Chapter 1 Mold Order and Solution

1.1 Request for Mold Quotation

`
Table 1-1: request for mold quotation from a customer

Request for Mold Quotation

1.

PART NAME

NO. CAV.

DRAWING NUMBER

REVISION

MATERIAL TYPE

SHRINK RATE

RFQ DATE
QUOTE DUE DATE
.

STANDARD FEATURES
[X] Locating ring:

mm diameter

SPECIAL FEATURES

[X]Sprue bushing

mm radius

[X] Guided ejector system

[X] Balanced Lift Hole in Mold Strap

[X] Early ejector return

[X] Cycle Counter

[X] Lift holes on All Mold Plates

[X] Parting line locks

[X] Pry slots NO Corners

[X] Cavity I.D. on molded part (for multi-cavity)

[X] Unscrewing cores

[X] Recessed cooling connectors 1/4" NPT (JP-252)

[X] Center KO is NOT used in our shop

[X] Engrave Part number and Mold Number

MOLD DESIGN

MOLD CONSTRUCTION

Design by:

[X] Mold maker

[X] Customer

[X] Standard 2 plate

[X] Hot Sprue Bushing

Type of design:

[X] Full detail

[X] Lay-out only

[X] 3 plate

[X] Two Shot Mold

[X] Hot Runner

[X] M.U.D. Inserts

EJECTION

GATE TYPE

RUNNER

[X] Knock Out Pins

[X] Sub-gate

[X] Trapezoid

[X] Sleeves

[X] Edge Gate

[X] Full Round

[X] Stripper Plate

[X] Hot Bushing

[X] Hot Manifold

[X] Ejector Blade

[X] Sprue

[X] Runner Shut-offs

[X] Air Assist

[X] Pin Point

SIDE ACTION

COOLING

MOLD BASE MATERIAL

CORE

CAVITY

[X] Mechanical Slides

[X] Inserts

[X] Hardened Tool Steel

[X] Hardened Tool Steel

[X] Wear Plates (Lamina)

[X] Retainer Plates

[X] Hardened Stainless

[X] Hardened Stainless

[X] Positive Locks (Superior)

[X] Support Plate

[X] Pre-Hardened Steel

[X] Pre-Hardened Steel

[X] Hydraulic Cylinder

[X] Bubblers

[X]

[X]

[X] Air Cylinder

[X] Slides

[X] Finish

[X] Finish

[X] Lube grooves on slides

[X] Core Pins

[X] Individual Core Inserts

[X] Individual Core Inserts

[X]Pins

[X] Slides

VENTS
[X] Venting where practical

[X] Cavities

[X] Cores

[X] Pilots

[X] Runners

Primary vent depth : 0003 /.0005 , Secondary vent depth: 003 /.005
Additional Requirements:
[X] Mold Status Report due each week
[X] Stamp steel type and Rockwell hardness on components.
[X] Preliminary drawings to be approved by the customer.
[X] One set of final mold drawings to be supplied to the customer.
[X] Electronic copy of final mold drawing to be supplied to the customer.
[X] Mold sampling required and parts approved by the customer prior to mold shipping.
[X] Try Out material to be supplied by [X] Customer

[X] Mold maker.

[X] Spare parts required:

% Cavities

% Cores

% Ejectors

% Slides

% Other

Table 1-1 is a typical format of request table for mold quotation from a customer. The mold
designer starts with the design of a new mold when he receives a part drawing, its CAD model and its
request for mold quotation. Additional information includes the machine the mold will be run in, the
number of cavities required, and, if it is not shown on the drawing, the type of plastic that will be used
for this product. While the above information is important, it is incomplete. There are other concerns
which should be addressed before going into the mold design:
Molding characteristics of the specified plastic?
How many parts will be molded? This is, Anticipated molding cycle times?
Where and how is the product used?
Must the product fit with other parts?
Tolerances?
Shrinkage?
Draft angles?
What type of feed system is required?
Basic mold structure (2 plates/3 plates)?
Hot runner?
Gate location, flow and weld lines, ejector marks?
Surface finish?
Cavity numbering?
Spares required with mold?
Is indicated machine suitable: Tonnage? Shot size? Plasticizing capacity?
Is mechanical product removal planned?
Timing of project? Date for T1?
Some of these questions and concerns may have been answered with the accompanying the request
for mold quotation from the customer. There may be other questions which will have to be answered
by dialogue with the customer. After a request for mold quotation has been received, it is important to
find out how the quoted price for this mold has been arrived at. Mold prices are usually estimated by
an experienced mold designer or estimator, often by the owner of the mold making business. At the
time when the estimator receives a request for a quotation, he or she may sketch a mold design which is
believed to be appropriate for the product, based on experience or from records of similar molds. The

designer then bases all cost figures on this sketch. The designer may, according to the complexity or
novelty of the product, add a safety factor before arriving at an estimated mold price.
There is a risk that the quoted mold price is lower than it might have been if all the parameters had
been considered at the time of the quoting. The quoted mold price must be competitive with that quoted
by other mold makers.
Another problem is that many more molds are estimated than will eventually result in orders. It is
common practice in all industries to send out requests for at least three quotations from different mold
makers before a mold order is placed.
It is important to understand that the mold designer must know the type of mold that the estimator
had in mind when quoting a price. If not, he or she may design a mold that greatly exceeds the quoted
price. Note that the purpose of any industry is to make money with their product.
The mold envisaged by the estimator is not necessarily the best design. There is a good chance that
in the course of the design process a better design will be found. But it is necessary that the mold
designer is aware of the quoted mo1d price at the start of a mold design project. It is quite possible that
the estimator has erred, has underestimated some difficulties in molding the product, or was missing
some important information which was subsequently supplied with the mold order.
If, after a preliminary study by the mold designer of the product and the final specifications, it
becomes apparent that sometimes some parameters have been either inadvertently or deliberately
changed, the customer must be immediately advised of any increase in the mold cost caused by such
changes before more time is spent on the project. In this way, much aggravation can be avoided.
On the other hand, if the error was due to poor estimating, there is nothing that can be done by the
mold maker but to try to stay within budget and to design whatever is necessary to build the mold as
quoted. Under no circumstances must the quality or the performance of the mold be compromised.
Since the reputation of the mold maker is at stake, any loss suffered due to poor estimating must be
written off as learning experience and credit standing. There is a possibility that the customer may agree
to carry some or all of the extra costs involved, but it is a policy decision of the mold maker whether to
approach the customer for an increase of the contracted mold price.
Occasionally, a mold price may be deliberately quoted low as the result of a sales policy. For
example, to win a new customer or to enter a new field of products in which the molder has little or no
experience. Regardless of the low price, the mold maker must still devolop the best possible mold to
perform as specified, at a reasonable cost.
We will here consider only characteristics which directly affect the mold design:
1. Flow characteristics. Easy flowing materials usually present no problems, but "stiff materials
require higher injection pressure and, therefore, heavier construction of the mold. This will also affect
the need for more accuracy and strength of the alignment elements.
2. Melt processing temperature. The higher this temperature, the more important becomes the
heating and cooling design and, sometimes, the method of heat insulation between hot and cooled
portions of the mold.
3. Material degradation. Every thermoplastic is to some degree heat sensitive or subject to
degradation when exposed to high temperatures over a length of time.
Some materials, give off poisonous gases when heated for even a short time above their upper
permissible temperature and corresponding safe time, if even the material does not have visible signs of
degradation at the very first. Other materials give off highly corrosive gases and will require specially
selected mold materials and finishes.

All materials show degradation by changing color to yellow or brown. The ultimate form of
degradation is when the plastic becomes charred and black. All products containing even small portions
of degraded material must be discarded, not only because of poor appearance of the product but because
physical properties may have been lost and the product will not perform as expected.
There are several reasons why the estimator and the designer should know the anticipated molding
cycle. It is always desirable to build a mold with the shortest possible molding cyc1e, but this can only
be achieved at a cost. Special cooling methods, added ejection features, special mold materials,
lubrication, etc., will certainly add to the cost of the mold. From one to the other, differences in the
plastic, wall thicknesses, draft angles, methods of gating, and other factors may have a significant impact
on the molding cycle.
This is probably the most important area to be checked before the mold design should be started.
The estimator should check and question the tolerances at the time when the job is quoted. The final
drawing released with the order must be compared with the product drawing used for the quotation to
make sure that there were no changes made. Quite often, the drawings used for quotations are only
preliminary and incomplete, and tolerances may not have been shown. Since a large portion of the
machining cost of them old components is directly related to the tolerances. If the new tolerances will
affect the mold cost, the mold maker must immediately approach the customer to bring the tolerances
back to what was quoted or to have the contract requoted.
Often, the product designer assigns close tolerances to the product that are not necessary for the
function of the product. The proper method is to give a relatively large general tolerance and tighten up
dimensions only where it is necessary for the function of the product or where it is required in the
assembly with matching products.
Whichever method is specified, the designer must make sure that the to1erances shown on the
product drawing make sense and can be achieved. The mold designer must not forget that the sizes also
depend on the operating temperatures. In some cases, the product keeps shrinking hours and even days
after molding. With some critical dimensions and certain materials, it must be established before hand
when, and under what conditions, the product will be measured. This study of the tolerances at the
beginning of the job will prevent arguments later on. If the tolerances specified are unreasonable, the
mold maker must discuss them with the customer and get a release in writing so that the mold maker will
not be held responsible for sizes of the molded product which are outside the specified ones.
Where and how is the product to be used? This question must be asked not just out of idle curiosity.
It will give the mold designer some idea of the importance of certain aspects and critical areas of the
product such as required fits with other products, finish, strength, location of gate, ejectors, etc. The
designer may then suggest changes, especially in the areas of fragile mold cores or thin ribs, not only to
make the mold easier to build but also to extend the life of the mold and to improve its serviceability.

1.2 Plastic Part Manufacturability

The design of plastic parts is largely determined by its purpose, functionality, and appearance.
Most plastic parts are made with injection molding. The molding process has its own unique features
and limitations. Thus, the manufacturability of each part design must be thoroughly considered for its
economics, as well as its application and aesthetic expectation. To each mold designer, it is critical to
acquire a basic understanding of the plastic part design.

1.2.1 Plastic Part Dimensional Accuracy

Plastic parts are molded under elevated temperature. Their dimensional accuracy is affected by
accuracy of the mold and shrinkage of the plastic material, which is affected by the following factors.
1. Each plastic material has a unique shrinkage rate, which may further vary by its manufacturer,
batch number, and water and volatile contents.
2. During the injection molding process, the change in the injection conditions such as injection
force, time, and temperature all directly affect its shrinkage. For example, plastic parts usually shrink
less at a higher injection pressure.
3. The wall thickness and shape of plastic part also affects its shrinkage. For example, the plastic
part with a thin wall shrinks less.
4. The mold structure also directly affects plastic parts shrinkage. A larger gate size leads to a small
shrinkage. Parallel flow leads to a larger shrinkage. Thus it can be seen that the shrinkage of plastics is
unstable, which shall inevitably influence the dimension precision of plastic parts. Considering this
factor as well as other complications such as the draft, the flash on parting line and the abrasion of
molding parts etc, it is unnecessary to select high dimension precision when designing plastic structural
parts if not need be.
Table 1-2: recommend grades of molding part precision
Category

Recommend Selecting Precision Class

Plastic Types

High Precision

General Precision

Low Precision

ABS
General Purpose
Polystyrene(PS)
Polymethyl
1

Methacrylate(PMMA)
Polycarbonate(PC)
Phenylene oxide(PPO)
30% of Glass Fiber
Reinforced Plastics
Polyamide666610.9.1010

Chlorinated Polyethers(CPT)
PVC-U
High Density

Polyethylene(HDPE)
Polypropylene(PP)
Polyoxymethylene(POM)
PVC-F

Low Density
Polyethylene(LDPE)

Recommend grades of molding part precision are shown in Table 1-2. Aside from dimensional
accuracy, the surface quality of plastic parts depends on whether there exist defects such as spots,
wrinkles, porosity, dents, welding marks, and their surface luster and finishes. Defects occur during the

injection process. Surface luster and finish relate to mold surface, wear, plastic material brand and
quality, and injection molding conditions. The molding surface quality must be higher than the surface
requirement for the plastic parts. Transparent plastic parts typically require a very high surface finish,
which is normally a Ra of 0.025m or better.

1.2.2 Wall Thickness

Plastic parts require a reasonable thickness. It should not be too thin, as it needs to have sufficient
strength for its application, fastening during its assembly, filling out its cavity during molding, and
impact during ejection. It should not be too thick, for it increases the shrinkage, further varies its
dimensions, prolongs the cooling time, and wastes the material. It may also cause porosity, shrinkage
cavity, dent and warpage. The thickness decision needs to carefully strike a balance between economics,
and part quality and strength, though it also depends on the material type, part size, and molding
conditions. thermoplastic materials are good for parts with a think wall, which usually varies between
1.5~4 mm, though it could be as thin as 0.6~0.9 mm, or even 0.25 mm at times. The thickness should be
homogeneous all around the part, to avoid residual forces and defects, caused by uneven shrinkage
during the solidification and cooling process. Fig.1-1(a) shows an undesired part structure, while
Fig.1-1(b) is a reasonable structure. It is a practice to vary the thickness of a part design, in order to
probably locate the welding mark. Fig.1-2 shows an effort of assuring the part quality on the top, by
increasing the thickness of the top area, thus avoid leaving welding marks in the top area.

Fig.1-1: wall thickness design of plastic parts

Welding marks

Gate
Fig.1-2: non-uniform wall thickness of plastic parts

1.2.3 Ribs
Ribs are often used to enhance the plastic part strength and stiffness without a thicker wall.
could also improve material flow conditions during molding.

Ribs

Air bubbles

Fig.1-3: adding ribs to reduce wall thickness

Fig.1-3(a) shows a thick and uneven wall design. Fig.1-3(b) shows a wall design of even thickness.
It saves material and enhances its strength and stiffness, while avoiding air bubbles, shrinkage cavities,
dents and warpages. Rib dimensions are shown in Fig.1-4. Their thickness is usually smaller than the
wall thickness.
When considering adding ribs to a plastic part design, the focus is to minimize the concentration of
the material in an area, to avoid air bubbles and shrinkage cavities. Fig.1-5 shows a rib arrangement.
Fig.1-5(a) shows an undesired arrangement where material concentrates in one area. Fig.1-5(b) shows a
better arrangement. Rib should not be too big; they should be short and more in quantity. The distance
between ribs should be equal or greater than twice the wall thickness. As shown in Fig.1-6, a good
design can avoid shrinkage cavities and increase part strength and stiffness. The orientation of rib
arrangement should be in line with the material flow direction, to ease filling out the cavity and to avoid
disturbing the flow. There should be a gap between ribs end and the part support surface.

< (0.5~0.7) t

<3t
R=t/8
t

Fig.1-4 Rib dimensions

Fig.1-5: rib arrangement

Fig.1-6: rib design

1.2.4 Support Surface

When plastic parts need to have a support surface, it is not desirable to use the whole part bottom
surface as the support. Fig.1-7 shows the bottom surface becomes uneven, when the plastic part deforms
a bit. A Frame, three or four bottom feet are usually a better support surface.

