(1) Introduction

It is very difficult to realize how important plastics have become to our everyday lives. We always seem

To have known these materials, and we tend to take it for granted that they occur every Day and all around

Us, for example in our clothing, the pen that we write with, the chair that we sit on or the wrapping of the

Food that we eat.

Look around you; how much plastic do you see?

So it is sometimes hard to believe that plastics have only been commonly available for about the last one

Hundred years. Yet in this time the impact that they have made upon the Quality of our lives and on the

Products that we have access to has been enormous.

Procedure from your Idea to Final Product
Part Design:

 How to convert your idea into 3d Model?

 What about plastic part design considerations?
 Select your material based on application.
Simulation:

 Validate and optimize your design.

 Predict defects and injection parameters.
Mold Design:

 Build-up your Complete Mold set.

 Design your Process System (Ejection, Cooling, Feeding, Venting and Sliding).
Mold Manufacturing:

 Select your suitable Material for components.

 Heat treatment if required.
 Machining and Finishing Processes (Milling, Turning, EDM, Grinding, Polishing, etc……)
Part Manufacturing:

 What about Injection M/C Parameters (Injection Pressure, Clamping force, Ejection
force, Cycle time, etc…)
(2) Classification of plastic

1. Natural plastics - these are naturally

Occurring materials that can be said to be plastics because they can be shaped and molded by

Heat. An example of this is amber, which is a form of fossilized pine tree resin and is often used in

Jeweler manufacture.

2. Semi synthetic plastics - these are

Made from naturally occurring materials that have been modified or changed but mixing other

Materials with them. An example of this is cellulose acetate, which is a reaction of cellulose fiber and

Acetic acid and is used to make cinema film.

3. Synthetic plastics - these are

Materials that are derived from breaking down, or cracking carbon based materials, usually crude oil,

Coal or gas, so that their molecular structure changes. This is generally done in Petrochemical refineries

Under heat and pressure, and is the first of the Manufacturing processes that is Required to produce

Most of our present day, commonly occurring plastics. Synthetic and semisynthetic Plastics can be

Further divided into two other categories.

These two categories are defined by the ways in which different plastics react when heated.

4. Thermoplastics - these are plastics

That can be softened and formed using heat, and when cool, will take up the shape that

They have been formed into. But if heat is reapplied they will soften again.

Examples of thermoplastics are acrylic and styrene, probably the most common plastics found in school

Workshops.

5. Thermosetting plastics - these are Plastics

That soften when heated, and can be molded when soft, and when cool they will set into the molded

Shape. But if heat is reapplied they will not soften again, they are permanently in the shape that they

Have been molded into.

(3) The most popular and commonly used plastics

 Acrylic or Polymethyl Methacrylate (PMMA)

 Polycarbonate (PC)
 Polyethylene (PE)
 Polypropylene (PP)
 Polyethylene Terephthalate (PETE or PET)
 Polyvinyl Chloride (PVC)
 Acrylonitrile-Butadiene-Styrene (ABS)

Let’s take a look at each of these distinctive plastics in more detail.

1. Acrylic or Polymethyl Methacrylate (PMMA)

Well-known for its use in optical devices and automotive products, acrylic is a transparent
thermoplastic used as a lightweight, shatter-resistant alternative to glass. Acrylic is typically used in
sheet form create products such as acrylic mirrors and Plexiglas. The transparent plastic can be made
colored and fluorescent, abrasion-resistant, bullet-resistant, UV-tolerant, non-glare, and many more.
In addition to being than glass and polycarbonate sheeting, acrylic is seventeen times more impact
resistant than glass, easier to handle and process, and has endless applications.

2. Polycarbonate (PC)

Tough, stable, and transparent, polycarbonate is an excellent engineering plastic that is as clear as glass
and two hundred and fifty times stronger. Thirty times stronger than acrylic, clear polycarbonate
sheets are also easily worked, molded, and thermo-formed or cold-formed. Although extremely strong
and impact-resistant, polycarbonate plastic possesses inherent design flexibility. Unlike glass or acrylic,
polycarbonate plastic sheets can be cut or cold-formed on site without pre-forming and fabrication.
Polycarbonate plastic is in a wide variety of products including greenhouses, DVDs, sunglasses, police
riot gear, and more.
3. Polyethylene (PE)

The most common plastic on earth, polyethylene can be manufactured in varying densities. Each
different density of polyethylene gives the final plastic unique physical properties. As a result,
polyethylene is in a wide variety of products.

Here are the four common polyethylene densities:

 Low-Density Polyethylene (LDPE)

This density of polyethylene is ductile and used to make products like shopping bags, plastic bags, clear
food containers, disposable packaging, etc.

 Medium-Density Polyethylene (MDPE)

Possessing more polymer chains and, thus, greater density, MDPE is typically in gas pipes, shrink film,
carrier bags, screw closures, and more.

 High-Density Polyethylene (HDPE)

More rigid than both LDPE and MDPE, HDPE plastic sheeting is in products such as plastic bottles, piping
for water and sewer, snowboards, boats, and folding chairs.

 Ultra-High Molecular Weight Polyethylene (UHMWPE)

UHMWPE is not much denser than HDPE. Compared to HDPE, this polyethylene plastic much more
abrasion resistant due to the extreme length of its polymer chains. Possessing high density and low
friction properties, UHMWPE is in military body armor, hydraulic seals and bearings, biomaterial for
hip, knee, and spine implants, and artificial ice skating rinks.

4. Polypropylene (PP)

This plastic material is a thermoplastic polymer and the world’s second-most widely produced synthetic
plastic. Its widespread use and popularity are undoubted because polypropylene is one of the most
flexible thermoplastics on the planet. Although PP is stronger than PE, it still retains flexibility. It will
not crack under repeated stress. Durable, flexible, heat resistant, acid resistance, and
cheap, polypropylene sheets are used to make laboratory equipment, automotive parts, medical
devices, and food containers. Just to name a few.
5. Polyethylene Terephthalate (PETE or PET)

The most common thermoplastic resin of the polyester family, PET is the fourth-most produced
synthetic plastic. Polyethylene Terephthalate has excellent chemical resistance to organic materials and
water and is easily recyclable. It is practically shatterproof and possesses an impressive high strength to
weight ratio. This plastic material is in fibers for clothing, containers for foods and liquid, glass fiber for
engineering resins, carbon nanotubes, and many other products that we use on a daily basis.

6. Polyvinyl Chloride (PVC)

The third-most produced synthetic plastic polymer, PVC can be manufactured to possess rigid or
flexible properties. It is well-known for its ability to blend with other materials. For example, expanded
PVC sheets are a foamed polyvinyl chloride material that is ideal products like kiosks, store displays, and
exhibits. The rigid form of PVC is commonly in construction materials, doors, windows, bottles, non-
food packaging, and more. With the addition of plasticizers such as phthalates, the softer and more
flexible form of PVC is in plumbing products, electrical cable insulation, clothing, medical tubing, and
other similar products.

7. Acrylonitrile-Butadiene-Styrene (ABS)

Created by polymerizing styrene and acrylonitrile in the presence of polybutadiene, ABS is robust,

Flexible, and glossy, highly processable, and impact resistant. It can be manufactured in a range of

Thicknesses from 200 microns to 5mm with a maximum width of 1600mm. With a relatively low

Manufacturing cost, ABS plastic sheeting is typically used in the automotive and refrigeration industries

But is also in products such as boxes, gauges, protective headgear, luggage, and children’s toys
(4) Types of Plastics Molds
Injection Molding:-
In Injection Molding, melted plastic is forced into a mold cavity. Once cooled, the mold can be removed.
This plastic molding process is commonly used in mass-production or prototyping of a product. Injection
molding machines were made in the 1930’s. These can be used to mass produce toys, kitchen utensils,
bottle caps, and cell phone stands to name a few.

