OBJECTIVES

VARIOUS MOLDING TECHNIQUES FOR DIFFERENT TYPES OF COMPONENTS

ABOUT INJECTION MOLDING MACHINE.
ABOUT MOLD
FEEDING SYSTEM
MOLD FLOW ANALYSIS
UNDERCUT AND REMOVAL PROCIDURE
PLASTIC PRODUCT DESIGN
COMMON DEFECTS IN PLASTICS PARTS
 VARIOUS MOLDING TECHNIQUES FOR DIFFERENT TYPES OF COMPONENTS.

INJECTION MOLDING : I/P & CHILD PARTS,BUMPERS, PILLAR TRIMS.

EXTRUSION : SEALING SYSTEMS OF AUTOMOBILE, PIPE (PLASTIC & RUBBER)
BOLW MOLDING : DUCTS , BOTTLES, TOYS.
THERMO/ VACUUM FORMING : DISPOSABLE CUP & TRAY,
EXPANDED FOAM MOLDING : STEERING WHEEL,
ROTATIONAL MOLDING : WATER TANK,SPEARS.
ABOUT INJECTION MOLDING MACHINE.
MAJOR PARTS OF MOLDING MACHINE

Clamping& Ejection Unit Injection Unit

DETAIL PARTS OF INJECTION MOLDING MACHINE &
THEIR FUNCTION
ABOUT MOULD.
 TYPES OF MOLD

BASED ON FEEDING SYSTEM BASED ON NUMBER OF PARTS

•COLD RUNNER MOLD •SINGLE CAVITY MOLD
•HOT SPRUE MOLD •MULTY CAVITY MOLD
•HOT RUNNER MOLD

BASED MOLD OPENING BASED ON TYPE OF COMPONENT

•2 PLATE MOLD •SINGEL PART MOLD
•3 PLATE MOLD •FAMILY MOLD

BASED ON SPECALITY
•COINJECTION MOLD
•INSERT MOLD
 BASED ON MOLD OPENING
2 PLATE MOLD
ADVANTAGE
1)MOLD WILL BE SIMPLE & CHEAP SINGLE
2) VARIOUS TYPE OF GATES CAN BE ADOPTED. OPENING
DISADVANTAGE
1)MOLD WIDTH AND LENGTH WILL BE MORE THAN 3
PLATE MOLD
2) AUTO DEGATING WILL BE POSSIBLE ONLY IN
SUBMARRINE GATE

3 PLATE MOLD
FIRST
OPENING
ADVANTAGE
1) MOLD SIZE WILL BE LESSER AS THE FEEDING
SECOND SYSTEM WILL BE ON UPPER PLATE
OPENING 2) AUTO DEGATING POSSIBLE
DISADVANTAGE
1) MORE COSTLY
2) SLOWER PRODUCTION RATE
3) MOLD HEIGHT WILL BE MORE
BASED ON FEEDING SYSTEM

Hot Runner Benefits

HOT SPRUE MOLD
• Faster Cycles
- 15-20% Faster

• Eliminates Material
Waste
- No Sprue or
Runners(IN HOT
HOT RUNNER MOLD
RUNNER SYSTEM)

• Improves Part Quality

- Less Stress
- Better Appearance
 SPRUE BUSH

MOLD PARTS
TOP PLATE
GUIDE BUSH`
GUIDE PIN

CAVITY PLATE

SLIDER ASSLY

COMPONENT

CORE PLATE

CORE BACK PLATE

RETURN PIN

GUIDE BUSH

EJECTOR GUIDE PIN

SPACER BLOCK

BOTTOM PLATE
FEEDING SYSTEM
 SPRUE
-It is the connecting path
between machine nozzle &
runner system.

 RUNNER
-It is the connecting path
between sprue & gate.

 GATE
-It is the connecting path
between runner and
component.
SPRUE
•Sprue is the beginning of the melt delivery system within the mold
•The interface between the nozzle & the mold
• Taper shape has been made for avoiding the back flow of material.
SPRUE PULLER

REVERSE Z PULLER GROOVE

TAPER TROUBLE-
BEST GOOD SOME
 RUNNER SYSTEM
A runner system that has been designed correctly will:
Achieve the optimal number of cavities
Deliver melt to the cavities
Balance filling of multiple cavities
Balance filling of multi-gate cavities
Minimize scrap
Eject easily
Maximize efficiency in energy
consumption
Control the filling/packing/cycle time.
RUNNER BALANCING
B A A B
-FOR UNIFORM FILLING OF
COMPONENT
-FOR MAINTAINING UNIFORM
PRESSURE INSIDE MOLD
-REDUCE FILLING TIME
B A A B

UNBALANCED RUNNER SYSTEM

A A A A

A A A A
BALANCED RUNNER SYSTEM BALANCED RUNNER SYSTEM
(CHANGING RUNNER LAYOUT) (CHANGING RUNNER DIA)
COLD SLUG WELL
Flow Direction Cold
-Plastic looses its temp SlugWell
during flow through runner.

-Cold slug well is provided

to accommodate the initial
cold material and release
behind hot material into
cavity.