Fig.1-7: design of support surface

1.2.5 Draft
Draft is used to protect plastic part surface from scratch during ejection. It is a draft reserved along
with the ejection direction. The draft depends on the material shrinkage, part shape, wall thickness, and
ejection location.
For inner holes on a plastic part, the smaller end of core is used as reference. Its draft is shown
along with the rising direction. For exterior of a plastic part design, the larger end of cavity is used as
reference. Draft is dimensioned along with the reducing direction. Please refer to Table 1-3 for various

draft designs. A typical draft ranges between 30 1 30 . Normally a tall or large plastic part design has
'

a smaller draft.

'

When there is a special need or higher precision requirement, a smaller daft is used.

External draft can be as small as 5 . Internal draft can be as small as 10 20 . A complex plastic part,
'

'

which is difficult to eject, should adopt a larger draft.

'

Usually a draft of 4 5 on each side is

considered for a plastic part design with ribs or bosses.

Larger draft should be chosen for a plastic
product with large wall-thickness; during mold opening, in order that the product is retained on the side
of the moving mold, draft of the inner surface should be smaller than that of the outer surface and the
other way round, draft of the outer surface should be smaller than that of the inner surface so as to retain
the product on the side of the fixed mold.

Fig.1-8: draft
Table 1-3: drafts for common plastic materials
Draft

Plastic Types

Draft

Plastic Types

Core

Cavity

Core

Cavity

PE

20~45

25~45

PMMA

35~1

35~130

PP&PVC-F

20~50

50~1

PA

20~40

25~40

50~145

50~2

PC

30~50

35~1

PS

30~1

35~130

CPT

20~45

25~45

ABS

35~1

40~120

POM

30~1

35~130

PVC-U

1.2.6 Hole Design

Holes may exist on a plastic part, including through holes, blind holes, screwed holes, and irregular
shaped holes. In principle, holes should be as simple as possible. A complex hole increases the difficulty
of mold making. As shown in Table 1-4, a sufficient gap should be reserved between holes or between a
hole and the wall. The diameter of a hole also relates to its depth as shown in Table 1-5. When the
distance between two holes or from the hole to the edge is smaller than the one specified in Table 1-4,
please refer to the pattern design shown in Fig.1-9.
Table 1-4: holes pitch, space to wall and diameter of thermoset plastics
Hole diameter mm

1.5

1.5~3

3~6

6~10

10~18

18~30

Holes pitch, space to wall /mm

1~1.5

1.5~2

2~3

3~4

4~5

5~7

Table 1-5: relations of holes diameters and depths

Molding types

Compression molding

Hole depth
Through hole

Blind hole

Horizontal hole

2.5d

1.5d

Vertical hole

5d

2.5d

10d

4~5d

Extrusion or injection molding

Fig.1-9: improvement design for too small holes pitch and space to wall
The holes used for fastening on the plastic products as well as other holes under stress should be
reinforced with a convex edge designed thereon, as indicated in Fig. 1-18. The fixing hole can be
designed in the form of a screw hole with sinking head as illustrated in Fig. 1-19a), whereas that in Fig.
1-19b) is generally not recommended. The form as shown in Fig. 1-19c) can be used instead so that the
core can be better set.

Fig.1-10: reinforcement of holes

Fig.1-11: types of fixing holes

1.2.7 Screw
Screws on a plastic part can be formed during the injection process. They may be created by
machining after the injection process. For a plastic part which is subject to frequent assembly and
disassembly, the part may be inserted with a metal screw.

Fig.1-12: screw design on plastic parts

For design of screws on a plastic part, the following principles are followed:
1. The diameter of injected external screws should not be smaller than 4 mm. Internal screws should
not be smaller than 2 mm. Length of fit should be reduced to less than 1.5~2.0 times of the screw
diameter, in order to minimize the accumulative error on the screw pitch.

2. There should be an area larger than 0.5 mm without screw on its end, to facilitate manufacturing,
avoid burr, and effect guidance at use, as shown in Fig.1-12.
3. For a plastic part which has two screws located along the same axis, the pitch and tightening
direction should be the same. It simples mold structure design and the part production.

1.2.8 Gear

Fig.1-13: dimensions of a plastic gear

The following principles are followed for plastic part design with gears.
1. The same material should be used for gears that match, to avoid problems caused by thrinkage.
2. Follow the dimensional relations as below.

H =D
D1 > 1.5 D
t1 = 3m
where
H the spoke thicknessmm
D the hub hole diametermm
D1 the hub diametermm
t1 the spoke widthmm
m the gear modulus
3. Adopt the transition fit between the hole and shaft on a plastic gear.
design. Use the fastening method as shown in Fig.1-13.

Avoid the key and key way

1.2.9 Structure of Inserts

Inserts are a metal part permanently inserted into a plastic part. They are used for various
purposes. Some are used to enhance local strength, hardness, or wear of a plastic part. Some are used
for electricity reasons, while others are used to improve the stability of its shape and dimensional
precision. Though most inserts are typically made of metal, other materials may also be used.
Fig.1-14 shows some commonly used inserts. Fig.1-14(a) shows tubular inserts, with through holes,
blind holes, screw inserts, shaft inserts, and thin-walled tube inserts. Fig.1-14(b) shows cylindrical
inserts such as screw bolts, pins, and connection pole and so on. Fig.1-14(c) shows non-cylindrical
inserts such as conductive sheets and weld pieces. Fig.1-14(d) shows the small rod-shaped cross-cutting
inserts of the car steering wheel. Fig.1-14(e) illustrates a PMMA housing inlaid with ABS plastic,

thereby forming a nonmetal insert.

For design of a plastic part with inserts, the first concerns are the stability of fastening the insert, the
strength of the plastic part, and the stability of the locating the insert during injection molding. The
solution depends on the structural design for the insert and its fit with the plastic part design.
1) The expansion coefficient of the materials for insert and the plastic part should be as similar as
possible. It should assure that the insert does not rotate or pop out, when it is under load. There are
several structural designs. Fig Fig.1-14 shows the use of knurling and notching. Only knurling is
applicable to small part designs, as shown in Fig.1-14(b). Fig.1-15(a) shows flattening of the inserted
portion of the insert. It applies to the conductive part to assure a certain area exists on its section.
Fig.1-15(b) shows the use of cut, hole-punching, and bending on the planer end of the insert. Fig.1-15(c)
shows the use of flanging on the edge of the insert to fix. Fig.1-16 recommends sizes for cylindrical and
tubular inserts where H=D, h=0.3H, h1=0.3H, d=0.75D. In extreme cases, the maximal H cant exceed
2D. All corners along the insert should be rounded.

Fig.1-14: types of common screw inserts

Fig.1-15: inserted structures

Fig.1-16: dimensions of an insert

2) The location of the insert inside the mold must be accurate and secure, to avoid disorientation or
deformation during injection molding. In addition, it needs to prevent the plastic material from leaking
into other parts of the insert such as hole or thread. Cylindrical inserts are usually inserted into a
corresponding hole on the mold to fix it. Fig.1-17 shows a structure used to enhance the stability of the
insert on the mold and prevention of the material from leaking. Inserts with threaded blind holes and
threads are usually inserted onto a cylindrical shaft on the mold, as shown on Fig.1-18(a). Fig.1-18(b),
(c), and (d) show the use of external bulges or internal steps to further improve the inserts stability in the

mold. Fig.1-18(e) shows an insert with threaded through holes is mounted on a component with external
threads. Smooth shafts can be applied to the type of small insert designs (M3.5 or less), when the
injection force is not high. For both cylindrical and ring-shaped inserts, their stick-out portion cannot be
more than twice the inserted portion, or the flow pressure may dislocate or deform the insert. Additional
support from the mold should be considered for inserts which have a thin, plate shape or exceeds the
ratio, as shown in figure Fig.1-19. However, the hole left by the support cannot affect the use of the
plastic part. Figure Fig.1-19(c) shows holes are added to the thin insert part to ease the material flow and
thus reduce the pressure on the insert.

Fig.1-17: fixation of cylindrical inserts in molds

Fig.1-18: fixation of ring-shaped inserts in molds

Pillar

Plastic flow direction

Fig.1-19: support methods for thin inserts in molds

Fig.1-20: location and dimensions for inserts

3) Residual force may linger in the plastics around the insert. The amount depends on the plastic

material type, insert material, insert structure, and the difference in expansion coefficients between the
two materials. Some may cause cracking on the plastic part. To avoid cracking, inserts are usually
located in the part area where there is a sufficient thickness as shown in Fig.1-20.

1.2.10 Surface Marking

Markings of protrusions, depressions, or leather-like wrinkles may exist on a plastic part as shown
in Fig.1-21. Some are for functional requirement, while others are for decoration. Markings should be
easy for molding, ejection and mold making. Usually the marking should be in parallel to the ejection
direction. A side draft must be considered to assure the wrinkle design on the side of the plastic part can
be properly ejected.

Fig.1-21: structure of characters on plastic parts

Markings, symbols, and characters on a plastic part can be classified into three structures. The
first is protrusion as shown in Fig.1-21(a). It is easy to make the mold but also easy to wear off. The
second is a depression as shown in Fig.1-21(b). Various paints can be added to the depression to create
bright markings. Its drawback is the difficulty of making the mold by traditional machining, unless a
non-traditional machining approach such as ECM, EDM or cold extrusion is used. The third is
depression on a boss as shown in Fig.1-21(c). An insert is usually used in this type of structure.
Characters are made on the insert, which is in turn inserted into the mold. Wear resistance and ease of
mold making are both its advantage.

1.3 Mold Specification

1.3.1 Basic Mold Structure
1 Two-plate Mold
Two-plate molds are molds whose sprue, runners, gates, and cavities are all on the same side of the
mold as shown in Fig.1-22 ,divided by the parting line into moving half and fixed half. Their features
are:
1) Simple structure, easy to operate, and satisfactory to have the plastic part to drop off freely.
2) Minimal operational problems, long lifespan, and shortened molding cycle.
3) Inexpensive mold cost.
4) Easier to choose gate shape and location.
5) Other than direct gates, gate location is limited to the side of the plastic part, with certain
exceptions.

6) After molding, there is a need to cut off the gate from the part.

1. sprue bush2.guide pin3. cavity-retainer plate4.core5. core-retainer plate6.support plate

7. sleeve8. stop pin9. spacer block10.core11.screw12. clamping plate of the moving half
13.ejector-retainer plate14. sprue puller pin15.ejector-support plate16. return pin

Fig.1-22: two-plate injection mold

Fig. 1-23 is the photos of two-plate injection mold with one cavity for a plastic ear rack of
Bluetooth product which has been installed on a plastic injection molding machine.

a) fixed half mold

b) moving half mold

Fig. 1-23: two-plate injection mold with one cavity for a plastic ear rack of Bluetooth product

2 Three-plate Mold
Three-plate mold is a mold which has a runner plate in between moving half and fixed half. The
runner exists between the runner plate and the fixed half as shown in Fig.1-24. The cavity is located in
between the runner plate and moving half of the mold. Pin-point gates typically locate at the middle of
the plastic part, away from its edge, satisfying the aesthetic requirement and eliminating the process for
cutting off the gates.
A three-plate mold has the following features:
1) Its gates can be located at the middle of the plastic part
2) It allows pin-point gates
3) It may eliminate cutting off the gates manually, when pin-point gates or submarine gates are
used.
4) It has to take out both the part and the runner respectively.
5) The injection molding machine should have sufficient mold opening distance.
6) It has a complex structure, more problematic and less durable.
7) It carries a higher mold cost

8) It has a long molding cycle.

1. sprue bush2. guide pin3. clamping plate of the fixed half4. cavity-retainer plate5.spring
6.stop pin7.core8. core-retainer plate9.suport plate10. spacer block11.screw
12. return pin13.ejector pin14. clamping plate of the moving half15. ejector-retainer plate16. ejector-support plate
Fig.1-24: three-plate injection mold

Fig. 1-25 is the photos of three-plate injection mold with two cavities for a plastic cover of
Bluetooth product which has been installed on a plastic injection molding machine.

a) fixed half mold

b) moving half mold

Fig. 1-25: three-plate injection mold with two cavities for a plastic cover of Bluetooth product

1.3.2 Types of Mold

1. Angle Pin Side Core-pulling Mold Structure
Fig. 1-26 illustrates a mold structure adopting angle pin side core-pulling mechanism, which shows
how to demold the side concave structure on the molding product to be used as shell of a kitchenware.
While the mold is being clamped, slide 23 is retained by wedge plate 26, and therefore angle pin 24
essentially bears no force during injection. As the mold gradually opens, angle pin 24 pushes slide 23 to
move outward until the side concave structure on the product is completely ejected. The molded product
is then left in the moving half and will be further ejected there out by ejector pin 4 and ejector bush 9.
When the mold closes, the ejection system and slide 23 will return to their original position by means of
return pin 12 and angle pin 24. The same method is employed for the ejection of shells for beverage
cartons, wind wheel of hair driers as well as winding bushes. The possible number of cavities and their
arrangement in the mold are mainly determined by the number and position of slides.

One single cavity is allowed for a mold with a multiplicity of radial slides, such as the mold for
steam turbine blades. The parting of a slide or a cavity can also be made by means of compressed air or a
hydraulic cylinder. A mechanical clamping mechanism is usually used to avoid unnecessary
displacement of the mold.

1.ejector-retainer plate2. ejector-support plate3. straight pin4.ejector pin5.back locating ring

6.back ejector-support plate7.pillar8.sprue puller pin9.ejector bush10.location pin
11.screw12.return pin13.guide pin
14.guide bush15.core-support plate16.return pin17.core insert18.cavity insert
19. locating ring20.sprue bush21.cavity insert22. cavity-support plate23. slanted slide
24 angle pin25.wear plate26. wedge plate27. cavity-retainer plate28.slide insert
29.cooling pipe30. core-retainer plate31. wear plate47.spacer block48. clamping plate of moving half
Fig.1-26: angle pin side core-pulling mold

2. Slanted Lifter Side Core-pulling Mold Structure

A lifter mold is shown in Fig.1-27. It consists of slide 2 and lifter 5, core-retainer plate 4 and main
core 3. The lifter 5 is guided by the side hole on the moving half. After opening the mold, ejector-retainer
plate 8 pushes the lifter 5 and ejector pin 1, making the slide 2 and the ejector pin 1 to eject the plastic
part while pulling out the internal side core-slide. While locking the mold, the ejector plate on the
moving half retracts backward by spring 6 for rough return. The moving half continues moving
backward to push the slide for precision return. As the lifter is pushed back, friction is created between
the ejector-retainer plate and the bottom of the lifter. To reduce the friction and prolong the mold life, the

lifters bottom is usually made in a ball shape hardened with local quenching process. The insert 9 on the
ejector-retainer plate which comes in touch with the lifter also requires the hardening process.