Blow Molding:-
Blow molding is like injection molding except that hot liquid plastic pours out of a barrel vertically in a
molten tube. The mold closes on it and forces it outward to conform to the inside shape of the mold.
When it is cooled, the hollow part is formed.
Compression Molding:-
In this type of plastic molding, a slug of hard plastic is pressed between two heated mold halves.
Compression molding usually uses vertical presses instead of the horizontal presses used for injection
and blow molding. The parts formed are then air-cooled.

Film Insert Molding:-

This plastic molding technique imbeds an image beneath the surface of a molded part. A material like
film or fabric is inserted into a mold. Plastic is then injected.

Gas Assist Molding:-

Also called gas injection molding is used to create plastic parts with hollow interiors. Partial shot of
plastic is then followed by high-pressure gas to fill the mold cavity with plastic.
Rotational Molding:-
Hollow molds packed with powdered plastic are secured to pipe-like spokes that extend from a central
hub. The molds rotate on separate axes at once. The hub swings the whole mold to a closed furnace
room causing the powder to melt and stick to the insides of the tools. As the molds turn slowly, the tools
move into a cooling room. Here, sprayed water causes the plastic to harden into a hollow part.

Structural Foam Molding:-

Structural foam molding is a process of plastic molding usually used for parts that require thicker walls
than standard injection molding. Inserting a small amount of nitrogen or chemical blow agent into the
plastic material makes the walls thicker. Foaming happens as the melted plastic material enters the
mold cavity. A thin plastic skin forms and solidifies in the mold wall
(5) Types of plastic injection mold
There are two main types of injection molds: cold runner and hot runner. A runner is the channel in the
mold that conveys the plastic from the barrel of the injection molding machine to the part. In a cold
runner mold, the runner is cooled and ejected with the part. Every cycle, a part and a runner are
produced.

Cold runner mold: In a cold runner mold, the runner is cooled and ejected with the part. Every cycle, a
part and a runner are produced. The obvious disadvantage of this system is the waste plastic generated.
The runners are either disposed of, or reground and reprocessed with the original material. This adds a
step in the manufacturing process. Also, regrind will increase variation in the injection molding process,
and could decrease the plastic's mechanical properties.

There are two major types of cold runner molds: two plate and
three plate.

A two plate cold runner mold:

It is the simplest type of mold it is called a two-plate mold because

there is one parting plane, and the mold splits into two halves. The
runner system must be located on this parting plane; thus the part
can only be gated on its perimeter.

A three plate mold:

Differs from a two plate in that it has two parting planes, and the
mold splits into three sections every time the part is ejected. Since
the mold has two parting planes, the runner system can be located
on one, and the part on the other. Three plate molds are used
because of their flexibility in gating location. A part can be gated
virtually anywhere along its surface.
Hot runner mold:

In a hot runner mold, the runner is situated internally in the mold and kept a temperature above the
melting point of the plastic. Runner scrap is reduced or eliminated. The major disadvantages of a hot
runner is that it is much more expensive than a cold runner, it requires costly maintenance, and requires
more skill to operate. Color changes with hot runner molds can be difficult, since it is virtually impossible
to remove all of the plastic from an internal runner system.

Hot runners have many advantages. They can completely eliminate runner scrap, so there are no
runners to sort from the parts, and no runners to throw away or regrind and remix into the original
material. Hot runners are popular in high production parts, especially with a lot of cavities.
(6) A conventional Injection machine
Machine Base Unit
Often described as the machine ‘bed’, its
function is to provide a rigid base to
impart Dimensional stability, accuracy
and strength.

The Injection Unit

This is the part of the machine that
stores and heats the Material prior to
injecting it into the mold tool. The
Injection unit has several functions:

1-Metering the amount of material required for each shot.

2-Plasticising (or heat softening) the material.

3-Rotating an internal screw to transport the material via its screw flights to the front of the cylinder

While moving backwards ready to pick up the next shot of material

4-Advancing and retracting the injection carriage to bring the nozzle into contact with the mold sprue

Bush providing a sufficient contact force between the injection cylinder and the mold tool to prevent

Material leakage

5-Providing a variable speed of injection and variable injection and backpressure.

Clamp Unit
This is the part of the machine that carries, closes and opens the mold. It provides the Force required to

Keep the mold closed during the injection phase and it eject the molding once the Mold is opened.

The clamp unit consists of three plates or platens:

A fixed, stationary platen on to which is mounted the half of the mold that contains the runner and

Sprue bush (the fixed or stationary half)

A moveable platen on which is mounted the other mold half – the one containing the ejection system

(The moving or ejection half) the tail plate

Mold Height
The thickness or height of mold that can be fitted into a machine is dependent on the amount of mold
height adjustment that is available on the machine. This is the maximum amount of space with the
machine toggles closed or the ram fully extended that is available between the fixed and moving
platens. The mold height available is dependent on the type of clamping mechanism that is used.

Daylight
The amount of daylight on a given machine is the furthest distance that the machine platens can be
separated from each other. The amount of daylight should be at least twice the depth of the molding
(d). This gives sufficient space for the moldings to
fall freely out of the tool.

Distance between Tie Bars

The internal horizontal or vertical distance between the tie bars also determines the maximum size of
mold tool that can be mounted on a machine. Normally the mold is designed so that it will drop down
between the tie bars from above. Once the mold has been in the register ring hole in the platen, it can
be secured to the platen directly with cap screws or indirectly with tool clamps.
(7) Injection cycle
Mold Closing Phase

The mold should be closed as quickly as possible

Mold Protection Phase

This is applied at the final stage of mold closing

just before the two mold halves meet so as to
avoid damage to the mold tool due to trapped
moldings or location of delicate shot off areas on
either half of the mold. Both the distance and
operating pressure must be set to suit the
requirements on the machine control panel.

Injection (Mold Filling) Phase

In general, mold filling takes place rapidly care must be taken in order not to generate excessive shear

Stress in the material by excessively short fill times. An ideal fill time should prevent large reductions in

Melt temperature (less than 20 C) and avoid the generation of high injection pressure (more than

100MPa).The injection speed should be adjusted to produce the required filling time and the injection

Pressure should be set to enable this injection speed to be achieved. For example, a large cavity may

Require a lower relative injection speed to give the air in the cavity time to be displaced to prevent

Compressed air being developed giving rise to shorts or burning.

Holding Time and Pressurizing Phase

During this stage, a little more material is forced into the mold before the gate freezes off. The pressure
Prevents the material in the mold from flowing back into the injection cylinder. The length of time
Required for holding depends upon the material being molded, gate size, melt and mold temperatures.
The setting of the hold-on stage is critical to the size and dimensional stability of components.
Cooling and Refill Phase

This starts after the hold-on time finishes. Should the component become cool enough to be ejected?

Immediately after the screw back phase then no further cooling time is necessary and the parts may be

Ejected? The total cooling time required is largely dependent on the wall thickness of the component

And the material used.

Screw Back Phase

During the cooling time the screw rotates and is displaced backwards along the injection Cylinder. This

Backward displacement takes place entirely during the cooling phase of the components as previously

Described. Once the screw has transported sufficient material to the front of the cylinder, the screw

Trips a limit switch and stops rotating.

Mold Open Phase

The same principles apply to the mold open phase as to the mold closing phase. Sudden Opening should

Be avoided, to prevent damage to the machine and mold. The distance of opening should be just

Enough to allow for the moldings and any runners to be ejected cleanly. This will keep cycle time to a

Minimum.

Ejection Phase

Adequate time must be allowed for the ejection of the components from the mold.

Ejection can be employed in a semi-auto or automatic mode. Automatic ejection can be by mechanical,

Hydraulic or pneumatics systems, depending on the design of the ejector system.

Air ejectors may be used to blow the component clear.

(8) Plastic part design Consideration
Wall Section Considerations:

WALL THICKNESS:

Cost savings are highest when components have a minimum wall thickness, if that thickness is
consistent with the part’s function and meets all mold filling considerations. As would be expected, parts
cool faster with thin wall thicknesses, which means that cycle times are shorter, resulting in more parts
per hour. Further, thin parts weigh less, using less plastic per part. On average, the wall thickness of an
injection molded part ranges from 2mm to 4mm (.080 inch to .160 inch). Thin wall injection molding can
produce walls as thin as .05mm (.020 inch).

