INJECTION MOULD DESIGN: MARPLEX MATERIALS

Mould Types
Two-plate, three-plate, hot runner, or runner less moulds can be used with the majority of Engineering Thermoplastic. Two-Plate Mould: The two plate mould is simple in design, yet versatile. It consists of a front and stationary half. The cavity or core can be mounted on either half, depending upon the part design and the location of the location of the knock-out pins. This mould is easily adapted for different designs and all part ejection methods. Three-Plate Mould: This type of mould is used primarily to centre gate or submarine gate parts in multiple cavities. It consists of the standard two-plate design with the third movable between the two. Automatic degating is possible with three-plate moulds, but runner scrap is increased.

INJECTION MOULD DESIGN: MARPLEX MATERIALS

Hot-Manifold Mould: The hot manifold mould is similar to the three-plate mould in design. The runner system, however, is confined in a block and heated by cartridge heaters. This system will eliminate large quantities of runner scrap and improve automatic cycling. If heated torpedos are used, they should be made from a good grade stainless steel. Beryllium copper is not recommended. To obtain optimum results, the hot manifold system should be balanced properly, insulated from other parts of the mould to minimise heat loss or heat transfer to the mould plate, and provide uniform distribution of heat throughout the manifold. Insulated Runner Mould: This system utilises the hot manifold concept without the cartridge heaters. The insulated runner system depends entirely on heat generation in plasticising cylinder and insulation around the runner to maintain proper melt temperature. This system is not usually recommended for Marplex materials.

INJECTION MOULD DESIGN: MARPLEX MATERIALS

Venting
Moulds must be well vented to eliminate any possibility of gas or air being trapped as the part is moulded. The entire circumference of each cavity should have venting to prevent gas or air burns at the parting lines. In some instances a minimum of 40% venting is recommended for intricately designed parts. Vents should normally be 0.05mm deep. If internal vents are necessary, ejector pins, sleeves and core pins may be utilised if they are located where the trapped gas and/ or air occur. Ejector pins and sleeves are preferred because the movement of ejection in the moulding cycles automatically cleans the vents.

Sprue Bushes
Sprue bushes may be categorised as either cold (standard) sprues or heated sprues. The cold sprue bush is low in cost, easy to install and requires very little maintenance. This type of system however, generates more material that must be reground and reprocessed than the heated sprue. Should the cavity depth require a long sprue bush to accommodate the runner system, the heated sprue bush should be considered. Since the sprue is not ejected with the part, the sprue trimming and scrap are eliminated and moulding time can be reduced by the amount of time normally allowed for cooling the sprue.

INJECTION MOULD DESIGN: MARPLEX MATERIALS

The internal surface of the bushing should taper from a diameter of 16-19mm at the nozzle end to a diameter of 9.5mm at the cavity end, and should be perfectly smooth and polished. A 450 chamfer is desirable for nozzle seal-off and seating. The orifice (gate) should be a minimum of 3.2mm and a land length can be minimized by sinking 1.5mm to 2.3mm from cavity end. Counter sinking removes the gate land from the immediate vicinity of the cavity, thus preventing damage to the orifice and reducing the risk of freezing off.

The diameters of the outer surface of the bush should slip fit into the mould plate when both the bush and mould or cold. There should be a shoulder not more than 40mm from the cavity to prevent expansion of the bush into the cavity when heat is applied. For bushes more than 200mm long, a second shoulder, situated 75mm to 100mm from the cavity end, is recommended. The remainder of the outer surface of the bush should be machined to provide an insulated air gap which will minimize heat transfer to the mould plate and cavity, and also provide areas for mounting the heated bands. Two 125watt heater bands are usually satisfactory. Before the bush is installed in the mould, it should be heated to the operating temperature range of 1750-2050C, followed by tightening of the heater bands.

INJECTION MOULD DESIGN: MARPLEX MATERIALS

There are two methods of heating the hot sprue bush. The one most commonly used is the installation of heater bands around the outside diameter of the bush. The other method of heating the sprue is by installing heater cartridges within the wall of the sprue bush or directly in the melt flow chamber. Heated sprue bushes should be made from a good grade of steel, and be oil or air-hardened after machining.

INJECTION MOULD DESIGN: MARPLEX MATERIALS

Runners
For most normal injection moulding, runners with a circular (full round) section provide maximum flow. Main runners should have a cross sectional diameter of 6mm to 12.7mm. Secondary runners should have a cross sectional diameter of 4.8mm to 8mm. Normally all main runners to a given mould should be equal in diameter, and all secondary runners in the mould should be equal in diameter, but they need not be equal in length. When the runner system is cut into only one mould face, trapezoidal runners are preferred to half-round runners of the same depth. It is advisable to locate a cold slug well opposite the sprue, and to extend the main runners beyond each intersection with the secondary runners so that the extensions also act as cold slug wells. To help reduce friction and material hang-up, a highly polished chrome plated runner system may be used. The diameter should be a minimum of 8mm for small parts and 9.5mm to 11mm for larger parts. Hot runner moulds require runners of 12mm to 19mm diameter.

