Injection Molding

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

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