UNIFORM WALLS:

Parts with walls of uniform thickness allow the mold cavity to fill more easily since the molten plastic
does not have to be forced through varying restrictions as it fills. If the walls are not uniform the thin
section cools first, then as the thick section cools and shrinks it builds stresses near the boundary area
between the two. Because the thin section has already hardened, it doesn’t yield. As the thick section
yields, it leads to warping or twisting of the part, which, if severe enough, can cause cracks.
Uniform wall thickness can reduce warping

What if you cannot have uniform walls (due to design limitations)?

If design limitations make it impossible to have uniform wall thicknesses, the change in thickness should
be as gradual as possible.

Coring to eliminate sinks

Coring is a method where plastic is removed from the thick area, which helps to keep wall sections
uniform, eliminating the problem altogether.
Gusseting to reduce warping

Gussets are support structures that can be designed into the part to reduce the possibility of warping.

Voids and Shrinkage

Troublesome shrinkage problems can be caused by the intersection of walls that are not uniform in wall
thickness. Examples might include ribs, bosses, or any other projection of the nominal wall. Since thicker
walls solidify slower, the area they are attached to at the nominal wall will shrink as the projection
shrinks. This can result in a sunken area in the nominal wall. Such shrinkage can be minimized if a rib
thickness is maintained to between 50 and 60 percent of the walls they are attached to. To further our
example, bosses located into a corner will produce very thick walls, causing sink, unless isolated as in the
illustration below.

Warping

The dynamic of thin and thick sections and their cooling times creates warping as well. As would be
expected, as a thick section cools it shrinks, and the material for the shrinkage comes from the
unsolidified areas causing the part to warp.
Other causes for warping might include the molding process conditions, injection pressures, cooling
rates, packing problems, and mold temperatures. Resin manufacturers’ process guidelines should be
followed for best results. Warping caused by non-uniform wall thickness

Bosses

Bosses are used to facilitate the registration of mating parts, for attaching fasteners such as screws, or
for accepting threaded inserts. Wall thicknesses for bosses should be less than 60 percent of the
nominal wall to minimize sinking. However, if the boss is not in a visible area, then the wall thickness can
be increased to allow for increased stresses
imposed by self-tapping screws.

The base radius should be a minimum of 0.25 X

thickness. Bosses can be strengthened by
incorporating gussets at the base or by using
connecting ribs attaching to nearby walls.
RIBS

Ribs are used in a design to increase the bending stiffness of a part without adding thickness. Ribs
increase the moment of inertia, which increases the bending stiffness.

Bending Stiffness = E (young’s Modulus) x I (Moment of Inertia)

Rib thickness should be less than wall thickness to minimize sinking effects. The recommended rib
thickness should not exceed 60 percent of the nominal thickness. Plus, the rib should be attached with
corner radii as generous as possible.

RIB INTERSECTIONS

Because the thickness of the material will be greater at the rib intersections, coring or another means of
material removal should be employed to avoid excessive sinking from occurring on the opposite side.

RIB GUILDELINES
The height of a rib should be limited to less than
three times its thickness. It is better to use multiple
ribs to increase bending stiffness than to use one
very tall rib.
RIB/LOAD AFFECT ON STIFFNESS
A rib is oriented in such a way as to provide maximum bending stiffness to the part. By paying attention
to part geometry, designers must be conscious of the orientation of the rib to the bending load or there
will be no increase in stiffness.

DRAFT AND TEXTURE

Mold drafts facilitate part removal from the mold. The draft must be in an offset angle that is parallel to
the mold opening and closing. The ideal draft angle for a given part depends on the depth of the part in
the mold and its required end-use function.

Allowing for as much draft as possible will permit parts to release from the mold easily. Typically, one to
two degrees of drafts with an additional 1.5 degrees per 0.25mm depth of texture is enough to do the
trick.
The mold part line will need to be in a way that splits the draft to minimize it. If no draft is acceptable
due to design considerations, a side action mold may be required.
SHARP CORNERS
Sharp corners greatly increase stress concentration, which, when high enough, can lead to part failure.
Sharp corners often come about in non-obvious places, such as a boss attached to a surface, or a
strengthening rib. The radius of sharp corners needs to be watched closely because the stress
concentration factor varies with radius for a given thickness. As illustrated in the chart to the left, the
stress concentration factor is high for R/T values less than 0.5, but for R/T values over 0.5 the
concentration lowers. The stress concentration factor is a multiplier that greatly increases stress. It is
recommended that an inside radius be a minimum of one times the thickness.

INSERTS

Inserts used in plastic parts provide a place for fasteners such as machine screws. The advantage of
using inserts is that they are often made of brass and are robust. They allow for a great many cycles of
assembly and disassembly. Inserts are installed in Injection Molded parts using one of the following
methods.
 (9) Types of injection mold design:

1. Standard mold
2. Stripper mold
3. Slide mold
4. Three plates mold
5. Unscrewing mold

Standard Molds
the standard mold is the most simple design, basically
the standard molds is same as two plate molds
construction, they divided in two side : cavity side and
core side, cavity side is the side that construct to
flowing plastic material from nozzle to cavity parts,
basically they consist of sprue, runner.
Core side construct to make shape for core, de-molding system and ejection system, at this side we design ejection
system. Standard mold have one parting line, and have one opening direction. This type of mold use in all kinds of
plastic parts that doesn't have undercut, inner and outer screw.
Light brown color little and straight in ejection system is shown ejector pin.

Stripper Ejector Mold

this type of mold have special purpose to
make a cup shape without undercut,
stripper ejector will make ejection more
easy, same movement and power at the
product and without a lot of marks in
product Molds with complex and difficult
design can be integrated or combined one to the others mold type.
Slide mold
development from this mold type is the used slider
parts in various molds types, basic slide mold is
transfer horizontal movement of mold to vertical
movement, this types of molds is used to make
parts with undercut, you should see more at the
post when we need slider for learn more.

Three plate molds

basically three plate molds has two parting line, and
floating plate, floating plate support by support pin, Since
the mold has two parting planes, the runner system can be
located on one side of floating plate or make special plate
that attach in floating plate, we called runner plate, see
post about runner plate. Three plate molds are used
because of their flexibility in gating location. This types of
molds is flexible even use in multiple cavity.
Note: floating plate also called cavity plate or plate
number 3, to know more the different between two plate
mold and three plate mold see the posting about Basic and
Types Molds Construction.

Mold with Screw Device

this mold special to make thread forming, the core can
be rotate when de-molding process, both internal and
external threads can be forming by this type mold. From
those picture we can see that they have gear device, the
gear will rotate when thread form.
(10) Main component of plastic injection 2 plate mold
Top clamp Plate:-

There are many alternative names for this

plate:

1- Front plate

2- Fixed half front plate

3- Fixed half clamping plate

Its function is to allow the tool to be secured

to the fixed Platen with cap screws to hold it
in position.

It is usually made from low -carbon steel or

perhaps alloy tool steel for very long-
running jobs.

Bottom clamp plate:-

There are many alternative names for this plate:

1- Back plate

2- Moving half front plate

3- Moving half clamping plate

Its function is to allow the tool to be secured to

the moving platen with cap screws to hold it in
position.

It is usually made from low -carbon steel.

Locating or Register Ring:-

This is a circular ring, screwed to the front clamping plate. It

enables the tool to be centered on the injection cylinder axis by
locating it into a machined hole in the fixed platen. It is usually
made from good-quality low-carbon steel.
Sprue:-

During the injection process plastic material is

delivered to the nozzle of the machine as a melt; it
is then transferred to the impression through a
passage.

In the simplest case this passage is a tapered hole

within a bush the material in this passage is termed
the Sprue. And the bush is called a Sprue bush
which usually made of alloy steel.

Runner & gate system:-

The material may be directly injected into the

impression through the Sprue bush or for molds
containing several impressions (multi-impression
molds) it may pass from the Sprue bush hole
through a runner and gate system before
entering the impression.