INJECTION MOULD DESIGN: MARPLEX MATERIALS

3 Plate Mould Pin Gate
Advantages: The design is useful when multiple gates per cavity are needed to assure symmetric filling or where long flow paths must be reduced to assure packing to all areas of the part. Runners are torn from the part during ejection due to the reverse taper drops of a pin point gate. Disadvantages: Gate vestige can cause problems, this can be rectified with the use of a sunken contour to keep the vestige below the design surface. The gate could also be placed in a non visible area. Pneumatic nozzles can also be used for automatic ejection of a runner with a pin point gate. Pin point gates should not be used with highly viscous polymers, or those which are heat sensitive.
mPP

Pin Point Gate Orifice Land Length 1.2mm 1.27mm min 1.27mm 2-3mm 0mm 1-2mm

Direct Sprue Orifice 3.0mm 4.50-6.40mm min 3.80-6.40mm min 4.75mm min 4.50-6.40mm min 4.75mm min 4.8-6.4mm min 5.60mm min 4.50-6.40mm min Not recommended except very small parts

Direct Sprue
Advantages: A direct sprue is commonly used for single cavity moulds, where the sprue feeds material directly into the cavity rapidly with minimum pressure drop. This design can also be used in thick walled parts or for gentle processing of high viscosity material. Disadvantages: The sprue must be removed after part ejection takes place. This design can leave a gate mark on the part surface after the sprue or runner has been removed. The part shrinkage near the sprue gate will be low, shrinkage in the sprue will be high, the result is high tensile stresses near the gate.

ABS POM PMMA ABS-PC PC mPPE PET/PBT PA TPE

Not recommended except very small parts Not recommended except very small parts Not recommended except very small parts Not recommended except very small parts 1.25-2.3mm 1.5-2.5mm GF 0mm 0mm

Not recommended except very small parts 0.80mm 3-5mm

INJECTION MOULD DESIGN: MARPLEX MATERIALS

Fan Gate
A fan gate is a wide edge gate with variable thickness. Advantages: It permits rapid filling of large parts or fragile mould sections through a large entry area. It can be used to create a uniform flow front into wide parts, where warpage and dimensional stability are concerns. Used to eliminate jetting. Disadvantages: Requires removal of sprue and runner.
mPP POM PMMA ABS ABS-PC PC mPPE PET/PBT PA TPE Suitability YES YES YES YES YES YES YES YES YES NO Orifice mPP 50-60% wall thickness 70-85% wall thickness 50% wall thickness 75-90% wall thickness 85-100% wall thickness 75-100% wall thickness 70-85% wall thickness 70-85% wall thickness 50% wall thickness Not recommended except very small parts Land Length 0.51-0.76mm Short as possible 0.51-0.76mm Short as possible 0.51-0.76mm Short as possible 0.51-0.76mm Short as possible 0.51-0.76mm Short as possible 0.51-0.76mm Short as possible 0-0.76mm Short as possible

Edge Gate
Advantages: An edge gate is located on the parting line of the mould and typically fills the part from the side, top and bottom Disadvantages: Jetting can occur. Trimming operation required.
ABS POM PMMA ABS-PC PC mPPE PET/PBT PA TPE

0.38-0.51mm Short as possible 0mm Short as possible

INJECTION MOULD DESIGN: MARPLEX MATERIALS

S Runner
Advantages: Slows the flow of polymer entering the part giving good surface appearance. Disadvantages: More material is used in the runner. This design is best done with a full round runner. Surface appearance is only better if material does not shear too much through gate.
Orifice Diameter mPP ABS POM PMMA ABS-PC PC mPPE PET/PBT PA TPE 1.27mm min 1.27mm min 1.27mm 1.27mm 1.27mm 1.27mm 1.14-2.54mm 1.25-2.3mm 1.5-2.5mm GF 0mm 0mm Land Length 0.51-0.76mm 0.51-0.76mm 0.51-0.76mm 0.51-0.76mm 0.51-0.76mm 0.51-0.76mm 1.0mm max 0.38-0.51mm Not recommended except very small parts Not recommended except very small parts

Not recommended except very small parts Not recommended except very small parts Land Length

Jump Gate
Advantages: Gate into wall has no visible marks on the appearance of surface or interference with fitment. Disadvantages: Prone to jetting if the gate was not wide enough, still possible if gate is wide. Difficult to trim gate off part and keep a clean square edge.
mPP POM PMMA ABS ABS-PC PC mPPE PET/PBT PA TPE

0.51-0.76mm 0.51-0.76mm 0.51-0.76mm 0.76mm 0.51-0.76mm 0.51-0.76mm 1.0mm 0.38-0.51mm 0-0.80mm Not recommended except very small parts

INJECTION MOULD DESIGN: MARPLEX MATERIALS

Advantages: A direct sprue is commonly used for single cavity moulds, where the sprue feeds material directly into the cavity rapidly with minimum pressure drop. This design can also be used in thick walled parts or for gentle processing of high viscosity material. Disadvantages: The sprue must be removed after part ejection takes place. This design can leave a gate mark on the part surface after the sprue or runner has been removed. The part shrinkage near the sprue gate will be low, shrinkage in the sprue will be high, the result is high tensile stresses near the gate.