1. ejector pin2. slanted slide3.main core4. core-retainer plate

5. slanted lifter6.spring7.return pin8.ejector-retainer plate9. insert
Fig.1-27: internal side core-pulling mechanism with a slanted lifter

Fig.1-28 illustrates the roller-type slanted lifter for external side core-pulling mechanism. Roller 9 is
connected onto slanted lifter 7 with axle 8, which means that the slanted lifter is in rolling contact with
ejector-retainer plate 10 through the roller, and the sliding friction is replaced with rolling friction,
thereby enormously reducing relative friction force.
As indicated in Fig.1-29, slanted lifter 7 is secured on channel frame 2 by rolling axis 3, which
reduces moving friction and meanwhile can drive slanted lifter to return during mold clamping.
Fig.1-30 illustrates the translational slanted lifter inner core-pulling mechanism. During the ejection,
slanted lifter 3 and ejector pin 4 act together to prop up the plastic part from main core 1, and when it is
moved to distance L, point A on the lifter 3 breaks away from the restriction of major core, while point B
bumps with B0 on the moving half, and the bevel forces the lifter to move horizontally inward, thereby
making inner core-pulling action. It should be noted that when the inner core-pulling action starts, the
plastic part should be partially retained in the major core so as to avoid horizontal moving of the part,
which can influence core-pulling. The uniform bevel at the end of the lifter is designed to prevent
damage caused by the collision of the lifter with straight end angle of the major core during the returning
of the lifter. Therefore, when designing make sure > , wherein during mold clamping, point D on
the lifter first bumps with D0 on the major core and moves outward so that the lifter all along does not
collide with end face of the major core.
As indicated in Fig. 1-31 is a swing slanted lifter inner core-pulling mechanism. The slanted lifter 5
is connected through a spindle with swing rod seat 7 that is mounted on the ejector plate. When the
ejection starts, swing rod 5 acts together with ejector pin 4 to prop up the plastic part from major core 2.
When it is moved to a pre-set distance, the convex block b of the swing rod touches the bevel on
core-retainer plate 1, forcing the swing rod to swing anticlockwise inward around core shaft 6, thereby
making core-pulling while ejecting.

1. side core insert2.core pin3.main core4. core-retainer plate5. ejector pin

6.return pin7. slanted lifter8. axle9.roller10. ejector-retainer plate
Fig.1-28: external side core-pulling mechanism with a roller-type slanted lifter

1. ejector-support plate2. channel frame3. rolling axis4. ejector pin5. core-retainer plate
6.core7. slanted lifter8. cavity-retainer plate
Fig.1-29: internal core-pulling mechanism with a slanted lifter

1. main core2. core-retainer plate3. slanted lifter4. ejector pin5. return pin6. ejector-retainer plate
Fig.1-30: translational slanted lifter inner core-pulling mechanism

1. core-retainer plate2.main core3. return pin4. ejector pin

5. slanted lifter6.core shaft7.swing rod seat ; 8.ejector-retainer plate
Fig.1-31: swing slanted lifter inner core-pulling mechanism

3. Mold with Unscrewing Equipment

High quality threads can only be molded economically and in large quantities by using an
unscrewing device. The mold components which form the threads, generally cores for internal and
sleeves for external threads, can be rotated in the mold. During demolding they are either screwed off or
out of the part while the mold is either open or closed. The part has to be designed in such a way that it
can be protected against rotation.
In all such molds attention has to be paid to an exact mounting and alignment of cores and drive
units. Insufficiently supported cores, particularly slender ones, can be shifted from their center position
by the entering plastic material more easily than rigidly mounted cores. This would impede or even
prevent the unscrewing process because the driving torque becomes insufficient for the deformed
molding part.
The drive force for these molds is transmitted from the opening movement by a lead screw with
coarse threads or a rack. Separate drives such as electric, pneumatic, or hydraulic drives are common,
too. The latter are often actuated by separate controls.
a) Unscrewing mold with racks
The number of threads that can be molded in these molds is limited by the diameter of the part, the
force of the machine or the rack drive, and the stroke of the rack. The stroke is actuated by the opening
movement of the machine or by a separate hydraulic or pneumatic actuator.

The functioning of such molds is only flawless if the rack has an accurate pitch, and rack and driven
pinion have precise bearings and guides. Otherwise there is a threat that teeth are skipped. This threat
is especially great if the required rotation is not transmitted directly to the core but with bevel gears or
another rack as shown in Fig.1-32.
Rack 2

Pinion

Driving box

Rack 1

Core

Moving half mold

Fixed half mold

Fig.1-32: unscrewing mold with racks

b) Molds with coarse lead screws

Coarse lead screws which are driven by nuts mounted in the machine are considered the simplest,
and at the same time, most reliable driving elements for thread-forming cores. They do not cause
extended setup time and need no special control of the stroke. During the demolding process they
transform the opening movement of the molding machine into a rotary action and drive the cores.
Opening stroke and force of the machine are determined by the kind, diameter and number of threads,
and the number of cores, which can be demolded. As a general rule single thread can be readily
demolded by this method. With diameters up to 10 mm, even some more threads are acceptable
because a smaller pitch is then used.
In the molds in Fig.1-33 the coarse lead screws are mounted in the molds with tapered-roller
bearings and the nut is firmly attached to a cross-tie bar of the machine. The design represents a special
case because the coarse lead screw is at the same time the thread core of the mold. The turning lead
screw moves the molding axially and pushes it from the core. It has to be kept in the cavity so that it
cannot follow the rotation.

Fig.1-33: mold with coarse lead screws

4Mold with Core-pulling Mechanism on Fixed Half

Some molds, which are not allowed to have the ejectors traces on the plastic parts, are designed in
such a way that the molding remains in the fixed mold half. These molds have to have a different
demolding action. Demolding takes place by stripping the part off the core. The stripper plate can be
actuated by a stripper bolt as shown in Fig.1-34, which is attached to the movable mold half by a
pin-link chain, or by hydraulic or pneumatic action. Thus the ejection occurs by traction in the direction
of demolding as shown in Fig.1-35. Two other options are shown with Fig.1-36. The ejector is actuated
by a lever or a crank.
Such a mold structure reduces the close-height of molds, which is very advantageous for some
special occasions. For example, a mold with deep cavity adopting common ejection form will fall short
of the technical requirements of injection machine due to the overlarge close-height of mold, yet the
problem can be properly solved by replacing with fixed mold ejection.

Fig.1-34: core-pulling mechanism on fixed half with stripper bolts

Fig.1-35: core-pulling mechanism on fixed half with gemels

1-push rod 2-return spring 3-lever 4-cam lever

a) Use of lever structure

1--push rod 2- return spring 5-cam lever 6-lever

b) Use of crank structure
Fig.1-36: use of lever or crank for core-pulling mechanism

5 Hot Runner System

In the hot runner system, the plastic in the runner between the major running channel of mold and
the gate of the molded product is kept at a sufficient temperature during the course of injection
processing; therefore, the plastic wont solidify and no freezing material will be formed in the runner.
1) Thermal Insulation Runner
This is one of the simplest in hot runner system. The poor thermal conductivity of the molded
materials in the hot runner as well as the large section of the runner causes the core part to fuse, and the
core part passing through the runner keeps injecting new fused materials into the mold, which
meanwhile also preserves the fusion state of the core part. For a mold with a single cavity, a thermal
insulative sprue bush can be used, as indicated in Fig.1-37. Should this principle be used for a
multi-cavity mold, then a thermal insulative runner will be formed, as indicated in Fig.1-38. The large
section of the runner therein should be as close to the cavity as possible. The air around the sprue bush
can reinforce insulation. When using such insulative runner, there requires uninterrupted production and
rapid production cycles, since when the production is interrupted, the runner will solidify, and under
such occasion the runner must be removed so that new insulative runner can form. If the mold is used
under occasions that require constant change of colors or materials, such runner will be more
advantageous. Inner surface of the main sprue bush and the gate connecting with the cavity must be
conical so that the solidified plastics within the gate can be drawn out with the product during each
injection cycle. A small conical mark of the gate is thereby left on the molded product.

Fig.1-37: thermal insulative sprue bush

Nozzle

Parting line

Melting runner

Fig.1-38: thermal insulative hot runner

2) Heated Hot Runner and Nozzle of Hot Runner

Through heating the runner system, working state of the mold can be restored after the production
interruption without filling the runner with fused materials first. Moreover, when setting the injection
time for each cycle, consideration for removing frozen runner can be saved. Currently, almost all hot
runner systems provided by standard mold elements suppliers are well-qualified, and therefore,
self-made hot runner systems are seldom seen. In principle, the heated runner falls into inner heated hot
runner system and outer heated hot runner system.
z Inner Heated Hot Runner
As indicated in Fig.1-39, in an inner heated hot runner system, the heating element 2 is located in
the center of runner groove, with the fused molding materials flowing there around. Since the material
feeding runner 3 lies in the manifold pipe plate 1 which will not be heated, a solidified fused material
layer is formed on the inner wall of the runner. Only those layers close to the heating element can flow.
The thermal uniformity of fused materials arriving at the cavity is determined by duration of fused
materials in the hot runner system as well as whether the materials are provided with broad softening
temperature range, or whether the decided fusing point is appropriate. Anyway, compared with outer
heated runner, the inner heated runner requires far less outer thermal insulation, which shall contribute to
more compact mold structure.

1. manifold pipe plate2. heating element3. feeding runner

Fig.1-39: inner heated hot runner

z Outer Heated Hot Runner

In the outer heated hot runner system, the feeding runner of fused materials is heated exteriorly. The
manifold pipe with a runner therein must be sufficiently insulated from the surrounding part of the mold
so as to reduce thermal loss and temperature fluctuation. As indicated in Fig.1-40, manifold pipe 8 which
contains a feeding runner is heated by a tubular heater 22, while fused materials in the manifold pipe are

transmitted by a hot nozzle 25 into the gate. A locating ring 13 and a locating pin 20 are set to ensure
correct position of the manifold pipe and the mold (i.e. no axial displacement or rotation). A gasket 11
supports the manifold pipe on the clamping plate of the fixed half 4. Except for the aforementioned
contact points, certain space is left between the manifold pipe and surrounding part of mold. A metal
reflection plate 9 controls thermal radiation loss of the hot manifold pipe within a minimum range.
Usually, the thermal transmission from a hot mold to the cold mold plate of an injection machine is
insulated by an insulative plate 5. The heating is controlled by a thermocouple 23. Fused materials in the
barrel of the injection system enter into the sprue bush 14 and are further transmitted into the manifold
pipe. The end hermetic seal 12 at the end of the runner must be in a shape without a dead angle, since the
materials shall change direction herein and flow into the hot runner nozzle. The nozzle 25 is mounted on
mold plate 1. Due to the effect of thermal expansion and cold contraction, the manifold pipe shall slide
on the nozzle which is harnessed with a metal O-ring 26 so that the contact point can be sealed. When
there are no impurities in recycled materials if they are used for production, the filter core 15 which is
located in the sprue bush 14 shall prove to be very useful.

1.mold plate2.bottom pad3. support plate4. clamping plate of fixed half5. insulative plate
613. locating ring7. cover plate8. manifold pipe9. reflection plate10. support bolster
11. gasket12. end hermetic seal14. sprue bush15. filter core16.heater collar
17. slot-head screw1819. clamping screw2021. location pin22. tubular heater
23. thermocouple24 connecting box25. hot nozzle26.metal O-ring27.mold inserts28. O-ring
Fig.1-40: outer heated hot runner

The design of the nozzle is determined by the requirement for dimension of the gate mark on a
product. A gate can be of various forms, depending on the removal measures of the gate mark. Due to
technical reasons, the type of gate, apart from meeting specific requirement for the dimension of gate,
should ensure minimum pressure loss during the process of injection. Fig.1-41 illustrates a heating
nozzle penetrating into the gate hole in the shape of a needlepoint, which forms very minute gate mark.
Under such instance, however, the pressure drop and the shearing stress acted on the molding materials
during injection are relatively higher, especially when recycled materials are used, the gate may even be
blocked.
A hot runner nozzle with a needle valve (valve gate) is indicated in Fig.1-42 in which the gate mark
produced by a valve gate tends to be clear, round and smooth, and meanwhile low pressure loss is caused
during the injection. Prior to injection, the needle valve is controlled by the cylinder, moves rightward

and opens the gate hole so that fused materials can pass. Before the fused materials at the gate
completely solidify, the needle valve is pushed to the left and closes, leaving a round and smooth gate
mark. Same with the multi-point hot runner as illustrated in Fig.1-43, that in Fig.1-42 is heated by a
tubular heater and an inner-hole insert is used to help fused materials alter their flow direction.
Fig.1-43 illustrates a gate form wherein a hot nozzle is matched with four small mold cavities.
Similar with the method of using a shearing gate, the multi-edge gate of a product can also be equipped
with one nozzle, as indicated in Fig.1-44.

Fig.1-41: heating nozzle penetrating into the gate hole in the shape of a needlepoint

1. needle valve17. inner-hole insert45. tubular heater

Fig.1-42: hot runner nozzle with a needle valve

Fig.1-43: multi-point hot runner

Fig.1-44: multi-edge gate hot runner

6The Structure of Stack Mold

A special mold design has come into use, the stack mold, for molding shallow parts in large
quantities such as tape cassettes. Here, cavities are located in two or more planes corresponding to two
parting lines and are filled at the same time. A molding machine with an exceptionally long opening
stroke is needed. An increase in productivity of 100% as one might expect from doubling the number of
cavities cannot be realized because of the time needed for the longer opening and closing strokes. The
increase in productivity is about 80%. The clamping force should be 15% higher than for a standard
mold.
The mold section is mounted on the movable platen and the center section is moved in the direction
of the machine axis during demolding. With this, the extension is removed from the nozzle. The
extension has to be sufficiently long that no leakage material can drop onto the leader pins and stick
there during mold opening. This would impede their proper functioning. For this reason many stack
molds are operated today with telescopic extensions and without nozzle reaction. While the outer section
on the clamping side is mounted on the movable machine platen and moves positively with it during
mold opening and closing, special elements are necessary to guide and control the movement of the
center section. Now the motion is primarily produced by toggles, sometimes by racks or hydraulic unit
as shown in Fig. 1-45. Toggle control also offers the option of using, within a certain range, opening
strokes of different lengths. This allows the molding of parts with one height in one stack and parts with
a different height in the other one. The curves of the opening path can be adjusted within a wide range
depending on pivotal point and toggle geometry. At the same time injection is actuated by the same
elements that move the center section. Fig. 1-46 shows different kinds of toggle mechanisms.

a) Use of hydraulic unit

b) Use of toggle mechanism c) Use of rack mechanism

Fig.1-45: movement method of stack molds center section

Fig.1-46: toggle mechanism for stack mold

The mold as illustrated in Fig. 1-47 contains two parting lines A and B as well as compound cavities.
At the central part of the mold lies cavity plates 4 and 5, hot runner systems 16 as well as hot runner

nozzle 17, from which fused materials shall be injected into the cavity. The materials, through an
extension sleeve 18 set at the center and connecting with main sprue bush 21, reach at the hot runner
system. When the mold is opened at A, the hot runner system and the extension sleeve begin to move
leftward so that main sprue bush 21 is separated from nozzle of the injection machine. To prevent that
the fused materials drip from the main sprue bush 21 and solidify in the protective tube 24, the main
sprue bush 21 is provided with a self-locking mechanism.
The synchronous opening of the two parting lines is achieved through two rack and pinion
mechanisms which are respectively fixed on two half-molds and are started up by a pinion mounted in
the middle section therein. To eject the product from parting line A, a cylinder (not illustrated in the
figure) is adopted to act on ejector plates 34 and 35, whereas the ejection movement of the injection
machine is used to eject the product from parting line B.