Guide pillar & bushing:-

The main function of it is that to make sure that the

cavity And core are kept in alignment. This is done by
incorporating guide pillars on one mold plate which
then Enter corresponding guide bushes in the other
mold plate as the mold closes.

The size of the guide pillars should be such that they

maintain alignment irrespective of the applied molding
force.

It is usually made from good-quality medium-carbon steel.

Space plate:-

Mounted between the movable clamping plate (bottom plate) and the movable cavity plate to give
space and allow the ejector plate to move when ejecting the part. The required length of spacer block
depend on ejector stroke that needed to eject product.

The core & cavity:

-At the most basic level, molds consist of two main

parts: the cavity and core.

The core forms the main internal surfaces of the part.

The cavity forms the major external surfaces.

Typically, the core and cavity separate as the mold

opens, so that the part can be removed.

This mold separation occurs along the interface known

as the parting line-This is the plane or position at which
the tool separates into two distinct parts the fixed half
and the moving or ejection half.

After the tool has split at this point, space is created for the moldings to be pushed or ejected from the
tool-there are two type of this component:-

1-the integer method:-

Where the cavity and core can be machined from steel plates which become part of the structural build-
up of the mold

2- The insert method:-

The cavity and core can be machined from small blocks of steel and assembled into the cavity and core
plates.
Ejection system:-

After the parts have been molded and have

solidified sufficiently, they have to be pushed out
of, or ejected from the mold tool after it has
opened at the parting line. The ejector assembly
carries a number of ejector pins that push or eject
the parts from the cavities.

The parts usually fall into a bin or onto a conveyor

for packaging or for further operations to be
carried out on them.

As well as ejector pins, the ejection system may

use sleeve ejectors and blade ejectors or may also operate stripper plates, double ejection systems.

Ejector guide pillar and guide bush:-

These components ensure the alignment of the ejector assembly so that the ejector pins are not
damaged. They are usually made of alloy steel. The guide pillar typically has higher hardness than the
guide bush.

Ejection Gap:-

This is the amount that the ejector system or assembly can move towards the cavity support plate from
its rest position. It must be large enough to permit the whole form of the component to be fully ejected
from the tool. It is essential that the parts are cleanly ejected from the tool to prevent them becoming
trapped in the tool.

Ejector plate:-

This holds the ejector pins.it is usually made of mild steel.

Ejector back plate:-

It prevent the ejector pins from failure &hold return pins, it is usually made of mild steel material.

Return pin:-

Ensure the ejector pin pull back before the mold close, it protects the injection mold from damage

Made of alloy steel.

(11) Mold Materials and Manufacturing processes

It is very important to ensure that the correct materials are specified in all new injection mold designs.
Use of incorrect or inappropriate materials can lead to poor mold performance in production and to
early failure of the tool.
In all mold materials we are looking for certain characteristics for ease of tool making and good
performance during production from the mold tool. Ideally we would prefer the material finally selected
to have the following properties:
 Good machining properties
 Ease of heat treatment where hardening is required
 Good toughness and strength
 Polishes and accepts texturing well
 Good resistance to heat and wear
 Good fatigue resistance
 High thermal conductivity for effective water cooling
 Good corrosion resistance

Unfortunately, in practice no single material will exhibit all these characteristics and therefore a
compromise has to be reached depending on the type of tool design being employed. Among the major
governing factors that should be considered are:
 The tool life in terms of the quantity of parts required to be produced from the tool
 The molding material being used (e.g., abrasive or corrosive)
 Texturing and polishing requirements
 Whether hardening is required (e.g., for long running tools or for side cores and splits, etc.)
 Whether high thermal conductivity will be required
 Exceptional requirements like the use of very high injection pressures or speeds
Selecting The Material for the Application:-

For most normal applications steel is used because it has most of the properties we require. There are
several other applications, however, where alternative materials may be used. The following sections
discuss the materials used for most normal situations encountered. Table 16.1 gives an overview of the
materials most often used.
Mold Steel Application:-

The different types of steel available for mold plates together with a brief Account of their properties
and uses.
 Manufacturing process
The fundamental goal of manufacturing process is to produce a product that has a useful form.
Manufacturing process is one of the important steps in production process. It mainly concerns with the
change of form of material or dimensions of the part being produced. Transportation, handling or
storage of parts does not comes under steps of manufacturing process, because these steps are not
involved with the change of form of material or dimensions of the part being produced. The geometry of
the finished product must have certain tolerances, that it must meet in order to be acceptable and being
useful.
The three different types of functions that involve in manufacturing process are as follows:

1. To change the physical properties of the materials the following process are performed:
 Hardening, Tempering, Annealing, and Surface Hardening.
2. Metal working processes involves the following:
 Rolling, forging, extrusion, wire drawing
3. Machining Processes involves the following:
 Turning, drilling, milling, grinding, EDM.
4. Casting Processes involves the following:
 Sand Casting, Permanent mold casting, die casting, Centrifugal casting
5. Joining processes involves the following:
 Welding, brazing, soldering, joining
6. Surface finishing processes involves the following:
 Lapping, honing, super finishing.
7. Shearing and Forming processes involves the following:
 Punching, blanking, drawing, bending, forming
(12) Mold Calculations

(1) Clamping Force

Clamping force: The force that holds the mold together from mold closing to the start of mold

Opening so that the injection pressure of the material inside the cavity space cannot force the mold

Open and cause it to flash at the split line

Locking force = (Projected area of part) x Injection

pressure x Factor of safety
(2) No. of Impressions in Mold
There are two ways to calculate the proper no of impressions in plastic injection mold:

 Max shot size

 Plasticizing capacity
(3) Molding Cycle Time

T Filling:
Represents the filling time, is defined as the time needed for filling, not only the mold cavities, but also

The melt distribution system (runners, Sprue, gates, etc.)

T Packing:
Represents the time of packing.

T Packing
Where:-

α [m2/s] represents the coefficient of thermal diffusivity of the material,

D Gate [m] represents the gate diameter,

D Sprue [m] represents the diameter of the Sprue.

TM [K] represents the temperature of the front of molten plastic.

TW [K] represents the mold temperature.

TE [K] represents the ejection temperature.

T Mold Resetting:
Represents the time of opening and closing the mold and ejection of the part.

Depend on machine normally equal 1:3 sec

T cooling:
Represent the time for perfect cool for the part.

Cycle time estimation based on part wall thickness:

Wall thickness, in. (mm) Overall cycle time, seconds

0.060(1.5) 18
0.075(1.9) 22
0.100(2.5) 28
0.125(3.2) 36
 Parameter Average Value(second)
Gate closing time 1
Mold closing time 4
Initial injection time 3
Injection hold time 5
Cooling time 12
Screw return time 8
Mold open time 4
Ejection time 1
Part removal time 2
Mold inspection,clean,spray,etc. 2

(4) Plastic Materials Shrinkage

(5) Plastic Product Wall Thickness

(1) Design guidelines:

 All walls should be equal thickness if possible.

 If a thicker wall is needed, a gentle transition should be specified.
 To avoid sink marks, ribs should be 2/3 the wall thickness, gussets should be 1/2
the wall thickness.
 Sharp corners should be eliminated by using radii.
(2) The wall thickness is mainly determined by the flow ability of the plastic. The ability to flow also
determines how far a plastic can be injected for a specific wall thickness of product.

The approximate maximum flow-path-to-thickness ratio of some common thermoplastics are listed
here:

ABS 175:1
Acetyl 140:1
Acrylic 130~150:1
Nylon 150:1
Polycarbonate 100:1
Polyethylene(low density) 275~300:1
Polyethylene(high density) 225~250:1
Polypropylene 250~ 275:1
Polystyrene 200~250:1
Polyvinyl Chloride, rigid 100:1

The following table is a listing of common materials and the wall thickness they can flow through. This
table shows that an easy-flow material (such as crystalline nylon) allows thinner wall.