Direct Center Sprue

Orifice mPP POM PMMA ABS ABS-PC PC mPPE PET/PBT PA TPE 3.0mm 3.80-6.40mm min 4.75mm min 4.50-6.40mm min 4.50-6.40mm min 4.75mm min 5.10mm min 5.60mm min 4.50-6.40mm min 0.8mm

Diaphragm Gate

Thickness of Gate mPP POM PMMA ABS ABS-PC PC mPPE PET/PBT PA TPE 1.0mm min 1.0mm min 1.0mm min 1.0mm min 1.0mm min 1.0mm min 1.0mm min 1.0mm min 1.0mm min Not recommended

Land Length 0.51-0.76mm 0.51-0.76mm 0.51-0.76mm 0.76mm 0.51-0.76mm 0.51-0.76mm 1.0mm 0.38-0.51mm 0-0.80mm

A diaphragm gate is often used for gating cylindrical or round parts that have an open inside diameter. Advantages: It is used when concentricity is an important dimensional requirement and the presence of a weld line is objectionable. Uniform flow to all parts of the gate is easy to maintain. Disadvantages: Sprue must be removed after moulded

INJECTION MOULD DESIGN: MARPLEX MATERIALS

Sub Gate
Orifice mPP POM PMMA ABS ABS-PC PC mPPE PET/PBT PA TPE 1.5-2.3mm 1.27-2.4mm 1.5-2.3mm 1.5-.2.3mm 1.27mm min 1.27mm 1.52mm 1.27-2.3mm 1.5-2.5mm GF 2.4mm Not recommended except very small parts Orifice mPP POM PMMA ABS ABS-PC PC mPPE PET/PBT PA TPE 1.5-2.3mm 1.27-2.4mm 1.5-2.3mm 1.5-2.3mm 1.0mm min 1.27mm 1.52mm Not recommended except very small parts 1.27-2.2mm 1.5-2.4mm GF Not recommended except very small parts Land Length 2-3mm 0mm 0mm 0mm 0mm 0.51-0.76mm 0mm 0.38-0.51mm 0-0.80mm Taper from Part 50mm 50mm 50mm 50mm 50mm <50mm 50mm 50mm 50mm Land Length 2-3mm 0mm 0mm 0mm 0mm 0.51-0.76mm 0mm 0.38-0.51mm 0-0.80mm Taper from Part 50mm 50mm 50mm 50mm 50mm <50mm 50mm 50mm 50mm

A submarine gate is used in twoplate mould construction. An angled, tapered tunnel is machined from the end of the runner cavity, just below the part line. Advantages: As the parts and runners are ejected, the gate is sheared at the part line. A full round runner should be used. Disadvantages: Poor results in reinforced materials. Premature gate freeze can be a problem.

Sub Gate with Knockout Pin

If a larger diameter pin is added to a non-functional area of the part, the submarine gate can be built into a pin. Advantages: This avoids the need for a vertical surface for the gate to be placed. If the pin surface is hidden, it does not have to be removed. Disadvantages: Poor results in reinforced materials. Premature gate freeze can be a problem.

INJECTION MOULD DESIGN: MARPLEX MATERIALS

Chisel Gate
Advantages: Similar to applications which require a fan gate. Good for reinforced materials. Disadvantages: A disadvantage with chisel gates is the large blemish which occurs on removal of the sprue/runner. Very hard to trim vestige.
mPP POM PMMA ABS ABS-PC PC mPPE PET/PBT PA TPE Orifice 3.0mm 4.50-6.40mm min 3.80-6.40mm min 4.75mm min 4.50-6.40mm min 4.75mm min 4.8-6.4mm min 5.60mm min 4.50-6.40mm min Not recommended

Curved Tunnel Gate

Advantages: Best gate design for TPE. Leaves non visible vestige on part. Disadvantages: Not easily used on many other materials due to the shear which the material will incur through the gate.

Orifice Diameter mPP POM PMMA ABS ABS-PC PC mPPE PET/PBT PA TPE Not recommended Not recommended Not recommended Not recommended Not recommended 1.25-2.3mm 1.5-2.5mm GF 0mm 0mm 1.2mm

Land Length 2-3mm

Not recommended Not recommended Not recommended Not recommended Not recommended 0.38-0.51mm Small as possible. 3-5mm

Not in GF. Small parts only. 0.8mm

INJECTION MOULD DESIGN: MARPLEX MATERIALS

The content of this report is based on test methods and results we believe reliable, but any results or recommendations contained should not be construed as a guarantee of final product performance by Marplex Australia Pty Ltd.