A, Bparting line1, 2, 3mold plate4, 5cavity plate6, 7inner core

9, 10core-retainer plate11guide pin12guide bush15, 16hot runner
17hot-runner nozzle18extension sleeve19~23main sprue bush with self-locking mechanism
24protective tube27ejection plate28ejector pin32, 34, 35ejector plate
42nozzle pipe45location ring46location pin
Fig.1-47: stack mold with hot runner

7 The Structure of Two-colored Mold

Two-component combination injection molding in which two melts are introduced into the cavity in
succession via separate gating system requires special mold techniques since those areas of the mold that
become filled by the second melt must be blocked off when the first material is injected, in order that it
does not penetrate into those areas.
The separation may be effected in either of two ways: by the rotating mold systems as shown in
Fig.1-48 and by the non rotating core-back systems as shown in Fig.1-49.
a) Molds with rotating mold platen or rotating mold half
A rotating mold has several gating stations and different cavities. For a two-colored part, the first
colored section is created by injection at the first mold position. After sufficient time has lapsed for the
melt to cool, the mold opens and the mold part section turns 180into the section position. The mold
closes to form the second cavity and the second color or another material is injected via a second
injection position. In the first mold position, meanwhile, the first molded-part section is being created
again. In a similar fashion, three colored parts can be made using three injection and mold positions and
rotations of 120. The mold is rotated either by means of a standard rotary platform that can be attached
to the machine, irrespective of the mold, or by means of a rotary device integrated into the mold that
allows a rotary plate to operate. The advantage of the standard rotary platform is its universal method of
use, and in the smaller and less expensive design of the molds used. Usually the mold platen on the
ejector side is designed to be the rotating side since rotation of the nozzle-side mold platen is more
complicated in terms of gating system and rotating system. These molds require high precision mold
making but are dependable in operation. Typical applications are car tail light covers and the vent flaps
of the Golf motorcar.

Fig.1-48: rotating mold system for combination injection

Fig.1-49: supporting method of core

b) Molds with rotary cores or spiders

In this technique, only part of the ejector- or nozzle-side cavity with injected pre-molding is rotated.

Both mold platens remain in position.

c) Molds with transfer or insert technique
After the pre-molding is made in the first cavity, it is transferred by a handling device or by hand
into the second cavity and molded to produce the final part with a second material. The term transfer
technique is also used to describe using a different machine for molding to produce the final part.
Generally, these molds are preferred to rotary molds for economic reasons because the complicated
rotary device can be dispensed with, and usually more cavities can be accommodated on the mold platen.
Furthermore, thermal separation of the pre-molding and final-molding positions is easier to accomplish
(particularly important for thermoplastic-thermosetting laminates). Disadvantages are the need for
precise centering of the pre-moldings.
d) Molds with retractable slides and cores(Core-back molds)
With comparatively low mold cost, it is possible to produce multicolor or multi-component
injection molded parts in one mold without the need for opening the machine and further transport of a
molded part by means of the core-back technique. The cavity spaces for the second material are first
closed by movable inserts or cores and are opened only after the first material has been injected. The
components can be arranged beside, above, or inside each other. This method does not suit material pairs
that will not join or bond to each other. Furthermore, injection in these molds can only be carried out
sequentially and not in parallel as in other methods. This results in longer cycle times. Separate
temperature control of the cores or inserts is beneficial since the temperature of the impact surface onto
which the second melt is injected can be controlled more accurately.
In combination injection molding, the rotary mold systems often employ hot runners for the
pre-molding so as to yield a gateless pre-molding, since the gate interferes during rotation or transfer and
would otherwise have to be removed prior to transfer.
The choice of method for a particular molded part must be established individually from technical
and, economic aspects for every application. It must be remembered, however, that rotary mold systems
are generally more expensive because of the need for two cavities and from the machine point of view,
need a large distance between tie bars in order to be rotatable. Rotary molds do, however, offer greater
design freedom.
8Highlight and No-welding-line Mold
Traditional water-cooled injection molds are made of tool steels via the material removal process.
Their water lines are made with drilling simple, intersecting, straight holes, leading to lower heat transfer
efficiency, uneven temperature on the cavity surface, and warpage on the plastic part.
Highlight and no welding-line molds have an innovative mold design and manufacturing process,
making use of pressured vapor or fluids as a media to more efficiently and evenly control the heating and
cooling process. The design also maximizes the pipelines inside the mold and thus allows rapidly raising
the temperature to the thermo plastic level. It ensures a smooth flow of the plastic material inside the
runner and mold cavity, realize rapid injection, and achieve the production of plastic parts with high
strength, stiffness, and luster on its surface. It also minimizes the problems of deformationdents
welding lines and waves. After the injection, it allows pumping cool water into the mold to quickly
lower the mold temperature and thus shorten the molding cycle, up to 70%. It is an ideal solution for
precision injection molding.
Fig.1-50 demonstrates the contrast between a no-welding-line plastic part and a traditional plastic
part. The no-welding-line plastic part is lustrous, shows no welding line on the part; thus it requires no

painting.
Its mold developed by the Authors is demonstrated in Fig.1-51, which divides the molds fixed
component into two parts: highlight shell and background plate. The highlight shell should have a
homogeneous thickness around its all areas, while the background plate is machined to acquire the
conformal channels of the cooling/heating media, which have the same shape as the plastic part surface.
Fig.1-52 is a highlight and no-welding-line mold made at Hitachi. Its principle is the same as the
one shown in Fig.1-51. It divides the fixed mold component into highlight shell and background plate.
However, its cooling/heating line is made on the back of the highlight shell.

No-welding-line green plastic part

Welding line

Traditional plastic part (require painting)

Fig.1-50: the contrast between a no-welding-line plastic part and a traditional one

Sprue gate

background plate

Packing ring groove

cooling/heating line

a) plastic part

b) highlight shell

d) fixed half mold

c)background plate

e)fixed half mold without highlight shell

Fig.1-51: highlight and no-welding-line injection mold developed by the Authors

Fig.1-52: highlight and no-welding-line injection mold developed by Hitachi

The manufacture of a highlight and no-weld-line mold is a challenge, which usually means both
more machining work and more technical difficulty. It requires better machines and skilled workers. In
principle, the thinner the highlight shell, the better heat transfer efficiency, and thus the easier to acquire
a better no-weld-line plastic part. On the other hand, it may lead to deformation, losing its dimensional
accuracy. Highlight shell requires machining on both sides and thus requires high precision alignment of
the workpiece on the machine table, when machining the other side. Additionally, due to the division of
the fixed mold component into two parts, the tightening requirement is extremely high in order to seal
the media channels, especially after repeated exchange between cooling and heating cycles.
Currently, highlight and no-weld-line molds are used to make planer no-weld-line plastic parts. In
the case of flat-panel TV frames, they may not have to require making highlight shell. Instead, deep-hole
drilling is sufficient to create the media channels on the cavity. Most plastic parts have some curvature
on its surface. It is difficult to transfer the heat homogenously without using highlight shell, leading to
weld lines and deformations.
Since molds of high gloss can be directly used to manufacture high-gloss, markless and
environmental-friendly plastic parts, avoiding follow-up painting technics and corresponding lead
content control, which is very beneficial for environmental protection, this public technology shall bring
revolution to the concept of designing and manufacturing injection molds in the future, promote
technical upgrade in mold manufacturing industry and producing enormous social and economic benefit
for the construction of a people-oriented harmonious society.
9Gas-assisted Injection Molding
Through gas-assisted injection molding, products with uneven wall-thickness can be produced. The
products thereby acquired not only show no sign of surface shrink mark, warp and distortion and
meanwhile consume very small amount of materials, but also are easy to be controlled; above all, the
outer surface of such products is pretty smooth and glabrous and no air bubble can be found thereon. It is
a technology where in high-pressure inert gas is injected into core part of the plastic fusant to form a
hollow section and further help pushing fusant flow, thereby achieving injection, dwell as well as
cooling.
The technical process of gas-assisted injection molding falls into the following four stages.
1) Fusant injection. The plastic fusant is quantitatively injected into the mold cavity, which is
similar with traditional injection molding except that gas-assisted injection is an underfeeding
injection, namely, the injection volume takes up only 55%-80% of the volume of mold cavity, whereas
the specific injection volume varies with different molding products to ensure that the surface of fusant

will not be blown through upon the injection of high-pressure gas and thereby acquiring an ideal aeration
volume.
2) Gas injection. Inject high-pressure inert gas such as nitrogen into the core of fusant and the gas
enveloped by plastic fusant shall move forward along a direction with minimum resistance and
meanwhile push the flowing front of fusant to move further forward until the mold cavity is fully filled.
At this stage, pressure of the gas must be larger than that of the plastic fusant so that a hollow section can
be formed in the product. This stage plays a very significant role in the whole production process in
which it directly influences the final quality of a product. Many defects during the gas-assisted injection
molding such as air cavitation, blowing through, underfeeding injection as well as the infiltration of gas
into parts with thin walls are produced during this stage.
3) Gas dwell. Upon the completion of filling in the mold cavity and on the premises that the gas
pressure is preserved, the product should be put aside until it gradually cools to compensate shrinkage of
the product due to the cooling of materials. At this stage, the gas applies uniform pressure on the plastics
from inside to outside so that outer surface of the product always clings to the inner wall of mold cavity,
thereby leaving no depression on the outer surface of parts with thick walls and improving quality of the
product.
4) Discharge of gas. When the product is cooled until it takes on certain level of rigidity and
intensity, pressure of the gas shall be discharged and recycled. Finally open the cavity and eject the
product.
Gas-assisted injection molding is endowed with the following merits:
1) Low injection pressure and locking force, thereby reducing cost for equipment. Since
gas-assisted injection adopts underfeeding injection, wherein the fusants filling of the mold cavity is
accomplished under the pushing force of gas in the fusant, the injection pressure required thereof is
relatively lower and the locking force is also low (which can be reduced by 25%~90%), thereby saving
energy, prolonging the service life of molds and reducing manufacturing cost.
2) Slight warp and distortion of products. Owing to the low injection pressure and the uniform
distribution of fusant after the injection of gas, internal stress of products during the cooling is small,
resulting in very slight warp and distortion after the molding.
3) High surface quality. The pressure of gas in the hollow section of the products is referred to as
the dwell pressure which is distributed uniformly so that no defects like shrinkage hole or dent shall not
be formed on the surface of products, thereby improving the surface quality of products and reducing
defective index.
4) Can be used to mold products with diverse wall-thickness. Using gas-assisted injection molding
can achieve uniform filling for products with diverse wall-thickness and, on the premises that the weight
of products is not added, increase the rigidity and intensity of products (especially the edge section) by
setting the core part as stiffener of gas passage.
5) Short production cycle. Owing to the small injection volume of gas-assisted injection molding,
the injection duration is shortened, and meanwhile the hollow part in products with thick section
contributes to fast heat dissipation and cooling, thereby shortening molding cycle.
6) Strict requirement for technical control. First, the time and pressure for gas injection should be
strictly controlled. Premature injection, when the outer layer of fusant has not fully cooled, shall result in
the breaking of gas through the front of fusant, whereas late injection, when fusant has cooled and
solidified, shall prevent the forming of gas cavity. The pressure for gas injection should be first high then
low, wherein at the beginning of injection, higher pressure should be preserved so that the fusant can be

forced to fill in the mold cavity and form hollow gas cavity, and upon the completion of this action, the
pressure of filling gas, as dwell pressure, should be lowered to avoid overflow and internal stress.
Second, temperature of the mold should be strictly controlled, so that the cooling of fusant in the cavity
can be kept at an appropriate speed, which shall be of avail for the forming of gas cavity.
7) Saving plastic materials. Since gas in the cavity occupies part of the volume, the product shall
become thinner and lighter, generally by 20%~40%.
However, gas-assisted injection molding can result in different gloss on product surfaces with and
without gas injected. The defect shall need to be decked or covered with patterns.
Equipment used for gas-assisted injection molding generally comprises a common injection
machine and a gas injection device. A gas injection device contains such three components as a gas
pressure preparation system, an air nozzle and a special gas pressure control system. The gas usually
used is nitrogen and the pressure and purity of gas are determined by the molding materials and the
shape of products, wherein the pressure is generally at 5~32MPa, with a maximum level of 40MPa.
High-pressure gas, during each injection, is injected with the pre-set pressure from the air nozzle within
a definite time. One (or a multiplicity) of air nozzle (nozzles) is (are) mounted on the nozzle of injection
molding machine or runner or cavity of mold.
Gas-assisted injection molding can be applied to various thermoplastic plastics, despite certain
technical difficulties for highly viscous plastic which requires high gas pressure. For gas-assisted
injection molding, changing materials as compared with changing processing parameters tends to be
more effective in influencing the wall-thickness and surface effect of products. Furthermore, the fusant
must be rigid enough so as to control the forming of gas passage and to avoid the blowing through of
fusant.

1.3.3 Parting Line

Parting line is a reference plane in a mold. It significantly affects the quality of injection-molded
plastic parts, molds manufacturability, molding operation efficiency and so on. Therefore selecting the
parting line is a critical decision in the mold design.
The principles for deciding on the parting line are:
1) Assure the plastic parts appearance. Fig.1-53(a) (right) shows the parting plane may easily lead
to flow marks or overflow. It is hard to clean the mold. Fig.1-53(b) (left) shows a better choice of the
parting plane. It helps to form smooth, rounded corners on the plastic part.

(a)

(b)
Fig.1-51: principles for deciding parting line

2) Facilitate venting. The end of the material flow line is a good candidate for venting. Fig.1-52
shows a shape like caecum at the spot A, which is difficult for venting and thus difficult to fill out the
cavity, leading to air bubbles. The one on the left can easily vent the air, and thus a better design.

Fig.1-54: parting line to facilitate venting

3) Keep the plastic part on the side of moving half of its mold. In general, while opening the mold,
it is easier to eject the part, if it stays with the moving half which has an ejection mechanism. Fig.1-55
shows the fastening force exerted by the plastic part shrinkage on the core is greater than the one on the
cavity; thus as shown in figure on the right, the plastic part remains on the core and with the core,
separate from the moving half. Typically it is difficult to eject the plastic part. The left figure shows the
plastic part fastening the core is left with the moving half and is ejected with an ejection mechanism.

