Injection Mould Design

INJECTION MOULD DESIGN
CORPORATE TRAINING AND

PLANNING
CONTENTS
 Chapter 1 : Introduction
 Chapter 2 : Selection of Moulding Machine
 Chapter 3 : Fundamental Aspects of Injection Mould
 Chapter 4 : Parting Surface
 Chapter 5 : Feed System
 Chapter 6 : Ejection System
 Chapter 7 : Mould Temperature Control
 Chapter 8 : Types of Injection Moulds
CORPORATE TRAINING AND PLANNING

INJECTION MOULD
The Injection mould consists of two or more pieces of metals in which

impression of the piece to be moulded is machined.
For multi article moulds the impressions are joined to the sprue by runner
channels cut in one of both sides of the mould halves through which the
plastic material will flow without constriction.

CLASSIFICATION OF INJECTION MOULDS
The main requirements :
 The type of gating and means of degating .

 Types of ejection used for the mould part.
 Presence of internal and external undercuts on the component.
 The manner in which the part is released.
Moulds :
 Hand Operated Mould
 Semi Automatic Mould
 Fully Automatic Mould

INJECTION MOULD

INJECTION MOULDED ITEMS

SELECTION OF MOULDING MACHINE
 Shot Capacity
 Plasticising Capacity
 Clamping Force
 Daylight of the machine
 Machine Nozzle

MACHINE NOZZLE
• Spherical Nose
• Flat Nose
DRY CYCLE TIME
In an Injection Moulding machine, the cycle time without any plastic material
is referred as dry cycle time.

FUNDAMENTAL ASPECTS OF INJECTION MOULD
CLASSIFICATION :
 Core and cavity
 Reminder part of mould which includes various mould plates, mould

ancillary parts etc.

Basic Terminology of Injection
Mould
 Core
 Cavity
 Impression
 Register /Locating Ring
 Sprue/ Bush
 Guide Pillar & Guide Bush
 Ejector Plate Assembly
 Ejector Elements

Support Pillar

For proper alignment of core and cavity in order to get even walled moulding,
the following methods are incorporated.
• Incorporation of Guide Pillar and Guide Bush in moulds

• Taper alignment method.
1. GUIDE PILLAR
The main function of Guide Pillar is
• Alignment of mould faces during closing of the mould.

• To protect the core.

2. GUIDE BUSH
Guide Bush is incorporated in a mould to provide a suitable wear resisting

surface for the guide pillar.
It is generally positioned in the fixed half of the mould.

3. TAPER LOCATION
To provide accurate location on cylindrical mouldings, a taper spigot is made on

one half of the mould to engage a similar tapered seating in the other half.
The angle of taper is usually between 100 and 300.
The preferred method of incorporating tapered location is on the cavity side ,

fitting into a recess on the core side.

SPRUE BUSH
It acts as a connecting member between the machine nozzle and the mould face.
Types of Sprue Bush :
1. Spherical seated 2. Flat seated
1.0 mm (minimum)
Spherical radius to accommodate machine nozzle

REGISTER RING
Register or Locating Ring fits into a circular hole which is accurately

machined in the injection platen on the cylinder –nozzle axis.
Types of Registered Ring :
• Front Plate Mounted Registered Ring

• Sprue Bush Mounted Registered Ring
Types of Front Plate Mounted Registered Ring :
• Reduced Diameter type

• Constant Diameter type
• Increased Diameter type
• Increased Depth type

FRONT PLATE MOUNTED REGISTER RING
Constant Increased Increased

Reduced
Diameter Type Diameter Type Depth Type
Diameter Type
DEVELOPMENT OF CORE & CAVITY
Generally two methods are incorporated for development of core and cavity.
• Integer Method
• Insert Bolster assembly Method
Integer Method
In this method, the core and cavity are machined from a piece of steel plate
or is cast in one piece.
The core plate machined by this method is called Integer Core plate and the
cavity plate is called Integer Cavity plate.

Insert & Bolster Assembly Method
For multi impression and intricate shaped moulds, the cores and cavities are
made out of small steel blocks which are called as Inserts.
The core block is termed as Core Insert and cavity block is termed as Cavity
insert.
The inserts are securely fitted into holes in a separate steel plate which is called
Bolster.
Types of Bolster :
1. Solid Bolster 2. Strip type Bolster 3. Frame type Bolster

4. Chase Bolster : Open Channel Chase Bolster and Enclosed Chase
Bolster
5. Bolster Plate

Solid Bolster
Strip Bolster Frame Bolster
Chase Bolster Bolster Plate

MOULD CLAMPING METHOD
Mould clamping is of two types :
1. Direct Clamping Method 2. Indirect Clamping Method

MOULD MATERIALS
Main requirements :
• Excellent machinability
• High wear resistance
• Good polishability
• Excellent heat treatability
• Sufficient corrosion resistance

STANDARD MOULD BASE
Standard Mould Base includes all elements of a plastic mould, excepting

the core and cavity inserts.
Recommended two standards :
• DME Standard
• HASCO standard

STANDARD MOULD BASE

MOULD VENT
It is a shallow recess or hole incorporated in the design to permit

entrapped air or other gases to escape freely.
Recommended position for a vent :
 The furthest point from the gate on symmetrical mouldings.
 At the point where flow paths are likely to meet.