Material Minimum (in./mm) Maximum (in./mm)

ABS 0.030/0.762 0.125/3.175
Acetal 0.015/0.381 0.125/3.175
Acrylic 0.025/0.635 0.250/6.350
Nylon(amorphous) 0.030/0.762 0.125/3.175
Nylon(crystalline) 0.015/0.381 0.125/3.175
Phenolic 0.045/1.143 1.000/25.400
Polycarbonate 0.040/1.016 0.400/10.160
Polyester(TP) 0.025/0.635 0.125/3.175
Polyester(TS) 0.040/1.016 0.500/12.700
Polyethylene(HD) 0.020/0.508 0.250/6.350
Polyethylene(LD) 0.030/0.762 0.250/6.350
Polypropylene 0.025/0.635 0.300/7.620
PPO 0.030/0.762 0.400/10.160
Polystyrene 0.030/0.762 0.250/6.350
PVC 0.040/1.016 0.400/10.160
(6) Melt and Mold Temperature for common plastics

Material Melt Temperature(C)

Acetal (copolymer) 204
Acetal (homopolymer) 217
Acrylic 217
ABS (medium-impact) 204
Cellulose acetate 197
Nylon (Type 6) 256
Polyallomer 248
Polyamide-imide 332
Polyarylate 358
Polybutylene 243
Polycarbonate 281
Polyethylene (Low density) 166
Polyethylene(High density) 204
Polypropylene 179
Polystyrene (general purpose) 179
Polystyrene (medium-impact) 194
Polystyrene (high-impact) 199
PVC (rigid) 179
PVC (flexible) 166

Material Mold Temperature(C)

Acetal (copolymer) 102
Acetal (homopolymer) 107
Acrylic 92
ABS (medium-impact) 92
Cellulose acetate 77
Nylon (Type 6) 102
Polyallomer 102
Polyamide-imide 204
Polyarylate 141
Polybutylene 102
Polycarbonate 112
Polyethylene (Low density) 41
Polyethylene(High density) 56
Polypropylene 61
Polystyrene (general purpose) 72
Polystyrene (medium-impact) 82
Polystyrene (high-impact) 92
PVC (rigid) 72
PVC (flexible) 41
(13) Process System Design

There is many system that work together to achieve a good injection process, each system must be

Properly designed based on scientific back ground and well understanding to the application that the

Part is manufacturing for in this topic we represent the major systems used in injection process

Which are:-

1-ejection system
2-Cooling system
3- Feeding system
4-venting system
5-sliding system

(1) Ejection system:-

After the product has cooled in the cavity and the mold has opened, the product must be ejected from

The mold in order to make for injecting another shot, most common forms of ejection are as follows:

 Pins and blades

 Sleeve ejectors
 Stripping actions
 Valve ejectors

1-Ejector Pins and Blades

Ejector pins are the most common method of ejecting parts from the cavity.

Three types of pins are normally used:-

1-Nitrided pins:
These are pins that have been heat-treated in a molten salt ferritic bath or gas to introduce nitrogen
into the surface of the pin. They have good wear resistance and are used for all normal ejector pin
applications.

2-Tuftrided pins:

Tuftriding introduces nitrogen and extra carbon into the pin surface, giving a harder surface and leaving
A softer core.
3-Through-hardened pins and blades:
These are hardened in the same way as cavity parts, using nickel–chrome steels. This technique is used
For larger core pins and pins that form the core of a sleeve ejector.

2-Sleeve ejectors

Sleeve ejectors are used to eject on circular features such as circular pads, bosses or Recessed holes.
Like ejector pins, sleeve ejector assemblies are available as standard components in a wide variety of
sizes. Nonstandard sleeves can be made by adapting standard ones; failing this, they will have to be
specially made.
3-Air valve

With this ejection method the ejector force is. Provided by compressed air, which is introduced directly
on to the molding face via a small air ejector valve. For this method to operate efficiently the adhesion
between the molding wall and the core must be broken, to permit the compressed air to be introduced.

Advantages of air ejection:

1-No ejector grid or ejector assembly is required. This reduces the cost of the mold.
2-Air ejection can be fitted in either mold half. It is therefore a suitable.
3-The ejection can be operated at any time during the opening stroke.

The following limitations should be noted:

1-The method is only effective on certain types of component.

2-A compressed air supply must be readily available.

3-Air is an expensive service and if incorrectly used this system can be Wasteful.
4-Stripper plate

Stripper plate systems are very effective and usually more efficient than pins wherever they can be used
as they support the maximum area possible during ejection. Typical applications are for tubular parts
and circular, square or rectangular boxes. Stripper plate systems are also often used in conjunction with
other forms of ejection. They are used with pins, sleeves and blade ejection, and sometimes with
compressed air.

To determining a proper system, a number of factors have to be taken into account, including:

1-The part geometry:

The component geometry will often restrict where ejectors may be placed.

2-The material:
The type of material being used will influence the choice of ejectors and the number of ejectors
required, Brittle materials are easily prone to cracking or even breaking during ejection unless sufficient
Attention has been paid to this point, some soft materials can lead to the material compressing and
‘bellying out’ at the point of ejection, resulting in the molding resisting being stripped from the core.

3-Gating
An ejection position must be chosen so that the gate is sheared off cleanly and ejected without any
tendency to hang-back.
4- Ejection balance
An ejection system can contain many ejector pins and often these can be quite slender.
Such pins can easily buckle or start to score if the ejection system is not balanced or
Guided.

5- Machine specifications
1- Opening stroke
2-Machine ejection features:
-mechanical dead stop on the crosshead of the clamping
-hydraulic ejection facilities
3-Movement control features:
All these specification help in choosing proper ejection technique

6- Component finish requirements

In some products it’s inappropriate to eject a component on one of its appearance faces,
Which would leave an undesirable witness marks

7-Draft Angle
The component drawing should be checked for suitable draft angles Draft angles are often an essential
requirement.

General Ejection Guidelines

1- There must always be enough clearance between the cores and the cavities to permit the products to
fall freely without getting caught up.
2- The mold designer must always carefully consider the placement of ejector pins.
3- Eject at points where the part is stiffest and deepest region.
4- Distribute ejectors to ensure that the part is lifted without cocking.
5 – Proper choose of the ejection system.
6- Carefully calculate ejection force.
Ejection forces calculations

Where:

Fp = the ejection resistance force (N)

E = Young’s modulus of the polymer (N/cm2)

A = total surface area of molding in contact with cavity or core, in line of draw (mm2)

μ = coefficient of friction, polymer on steel

m = Poisson’s ratio

d = the diameter of a circle whose circumference is equal to the total projected

Perimeter of the molding (mm)

α= the coefficient of linear expansion of the polymer (mm/C)

ΔT = (polymer softening temperature) - (mold tool temperature) (C)

t = average wall thickness of part (cm)

(2) Cooling system:-

What is importance of cooling for Injection Mold?

Mold cooling serves to dissipate the heat of the molding quickly and uniformly. Fast cooling is necessary

To obtain economical production and uniform cooling is required for product quality. Optimal properties

Of engineering plastics can be achieved only when the right mold temperature is set and maintained

During processing. The mold temperature has a substantial effect on:

 The part geometry

 The wall sections
 The material
 The type and size of the gate and
runner
 The mold material

 Molds must be cooled to remove heat from

molding and changing phase to solid so the
part can be ejected as quickly as possible.
 Inefficient cooling increase cycle time therefore increase costly.
 It is also wasteful to continue cooling the mold until the part has reached ambient
temperature as many materials may be safety ejected up to 50 °c.
 The cooling phase can be up to 80% of the overall injection cycle.
 Cooling is accomplished by circulating a coolant (water is common) through a passages in
mold halves.
 Water temperature range is (5 to 80) °c.
 We can use an oil as a coolant for mold temperature above 100 °c.
 Cooling channels diameter should be in the range of (6 to 10) mm, hoses used to
interconnect channels should have the same inside diameter.
 Practical experience: distance between cooling diameter quadrant and nearest cavity
surface should be at least 20 mm.
 Distance between cooling channel and cavity can be increased to make the temperature at
the cavity surface more uniform
 Parallel cooling to each individual cooling unit is preferred (multi moldings).
 Beryllium copper alloys can be used in mold to improve cooling condition, as it has excellent
thermal conductivity with high strength and hardness.
 Channels or Cooling pockets with rough surface finishing are more efficient than smooth
surface finishing because turbulent flow
Mold cooling system components
A mold cooling system typically consists of the following items:

•Temperature controlling unit

•Pump
•Supply manifold
•Hoses
•Cooling channels in the mold
•Collection manifold
•coolant (water, oil, chiller, Thermal Conductance of Metals).