Fig.1-55: parting line to facilitate demolding

4) Assure plastic part accuracy. Fig.1-56 is a partial injection mold for making a plastic gear. Its
diameters d and D must be concentric. The right figure shows they are accomplished separately with the
fixed and the moving half. It is hard to assure the concentricity while closing the mold. The left figure
shows both the diameters d and D are on the moving half, easily satisfy the concentricity requirement.

Fig.1-56: parting line to assure plastic part accuracy

5) Easy to machining. Fig.1-57 shows the examples of a slanted parting line and a curved parting
line. The left figure shows it requires only one slanted or curved surface to match the mold plate.
Therefore, it is a better design. The right figure shows a design which requires matching multiple
surfaces, creating more technical challenge, while wasting time and effort.

Fig.1-57 parting line to facilitate machining

6) Coordinate the lateral parting line and major parting line. For plastic parts with side holes or side
slots, the location for the side core is usually placed on the moving half to ease core-pulling. Slides are
usually located inside the moving half, while angle pins and wedge blocks are located inside the fixed

half, to ease fit. Avoid placing the side core on the fixed half to simplify mold structure. The figure on
the right in Fig.1-58 shows the side core is on the fixed half. No matter where the angle pins are located,
it all requires a sequentially distancing mechanism, which complicates the mold structure design. The
figure on the left shows a common mold structure design where core-pulling on the side of moving half
and the angle pins are located on the fixed half. Thus core-pulling can begin as the mold is opening.

Fig.1-58: coordination between lateral parting line and major parting line

When there should be an option for selecting the side core with the shortest core-pulling distance.
The solution for core-pulling greatly affects the fastening force on the slide. The requirement for the
fastening force goes up, as the side core section area exerted by injection pressure increases.
7) Parting line should be compatible with injection molding machine parameters. After the injection
molding machine is selected, mold design should always refer to the machines technical parameters.
Fig.1-59a) shows a way to locate the plastic part, when its projection area A is close to the maximal
injection area allowed by the injection molding machine. When the A can be satisfied but the mold shut
height is too long, Fig.1-59b) is a better design.

a)

b)

Fig.1-59 parting line compatible with injection molding machine parameters

8). Consider the impact of draft. Avoid or minimize the problem of having an uneven wall thickness,
due to the dimensional difference at the two ends of a drafted plastic part. This phenomenon becomes
apparent for a long plastic part. Fig.1-60b) shows an uneven wall thickness and difficulty in part ejection,
because the drafts for the cavity and core are in opposite directions. For plastic parts with high
appearance requirement, Fig.1-60a) shows a design which locates the parting line in the middle, that
partially compensates for the problem caused by uneven wall thickness and helps eject the plastic part.

a)

b)

Fig.1-60: draft to impact parting lines

1.3.4 Feeding System

Feeding system design is a critical effort in mold design. It significantly affects the appearance,

physical properties, dimensional accuracy, and molding cycle time of a plastic part. A feeding system
consists of sprue, runners and gates.
Melt plastic flows out of the nozzle of injection molding machine into the mold. To a single cavity
mold, the plastic flows through the sprue into its cavity. To a multi-cavity mold, the plastic flows through
the sprue and then runners to reach individual cavities. The narrow section at the entrance to the cavity is
called gate.
While the melt plastic passes the sprue, runnesr and gates, it fills out the cavity at elevated
temperature and reduced pressure, due to friction. The melt plastic material gradually cools off in the
cavity by heat transfer.
Although the design of runner and gate has a great impact on the parts molding, and quality, it is
difficult to calculate and design an optimal feed system with a simple formula, for it is difficult to model
the acceleration of the flow inside the cavity, going through the gate at an elevated temperature due to
friction. In practice, the decision on the gate and runner design is based on the shape and size of the
plastic part and its material properties. Ideally, the runner and gate should be an integral effort in the
plastic part design and mold design process.
In selecting a feed system, the primary principle is to maintain the temperature and pressure as it
flows out of the nozzle and fill out the cavity easily. Commonly, it prefers a short and thick sprue,
runner, and gate. Other considerations are also given to the requirement of machines injection volume,
plastication ability, parts appearance, machining, dimension precision, physical properties, cycle period,
and material waste. Therefore, they could be thin and short as well. In addition, all areas around
the feed system must be fully polished. Fig.1-61 shows the layout of a feed system with sprue, runner,
and gate.
1Feed system assembly

1. cold-slug well2. sprue3. runner4. gate5. plastic part6. vent groove

Fig.1-61: feeding system of an injection mold

2 Sprue
Sprue is located at the entrance of a mold. It allows the melt plastic material to flow into the runner
or cavity. A sprue bush is inserted on the cavity plate or runner plate. When direct gate is used, the plastic
part will be left with a trace by the sprue. To keep the sprue bush in place, while being under pressure, a
step design is used to fix it on a locating ring. The hole inside the sprue bush is usually conic in shape.
The curve R is at the smaller end of the hole. The larger taper the hole has, the easier the sprue to pop out.
Sprue bush and nozzle may come in contact on a planer surface; it facilitates a right location and tight fit.
The following principles are applied to sprue bush design.
1) The radius R of the sprue bush should be larger than the radius R of the nozzle by about 1mm.
2) The smaller diameter of the cone-shaped hole should be larger than nozzles diameter by

0.5~1mm.
3) Minimize its length
4) Polish the cone-shape hole along its lengths direction.
Cold-slug well usually locates at the end of the sprue. That is, at the end of the runner and on the
core-retainer plate, on directly opposite side of the sprue. Its purpose is to store cold slug created
intermittently by the nozzle due to heat loss and low temperature. Cold slugs could clog or slow down
the material flow in runner and cavity and cause cold scars or cold marks on the plastic part. During
mold opening, the well can pull the slug off the sprue bush. The diameter of a cold-slug well should be
larger than the larger diameter of the sprue, while its length should be about the same as the larger
diameter of the sprue, to promote the material flow.
A sprue puller pin consists of cold-slug well and ejector pin. There is an ejector pin at the bottom of
the cold-slug well. The ejector pin is fixed on an ejector retainer plate and co-actuated with the ejection
system. Its basic structure and major dimensions are shown in Fig.1-62. Fig.1-62a) has a Z shaped sprue
puller pin. When the mold is opened, the end of the sprue puller pin pulls the slug out of the sprue. When
the ejection system begins to the ejection activity, both the plastic part and the slug are simultaneously
ejected out of the mold. This is a typical sprue puller ejection mechanism. While ejecting the slug, there
is a lateral motion. It is difficult to automate the slug ejection process. At times, due to constraints
imposed by the mold structure, the plastic part is not allowed for lateral motion during ejection.

Fig.1-62: sprue puller pin mechanism

Another form of sprue puller is to install a mechanism on the wall inside the cold-slug well to
prevent the cold slug being pulled out. An internal ring slot design and an inverse cone design both
utilize the concave inside the cold-slug well to pull the slug off the sprue from the sprue bush. It is easier
to automate injection molding. They are applicable to only soft materials with good toughness. A simple,
effective approach is to utilize the rough surface inside the cold-slug well to fulfill the sprue puller
function. Another approach is to tap an incomplete internal thread at one end of the cold-slug well.
Incomplete means a shallow thread, such that it can reliably pull out the cold slug from the sprue.
The sprue puller with an ejector plate is shown in Fig.1-63. The sprue puller pin is mounted on the
core-retainer plate, but does not actuate along with the ejection system. Fig.1-63a) shows a sprue puller
with a ball head. Fig.1-63b) shows a sprue puller with a conical head. Both utilize an inverse cone design
which is smaller than 0.3 mm in size, to pull out the slug. A sprue puller with a conical head is easy to
manufacture and serve the purpose of difference. Fig.1-63c) is a simple sprue puller, where the end of

the sprue puller is made into a column with rough surface, or tapped with thread of 0.1~0.2 mm height.

Fig.1-63: sprue puller with an ejector plate

3Runner
Various runner designs can be found in a multi-cavity mold. Runner layout is designed for the
mold cavities and thus depends on the cavity layout. Balanced and unbalanced are the two basic
types of layouts for runners and cavities.
1) Balanced Runner
The main feature of the balanced runner is that all runners have identical length, shape, and
sectional dimensions, from the sprue to each cavity. The design is to ensure each cavity has a
balanced material flow and is filled out at the same time.
(a) Radiate Runners
With radiate runner, cavities are evenly distributed around a circle centered at the sprue. Each
runner links a cavity to the sprue, as shown in Fig.1-64. Fig.1-64a) shows a layout where no
cold-slug well exist in the runner. It is possible that a cold slug may enter the cavity. Fig.1-64b) is
a better design where a cold-slug well exists at the end of runner. Fig.1-64c) is an ideal design,
which overcomes the problem caused by densely distributed runners. It reduces material waste, and
facilitates its manufacture.
The drawback with radiate runner design is not compact. It requires a larger forming area and
longer runners which need ejector pins. It uses polar coordinate system for layout design and
machining.
Fig.1-64d) shows an ideal plastic part cavity design where radiate runner is used. It has a
compact arrangement, reducing the required forming area.

Fig.1-64: radiate runner

(b) Linear Runners

Fig.1-65 shows a basic layout of linear runners, used in a multi-cavity mold. This is a design used
typically to simplify mold structure and feed balance. It requires having the runners on the fixed half,
to ease the extraction of slug and avoid hindering the motion of the side core-pulling. Fig. 1-66 is a
photo of feed system with linear runner.

Fig.1-65: linear runner

Fig.1-66: photo of feed system with linear runner

(c) Y-shape
Fig.1-67 shows Y-shaped runners, which consist of three sets of cavities arranged in a Y shape.
The total cavities can be a multiple of 3, such as 3, 6, or 12. Fig.1-67a) is similar to the radiate
runner. Their common drawback is there is no cold-slug well on the runners. It can be significantly
improved by adding a cold-slug well with a puller at the intersection area of the runners.

Fig.1-67: Y-shape runner

(d) X Shape
Fig.1-68 shows an X-shape of runner design, consisting of four set of cavities with ruuners
arranged in an X shape.

Fig.1-68: X-shape runner

(e) H shape
H-shape is the most common one. Four cavities forms a set arranged in an H shape. It can
accommodate any cavities of 4 or its multiples as shown in Fig. 1-69.
Its features include compactness and balance. In addition, their dimensions all vary along the X
and Y coordinates on the mold.
Runner design for molds of multiple cavities may be a hybrid of Y, X, and H shapes.
Fig.1-70a) is a runner design of X and H shapes combined. Fig.1-70b) is one of Y and H shapes
combined. In practice, one should be flexible in runner design.

Fig.1-69: H-shape runner

Fig.1-70: compositive runner

2) Unbalanced Runner
Fig.1-71 is an unbalanced runner design. Unlike a balanced runner design, the runner lengths from
the sprue to each cavity may be different. Fig.1-71(a) shows the gate has different sizes. The length Ll
of the gate near the sprue should be greater than the one away from the sprue, L2, that is, Ll>L2; or the
sectional area near the sprues gate Sl should be smaller than the one away from the sprue S2, that is,
Sl<S2. The purpose is to increase the resistance to the material flow at the near-by cavities. For practical
reason, a smaller gate size is used, to allow enlargement after mold test, when necessary, until all cavities
have the same material intake at the same rate. Unbalanced runner design is not appropriate for plastic
parts of high technical requirements.
Unbalanced runner designs have the advantage of shortening runners total length and thus enjoy an

extensive application in the industry. Fig.1-72 is a photo of feed system with unbalanced runner.

Fig.1-71: unbalanced runner

Fig.1-72: photo of feed system with unbalanced runner

3) Single Cavity Runner

Typical single cavity mold designs use a central feed approach, if the plastic parts projected area on
the parting line is continuous. That is, it does not have a runner. The slug flows directly to the cavity
from the gate through the sprue, as shown in Fig.1-73.
As shown in Fig.1-73, some plastic part designs of frame-, ring-, or U-shapes may have a sufficient
space in their external shape to accommodate the feed system for a compact mold design. Fig.1-74
shows such an application; that is, from sprue, runner and then gate to the cavity. It combines the
design of the gate.
A complex plastic part design may require feeding from the side. When the batch is small,
especially during the pre-production stage, a single cavity mold design is often used to cut down cost or
reduce the lead time. As a result, the mold cavity will deviate from the center of the molds locking force.
One way to overcome this problem is the use of a balance block of the same weight of the plastic part on
the opposite side of the cavity.
The location for the balance block is the candidate for adding another cavity, when the demand
surges.

Fig.1-69: direct feeding system of single cavity

Fig.1-70: feeding system to utilize a central hollow

Table1-6 Recommended runner diameter ranges for injection molds of partial plastic materials
Material Types

Diameter/mm

Material types

Diameter

Material types

Diameter/mm

ABSAS

4.8~9.5

PP

5~10

TPF

3.5~8

PE

1.6~9.5

PS

3.5~10

PPO

6.5~10

PA

1.6~9.5

PVC-F

3.5~10

PTFE

6.5~10

POM

3.5~10

PVC-U

6.5~16

PPS

6.5~13

PAP

8~10

PU

6.5~8

The diameter of a runner depends on the plastic parts volume, wall thickness and shape, in addition
to its material properties and the runners length. The following empirical formula usually apples to
plastic parts with wall thickness less than 3 mm and quality less than 200g.

D = 0.2654W 1/ 2 L1/ 4
Where,
D the runners diameter (mm) ;
W The amount of plastic material passing the runner (g) ;
L the runners length (mm)
For materials with a greater viscosity, multiple the D value computed with the above formula by a
coefficient ranged from 1.2~1.25. Table1-6 lists the diameter ranges for runner design for injection
plastic part materials.
4Gate
Gate is the end of the runner. It is the entrance to the cavity. The location, quantity, and size of the
gate have a great impact on the parts appearance, molding efficiency and dimensional accuracy.
Therefore, gate design needs to consider the plastic parts shape, material flow direction, weld mark
creation, and gate processing. In general, it is easier to fill up the cavity with a gate design of a larger
sectional area. But it will take a longer time to cool and seal the gate, which is more difficult to cut off
after injection molding. A smaller gate sectional area leads to the opposite result. Subject to the
constraints of the plastic part material, shape, and appearance, a good gate design is the one that leads to
the least residual stress and deformation. The functions and purpose of a gate are further described

below.
(a) Control the amount and flow direction of the melt resin, seal the resin inside the cavity until the
parties sufficiently solidified enough for ejection, and prevent it from flowing back.
(b) Elevate the temperature of the cooling resin by friction as it flows through the narrow gate, to
reduce flow marks and weld marks.
(c) Facilitate cutting off the connection between the runner and the plastic part, easing secondary
processing.
(d) Balance the resin filling activities among cavities, via adjusting the gate size. The gate location,
size and quantity are decided with input from the plastic part shape, appearance, resin selection, molding
machine capability, molding cycle time, secondary processing requirement, economic factors, and so on.
1) Direct Gate

Fig.1-75: direct gate

A typical direct gate locates at the mold center, as shown in Fig.1-75. It has a larger sectional
area and less flow resistance. It is typically applied to single cavity molds for large and deep plastic
parts. It is the sprue in a multiple cavity mold. To avoid cold slugs from flowing into a cavity, there
should be a cold-slug well design at the bottom, which is about of the plastic parts thickness.
It is more difficult to remove the slug from a direct gate. It cools off more slowly at the gate,
affecting production yield. Direct gate designs often lead to part defects of gate marks, residual
stress, deformation, air bubbles, and shrinkage cavities.
As there is little flow control at the gate, direct gate designs are called non-regulated. A
regulated gate design on the other hand, controls the material flow speed, volume, and direction.
Below are regulated gate designs.
2) Disk Gate
Disk gate is a variant of direct gate design, as shown in Fig.1-76. Melt material flows through
the sprue with regulation to reach cavities through the gates in a disk shape. The material inflow is
homogenous, while minimizing residual stress and enhancing the parts dimensional stability. It is
easier to remove slugs at the gates and thus good for plastics parts with large through holes.
A disk gate forms a sealed space with the cavity. While ejecting the part, a vacuum state is
created inside, which hinders the ejection process. Thus an air pin or passage design is required.