PARTING SURFACE
Types of Parting surface
• Flat Parting Surface
• Non Flat Parting Surface

Classification of Non Flat parting surface :
 Stepped Parting Surface
 Profile Parting Surface
 Angled Parting Surface
 Complex Edge Parting Surface

Profile Parting Surface

Angle Parting Surface
Complex Edge Parting Surface

FEED SYSTEM
The flow ways which connects from nozzle of the injection

moulding machine to the impression is called feed system.
Feed system comprise
• Sprue
• Runner
• Gate

SPRUE
It is the solidified plastic material formed in the tapered passage of parting

surface.
RUNNER
It provides the connection between sprue and cavity via the gate.
Runner design depends on :
• Cross sectional shape of runner

• The size of runner
• The runner layout

Cross Sectional shape of Runner
• Fully Round Runner
• Square Runner
• Trapezoidal Runner
• Modified Trapezoidal Runner
• Half Round Runner
• Rectangular Runner
• Hexagonal Runner

Round Runner
Trapezoidal Runner
Modified Trapezoidal Runner
CORPORATE
Hexagonal TRAINING AND PLANNING
Runner
Runner Size
Main factors :
• Plastic material to be used.

• The volume of the moulding .
• The distance of the impression from the main runner or sprue.
The formula for calculating runner size is :
D = (√ W x 4√L ) / 8 in emperical system
Where D = Runner diameter; W = Weight of moulding ;
L = Height of runner

Runner Layout :
The number of impressions

• The shape of the components
• The type of mould
• The type of gate
Runner Balancing
The distance the plastic material travels from the sprue to the gate is same for
each moulding.

BALANCED RUNNER LAYOUT

3. GATE
It is a small orifice which connects runner to impression.
• It freezes soon after the impression filled It should de gate easily.
• Small witness mark remains after degating.
• Better control of filling.

The cross sectional dimensions of a gate are determined by the plastic used
and the wall thickness of the moulding.
The depth of gate is h = n t

h = depth of gate (mm.) , t = wall thickness (mm.) , n = material constant
n x √A
Gate width W = -----------
30
W = Gate width (mm); A = Surface area of cavity (mm2 ) ; n = Material constant
Gate Balancing
When moulds incorporate a large number of differently shaped impressions,

balanced filling of impression can be achieved by varying the gate dimensions,
which is termed as gate balancing .

Examples of Gate Balancing

Types of Gates
• Sprue Gate
• Rectangular Edge Gate
• Overlap Gate
• Fan Gate
• Tab Gate
• Diaphragm Gate
• Ring Gate
• Film Gate
• Tunnel / Submarine Gate
• Pin Point Gate

Sprue Gate :
This type of gate is used for single impression mould. Here the moulding is
directly fed from the sprue which acts as a gate.

Rectangular Edge Gate :
This gate feeds the material from one side into the mould cavity.

o Overlap Gate :
This gate prevents the formation of jetting by directing the melt flow against an
opposite face of the impression.

Fan Gate :
This type of gate is used for thin walled large area mouldings

Tab Gate :
This type of gate is useful for transparent solid block type components.
It consists of a tab or projection and a rectangular edge gate.

Diaphragm Gate :
This gate is often used for gating cylindrical or round parts that have an
open inside diameter . It is used for single cavity moulds that have a small
to medium internal diameter .

Ring Gate :
This gate is used for cylindrical or round parts in a multi cavity mould or
when a diaphragm gate is not practical

Film Gate :
For thin flat mouldings, especially made of semi crystalline

thermoplastics, where the shrinkage depends on the flow direction,
a film gate is used.

Submarine / Tunnel Gate :
This gate is a form of edge gate in which the gate tunnels the material
below the parting line into the mould cavity at a point just below the
edge of the moulding.
Curved Tunnel Gate

Submarine Gate TRAINING AND PLANNING
CORPORATE
Pin Point Gate :
This type of gate is round shaped and lies in the centre of the runner.
This gate is used for the following types of moulds :
• Three plate underfeed type of mould
• Hot runner moulds

EJECTION SYSTEM
The ejector system consists of the following :
• Ejector Grid
• Ejector Plate Assembly
• Types of Ejection
Ejector Grid :
Types of Ejector Grid :
• In Line Ejector Grid

• Frame type Ejector Grid
• Circular Support Block Grid

Ejector Plate Assembly :
It is that part of the mould to which the ejector element is fitted. It

normally consists of
• Ejector plate
• Retaining plate
• Ejector rod.