Position of Cooling Channels

Mold Tool Designers are mostly concerned about the quantity of coolant in cavities and cores
to remove heat in those areas. There must be enough coolant where it is needed and that it is
evenly distributed and uniform.
Cooling Channel Configuration

In general, the cooling system will be roughly drilled or milled. Rough inner surfaces enhance
turbulent flow of coolant, thus providing better heat exchange. Turbulent flow achieves 3 to 5
times as much heat transfer as doing non-turbulent flow. Cooling channels should be equal
center distances with cavity surface.

Cooling Efficiency

The major factors that influence cooling efficiency are:

 The cavity material and construction
 Channel geometry
 Number of channels
 Rate of coolant flow
Circuit Efficiency

There are two basic ways of arranging cooling circuitry: in series and in parallel. Both of these
have advantages and disadvantages, but wherever it is possible parallel systems are preferred
because of their greater efficiency.

Considerations for choice:-

•Quality of Cooling Required

•Space choice available
•Strength of Mold Material
•No. Of Cooling Circuits Available At the Machine.

Core Cooling:-
Several different methods are used for cooling cores and cavities depending on their size and
construction.
 Baffle system
 Fountain system
 Angled hole
 Stepped hole
 Spiral cooling
 Heat rods
 Heat pipes
 Beryllium copper cores and cavities
  Baffle System

This is a simple method of cooling smaller cores, although arrays of baffles may be used in
larger cores. A hole is bored into the core and a copper strip is inserted into it. It must be a
good fit in the hole so that fluid does not leak.

 Fountain System

Fountain designs are more efficient than baffle systems because the cooling circuitry is usually
in parallel not series. This gives a more uniform temperature control over the entire molding
area. With this design a tube is fitted into the center of a hole in the punch or core pin.
  Angled Hole Design

This method consists of drilling holes at angles in larger punches so that they intersect each
other to create a path for the cooling fluid to flow through. In practice the length of the holes is
restricted to a maximum of about 150 mm to ensure full diameter intersection. Small- bore
deep holes may be machined with EDM techniques.

 Stepped Hole Design

This is an easier system for toolmakers to make than the angled hole design, as it is not so
difficult to match up the drilling. Where drilled holes break through into the punch surface they
have to be plugged and then brazed or welded over. This system can cause problems where the
job is of a critical appearance nature. A witness can often be seen on the molding where the
plugs are positioned, either in the form of a ring or sometimes a blush mark.
  Heat Rod

For smaller punches and core pins it can be difficult to fit fountains or baffles. In these cases
heat rods are often used. These consist of high thermal conductivity materials that are inserted
into the core pin. The material most frequently used is copper, which is both ductile and an
excellent conductor of heat.

 Spiral Cooling

For larger cylindrical cores above 50 mm diameter, spiral cooling systems provide more uniform
and efficient cooling permitting quite good temperature control. Seals have to be used to
prevent leakage in this type of design. Where space permits, a double helix may be used to
provide two cooling channels that run next to each other. The single-channel and double-
channel systems are very similar to a single-start and two start screw thread respectively.
The remaining wall section of the core must also be thick enough to withstand the forces
generated during injection of the polymer. Cooling channels must also be far enough away from
the core surface to prevent excessive chilling of the polymer too quickly.
  Heat Pipe
Heat pipes are also used for cooling small core pins. They act as heat exchangers just like a heat
rod but operate on a different principle. A heat pipe consists of a copper tube sealed at both
ends with a fine ‘wick’ running along the length of the inside wall of the tube. The tube is filled
either with water or with a low-boiling-point alcohol. The efficiency of heat transfer depends on
the contact between the outside of the heat pipe and the inner wall of the core pin. In order to
assist in this respect, a heat transfer paste is normally spread over the heat pipe before it is
inserted into the core pin.

Beryllium-Copper Cores and Cavities

There are occasions when cores and cavities may be difficult to cool by any of the methods so
far described.
There are two principal reasons for this:
 Long, slender, round core pins that cannot be cooled owing to the difficulty of
incorporating fountains or heat rods or heat pipes in them.
 Cavity inserts or core inserts that have complex constructions that prohibit conventional
cooling techniques.
In the first case it is possible to construct the entire core pin from beryllium-copper, albeit with
a loss of mechanical strength. However, it is quite possible to increase the beryllium content to
3–5% or more to increase the strength to around 75% of that of alloy tool steel with induction
hardening. This is often the only way these types of cores can be cooled satisfactorily in
production. In fact they will permit much faster cooling cycles than would alloy tool steel. Note,
however, that the normal beryllium content of beryllium-copper is around 2.7%, so the
standard material may not be able to be used .The specification should be discussed with the
manufacturer of the beryllium-copper in conjunction with the tool maker. Cavity inserts can be
made from this material with great success and perform well in production if reasonable care is
taken. In this case the material may be machined or cast by a specialist casting company. Again
cooling cycle times are considerably improved. It must not be forgotten that, when using this
material, provision must be made for removal of the heat from it.Therefore, part of the cavity
or core must be in contact with a suitably placed water-cooling channel

Selection Guide line for cooling type:-

Cavity Cooling:-
Cooling calculations
 (3) Feeding Systems
The main function of feeding system is to get plastic properly into the mold, feeding system
consists mainly from:-
1) Sprue bushing
2) Cold slug well
3) The Runner
4) The Gate

(1) Sprue bushing:

This should be tapered 3–5 angle in order for it to be pulled out of the tool more easily. It
should also be highly polished for more efficient flow. The diameter at the narrow End should
be larger than the machine cylinder nozzle opening.
 Orifice diameter (Sprue diameter at runner system) should be larger than maximum thickness
of part and runner system by 1mm to freeze last for holding pressure.

 Sprue diameter(at nozzle machine) should be greater than nozzle machine diameter by 1.5
mm
(2) Cold slug well:

This is designed to trap the cooler advancing front of the melt, thus permitting hotter
Melt to reach the cavities and gates. It usually has a snatch or pull pin or sucker pin underneath
it to positively pull the Sprue out of the Sprue bush.
(3) Runner system:

The purpose of the runner is to transport the melt from the Sprue to the gates. There are
three basic parameters for runner geometry:

 The cross-sectional shape.

 The diameter and Length.
 The cavity layout.