Fig.1-76: disk gate

3Subsprue Gate

Fig.1-77: subsprue gate

Subsprue gate is a variant of the disk gate design. Due to flow distribution through a cone, the
flow turns at a smaller angle, thus smoothing the flow, as shown in Fig.1-77.
4Spoke Gate
Spoke gate is also a variant of the disk gate design with a smaller gate to ease slug removal at
the gate. Compared to the disk gate, it consumes less plastic material for large part designs. It
overcomes the ejection difficulty caused by the vacuum formed by the disk gate, as shown in
Fig.1-78.

Fig.1-78: spoke gate

5Clawed Gate
Clawed gate is a hybrid of the subsprue gate and the spoke gate designs, as shown in Fig.1-79.

Fig.1-79: clawed gate

6Pin-point Gate
Pinpoint gate is also known as needle gate. It has a smaller sectional area, typically with
d=0.5~1 mm. It applies to plastic part materials that flow well in injection molding. When the melt
material flows through the gate, it elevates the temperature and lowers its viscosity due to shearing
and friction at a high speed. It helps material flow and acquires a good surface finish on the plastic
part.
A three-plate mold design is needed for removing slug. As shown in Fig.1-80, it is possible to
deploy an automatic slug ejection mechanism, though it increases the cost.
Pin-point gate has a smaller diameter. It consumes more injection pressure. Without
compensation, it may increase the shrinkage rate, residual stress, and deformation. It may leave weld
marks on large plastic parts. A design with multiple pin-point feed mechanism can compensate for
the weakness.

1.cavity-retainer plate2.core3. stripper plate4. sprue puller pin

5. sprue bush6. clamping plate of the fixed half7. ejector pin8. stop pin
Fig.1-80: three-plate pin-point mold with Auto-removing slug

7Submarine Gate
Submarine gate is a variant of the pin-point gate design. It can be applied to two-plate mold
designs. It can be accompanied with an automatic slug ejection mechanism. Compared to a
three-plate mold design with a pin-point gate, this one is simpler and lower in mold manufacturing
cost. Fig.1-81 and Fig.1-82 show respectively the basic structures of submarine gates which are
known as pulling-break off and pushing-break off.

Submarine gate requires a larger flexibility to accommodate elastic deformation of the gate slug
at ejection. Its gate size should be smaller, in order to improve the softness of the gate. Thus brittle
materials are not appropriated, to avoid breaking off and clogging the run way.

Fig.1-81: submarine gate with pulling-break off

Fig.1-82: submarine gate with pushing-break off

8Edge Gate
Edge gate is normally located on the parting line as shown in Fig.1-83, Fig.1-84 and Fig.1-85.
Material is feed from the edge side. It is popularly applied to mold designs of multiple cavities for
all shapes of plastic parts.

Fig.1-83: rectangular edge gate

Fig.1-84: edge gate to feed material from the side edge

Fig.1-85: edge gate to feed material from the inner edge

9Tab Gate
Tab gate is only applied to materials that are difficult to mold. Tab slots locate at the edge of
the plastic part, as shown in Fig.1-86. The material flows from the runner through the gate, and then
the tab slot, before reaching the cavity. The problems of deformation, warpage and shrinkage
cavities because of the gates all occur in the tab slots. By cutting off the tab slot, the quality of the
plastic parts can be assured.
Tab slot should be located at the thicker wall of the plastic part. The problem with a tab gate
design is it is difficult of removing slug.

Fig.1-86: tab gate

10Stack Gate
Stack gate as shown in Fig.1-87 has two or more regulated gates stacked on the same runner. It
is a good design for plastic materials which has a narrow range of melting temperature and poor
fluidity. The melt material is reheated due to friction as it passes the regulated gates and flow
resistance pin. It re-plasticizes the melt material and improves its liquidity.
Stack gate causes significant drop in injection pressure. An injection molding machine with
sufficient injection pressure needs to be used with a stack gate design.

Fig.1-84: stack gate

1.3.5 Mold Grades

Molds are subject to normal wear during its use, until the plastic part fails to meet its quality
requirement. Based on the requirement for molding cycle time and part quality, various materials and
processing techniques are used for mold making. Their cost thus varies significantly. The Society of
Plastics Industry (SPI) classifies molds that are applied to molding machines of 400 tons or less, into five
grades.
101 gradeThe number of molding cycles is higher than 1M repetitions, used to produce plastic
parts at high volume. The molding area (including the slides and lifters in contact with melt plastic
materials) is hardened. Best mold materials are used. Additional requirements are listed below.
1). It needs to have detailed mold design document.
2). The mold base hardnessBHN280.
3). The cavity surface (on both fixed and moving half) hardnessHRC48. Tool steels of high
hardness are used for all other auxiliary components such as the slides and lifters.
4). The ejection mechanisms should have guide components.
5). There should be a wear block on the side slide.
6). It needs to install a temperature controller on the fixed half, moving half, and slide, among the
others.
7). It should apply anti-corrosion treatment to each component which has contact with circulating
water.
8). It should install a parting line locking mechanism.
102 gradethe number of molding cycles is between 500K and 1M, used for volume production.
The molding area and related mold components needs heat treatment. Good mold materials are used.
Additional requirements are listed below.
1) It needs to have detailed mold design document.
2) The mold base hardnessBHN280.
3) The cavity surface (on both fixed and moving half) hardnessHRC48. All other functional
parts should be heat treated.
4) There should be a wear block on the side slide.
5) It needs to install a temperature controller on the fixed half, moving half, and slide, among the
others.
6) It should install a parting line locking mechanism.
103 gradeThe number of molding cycles is up to 500K, used for medium-sized
production volume. This is the most frequently used mold class. There is a wide range for selecting
mold materials. Additional requirements for this mold class:
1). It is recommended for having detailed design document.
2). The mold base hardnessBHN165
3). The cavity surface (on both fixed and moving half) hardnessBHN280.
104 gradeThe number of molding cycles is up to 100K, used to produce a low volume of
plastic parts. Mold materials do not have to be highly wear-resistant. It is less expensive. Additional
requirements are listed below.

1). It is recommended to have some mold design document

2). Soft steel or aluminum alloy may be used for its mold base.
3). Soft steel or aluminum alloy may be used for the fixed half of a mold.
105 gradeThe number of molding cycles is less than 500 repetitions, used for a low-volume
production such as prototypes. Mold material requirements are low and at low cost. Die casting
materials are permissible. Epoxy resin or its alike are frequently used plastic part materials.

1.3.6 Mold Surface Roughness

The surface finish of the molding area directly affects the surface roughness of the plastic part. A
range of polishing tools is used to meet a different surface finish requirement. The Society of Plastics
Industry classifies mold surface finishes into 12 grades in 4 categories.
Amirror image. It is typically polished with diamond paste. Its surface finish Ra is between
0~0.1m, applicable for plastic parts whose surface should have high luster. In general, mirror image is
further classified into A1, A2, and A3.
Bsmooth. It is usually polished with sand paper. Its surface finish is between 0.1~0.2m,
applicable for plastic parts with a typical surface requirement. This category can be further classified into
B1, B2, and B3.
CSemi-smooth.. It is polished with whetstone. Its surface finish is between 0.2~0.8m,
applicable for plastic parts without a specific surface finish requirement. This category is also further
classified into C1, C2, and C3.
Different processing materials are used for a specific surface finish requirement. According to SPI,
H13 steel of 3/8 thick and 1 in diameter is used.

1.4 Cost Analysis

As the mold industry grows, its competition intensifies. Accurate mold costing and quick response
to a quotation inquiry become a critical step in this engineering tooling industry. Voluminous studies
are available in the literature on cost estimation. They can be grouped into four types of cost estimation
approaches: direct, empirical, item by item, and template. Direct estimation basically depends on the
experience of the estimator. The estimate can vary widely. The empirical approach is limited to a
specific product type in each trade. The item by item approach usually takes too long time to estimate, as
the customer often expects a turnaround time of several hours for a quotation. The template approach is
built on sufficient data collected from successful deployment of the other three approaches. Therefore,
the practice of each approach only has acquired limited success in the mold industry.
Quick and accurate quotation is a key to a mold companys ability to acquire orders. Too high a
quotation implies losing the order to its competitor, and thus weakening its own competitive edge. Too
low a quotation may lead to a customer order; yet lowering its profit or possibly losing money. Thus the
ability of delivering quick and accurate quotations is an important measure for a companys competitive
ability.
Mold structure is rather complex. Many of its features have a direct impact to its cost.
Furthermore, some parameters are not available in detail at the time of quotation, until a DFM analysis is

conducted. Therefore, cost estimation can only rely on some major specifications available at the time.
Presented below is a quick cost estimation model for injection molds.

PQ = C r1 r2
Where
PQ
r1
r2
C

(1-1)

Quotation for an injection mold

Product type coefficient
Customer coefficient
Molds production cost, consisting of four elements

C = C

+ C M + C H + CT

(1-2)

CW processing cost
CM material cost
CH hot runner expense
CT mold test expense

1.4.1 Processing Cost (CW)

The processing cost includes the expense for mold design, fabrication, assembly and test, prior to
delivery. The cost is estimated with the formula below

CW = T A

(1-3)

where
A An average rate (cost) for processing
T Total processing time in hours
According to mold specifications, the total processing time is estimated by:

T = F F
1

F3 F4 F5 F6 F7 T0

(1-4)

where
F1Coefficient for basic mold structure
F2Coefficient for mold type
F3Coefficient for mold grade
F4Coefficient for material used for the molding area
F5Coefficient for surface finish required for the molding area
F6Coefficient for molds parting plane and the shape of the plastic part
F7Coefficient for mold cavity
T0Processing time for mold
1) Coefficient for Basic Mold Structure (F1)
Molds have a complex structure and many features. It is difficult to enlist all of them at the time of
quotation. Also it is difficult to adjust the parameters, if too many are included in the model. As a
consequence, only parameters available at the time of inquiry should be included in the model such as
basic mold structure and side core-pulling mechanism. For example, total work hours are thus estimated
via adjusting the coefficient for mold structure.

(a) 2/3-plate Coefficient (f11)

The selection of basic mold structure is important, as it affects its detailed design, manufacturing,
and subsequently cost. Common mold structures are:
2-plate (single parting line) molds, which are simple and inexpensive.
3-plate (double parting line) molds, which usually have a long molding cycle and are more complex
and costly.
An f11 is assigned to each of the two mold structures. Two-plate mold is used as reference and
assumes the coefficient of 1. Thus the coefficient for 3-plate mold assumes a higher coefficient.
(b) Side Core-pulling Mechanism Coefficient (f12f13f14)
For plastic parts with edge holes and groove, the mold structure usually has a side core-pulling
mechanism, to assure part ejection, dimensional accuracy, and mold life. A side core-pulling mechanism
is complex and thus adds complexity to its manufacturing and assembly process. Consequently it
significantly increases the mold cost and needs to be reflected in its quotation.
There are two side core-pulling mechanisms: angle pin and lifter. The first is used for the plastic
parts edge holes and groove. The other is used for internal holes. To facilitate computations at the time
of quotation, slide size and quantity are used to compute the impact of side core-pulling mechanism to
the total work hours. The parameters are set as follows.
The number of large slides on the side core-pulling mechanism with angle-pin is N1, coefficient for
the corresponding side core-pulling mechanism is f12;
The number of smaller slides on the side core-pulling mechanism with angle-pin is N2coefficient
for the corresponding side core-pulling mechanism is f13;
The number of lifters on the side core-pulling mechanism with lifter is N3coefficient for the
corresponding side core-pulling mechanism is f14.
In summary, the coefficient for basic mold structure, F1 is defined as follows:

F1 = f11 + f12 + f13 + f14

(1-5)

2) Mold Type Coefficient (F2)

In addition to the basic mold structure, other mold structures may be considered for a special plastic
material. Their structures are usually more complex and have a significant impact on cost estimation.
Some examples are given below.
1. Stack molds.
2. Unscrew molds.
3. Reverse molds.
4. Two-shot molds.
3) Mold Grade Coefficient (F3)
Each mold grade has a unique reference manufacturing process. Molds designed for higher
injection repetitions demand better mold material quality with higher wear resistance. Grades 101 and
102 require a higher surface hardness, usually higher than HRC44. They have a more complex
manufacturing process which usually includes heat treatment and thus cost more. Their F3 value thus is
also higher. The F3 value is lower for the other grades, as their manufacturing process is relatively
easier and thus costs less. The F3 for Grade 103 is typically set at 1.0 and used as a reference. Others are
adjusted accordingly.

4) Coefficient for Mold Material of the Part Molding Area (F4)

The material is selected for the part molding area according to the surface roughness of the plastic
part and the expected number of injection cycles. Thus this material cost is an important input to the
quotation. There should be a specific coefficient, each corresponding to a material type. A typical mold
has the same material for both its core and cavity. Yet a unique coefficient is assigned to core and cavity
separately, to address the situation where a different material is used.

F4 is an average of the two

coefficients, f41 and f42 as shown below.