Ejector Pin Return System :
There are two types of ejector return system generally adopted in a

standard mould.
• Push Back Pin return system

• Spring Return system :
Push Back Return

System

Types of Ejection :
The normally used ejection systems are as follows :
1. Pin Ejection :
 Plain Diameter Ejector Pin :
a) Moulding Face Ejector Pin

b) Parting Face Ejector Pin
 Stepped Ejector Pin

 D shaped Ejector Pin
2. Sleeve Ejection 3. Blade Ejection 4. Valve Ejection

5. Air Ejection 6. Stripper Plate Ejection 7. Stripper Bar Ejection

Plain diameter Pin Ejection :
• The ejector pins, attached to the ejection plate assembly, are moved forward
relative to the mould plate.
• The ejector pins, which are machined circular steel rod, push the moulding
from the mould.

Stepped Ejector Pin :
This type of ejector pin is used for the ejection of moulded ribs,
slender projections which can not be ejected by plain diameter ejector pin.

D Shaped Ejector Pin :
This type of ejector pin is generally used for thin walled box type mouldings.
This is one type of flat sided ejector pin which looks like the letter D .

Sleeve Ejection :
Sleeve is one type of hollow circular ejector pin which is fitted at

the rear end to the ejector assembly.
This type of ejection is generally restricted to the following types
of moulding:
 Certain types of circular mouldings

 Circular projections on a moulding

Valve Ejection :
This type of ejection is used for the ejection of large components.
 For single impression moulds, for centre fed moulding the

conventional ejector assembly is not required.
 For multi impression mould, the valve ejector is attached directly

to ejector plate by screws.

Blade Ejection :
 This type of ejector system is used for releasing very slender parts, which
 The cross section of a blade is rectangular.

Air Ejection :
In this ejection system , compressed air is used directly on to the

moulding face via a small air valve.

Stripper Bar Ejection :
In this ejection system, the ejector element, a stripper bar, pushes the
bottom edge wall of the moulding.

Stripper Plate Ejection :
In this ejection technique , a steel plate termed a stripper plate is
situated between the core and cavity plate for the purpose of ejection.
Different types of actuation of stripper plate are :
Tie Rod actuation

Length Bolt Actuation

Chain /External Link Actuation

Direct Actuation

Ejection force required to strip a moulding off a male core :
F = ( St x E x A x fp) / [ d x ( d/2t - d x Pp /4t ) ]

F = Ejection force required (kgf) ; E = Elastic Modulus (kgf/ cm2 )
A = Total area of contact between moulding & mould faces in line of
draw (cm2)
St = Co-efficient of thermal expansion X temperature difference
between softening point and ejection temperature X d (cm)
fp = Co-efficient of friction between plastics and steel.
d = Diameter of circle of circumference equal to length of perimeter of
moulding surrounding male core (cm)
t = Thickness of moulding; Pp = Poisson’s ratio of plastics.

Sprue Puller :
 It is an undercut pin situated opposite the sprue entry.

 This is generally used for multi impression moulds.
Sprue Pullers are of two types.

 In one design , the puller is below the parting surface.
 In another design , Sprue Puller work on the principle of

withdrawing through a plate .

Cold Slug Well type Sprue Puller
Grooved Slug Well Sprue Puller Reverse Taper Sprue Puller

MOULD TEMPERATURE CONTROL
Maintaining the optimum temperature in a mould is very

important as
 It improves the cycle time

 It improves the quality of the product
 It avoids distortion of the product

Types of cooling :
 Cooling Integer type Mould Plates

 Cooling Insert Bolster assembly
A) Cooling Integer type mould plates
1. Integer cavity plate 2. Integer core plate.
1. Cooling Integer Cavity Plate :
a. U Circuit b. Rectangular Circuit c. Balanced Z Circuit

d. Multi level cooling system e. Cooling Plate system

 In Rectangular circuit the water flows around the four walls of the
cavity resulting more even temperature control.
 Balanced Z Circuit is used for shallow, large area cavity plate. In this
circuit, the coolant inlets pass close to the sprue entry.
 Multi level cooling system is recommended for cooling of deep integer

type cavities.
 Cooling Plate system is used for cooling of irregular shaped
mouldings .