Runner Cross-Section

There is two preferable cross section shape

1) Circular
Consider as the ideal runner cross section as this ensures favorable melt flow and cooling.
However, it takes more effort to build circular runners because one half must be machined in
The fixed mould part and the other half in the moving mould part. The higher the surface to
Volume ratio, the more efficient the runner

2) Trapezoidal
Full TRAPEZOIDAL channels in one of the two mould halves provide a cheaper alternative. The
Rounded off trapezoidal cross section combines ease of machining in one mould half with a
cross-section that approaches the desired circular shape.
Runner diameter
The cavity layout
Cold slug well
At all runner intersections there should be a cold slug well. The cold slug well helps the flow of
material through the runner system by stopping colder, higher viscosity material moving at the
forefront of the molten mass entering into the cavity. The length of the well is usually equal to
or greater than the runner diameter and this is achieved by extending the length of the primary
runner at the intersection with the secondary runner.
Runner System Design Rules
 Runners must be designed to fill the cavity rapidly.
 Runner design must provide for easy ejection and easy removal (de-gating) from the
Molded part.
 For a multi cavity system, balanced runner layout is preferred for the best uniformity
And part quality. Runners may be balanced either naturally or artificially.
 Runner balancing may be achieved by changing the runner size and length.
 Changing the gate dimensions may seem to give a reasonably balanced fill but this
Will affect the gate freeze-off time, which is detrimental to part uniformity.
 Smaller runner sizes are preferred to larger ones in order to minimize scrap volume
And generate viscous (frictional) heating. Viscous heating generated in the runner
 system is an effective way to raise the melt temperature as opposed to using high
Cylinder temperatures, which may cause material degradation.
 The cross-sectional area of the runner should not be smaller than that of the Sprue,
To permit rapid, unaltered flow of material to the gating areas.
 Each time a runner is branched, the diameter of the branch runner should be smaller
Than that of the main runner. This is because less material flows through the branch
Runners and it is economically desirable to minimize the amount of material in the
Runner system. Where N is the number of branch runners, the relationship between
The main runner diameter (D) and that of the branch runner (d) is given by:

D main= d branch x N1/3

 The depth of a trapezoidal runner is approximately equal to its width with a 5–15°
Taper or draft angle on each side wall.
 The minimum recommended runner diameter for most materials is 1.5 mm (0.06 in).
For most materials, the runner surface and Sprue should be polished in the line of
Material flow. Cavities and cores should be polished in the line of draw unless an
Alternative finish has been specified.
 It is desirable to have multiple Sprue pullers and ejection locations in extended
Runner systems.
 The selection of a cold runner diameter should be based on standard machine tool
Cutter sizes.
 When designing hot runner systems, it is advisable to consult the suppliers for
Availability and recommendations for the correct manifold and drops.
(4) Gate:

A gate can be defined as a passage through which the plastic material enters the cavity space.
The location of gates is of great importance for the properties and appearance of the finished
part. The melt should fill the entire cavity quickly and evenly.

For gate design the following points should be

considered:

•Locate the gate at the thickest section

•Balance flow paths to ensure uniform filling and packing
•Prevent weld lines or direct to less critical sections
•Minimize entrapped air to eliminate burn marks
•Avoid areas subject to impact or mechanical stress

The gate design is largely determined by:

 The part geometry

 Part specifications (appearance, tolerances, etc.)
 Material used
 Fillers used
 Cycle time
 De-gating requirements

Types of gates

1- Manually trimmed

2-Automatically Trimmed

1) Manually trimmed gates:

Are those that require an operator to separate parts from runners during a secondary
operation? The reasons for using manually trimmed gates are:

•The gate is too bulky to be sheared from the part as the tool is opened.
•Some shear-sensitive materials (e.g., PVC) should not be exposed to the high shear rates
inherent to the design of automatically trimmed gates.
Types of manually trimmed gates

Sprue Gate

•Recommended for single cavity mould.

•This type of gate is suitable for thicker sections
•A short Sprue is favored, enabling rapid mould filling
•A cold slug well should be included opposite the gate
•Gate mark left on the part surface after the runner (or
Sprue) is trimmed off.
•The starting Sprue diameter is controlled by the machine
nozzle

Tab Gate

Tab gate is typically employed for flat and thin parts to

reduce the shear stress in the cavity. The minimum tab
width is 6 mm. The minimum tab thickness is 75% of the
depth of the cavity Tab gate is used extensively for molding
PC, acrylic, SAN, and ABS types of materials.

Fan / Edge Gate

•The edge or side gate is suitable for medium

And thick sections and can be used on multi cavity
two plate tools. The gate is located on the
Parting line and the part fills from the side, top or
Bottom.

•The typical gate size is 80% to 100% of the part

Thickness up to 3.5 mm and 1.0 to 12 mm wide.
The gate land should be no more than 1.0 mm
In length, with 0.5 mm being the optimum
Automatically trimmed gates incorporate features in the tool to break or shear the gate as the
molding tool is opened to eject the part. Automatically trimmed gates should be used to:

•Avoid gate removal as a secondary operation.

•Maintain consistent cycle times for all shots.

Types of Automatically Trimmed Gates

Pin Gate / Drop Gate

Pin gates are only feasible with a 3-plate tool because it must
be ejected separately from the part in the opposite direction
The gate must be weak enough to break off without damaging
the part. This type of gate is most suitable for use with thin
sections. The design is particularly useful when multiple gates
per part are needed to assure symmetric filling or where long
flow paths must be reduced to assure packing to all areas of
the part.

•Gate diameters for un-reinforced thermoplastics range from

0.8 up to 6mm. Reinforced thermoplastics require slightly
larger gates > 1 mm the maximal land length should be 1 mm.

Submarine / Tunnel Gates

A submarine gate is used in two-plate mould

construction. An angled, tapered tunnel is machined
from the end of the runner to the cavity, just below the
parting line. As the parts and runners are ejected, the
gate is sheared at the part. The tunnel can be located
either in the moving mould half or in the fixed half

•Typical gate sizes 0.8 mm to 1.5 mm, for glass

reinforced materials sizes could be larger materials
sizes could be larger.
Hot Runner Gates

Hot runner gates are also known as Sprue less

gating. The nozzle of a runner less mould is
extended forward to the part and the material is
injected through a pinpoint gate. The face of the
Nozzle is part of the cavity surface; this can cause
appearance problems (matt appearance and
rippled surface). The nozzle diameter should
therefore be kept as small as possible. Most
suitable for thin walled parts with short cycle
times, this avoid freezing of the nozzle.

Valve Gates

The valve gate adds a valve rod to the hot

Runner gate. The valve can be activated to
Close the gate just before the material close the
gate just before the material near the gate
freezes. This allows a larger gate diameter and
smoothed over the gate scar. Since the valve rod
controls the packing cycle, better control of the
Packing cycle is maintained with more
Consistent quality.
Gating Design Rules

 The gate design should deliver a rapid, uniform and preferably unidirectional
Mould-filling pattern.
 The gate location should allow the air present in the cavity to escape during the
Injection phase. Failure to vent the air will result in short shots or burn marks on the
Molding.
 If the gate location is likely to cause weld or meld lines, it should be positioned so
That these will occur at appropriate positions to preserve part quality and
Appearance.
 Gate location and size should avoid the possibility of jetting (the string appearance
Or spaghetti strands on short shots). Jetting may be prevented by enlarging the gate
Or by locating the gate in such a way that the melt is directed against a cavity wall.
 The freeze-off time at the gate should ensure maximum cavity packing time. A well-
designed gate freeze-off time will also prevent back flow of the injected material.
 The gate location should be at the thickest area of the part, preferably at a point
Where the function and appearance of the part are not impaired.
 The gate length should be as short as possible to avoid an excessive pressure drop
Across the gate. A suitable gate length ranges from 1 mm to 1.5 mm (0.04–0.06 in).
 Normally the gate thickness is 50–80% of the gated wall section thickness. For
Manually trimmed gates, the gate section can occasionally be the same as the gated
Wall section thickness. For automatically trimmed gates, the gate thickness is
Typically 80% of the gated wall section thickness to avoid part distortion during de-
gating. Typical diameters at the gate end for pin and submarine gates are 0.5–
 2.5 mm for the former and 0.25–2.0 mm for the latter.
 Fiber-filled materials require larger gates to minimize breakage of the fibers when
They pass through the gate. Using small gates such as submarine, tunnel or pin gates
Can damage the fibers in filled materials.
 Gates should always be machined smaller when the mould tool is first made, so that
They can be enlarged later if necessary. Enlarging gates is relatively easy but reducing
They can be both difficult and expensive.
For gate radius
(4) Venting System:-
The displaced air in the mold cavity must be able to escape during mold filling process.
If there are insufficient vents, the pressure and local temperature rise quickly, potentially
causing incomplete filling or even burning of the thermoplastic. The number of vents is often
limited by mold construction economics but ideally should be taken into account during the
design stage. In general the higher the viscosity of a material the larger the vent Dimensions.
They should be located in areas that are the last to fill in particular Section of the mould. We
can use natural vent method by ejection bin or we will use especial methods.