F4 = ( f 41 + f 42 ) / 2

(1-6)

5) Coefficient for the Surface of the Part Molding Area (F5)

The surface roughness for molds is usually of the B2 type. Therefore, B2 should be used as the base
for surface roughness and its coefficient is set at 1, which is used as the reference for setting others.
A typical mold has the same roughness for its core and cavity. Yet a unique roughness coefficient is
assigned to the core and cavity, separately to accommodate the situation when a different roughness
exists for core and cavity. F5 is an average of the two coefficients f51 and f52, as shown below:

F5 = ( f 51 + f 52 ) / 2

(1-7)

6) Parting Line and Part Shape Coefficient (F6)

There exist several parting line designs, considering various plastic part shape, its appearance, and
ejection method chosen for the mold. The selection of parting line greatly affects the mold structure and
its manufacturing process, especially the one for the molding area. As a rule of thumb, a complex parting
line design implies a more challenging manufacturing process. Typical parting line designs include
horizontal, vertical, stepped, angled, and curved. In practice, however the parting line is a hybrid of the
above. Therefore a number of coefficients are developed below for capturing factors that affect the
parting line decision.
f61 It is coefficient for parting lines of normal, totally planner or curved.
f62 It is coefficient for the major part contour (the parts projected shape on the parting line) such
as normal, circular, rectangular, L-shaped, U-shaped, and gear-shaped.
f63 It is coefficient for the major part shape (i.e., the shape of the largest surface element of the
plastic part, as the projected area on the parting line), including normal, totally planner, or totally curved.
f64 It is coefficient for the hole density of the plastic part, vertical to the parting line. The higher
hole density requires more inserts, thus adding up the manufacturing cost. This coefficient considers
mold designs with normal, extremely, highly, medium, lowly dense, and no through holes.
f65 It is coefficient for the density of protrusions and depressions on the plastic part in the
direction vertical to the parting line. When this density is high, the mold will have more inserts and cost
more to make. This efficient considers mold designs with normal, extremely, highly, medium, lowly
dense, and no depression/protrusion.
To facilitate the quotation process, each coefficient may assume 1.0 as its reference value. Each
salesperson can make adjustment according to the practice. The coefficient F6 for parting line and part
shape thus can be defined as below.

F6 = f 61 f 62 f 63 f 64 f 65

(1-8)

7) Base Labor Hour (T0)

Base labor hour is used to estimate the total labor hour. Though it is difficult to estimate at
quotation, it is somewhat related to the size of the plastic part. The formulas are presented below.
(a) By area

T0 = K k S

(1-9)

Where,
K It is adjustable coefficient by the user according to the need at practice. For example, K=2.7
k It is cost index, to reflect market fluctuation and customer relationship. The default value is
set at k=1
S It is the surface area of the plastic part (mm2which is available from a typical 3D CAD
software or by manual computation.
(b) By dimensions

T0 = T0' + T '

(1-10)
'

The initial base labor hour is T0 computed with the formula below:

0.0945 k (0.9 +
T0' =

0 .6 H
) (120 + (30 + 1.2 W ) (30 + 1.2 L) N ) 2
L W
1 .2 A

(1-11)

Where,
LWH are the length, width, and height of the plastic part, respectively in mm.
A the standard labor rate for mold machining.
N the number of cavities. From injection point of viewmulti-cavity molds are more efficient.
However, molds with more cavities become more complex and are significantly more costly to make.
The quantity for cavities on the mold is a critical factor to consider for cost estimation.

T ' is additional labor hour estimated for cavities, slides and lifters. Mold designs with a side
core-pulling mechanism usually lead to much more labor hours

T ' = MAX (T1' , T2' )

(1-12)

Where,

T 1'=

(1000 N1 + 500 N 2 + 300 N 3 ) N

1.2 A

( f12 + f13 + f14 ) N T0' (1)

T =
1.2 A
'
2

'

(1-13)

(1-14)
'

Please note that T0 (1) the value for T0 , when N=1

N1N2and N3 are the quantity of large slides, small slides, and lifters, respectively.
This formula has considered the slides and lifters in the side core-pulling mechanism. Therefore,
the subsequent labor hour estimation should exclude the coefficient f12f13f14 designated for the side
core-pulling mechanism, to avoid repetition.
8) Mold Cavity Coefficient (F7)
The complexity of mold cavity structure directly affects the manufacturing process for the mold.
Cavity in turn closely relates to the shape of the plastic part. Therefore, the mold cavity coefficient is set
by the following method. When the base labor hour is calculated with the dimensional method, or the
surface of the parts minimum wraparound box is close to 0, the mold cavity coefficient is set at 1.0.
Otherwise the formula below applies.

F7 =

S
S'

(1-15)

Where,
S the surface area of the plastic parts minimum wraparound box (mm2), with the following
formula:

S ' = 2 ( L W + 2 H ( L + W ))

(1-16)

1.4.2 Material Cost (CM)

1) Mold Base Coefficient (F8)
Many standard mold bases are available in the market, with a wide complete range of models and
costs. LKM, a major supplier for standard mold bases, classifies its standard mold bases into 3
categories:
Mold bases with side gate system. They are suitable for 2-plate molds, subdivided into A, B, C, and
D models. They are simple and less expensive; thus their F8 value is higher.
Mold bases with three plate type system. They are suitable for 3-plate mold, sub classified into FA,
FC, GA, and GC models. Their structures are complex and expensive; and thus their F8 value is higher.
Mold bases with pin-point gate system. They are suitable for 3-plate mold, sub classified into DA,
DB, DC, DD, EA, EB, EC, and ED models. Their structures are more complex and more expensive; thus
their F8 value is the highest.
2) Computational Method
In addition typical machining activities, the mold manufacturing process includes a large amount of
effort for purchase and assembly of standard components such as mold base, ejector pin, and ejector
plate. These components are provided by the suppliers directly. Therefore the purchase expense for these
components should be included. To expedite the quotation process, it is desirable to establish an expense
relationship between materials and labor as below. By skipping detailing material cost for each minor
component, the response time can be greatly reduced.

C M = C MB + C S + C A

(1-17)

Where,
CMB Mold base costwhich can be computed with the formula below

C MB = 15% CW F8

(1-18)

C S Steel cost for the forming area, which relates to the standard mold base as below:
C S = 25% C MB

(1-19)

C A Auxiliary materials cost, including those for the ejection mechanism, heating and
cooling system, which relates to the mold base as below

C A = 10% C MB

(1-20)

1.4.3 Hot Runner Cost (CH)

Hot runner system is used for production of large parts or long flow length. It saves material,
lowers the part cost, improves part quality, shortens the cycle time, and improves production yield. It is
popularly applied to plastic injection mold. From the mold design point of view, it complicates the
mold structure and increases its cost significantly. Hot runners are a commodity, available from multiple
supply sources. Due to its high cost, hot runner is usually listed as a separate cost item. For quick
response, the following formula is used to calculate its cost:

C H = C H 0 p1 p 2

(1-21)

Where,
CH0 hot runners base cost.
p1 hot runners nozzle coefficient.
p2 hot runners supplier coefficient.
1) Basic Cost (CH0)
The quantity of nozzles depends on the number of gates. It is the base for selecting for hot-runner
plates. The base cost can be computed from the price for the hot-runner plates, which is CH0.
2) Nozzle Type Coefficient (p1)
Typical nozzle types include hot sprue, hot tip, and valve gate. Each type has a different structure
design. Their heating and control are also different, leading to a significant difference in price.
3) Brand Name Coefficient (p2)
Brand names such as Husky and YUDO make a difference in their quality and cost, for they may
adopt a different technology. So brand name can also be used to reflect its cost differentiation.
Usually the customer specifies the need for a hot runner and thus its cost. If no hot runner is
specified, then it assumes the use of traditional runner; and thus the p2 value is 0, implying that the mold
expense does not include a hot runner.

1.4.4 Test Cost (CT)

A typical mold usually has to go through a vigorous process of testing, to ensure it meets its
customers expectation. The terminology, T1, T2, and T3, etc are often used to represent the sequence of
mold tests. Each test should be accompanied with a problem report and a mold modification instruction,
which leads to more rework and re-issuing materials. Therefore, mold testing is an expensive process
and must be included in the quotation, using the formula below.

CT = CT 0 + C P

(1-22)

Where,
CT0 standard test expense
CP plastic material cost for test
1) Standard Mold Test Expense (CT0)
Mold testing requires the use of injection molding machine. Depending on its tonnage, its hourly
rate varies significantly. Assuming each test consumes 3 hours of machine time, a table as shown in
Fig.1-84 can be prepared, with selecting the most appropriate injection machine. By comparing the work
area S0 of the injection molding machine with the projected area SP of the plastic part on the machines
table, select S0 that is closest to and greater than SP. CT0 is the base for computing for the mold test cost,
where

S P = 1 .2 L W N

(2-23)

2) Plastic Material Cost (CP)

CP =

1.5 40 N S ' A0
1000 1000

(2-24)

Where,
A0the materials density and unit cost.
Fig.1-7: tonnage of injection molding machines, cost and work area

Tonnage

Cost($)

Work area

Tonnage

cost($)

Work area

25

130

5000

180

292

36000

50

130

10000

190

309

38000

60

137

12000

200

325

40000

80

137

16000

220

357

44000

85

138

17000

250

407

50000

100

163

20000

260

422

52000

110

179

22000

280

455

56000

120

195

24000

290

471

58000

125

203

25000

300

487

60000

130

211

26000

320

520

64000

135

220

27000

350

568

70000

140

228

28000

400

649

80000

145

235

29000

450

730

90000

150

244

30000

500

812

100000

155

252

31000

550

893

110000

160

260

32000

650

930

130000

175

285

35000

1.4.5 Other Parameters

1) Product Type Coefficient (r1)
Product type is classified according to the use of the product which the plastic part is assembled
into such as computers, consumers appliances, communications, medicals, and automobiles, etc. Each
product type has a unique requirement and thus implies a unique production specification. Accordingly,
the quotation should reflect the difference among various product types. The value for consumer
appliances r1 is set to 1.0 and used as the reference for others.
2) Market Coefficient (r2)
Another factor for a major mold maker to consider at quotation is the market coefficient. Each
geographic location may capture a big difference in customers expectation, purchase power, and thus
pricing. Hence, market is a relevant factor and needs to be included in the quotation. Based on the level
of industrialization and consumption, potential customers can be classified by region into mainland
China (mold making only), mainland China (mold making and production), Hong Kong, Europe, Japan,
and North America. The coefficient for Hong Kong is set to 1 and used as reference. The value is
adjusted for other regions according to their consumption power.
3) Standard Rate (A)
Standard rate is the overhead rate assumed by the mold making company, depending on its size, the
number of employees, equipment, and operational efficiency. Therefore the A value may vary over time
and is subject to review and adjustment periodically.

1.5 Production Order

1.5.1 Order Management
1.

Order and Mold Status

Production orders are work orders that are in the production phase. A production order may be
originated from a customer order. It may be an internal order which does not correspond to a customer
order. Production orders are similar to customer orders, consisting of both work statements at both the
project and the deliverable-item layers. The major difference from a customer order is in its purpose for
production planning and control. Fig.1-88 lists the basic information for a production order, which
includes:

1) Mold type, name, ID, and quantity

2) Production department and controller, listing the department and the person responsible for the
molds production. The responsible person is usually the assembly leader worker for the mold.
3) Scheduled start time, scheduled finish time, actual start time, and actual finish time.
4) Date of creation, on which the mold production order was created.
5) On-hold. When it is activated, the on-hold date is recorded and all production activities
associated with this mold are temporarily put on hold from that date on
6) Cancellation. When it is activated, the cancellation date is recorded, and all production activities
associated with the mold are terminated.
7) T1,T2,T3. They are the dates set for each mold testing.
8) Approval. It is the date of approval by the customer.
9) Shipping. It is the date of delivery.
10) Status, by the sequence in the mold production process:
z New (NW). A mold production order is NEW, if it has no on-going, paused, or finished
operations (jobs).
z Working. It is in working status, if at least one operation (job) is being worked on, or
paused. Each mold status is considered a work in process (WIP), which usually is
color-coded into green (G), yellow (Y) and red (R) conditions, indicating its degree of
criticality (normality, warning and problem). A WIP usually goes through the following
major fabrication tasks
CAD
CAM
Elect
CNC
Mill (Lathe & Drill)
SG
WC
EDM
Polish
z Assembled
Assm
z Test (Trials)
Trial(T1)
T2
T3
z Approved. The project management department activates this status by entering the date of
approval by the customer
z Shipped. Activated by entering the date of shipping by the project management department.
Shpm
In addition, a production order also contains the following two states of status
z Paused. It is activated by the project management department, after entering the date/time to
pause. It is applied when the order is subject to cancellation or engineering changes. All
production activities should be put on hold immediately
z Canceled. It is activated by the project management department, after entering the date/time of

cancellation. It implies that the production has been cancelled; and the customer no longer
needs that mold.

Fig.1-88: mold information under a production order

2. Progress Control
The main purpose of any manufacturing execution system is to provide various reports, concerning
the molds progress, resource utilization, time, and cost data. These data are usually organized into
various formats and created for a range of management levels at the company. Fig.1-89 shows that the
first tier managers can view the overall progress report on all molds by a customer. The second tier
manager in turn can view a customers particular project/order. Typically a top-tier manager needs to
have a bird-eyes view, while a lower tier manager needs to see more specific data with more detail.
The first tier:

Customer

Project

The second tier:

The third tier:

Mold
View all operations
under a mold

The fourth tier:

The fifth tier:

Task

Component

View all operations under a

task/operation type

View all operations

under a component

Operation
Fig.1-89: output data under different tiers

Fig.1-90 shows output data which the third tier managers are interested in. They are
1) Plastic part ID.
2) Plastic part name.
3) Mold ID.
4) Assembly department.
5) Assembler in charge.
6) Mold quantity.
7) Progress.
8) Mold status.
9) Scheduled T1 date.
10) Scheduled start date.
11) Scheduled finish date.
12) Actual start date.
13) Actual finish date.
14) Actual work hours.
15) Quotation.
16) Direct cost.
17) Production cost.
18) Date of creation.
19) Date of confirmation.
20) Date of on-hold.
21) Data of approval.
22) Data of shipping.
23) Date of cancellation.
24) T1 date.
25) T2 date.
26) T3 date.

Fig.1-90: output data under a mold

By selecting a mold record in Fig.1-90, the tier-four data are generated. Fig.1-91 shows the statistics

for the mold, by task/operation types.

Reworking hours of a drilling task

under one mold

Fig.1-91: output data under a task of one mold

Major parameters include:

1) Task/operation names.
2) Budget (from quotation).
3) Actual cost. It is the current, real cost for the task.
4) Progress.
5) Scheduled hours, as budgeted at quotation.
6) Actual work hours. It is the current, actual work hours including rework hours.
7) Rework hours. It is including additional work hours caused by re-issuing new raw materials.
8) Hours before T1, Including all actual work hours leading to T1.
9) Hours between T1 and T2, the actual work hours between T1 and T2.
10) Hours between T2and T3, the actual work hours between T2 and T3.
11) Hours after T3, the actual work hours after T3.
Among them
The actual work hours= hours prior T1+ hours between T1T2+ hours betweenT2T3+ hours after T3
Fig. 1-92 shows a Gantt chart for additional work hour related data, consisting of
1) Scheduled start date.
2) Scheduled finish data.
3) Actual start date.
4) Actual finish date.

Fig.1-92: Gantt chart by task under one mold

Fig.1-92 shows selecting drill task leads to a record of 0.51hr for rework. Continuing this process
will lead to more specific operation data about the drill task as shown in Fig.1-93.

Reworking hours (0.51hr.) whose component

name begins with RW_

Fig.1-93: output data under one task of a mold

Selecting a mold record from Fig.1-90 can lead to output of material data at the fourth tier. Fig.1-94
lists all BOM materials specified for the mold.