Cold
SlugWell
GATING

Manually Trimmed Auto-Ejection Trimmed

• Direct (sprue) gate  Pin gate
• Tab gate  Submarine (tunnel, chisel) gate
• Edge (standard) gate  Hot-runner (hot-probe) gate
• Disc/Diaphragm gate  Valve gate
• Spoke gate
• Fan gate
• Film(Flash) gate
• Ring gate

* The shape of gate will be decided based no the shape &

appearance requirement of component.
DIRECT SPRUE GATE
Suitable for single cavity large
components.
Sprue
Molded Part
TAB/OVERLAP GATE
Suitable for stress free and high optical clarity components.

Single Tab Gate Multiple Tab Gate

6 in. 12 in.
Max Max

Tab
Tab Gate

Gate Sprue Sprue

Gate
Tab
EDGE GATE

Most commonly used.

Land
Length

0.030
Inches Maximum
DISC/DIAPHARGM GATE

Runner
Runner

Sprue Part
FAN GATE Suitable for larger area with thin
wall components.

RUNNER

PART RUNNER
GATE
LAND
FILM /FLASH GATE
Suitable for thin walled flat comopnents.
Used for the components required with stress and warpage free.
Used for transparent components where flow mark is not allowed.

Parallel
Runner

Gate

Parallel
Runner Runner
RING GATE

Gate
Runner
Disk

Gate

Part
PIN POINT GATE

0.050
0.020 Land Length

900
SUBMARRINE GATE

Molded Part
Sprue

Parting
Zero Land Length
Line

Grind Flat on Gate Side,

Min. 20 Tunnel
Gate
Knock Out Pin
Fasten Pin Head To
Prevent Turning
SUBMARRINE GATE

R
Gate
MOLD FLOW ANALYSIS
UNDERCUT AND REMOVAL PROCIDURE
UNDERCUTS ARE THE SHAPES

-WHOSE ORIENTATION ARE NOT ALLONG WITH MODLING

DIRECTION OF THE ENTIRE PART
-LOCATION OF THESE SHPAES WILL BE BELOW PARTING
LINE.

TYPES OF UNDERCUT

•INTERNAL UNDERCUT
•EXTERNAL UNDERCUT
TYPES OF UNDERCUT
INTERNAL UNDERCUT
It can be removed by
•Force ejection
•Use of collapsible core
•Use of lifters
•Use of unscrewing mechanism(for threads)

SNAP LID INTERNAL THREAD

TYPES OF UNDERCUT
EXTERNAL UNDERCUT
It can be removed by
Side core actuated by
• mechanical pins,
•Hydrolic &Phumatic cylinders

External Thread Detail on Side

TECHNIQUES FOR UNDERCUT REMOVAL
CORE CAVITY MATCHING
AREA FOR HOLE

CORE CAVITY MATCHING

SLIDER MECHANISM
COMPONENT
SLIDER
CORE CAVITY

HEEL
BLOCK

CAM

STOPPER PIN
SIDE CORE MOVEMENT BY HYDRAULIC CYLINDER

Cavity Core
Hydraulic Cylinder
Pin
DIRECTION

Plastic
MOLDING

Cored Hole

Core
LIFTER MECHANISM
PLASTIC PRODUCT DESIGN
 BASIC DESIGN CONSIDERATIONS
 The first requirement is to have a properly modeled part that is fully moldable
 Sufficiently drafted faces to easily eject the part.
 No undercuts (will require lifters or sliders)
 Wall thickness should be uniform(if changing then it has to be gradually for
avoiding shrink mark)
 When creating internal ribs, they should be no greater than 1/3t of the part’s wall
thickness to avoid sink marks on the outside of the part.

Drafted faces No draft = difficult to eject

COMMON DEFECTS IN PLASTICS PARTS
• Short Shot
• Flash
• Weld Lines
• Ejector Pin Marks
• Sink Marks
Short Shot
Cold material, cold mold, insufficient pressure, non uniform mold
temperature, insufficient feed, entrapped air, insufficient external
lubrication, insufficient plunger forward time, small gates.

Short defect
 Flash
Material too hot, Inj
Pressure too high, High
packing pressure, Less
clamping force, Poor
parting lines or mating
surfaces

Part w/ Moderate-Heavy Flash

Flash
 Weld Lines
Weld lines is the meeting face of 2 flows coming in opposite direction. Part is
weak at Weld line.

Can result from poor gate placement Unavoidable areas

Gate

Gate Weld
Gate Line

Weld Line
Weld lines occurs if material temperature is low, mold temperature will be
improper, improper gate position, improper runner balancing.
Ejector Pin Marks
Marks are often left on the part in the area where the ejector pins
pushed. Four possible cause:
1) Pin above
flush

2) Pin below
flush

3) Clearance
around pin

4) Improper cooling time

5) Ejection force more.

6) Part sticking.
Sink Marks
Sink mark occurs due to abrupt change of thickness.
Thickness to be considered for every shape(Rib, Boss,
Clip mountings)
Minor sink marks can be removed by texturing

Thick sections cause

sink marks

Bad
Design

Improved
Design
 Sink mark removed by optimizing the rib thickness to 1/3 t.

Result after redesigning

the Internal Ribs to be
Sink due to
1/3t or less of the nominal
ribs
wall thickness
THANK YOU