Injection Mould Design

• Introduction-Injection mould
• Cross-sectional view of injection mould
• Exploded view
• Function of mould components
• Parting line
• Types of injection moulds
• Runner system
• Runner balancing
• Gate
• Mould temperature and melt temperature
• Product ejection system
• Mould cooling system

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 Injection mould design

Injection mould

• Injection mold determines the size, shape, dimensions, finish, and often the physical
properties of the final product.

Cross-sectional View

Figure: Cross-sectional View of an injection mould

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 • Function of mould components

• The sprue is a channel in the stationary platen that transports the melt from the
plasticizing barrel to the runner system. The runner system basically transports the melt
from the sprue to the gate. The gate further transports the melt into the cavity.

Parting line

• Every mold has two basic parts to contain the cavities and cores. These are stationary
mold-half (on the side from where the plastic melt is injected) and a moving mould-half
(on the ejector side of the machine). The line on a plastic part which separates the two
mould halves is called the parting line.

Types of injection moulds

• There are many different types of molds, designed to meet different product
requirements. However, there are six basic types of injection molds for use with
thermoplastics.
• These types are (1) two-plate mold; (2) three-plate mold; (3) hot-runner mold; (4)
insulated hot-runner mold; (5) hot-manifold mold; and (6) stacked mold.
• A two-plate mold consists of two plates with the cavity and cores mounted in either
plate. The plates are fastened to the press platens, and the moving half of the mold
usually contains the ejector mechanism and runner system. A two-plate mold is the
most logical type of tool to use for parts that require large gates.

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• The three-plate mold is made up of three plate runner plate, cavity plate and force
plate.
• The stationary (or runner plate) is attached to the stationary platen and usually contains
the sprue and half of the runner. The middle (or cavity plate) contains half of the runner
and gate and is allowed to float when the mold is open. The movable (or force plate)
contains the molded part and ejector system for the removal of the molded part.

• In a hot runner mould, the runners are kept hot in order to keep the molten plastic in a
liquid state all the time. It is also known as “runner-less” molding process. In such
molds, the runner is contained in a separate plate. Hot-runner molds are similar to
three-plate injection molds, except that the runner section of the mold is not opened
during the molding cycle. The heated runner plate is insulated from the rest of the
cooled mold.
• Runner-less molding has several advantages over conventional cold-runner-type
molding. There are no molded side products (gates, runners, or sprue) to be disposed
off.

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• Insulated runner mould is a variation of the hot-runner mold. In this type of molding,
the outer surface of the material in the runner acts as an insulator for the molten
material to pass through.
• In the insulated mould, the molding material remains molten by retaining its own heat.
This type of mold is ideal for multi-cavity center-gated parts. The diameter of the runner
is almost twice that in a cold-runner system.
•

• The hot manifold mould is a variation of the hot runner mould. In the hot-manifold, only
the runner is heated (runner plate is not heated). This is done by using electric-
cartridge-insert probes in sprue, runners, and gates.

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 • Stacked mold is a multiple two-plate mold, with the molds placed one on top of the
other. This type of construction can also be used with three-plate, hot-runner, and
insulated hot-runner moulds.

Runner system

• The runner should be short and free of bends

• The cross sections of runners in multi cavity molds must be large enough to convey the
plastic melt rapidly to the gates without excessive chilling by the relatively cool mold for
thermoplastics. Runner cross sections that are too small require higher injection
pressure and more time to fill the cavities.
• The pressure loss in the runner system must be as low as possible.
• Large runners produce a better finish on the molded parts and minimize weld lines, flow
lines, sink marks, and internal stresses. However, excessively large runners should be
avoided.
• Correct and incorrect runner designs

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• Multi cavity mould of a bottle cap

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Gates

• The gate is given a smaller cross section than the runner so that the molding can be
easily degated (separated from the runners).
• Large-diameter gates require mechanical degating after ejection and always leave a
mark on the product.
• The gate must be located in such a way that rapid and uniform mold filling is ensured.
• Gate preferably be located at the thickest part of the molding.
• The positioning and dimensioning of gates are critical, and sometimes the gates must be
modified after initial trials with the mold.
• Types of gate designs are standard gate, Ring gate, Submarine gate etc.

• Standard gate

• Ring gate

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• Submarine gate

Tab gate

Disc gate

Film gate

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Fan gate

Spider gate

Sprue gate

Pin point tab gate

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Mould temperature and melt temperature

• Mould temperature and melt temperature for injection moulding of crystalline, semi-
crystalline, and amorphous thermoplastics

Ejector Systems

• The conventional mold ejector system moves between the clamp plate and support
plate. The ejector plate carrying the ejector pins must move freely in the mold.
• The ejector plate and pin plate are guided by return pins. Most mold bases use four or
more return pins.
• The number and location of the ejector pins are determined by the size and shape of the
moulded part.
• Ejection in a two-plate mould:

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Mold Cooling system

• Channels are provided in a mold for cooling. Channels (internal passage) are located
within the body of the mold through which the cooling medium is circulated.
• Rapid and uniform cooling is achieved by a sufficient number of properly located cooling
channels.
• The location of these channels depends on the shape of the molded product. Channels
are kept close to the cavity wall as allowed by the strength and rigidity of the mold.
• The cooling medium (also called as coolant) runs as turbulent flow, rather than laminar
flow to transfer heat out of the molded part at a faster rate.
• The coolant is usually water, but can be any liquid or gas (such as air) that can transfer
heat effectively from the mould.
• Water is one of the most effective and low-cost coolants. It can be mixed with anti-
freeze agent such as ethylene glycol for operation below the freezing point.
• Cooling channels for a simple plate-like product:

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