Reworking component name beginning with RW_

Fig.1-94: material list of a mold

Selecting a rework component from Fig.1-94 can lead to its operation data in detail, as shown in
Fig.1-95.

Fig.1-95: reworking operations

1)

Method for Computing Cost

The formula is given below
n

C = Ti Ri
i =1

where

C : Cost.

Ti : Work hours for operation i. When calculating scheduled costuse scheduled work hours for Ti ;
When calculating actual costuse actual work hours for Ti .

Ri : Equipment rate for operation i.

n : Total work hours.
2)

Method for Computing Progress

This method is to estimate the progress for a mold. A similar approach can be taken for project
and customer.
Step1: Calculate the maximum contribution of each task to the mold, using the following formula

Bti =

Tbi
n

Tb
i =1

where

Bti : The maximum contribution by task i to the mold.

Tbi : Budgeted hours for task i.

n : The number of tasks.

Table1-8 and Fig.1-96 show the hours budged for the tasks for the mold instance of DEC025506.
The total hours budgeted for DEC025506 = 0+0+7.5+7.5+7.5+7.5+60+80+20+30+50+9+0 = 279
Drilling has its maximum contribution at = 7.5/279 = 2.69%
The maximum contributions by others are listed in Table1-8.

Fig.1-96: work hours budged for the mold DEC025506.

Table1-8 Maximum contribution rate calculation of mold progress

Budget work hours (hr.)

Task

Maximum contribution rates of mold progress (%)

CAD

0/279 = 0%

CAM

0/279 = 0%

Milling

7.5

7.5/279 = 2.69%

Drilling

7.5

7.5/279 = 2.69%

Lathe

7.5

7.5/279 = 2.69%

Grinding

7.5

7.5/279 = 2.69%

CNC

60

60/279 = 21.51%

EDM

80

80/279 = 28.67%

W-cut

20

20/279 = 7.17%

Polishing

30

30/279 = 10.75%

Assembly

50

50/279 = 17.92%

Test

9/279 = 3.23%

QC

Machining

Total

279

0/279 = 0%
100%

Step 2: The progress for each task is computed as below:

n

Pt =

i
i =1& stati =CL
n

T
i =1

where

Pt : Current task progress.

Ti : Scheduled work hours for the operation i of the task.

n : The number of the operations for the current task.

stati : Status for the operation i of the task, where CL means that the operation status is finished.
Fig.1-97 shows the status for all drilling operations of the mold: DEC025506.

Fig.1-97: all drilling operations of the mold DEC025506

The sum of the scheduled work hours for the 9 drilling operations is =
4.78+4.78+5.11+7+7.5+8+11+0+0 = 48.17.
The sum of those finished operations is = 7+7.5+8+11+0+0= 33.5.
Therefore, the progress of the drilling task, the highlight bar in Fig.1-95, is = 33.5/48.17=69.56%.
Table1-9 is a progress summary of all other tasks.
Table1-9 Progress calculation of all tasks of one mold
Task

Quotation

Maximum

hours(hr.)

Contribution (%)

Progress (%)

Contribution rate
(%)

CAD

0%

100%

0%

CAM

0%

100%

0%

Milling

7.5

2.69%

100%

2.69%

Drilling

7.5

2.69%

69.56%

1.87%

Lathe

7.5

2.69%

100%

2.69%

Grinding

7.5

2.69%

96.20%

2.59%

CNC

60

21.51%

0%

0%

EDM

80

28.67%

82.26%

23.58%

W-cut

20

7.17%

0%

0%

Polishing

30

10.75%

0%

0%

Assembly

50

17.92%

0%

0%

Test

3.23%

0%

0%

QC

0%

0%

0%

Machining

Total

279

100%

Step 3Compute tasks actual contribution, using the formula below

Ati = Pti Bti

33.35%

where

Ati : Actual contribution by task i.

Pti : Progress of task i on the current mold.
Bti : Maximum contribution by task i to the current mold.
For example, the actual contribution by drilling is = Drillings progress * Drillings maximum
contribution
= 69.56%*2.69%
= 1.87%
Table1-9 summarizes the actual contributions by all other tasks.
Step 4: Compute the overall progress by using the formula below:
n

Pm = Ati
i =1

where

Pm : The molds current overall progress.

Ati : Actual contribution by task i on the mold.

n : The total number of the tasks of the mold.

Therefore, the overall progress of DEC025506 is
= 0%+0%+2.69%+1.87%+2.69%+2.59%+0%+23.58%+
0%+0%+0%+0%+0%+
= 33.35%
Fig.1-98 shows the progress for the mold: DEC025506.
This concept of tasks contribution is important to mold project management. At the beginning of
each mold project, its design and process plan are incomplete. Therefore, completing those planned
operations may lead to a misperception that the mold was near its completion. By introducing the
concept of task contribution, the progress report can better reflect its actual progress.

Fig.1-98: progress for the mold DEC025506

3)

Actual Cost
Fig.1-99 details the production cost by mold, task, and operation type. It also lists the actual cost,
budgeted cost, and the difference.

Fig.1-99: actual cost

1.5.2 Production Management

1. Capacity Analysis and T1 Prediction
For planning and scheduling, machines may be classified into three different types, in relations with
its capability.

 Interruptible Equipment Pc
General purpose machines such as lathe, milling, drilling and grinding are interruptible, denoted
as Pc . They can be interrupted, when necessary such as workers taking a break, or changing shifts.

Non-interruptible without attention Equipment Pq

Some equipment such as CNC machines can not be stopped until the job is completed. However,
once these machines are set up and started, they can continue and stop themselves, without operators
attention or intervention. Therefore, workers may set up these machines and let them continue to run in
the off hours. These machine types are denoted as Pq .

Non-interruptible with attention Equipment Pn

In addition to being non-interruptible, some critical CNC machines require the operators attention
at all times. Therefore the operator or attendant should stay and attend to the machine, until its
completion. This type of machines is denoted as Pn .
On those machines of non-interruptible without attention, the start time for such an operation
should be scheduled within an on-duty time slot. Its finish time however, can be set at any time, whether
it falls in an off-duty or on-duty time slot.
On a machine of non-interruptible with attention, both the start and finish times for such an
operation should be within an on-duty time slot. It cant cut across an off-duty time slot either.
In practice, a mold making company has to handle thousands of machining activities each day.
There is no need to set their start and finish times at a great precision. The importance of the scheduling
effort is to ensure the timely availability of bottleneck resources, so as to set a realistic T1 date and set a
reasonable enough resources capacity.
1) T1 Date forecast for a mold
The T1 date for a mold is estimated by applying the formula below:

T1 = Cmax + Pasm
Where

T1 The molds T1 date

Cmax The latest scheduled completion among all operation of the mold. It comes from the result of
the auto-scheduling program

Pasm The number of days required for mold assembly and T1 test. It is a constant set for each
mold type for each industry. A complex mold may take up to about 7 days for Pasm

The formula above applies to estimate each T1 for each individual mold which is now being
fabricated. Comparing the T1 to the customers expected delivery date, a list as shown in Fig.1-100
summarizes all molds that are currently scheduled for late delivery.

Fig.1-100: T1 date and capacity forecast for molds

2) Capacity Forecast
Resources capacity can be estimated by applying the formula below:
n

L =

i=i

Ti

N e T max

100 %

where

L : The daily capacity for an operation type.

Ti : The scheduled work hours of the operation i among all the operations of an operation type
within a work day.

Tmax : Under an operation type, the utmost daily work hours for a machine, for example,
Tmax = 24 .
n : Total finished and on-going work hours that fall on the current work day for the machine.
N e : Total of available machines on the current work day for an operation type.
By applying the above formula, capacity requirement can be computed as shown in Fig.1-100 in
histograms. The left side of the figure shows the daily capacity and scheduled work hours by an
operation type, that is N eTmax

2. Equipment Status
Equipment status report is used to capture the current status of each machine by department. In
Fig.1-101, the status OP indicates the equipment is in operation. The viewer can further seek its
operators ID, equipment ID and name, mold ID, component ID and so on. The status PS indicates the
equipment is tentatively idle.

Fig.1-101: equipment status

3. Machine Load
Equipment load report reflects the work load by machine by department on a given day or period of
time. Fig.1-102 shows the work loads range from 0 to 100%. A typical work load for a mold maker is
88%. The equipment work load formula is given following.
n

L=

T
i =i

Tmax

100%

where

L : Current equipment load.

Ti : The actual work hours for the operation i on an equipment.
Tmax : The maximum work hours on the equipment within the time frame. The maximum daily
work hours are Tmax = 24 . The maximum weekly work hours are Tmax = 24 7 .

n : The total work hours for finished and on-going jobs within the time frame.

Fig.1-102: machine load

4. Customers Asset
Customer asset report summarizes for the all molds of each customer which are in the production
process and are not yet delivered. Fig.1-103 shows such a report, identifying each project name, mold ID
and name, plastic part ID, mold status and so on.

Fig.1-103: customers asset

1.6 Example
As shown in Fig.1-50 and Fig. 1-51 is a plastic cover of Bluetooth product on vehicle and its mold.
The plastic material is ABS, It requires the appearance of the surface gloss and mold surface rough
degree at the least grade A2, so highlight and no-welding-line injection technology should be taken,
1Plastic part and process analysis
1Material performance
ABS is a thermoplastic material. Its density is 1.03~1.07g/cm3, tensile strength 30~50MPa,
shrinkage is 0.3%~0.8%, average density 1.05g/cm3, and average shrinkage is 0.55%. The overall
performance of the material is excellent. It is easy to mold and has good size-stability, heat, cold
resistance and corrosion resistance.
2Manufacturability
The parts wall has a uniform thickness, about 1.5mm. Insufficient filling should not happen for
injection molding. Plastic injection flow simulation analysis can be completed with Moldflow software.
2Mold structure
The part needs a single parting line, edge gate mold structure adopting angle pin side core-pulling
mechanism. Its cavity is in the fixed half mold while the runner is on the parting line. The molded part
together with the slug in the sprue and runner should be retained in the moving half mold after
demolding. Ejector mechanism is set on the moving half mold and the molded part and its slug is ejected
together one time only by ejector pin. According to the parts sizes, the installation space of angled pin
side core-pulling mechanism, the stroke length of the slides and the maximum and minimum mold
height of the plastic injection machine, the mold base should be 2030-CI-60-80-70.
The part is on trial-manufacturing stage. According to economic considerations, only one cavity in a
mold is adopted, that is, one plastic part is molded in an injection cycle.
A horizontal parting line suits the structure characteristic of the part. The location of parting line is
on the maximum section of the parts bottom which shall not affect the appearance of the product.
2Selection of plastic injection molding machine
The part and its mold can be modeled with mold & die CAD/CAM systems which can calculate
automatically the volume of part and mass:
Single part: volume Vp4.3cm3, and mass MpVp1.054.34.52g
Where: p plastic mass1.05g/cm3
Feed system
The mass of feed system is Mg = 0.6 n Mp= 0.614.52= 2.71g
The volume of feed system is Vg=0.6 n Vp0.614.3=2.58 cm3
Where: n the number of cavities
Total mass of plastic part and feed system
MT= Mp+ Mg=4.52+2.71=7.23g
The actual injection amount of should be 20% to 80% of the rated injection amount, so the selection
is Yanhing 108A injection molding machine.
3Cost analysis and quotation
Table 1-6 lists the plastic part and its mold specifications as an example for analysis. The cost is

calculated by US$. The average cost rate is $15/hr. The parts surface area is 6924.94 mm2. Quick
quotation procedure is as follows:
Table 1-10: the plastic part and main specification of its mold
Part
dimensions
(mm)

length

83.01

width

39.90

height

10.52

2/3-plate
mold
Mold
structure

Steel materials
molding area

Surface roughness(SPI
standard))

2-plate type

large slides

small slides

Lifters

Plastic material

cavity

S136H

core

S136H

cavity

A2

core

A2

Parting line

Plastic
parts
shape

ABS

The number of cavities

of

Mold type

general

Mold grade
Hot runner system

general
Main
contour

general

Main
surface

general

Opening

general

Elevation/
depression

general

Type of product

automotive industry

103

Market

china(mass production)

none

Price index

100%

1) Machining cost
Basic mold structure coefficient F1 = f11 + f12 + f13 + f14 =1.0+0.25+0+0=1.25
Mold type coefficient: F2=1.0
Mold grade coefficient: F3=1.0
Mold material coefficient in molding area: F4 = ( f 41 + f 42 ) / 2 =(1.2+1.2)/2=1.2
Mold surface roughness coefficient in molding area: F5 = ( f 51 + f 52 ) / 2 =(1.2+1.2)/2=1.2
Composite coefficient for parting line and parts shape:

F6 = f 61 f 62 f 63 f 64 f 65 =1.01.01.01.01.0=1.0
F7 = S f / 2 (W L + 2 H (W + L)) = 6924.94 / 2 (39.90 83.01 + 2 10.52 (39.90 + 83.01))
= 0.766

T0 = K k S = 2.7 1 6924.94 =224.684

The total processing hour is

T = F F
1

F3 F4 F5 F6 F7 T0

=1.251.01.01.21.21.00.766224.684
=309.794310
Processing cost is CW =

T A =309.79415=4646.91

2) Material cost
Mould base coefficient: F8=1.0
Mould base cost: C MB = 15% CW F8 =0.154646.911.0=697.04
Material cost for the molding area: C S = 25% C MB =0.25697.04=174.26
Auxiliary material cost: C A = 10% CMB =0.1697.04=69.70
Material cost: C M = C MB + CS + C A =697.04+174.26+69.70=941

3) Hot runner system cost

The mold does not have a hot runner system, and thus the cost is 0.
4) Mold test cost
The projection area of the plastic part on the injection molding machine table:

S P = 1.2 L W N = 1.2 83.01 39.9 1 = 3974.52

Referring to injection molding machine cost table as shown in Table 1-7, Yanhing 108A injection
molding machine corresponds with the 100 ton machine in the table. Its work area is 20000 mm2. The
standard mold test cost is CT0=$163
ABS: specific gravity =1.05unit price A0=2.8The surface area of the enveloped box on the
plastic part is

S ' = 2 ( L W + 2 H ( L + W )) =2(83.0139.9+210.52(83.01+39.9))
=11796.251
The cost of plastic material for the test is

CP =

1.5 40 N S ' A0 1.5 40 1 11796.251 1.05 2.8

=
=2.081
1000 1000
1000 1000

Therefore, the mold test cost is: CT = CT 0 + 4 C P = 163 + 4 2.081 = 171

5) Mold quotation
Product type coefficient: r1=1.2
Market coefficient: r2=1.0
The mold manufacturing cost:

C = C

+ CM + C H + CT =4647+941+0+171=5759

Thus the mold quotation is:

PQ = C r1 r2 =57591.21.0=$6911

The product quotation is shown in Fig.1-104.

Fig.1-104: production Quotation ( M08009CHP.xls)