There are several method to make vents:-

Parting Line Venting

Vents can be placed anywhere along the parting line in particular they should be located in
areas that are the last to fill in particular section of the mold. A reasonable spacing is every
25mm. If the air is trapped with no way out to the mold parting line, it is advisable to place a
venting pin/ejector pin to permit the air escape through the clearance between pin and hole
another option is to through the clearance between pin and hole. Another option is to use
sintered metal inserts, these inserts allow gas to pass into them without clogging up with the
polymer. These inserts should only be used as a last resort and only on non-visual surfaces.
Vent pin method:-

The standard design for a vent pin has a light push

Fit (0.000 to 0.005mm) in the portion of the bore below
the vent groove to ensure that the vent is concentric
with the wall of the bore.

Insert vent:-

This type of venting is absolutely necessary to ensure the filling of any deep (plastic) rib created
in the insert. If feasible the vent should be over the whole width of the insert to permit
maximum air flow. Vent channels are usually machined in the insert but could be machined into
surrounding core or cavity.
Common Venting Problems and Fixes

Short shots: Increase the number of vents; check vent location or size.
Weak weld lines: Vent at weld-line location; check vent location or size.
Bubble/splay/ discoloration: Increase the number of vents; check vent size.
Warpage & Shrinkage: Increase the number of vents; check vent location or size
Flash on parts: Vent depth too deep; vent location is wrong.

SEVEN RULES OF EFFECTIVE VENTING

 Provide as many pathways as possible with sufficient area to allow trapped air and
gases to escape from the mold quickly and cleanly.
 The pathways should lead from the edge of the cavity directly to the outside of the
mold.
 Vents must be deep enough to let out air and gases, but not deep enough to let out
plastic.
 Vents should be regularly inspected and cleaned to prevent buildup.
 Pay attention to excessive clamp pressures that can close vents.
 Don’t forget to vent the runner, Sprue, and cold-slug wells. This will help the plastic to
inject quickly at lower pressures, reduce backpressure, improve flow rate, reduce part
stress, and shorten cycle times.
 Review inserts, slides, and cores for venting, too.
(5) Slider system:-
Complex molds for parts with undercuts or side cores may use several method to avoid.
These cores may be operated manually, mechanically, hydraulically, pneumatically or electro-
mechanically.

Side Cores

This is a typical method for producing mold undercuts and can come in various types and
configurations. When the mold is closed the cam pin is engaged into the slide body and forces
the slide nose forward into position ready for the injection of plastic. When the mold opens the
slide retracts by the desired stroke and allows the product ejected freely.

The cam pins that operate the slides are mounted maximum angle of 20 - 25 in injection side.
The angle is limited because of the enormous force that is exerted on these pins
During mold opening and closing.
Lifters

A lifter is a component in the mold that is normally attached to and actuated by the ejector
system and moves at an angle to free internal molding detail .They are typically attached
between the ejector retainer and ejector plates with some mechanism allowing the fixed end to
slide or pivot to compensate for the movement of the lifter position as it moves at the desired
angle. Lifters are frequently used when segmented plastic undercuts (raised mold core detail) is
necessary. The lifter has to move out of the mold core at an angle, typically 5° or less, to clear
the plastic from the mold lifter detail. As the lifters have to move inward from the inside wall
Of the plastic part to free the undercut, the part must be devoid of any detail that would
prohibit or impede lifter movement. Should the part design not allow this required movement
the only choice to form this part detail may be with the aid of internal or hidden slides?
(14) Injection common defects and ways to avoid them

Some of the molding defects that can occur in a part during injection

(1) Flow Lines

Description:

Flow lines - commonly off-toned in color - that show up

on the part as a consequence of the physical path and
cooling profile of the molten plastic as it flows into the
injection mold tooling cavity.

Causes:

Flow line defects are caused by the varying speed at which the molten plastic flows as it
changes direction through the contours and bends inside the mold tool. They also occur when
the plastic flows through sections with varying wall thickness, or when the injection speed is
too low causing the plastic to solidify at different speeds.

Avoiding procedures:

1. Increase injection speeds and pressure to the optimal level, which will ensure the
cavities are filled properly (while not allowing the molten plastic time to start cooling in
the wrong spot). The temperature of the molten plastic or the mold itself can also be
elevated to ensure the plastic does not cool down sufficiently to cause the defect.

2. Round corners and locations where the wall thickness changes to avoid sudden changes
in direction and flow rate.

3. Locate the gate at a spot in the tool cavity with thin walls.
(2) Sink Marks

Description:

Sink marks are small craters that develop in thicker

areas of the injection molded part when shrinkage
occurs in the inner portions of the finished product.

Causes:

Sink marks are often caused when the cooling time

or the cooling mechanism is insufficient for the
plastic to fully cool

Avoiding procedures:

1. Mold temperatures should be lowered, holding pressure increased, and holding time
prolonged to allow for more adequate cooling and curing.

2. Reducing the thickness of the thickest wall sections will also ensure faster cooling and
help reduce the likelihood of sink marks.

(3) Vacuum Voids

Description: Vacuum voids are pockets of air

trapped within or close to the surface of an
injection molded part.

Causes: Vacuum voids are often caused by uneven

solidification between the surface and the inner
sections of the prototype.

Avoiding procedures:

1. Locate the gate at the thickest part of the molding.

2. Switch to a less viscous plastic. This will ensure that less gas is trapped as air is able to
escape more rapidly.
3. Increase holding pressure as well as holding time.
4. Ensure that mold parts are perfectly aligned.
(4) Weld Lines

Description: Weld lines are actually more

like a plane than a line that appears in a part
where molten plastics meet each other as
they flow from two different parts of the
mold.

Causes: Weld lines are caused by the

inadequate bonding of two or more flow
fronts when there is partial solidification of
the molten plastic.

Avoiding procedures:

1. Raise the temperature of the mold or molten plastic.

2. Increase the injection speed.
3. Adjust the design for the flow pattern to be a single source flow.
4. Switch to a less viscous plastic or one with a lower melting temperature.

(5) Short Shot

Description:

As the term implies, short shots can be

described as a situation where a molding shot
falls short. This means that the molten plastic
for some reason does not fully occupy the
mold cavity or cavities, resulting in a portion
where there is no plastic. The finished product
becomes deficient because it is incomplete.

Causes:

Short shots can be caused by a number of things. Incorrect calibration of the shot or
plasticizing capacities can result in the plastic material being inadequate to fill the cavities. If
the plastic is too viscous, it may solidify before fully occupying all the cavities and result in a
short shot. Inadequate degassing or gas venting techniques can also result in short shots
because air is trapped and has no way to escape; plastic material cannot occupy the space that
air or gas is already occupying.
Avoiding procedures:

1. Select a less viscous plastic with higher flow ability. This plastic will fill the hardest-to-
reach cavities.
2. Increase mold or melt temperature so as to increase flow ability.
3. Account for gas generation by designing the mold so that gas is not trapped within the
mold and is properly vented.
4. Increase the material feed in the molding machine or switch to a machine that has a
higher material feed in the event that the maximum material feed has been reached.

(7) Burn Marks

Description: Burn marks are discolorations,

usually rust colored, that appear on the
surface of the injection molded part.

Causes: Burn marks are caused either by the

degradation of the plastic material due to
excessive heating or by injection speeds that
are too fast.

Burn marks can also be caused by the

overheating of trapped air, which etches the surface of the molded part.

Avoiding procedures:

1. Reduce injection speeds.

2. Optimize gas venting and degassing.
3. Reduce mold and melt temperatures.

A large number of the defects mentioned above can be prevented in the design
process by incorporating proper tooling design into the iterative process. Using
mold flow software like Solid works plastics will help you identify ideal gate
locations, anticipate air pockets, flow or weld lines, and vacuum voids. Most
importantly, it will help in design solutions to these problems ahead of time, so
that when it comes to production you do not have to worry about the defects
costing you money.