1. Injection Molding
MFG 355

4. 15 Ton Injection Molding Machine
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5. 77 Ton Injection Molding Machine
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6. 150 Ton Injection Molding Machine
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7. Equipment Injection Unit Screw drive arrangement Feed hopper
Barrel heaters
Nozzle
Tool
Screw
Check valve
Screw tip

8. Equipment
Injection Unit

11. Injection
Parts of the injection screw
Screw
Head and check ring

12. Equipment
Molds

13. Molds

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

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

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

17. Mold Parts
Guide pins
Align mold cavities
Guide pins

18. Mold Parts
Sprue Bushing
Hot sprue
Cold sprue

19. Mold Parts
Sprue Bushing
Hot sprue

20. Mold Parts
Sprue Bushing
Cold sprue
Sprue puller

21. Mold Parts
Sprue Bushing
Cold sprue
Sprue puller

22. Mold Parts
Runner

23. Mold Parts
Runner
Layout
Conventional
Improved
Balanced “H”
Circular

24. Mold Parts
Runner
Layout
Conventional
Improved
Balanced “H”
Circular

25. Mold Parts
Runner
Cold well

26. Mold Parts
Runner

27. Mold Parts
Gates
Submarine Gate
Fan or Edge Gate
Pinpoint Gate

28. Mold Parts
Gates
Tab Gate
Sprue Gate
Flash Gate

29. Mold Parts
Gates
Internal Ring Gate
External Ring Gate

30. Mold Parts
Gate

31. Mold Parts
Gate

32. Mold Parts
Gate

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

34. 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).

35. Mold Parts Cooling Reduce cycle time
Control formation of crystalline areas
Freeze part
Mold cavity
Cooling lines

36. Mold Parts
Ejector system
Ejector pins
Return Springs
Ejector Plate

37. Equipment
Clamping Unit

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

39. Equipment
Clamping Unit

40. Equipment
Clamping Unit
Toggle system
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41. Plant Concepts

42. Safety High clamping forces High pressure lines High voltage
High temperatures

43. Safety Position switches Shields Lock out/tag out
Mechanical, hydraulic and electrical
Shields
Lock out/tag out

44. 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

45. Sliding Mechanism

46. 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

47. 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)

48. Special Injection Molding Processes
Coinjection molding
Two separate screws
Two different material selections
Color, strength, flexibility

49. Special Injection Molding Processes
Coinjection molding 1 2 3

50. Special Injection Molding Processes
Coinjection molding
Part 1
Part 2

51. Special Injection Molding Processes
Flow-controlled injection processes
Sometimes called Scorim

52. Special Injection Molding Processes
Flow-controlled injection processes
Sometimes called Scorim

53. Special Injection Molding Processes
Gas injection molding
Employs gas to create hollow parts

54. 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

55. 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

56. Thank You