U Circuit Rectangular Circuit

Balanced Z Circuit
2. Cooling of Integer Core Plate :
• Angle Hole System
• Baffled Straight Hole System
• Stepped Circuit

Baffled Straight Hole Cooling System
Angled Hole Cooling System
Stepped Circuit
B) Cooling Insert –Bolster Assembly
It is classified into the following :
• Cooling the Bolster
• Cooling the Insert

Bolster Cooling :
The recommended circuits are :
• Rectangular Circuit
• Z Circuit

Cavity Insert Cooling :
 Rectangular insert
 Circular insert .
Cooling Rectangular Insert

Here single or multi level circuits are adopted depending upon the shape
and depth of cavity. Where mould space is restricted, inserts can be
cooled by use of copper pipes.

Cooling Circular Insert
 Coolant Annulus Method

In this method, a coolant annulus is machined on the periphery of the
insert .
 Interconnecting Groove Design

This design is adopted when inserts are arranged in line or on a pitch
circle diameter.

COLANT ANNULUS COOLING SYSTEM
Insert O- Ring Cooling Channel

Core Insert cooling
1. Shallow core insert cooling
2. Deep core insert cooling
Shallow Core Insert cooling
1. U circuit
2. Balanced Z circuit
3. Spiral circuit

Deep Core Insert cooling :
 Deep Chamber Design
 Baffled Hole system
 Bubbler system
 Helical Channel Design
 Heat Rod method

Deep Chamber Core Helical Channel
Insert Cooling Core Insert Cooling
Baffle Hole Core Insert

Cooling
Bubbler method of Core Insert Cooling

CHAPTER - 8
TYPES OF INJECTION MOULDS
In general two types of moulds are in common.
They are : 1. Two Plate Mould 2. Three Plate Mould
1. In a standard two plate mould , it opens at the parting surface. This is

sometimes referred as single daylight mould.
2. A standard three plate mould is a mould plate assembly consisting of

three mould parts . In this type, mould opens at two parts. The main
applications of this type of mould are :
 Centre –feeding of components in multi impression tools

 Area feeding of components with multiple restricted gates etc.

TWO PLATE MOULD
Core Plate Cavity Plate

Back Plate
Support Pillar
Guide Bush
Guide Pillar
Sleeve Ejector
Core Pin
Knock Out
Rod
Sprue Puller
Ejector Pin
Retaining Plate
Ejector Plate
Push Back Pin
Core & Cavity

Ejector
Stroke
THREE PLATE MOULD


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INJECTION MOULD DESIGN

CORPORATE TRAINING AND

CORPORATE TRAINING AND PLANNING

The Injection mould consists of two or more pieces of metals in which

CORPORATE TRAINING AND PLANNING

The main requirements :

 The type of gating and means of degating .

 Hand Operated Mould

 Semi Automatic Mould

 Fully Automatic Mould

CORPORATE TRAINING AND PLANNING

CORPORATE TRAINING AND PLANNING

 Daylight of the machine

CORPORATE TRAINING AND PLANNING

DRY CYCLE TIME

is referred as dry cycle time.

CORPORATE TRAINING AND PLANNING

 Core and cavity

 Reminder part of mould which includes various mould plates, mould

CORPORATE TRAINING AND PLANNING

CORPORATE TRAINING AND PLANNING

• Incorporation of Guide Pillar and Guide Bush in moulds

The main function of Guide Pillar is

• Alignment of mould faces during closing of the mould.

CORPORATE TRAINING AND PLANNING

Guide Bush is incorporated in a mould to provide a suitable wear resisting

CORPORATE TRAINING AND PLANNING

To provide accurate location on cylindrical mouldings, a taper spigot is made on

The angle of taper is usually between 100 and 300.

The preferred method of incorporating tapered location is on the cavity side ,

CORPORATE TRAINING AND PLANNING

Types of Sprue Bush :

1. Spherical seated 2. Flat seated

Spherical radius to accommodate machine nozzle

CORPORATE TRAINING AND PLANNING

Register or Locating Ring fits into a circular hole which is accurately

Types of Registered Ring :

• Front Plate Mounted Registered Ring

Types of Front Plate Mounted Registered Ring :

• Reduced Diameter type

CORPORATE TRAINING AND PLANNING

Constant Increased Increased

• Insert Bolster assembly Method

CORPORATE TRAINING AND PLANNING

1. Solid Bolster 2. Strip type Bolster 3. Frame type Bolster

CORPORATE TRAINING AND PLANNING

Strip Bolster Frame Bolster

Chase Bolster Bolster Plate

Mould clamping is of two types :

1. Direct Clamping Method 2. Indirect Clamping Method

CORPORATE TRAINING AND PLANNING

• High wear resistance

• Excellent heat treatability

• Sufficient corrosion resistance

CORPORATE TRAINING AND PLANNING

Standard Mould Base includes all elements of a plastic mould, excepting

Recommended two standards :

CORPORATE TRAINING AND PLANNING

CORPORATE TRAINING AND PLANNING

It is a shallow recess or hole incorporated in the design to permit