walled

components.

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INSERT

ANTECHAMBER

Fig:5.13 TRAINING
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INSULATED RUNNER
MOULD

In this type of mould the melt flows from standard or

extended nozzle into a large diameter runner via the
reverse taper sprue and gate.

The outer layer of the melt solidifies against the cold

runner wall which forms an insulating shell, while the
centre core of the material retain in the molten state.

The outer layer of runner acts as an insulating media

and avoids heat loss from the polymer melt to the mould.

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Fig:5.14
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EXPANSION PROBLEMS
The hot-runner unit mould is that metals expand when
heated.
The manifold block increases in all three dimensions
when the temperature is increased.
The distance between the centers of the secondary
nozzles increases with respect to the fixed distance
between the centers of the impressions machined in the
cavity plate.
When designing the hot-runner mould, allowance must
be made for this expansion to
ensure that the
centerlines are in line during production
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EXPANSION PROBLEMS

Fig:5.15
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NOZZLE
LENGTH

200

250

300

48 mm
68 mm

0.13
0.20

0.17
0.20

0.21
0.30

The equation for calculating expansion is as follows:

e=L X X T
Where e = expansion (mm or in)
L = length dimension (mm or in)
= Coefficient of thermal
expansion (mm/mm C or in / inC)
T = increase in temperature ( C)

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DESIGN OF HOT RUNNER

MOULD FOR CAP

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HOT RUNNER MOULD FOR

CAP SEAL

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THREE PLATE HOT RUNNER

MOULD FOR CAP

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THREE PLATE HOT RUNNER

MOULD FOR LEAD FRAME

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UNSCREWING HOT RUNNER

MOULD FOR CAP COMPONENT

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