Injection Molding

MFG 355

15 Ton Injection Molding Machine

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77 Ton Injection Molding Machine

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150 Ton Injection Molding Machine

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Equipment
Injection Unit
Feed hopper Barrel heaters Screw drive arrangement Nozzle

Tool

Screw

Check valve

Screw tip

Equipment
Injection Unit

Injection
Parts of the injection screw
Screw Head and check ring

Equipment
Molds

Molds

Mold Materials
Aluminum filled epoxy Aluminum Tool steel Stainless steel Hotwork die steel Beryllium-copper

Mold Materials
Choice based on critical properties
Machinability Coefficient of thermal expansion Specific heat capacity Thermal conductivity Density Hardness (abrasion resistance) Yield strength Weldability

Mold Parts
Bases
Standard sizes Hold mold inserts Can decrease overall mold costs

Mold Parts
Guide pins
Align mold cavities

Guide pins

Mold Parts
Sprue Bushing
Hot sprue Cold sprue

Mold Parts
Sprue Bushing
Hot sprue

Mold Parts
Sprue Bushing
Cold sprue Sprue puller

Mold Parts
Sprue Bushing
Cold sprue Sprue puller

Mold Parts
Runner

Mold Parts
Runner
Layout
Conventional Improved Balanced H Circular

Mold Parts
Runner
Layout
Conventional Improved Balanced H Circular

Mold Parts
Runner
Cold well

Mold Parts
Runner

Mold Parts
Gates

Submarine Gate

Fan or Edge Gate Pinpoint Gate

Mold Parts
Gates

Tab Gate Sprue Gate

Flash Gate

Mold Parts
Gates

External Ring Gate

Internal Ring Gate

Mold Parts
Gate

Mold Parts
Gate

Mold Parts
Gate

Mold Parts
Cavity
Where the part is made Layout is critical to material flow

Mold Parts
Cavity
Knit/weld lines

This shows where the weld lines (shown in red) will most likely occur with the part gated in the center (yellow cone).

Mold Parts
Cooling
Reduce cycle time Control formation of crystalline areas Freeze part

Mold cavity Cooling lines

Mold Parts
Ejector system
Ejector pins

Return Springs

Ejector Plate

Equipment
Clamping Unit

Equipment
Clamping Unit
Toggle clamping Hydraulic clamping Hybrid hydraulic-toggle clamping

Equipment
Clamping Unit

Equipment
Clamping Unit
Toggle system

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Plant Concepts

Safety
High clamping forces High pressure lines High voltage High temperatures

Safety
Position switches
Mechanical, hydraulic and electrical

Shields Lock out/tag out

Material and Product Considerations

Shapes
Possible to do very complex shapes
Structural features
Pins, ribs, bosses, threads, holes

Deep parts are possible Internal or external threads Undercuts require sliding mold sections

Sliding Mechanism

Material and Product Considerations

Part design
Uniform wall thickness
Helps reduce dimples, shrink marks and distortion

Ribs
Save weight at given strength

No sharp bends
Helps to fill the mold cavity easier

Oversize the mold

Shrinkage amount is dependant on material and additives/fillers

Operations and Control

Temperature of melt Temperature of mold Pressure of injection and hold Injection or fill rate and time Dwell time Freeze time Ejection (dead time)

Special Injection Molding Processes

Coinjection molding
Two separate screws Two different material selections
Color, strength, flexibility

Special Injection Molding Processes

Coinjection molding
1 2 3

Special Injection Molding Processes

Coinjection molding
Part 1 Part 2

Special Injection Molding Processes

Flow-controlled injection processes
Sometimes called Scorim

Special Injection Molding Processes

Flow-controlled injection processes
Sometimes called Scorim

Special Injection Molding Processes

Gas injection molding
Employs gas to create hollow parts

Special Injection Molding Processes

Injection-compression molding
Parts were made with the same mold. The only difference between the two parts is the use of the compression cycle
Injection-Compression Molding Injection Molding

Modeling and Computer-Aided Mold-Flow Analysis

Used to help identify potential problems with the mold/part design Models based on the CAD part Adjusted by resin

Thank You