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ATYPICALINJECTIONMOLDDESIGNGUIDETHISCHECKLISTCANBEUSEDASAGENERALREFERENCEGUIDEFORINJECTIONMOLDDESIGNENGINEERSITISDIVIDEDINTO3PARTSOFAMOLDDESIGNPROCESSPART1REQUIREMENTSTOSTARTYOURMOLDDESIGNCHECKTHEINJECTIONMACHINEWHERETHEMOLDISTOBEMOUNTEDTHISWILLHELPYOUDECIDETHESIZEANDSTRUCTUREOFTHEMOLDFOREASEOFINSTALLATIONANDOTHERFACTORSIMPORTANTNOTESLOCATINGRINGSIZEOROTHERPOSITIONINGMETHODNOZZLESIZEMETHODOFCLAMPINGAUTOORMANUALTEMPERATURECONTROLSYSTEMDETERMINETHENUMBEROFCAVITIESANDVOLUMEREQUIREMENTSTHISWILLHELPYOUDECIDETHEMATERIALTHATYOUAREGOINGTOUSEANDOTHERMOLDCOMPONENTSTHATYOUWILLCHOOSEFORCOSTEFFECTIVEDESIGNDETERMINETHEGATELOCATIONANDSIZEDETERMINETHELOCATIONWHEREEJECTORPINMARKSAREPROHIBITEDPART2MOLDBASELAYOUTPLACECAVITIESCLOSETOTHECENTEROFTHEMOLDTOMINIMIZEBASESIZEANDRUNNERLENGTHENSURETHATTHEMOLDEDPARTREMAINSONTHEMOVABLEHALFEJECTORHALFUPONOPENINGOFPLTOFACILITATEPROPEREJECTIONWATERLINESSHOULDBEPLACEDASEVENLYASPOSSIBLETOTHECONTOURSOFTHECAVITYUSESUPPORTPILLARSUNDERNEATHTHECAVITYPOCKETSUSEEJECTORGUIDESFORMOLDSWITHSMALLEJECTORPINSANDRECTANGULAREJECTORPINSPROVIDEEYEBOLTHOLEFOREASEOFMOUNTINGANDDISMOUNTINGINSTALLMOLDOPENINGPREVENTIONLOCKSONTHEOPERATORSIDEESTABLISHPRYBARGROOVEONTHECORNERSOFTHEMOLDPARTINGLINETOFACILITATEEASEOFMOLDOPENINGDURINGASSEMBLYANDMAINTENANCEBYTHISTIMEYOUMAYASKFORTHEMOLDLAYOUTAPPROVALFROMTHECUSTOMERPART3CAVITY/COREDETAILSCHECKMATERIALSHRINKAGELOCATEPORTIONSCORNERSFORPOSSIBLESIGNIFICANTDEFLECTIONANDDEFORMATIONMAINTAINUNIFORMWALLTHICKNESSDRAFTANGLESHOULDBEWITHINDIMENSIONTOLERANCEDIVIDECOREBLOCKSTOSIMPLIFYMACHININGANDPROVIDEGASVENTPATHGATE,SMALLCORES,ANDCORESWITHSHUTOFFFITTINGSAREBETTERDESIGNEDASINSERTABLECOMPONENTSFOREASYMODIFICATIONANDREPAIRWATCHOUTFORPOSSIBLEDEFORMATIONOFCOREPINSPOSITIONTHEEJECTORPINSONTHERIBSANDOTHERHIGHSTRENGTHLOCATIONSENSUREEJECTORBALANCEDETAILING/PARTDRAWINGINCLUDEALLPARAMETERSNEEDEDFORPROCESSINGMATERIAL,QUANTITY,SURFACEFINISH/TEXTURE,DIMENSIONS,TOLERANCESANDMANYMOREDONOTASSUMETHEMACHINISTUNDERSTANDSEVERYTHINGANYDESIGNCHANGEANDAMENDMENTSTOTHEMOLDMUSTBEREAPPROVEDBYTHECUSTOMERORMOLDOWNERSTANDARDHORIZONTALCLAMPPRESSESDELIVERMOLTENRESINTOTHEMOLDTHROUGHAHOLEINTHECENTEROFTHESTATIONARYPRESSPLATENAMATERIALDELIVERYSYSTEMUSUALLYCONSISTINGOFASPRUE,RUNNERS,ANDGATESTHENLEADSTHERESINTHROUGHTHEMOLDANDINTOTHECAVITYTHESECOMPONENTSOFTHEMATERIALDELIVERYSYSTEMAREDISCUSSEDINTHISSECTIONSPRUESTHESPRUE,ORIENTEDPARALLELTOTHEPRESSINJECTIONUNIT,DELIVERSRESINTOTHEDESIREDDEPTHINTOTHEMOLD,USUALLYTHEPARTINGLINETHOUGHTHEYCANBECUTDIRECTLYINTOTHEMOLD,SPRUEBUSHINGSAREUSUALLYPURCHASEDASOFFTHESHELFITEMSANDINSERTEDINTOTHEMOLDSEEFIGURE718THEHEADENDOFTHESPRUEBUSHINGCOMESPREMACHINEDWITHASPHERICALRECESSTYPICALLY05OR075INCHRADIUSTORECEIVEANDSEALOFFAGAINSTTHEROUNDEDTIPOFTHEPRESSINJECTIONNOZZLETHESPRUEBUSHINGFLOWCHANNELDIAMETERTYPICALLYTAPERSLARGERTOWARDTHEPARTINGLINEATARATEOF05INCHPERFOOTTHISEASESREMOVALOFTHEMOLDEDSPRUETHESPRUEORIFICESIZE,THEDIAMETERATTHESMALLEND,COMESSTANDARDINODD1/32SFROM5/32TO11/32INCHSPRUEDESIGNCANAFFECTMOLDINGEFFICIENCYANDEASEOFPROCESSINGINMANYMOLDS,THEGREATESTRESTRICTIONTOMATERIALFLOWOCCURSATTHEPRESSNOZZLETIPANDSPRUEORIFICETHESEAREASSEETHEHIGHESTVOLUMETRICFLOWRATEOFTHEENTIRESYSTEMANEXCESSIVELYSMALLSPRUEORIFICECANGENERATELARGEAMOUNTSOFMATERIALSHEARANDLEADTOMATERIALDEGRADATION,COSMETICPROBLEMS,ANDELEVATEDFILLINGPRESSURETHEPROBLEMCANBEWORSEINTHEPRESSNOZZLETIPBECAUSETHETIPORIFICEMUSTBESLIGHTLYSMALLERTHANTHESPRUEORIFICETOAVOIDFORMINGANUNDERCUTTHEVOLUMETRICFLOWRATEUSEDDURINGFILLINGLARGELYDETERMINESTHECORRECTSPRUEORIFICESIZESHOTSIZEANDFILLINGSPEED,ASWELLASTHEFLOWPROPERTIESOFTHESPECIFICRESIN,GOVERNTHEREQUIREDFLOWRATELARGEPARTSAND/ORPARTSNEEDINGFASTFILLINGSPEEDSREQUIRELARGESPRUEORIFICEDIAMETERSTOAVOIDPROBLEMSASSOCIATEDWITHEXCESSIVEFLOWSHEARASAGENERALRULE,AMORPHOUSRESINSANDBLENDSSUCHASMAKROLONPOLYCARBONATE,LUSTRANABS,ANDBAYBLENDPC/ABSRESINSREQUIRELARGERSPRUESANDRUNNERSTHANSEMICRYSTALLINERESINSSUCHASDURETHANPA6ANDPOCANPBTTHEDIAMETERATTHEBASEOFTHESPRUEINCREASESWITHINCREASINGSPRUELENGTHSTANDARDSPRUETAPER,TYPICALLYONEHALFINCHPERFOOT,LEADSTOLARGEBASEDIAMETERSINLONGSPRUESTHISLARGEBASEDIAMETERLENGTHENSCOOLINGANDCYCLETIMESANDALSOLEADSTOREGRINDPROBLEMSFIGURE719SHOWSTYPICALSPRUESIZESFORBAYERAMORPHOUSRESINSASAFUNCTIONOFSHOTSIZEANDFILLINGTIMEBECAUSETHEMAXIMUMSHEARRATEINASPRUEOCCURSATTHEORIFICEANDTHEMAJORITYOFSHEARHEATINGANDPRESSURELOSSTAKESPLACEINTHEFIRSTTWOINCHES,THESEGUIDELINESSHOULDAPPLYTOSPRUESOFVARIOUSLENGTHSPARTGEOMETRYINFLUENCESFILLINGTIMETOSOMEEXTENTFOREXAMPLE,PARTSWITHAMIXOFTHICKANDTHINFEATURESMAYNEEDAFASTFILLINGSPEEDTOPREVENTPREMATURECOOLINGOFTHETHINFEATURESOTHERGEOMETRIESMAYREQUIRESLOWERFILLINGSPEEDSTOPREVENTPROBLEMSSUCHASCOSMETICDEFECTSOREXCESSIVECLAMPTONNAGEREQUIREMENTSHOTSPRUEBUSHINGSPROVIDEONESOLUTIONTOTHISPROBLEMHOTSPRUEBUSHINGSHAVEAHEATEDFLOWCHANNELTHATTRANSPORTSMATERIALALONGITSLENGTHINMOLTENFORM,ELIMINATINGORSHORTENINGTHEMOLDEDCOLDSPRUEADDITIONALLY,SOMEMOLDSRELYONEXTENSIONPRESSNOZZLESTHATREACHDEEPINTOTHEMOLDTOREDUCESPRUELENGTHRUNNERSUNLIKESPRUES,WHICHDELIVERMATERIALDEPTHWISETHROUGHTHECENTEROFTHEMOLDPLATES,RUNNERST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DESIGNINGEDGEGATES,LIMITTHELANDLENGTH,THEDISTANCEFROMTHEENDOREDGEOFTHERUNNERTOTHEPARTEDGE,TONOMORETHAN0060INCHFORBAYERTHERMOPLASTICSEDGEGATESGENERATELESSFLOWSHEARANDCONSUMELESSPRESSURETHANMOSTSELFDEGATINGDESIGNSTHEYARETHEREFOREPREFERREDFORSHEARSENSITIVEMATERIALS,HIGHVISCOSITYMATERIALS,HIGHLYCOSMETICAPPLICATIONS,ANDLARGEVOLUMEPARTSFANGATESANDCHISELGATES,VARIATIONSOFTHEEDGEGATE,FLAREWIDERFROMTHERUNNERSEEFIGURE729TOINCREASETHEGATEWIDTHCHISELGATESCANPROVIDEBETTERPACKINGANDCOSMETICSTHANSTANDARDEDGEGATESONSOMETHICKWALLEDPARTSLIKETHESTANDARDEDGEGATE,THELANDLENGTHFORFANGATESSHOULDNOTEXCEED0060INCHATTHENARROWESTPOINTCHISELGATESTAPERFROMTHERUNNERTOTHEPARTEDGEWITHLITTLEORNOSTRAIGHTLANDAREAEDGEGATESCANALSOEXTENDTOTABSSEEFIGURE730THATAREREMOVEDAFTERMOLDINGORHIDDENINASSEMBLYTHESETABGATESALLOWQUICKREMOVALOFTHEGATEWITHOUTCONCERNABOUTGATEAPPEARANCEEDGEGATESMAYALSOEXTENDFROMTHESIDEOFARUNNERORIENTEDPARALLELTOTHEPARTEDGESEEFIGURE731THISDESIGN,COUPLEDWITHA“Z”STYLERUNNER,TENDSTOREDUCEGATEBLUSHBYPROVIDINGUNIFORMFLOWALONGTHEWIDTHOFTHEGATEANDACOLDSLUGWELLATTHEENDOFTHERUNNERTOHIDETHELARGEGATEVESTIGELEFTBYLARGEEDGEGATES,THEGATECANEXTENDUNDERTHEEDGEASSHOWNINFIGURE732BECAUSETHEYEXTENDUNDERTHEMOLDPARTINGSURFACES,TUNNELGATESCANREACHSURFACESORFEATURESTHATARENOTLOCATEDONTHEPARTINGLINETHEGATESTYPICALLYFEEDSURFACESORIENTEDPERPENDICULARTOTHEMOLDFACEDEPENDINGUPONTHEIRDESIGN,THEYDEGATEDURINGEJECTIONORMOLDOPENINGSEEFIGURES733AND734TUNNELGATESTHATDEGATEDURINGMOLDOPENINGOFTENREQUIREASUCKERPINORAFEATURESIMILARTOASPRUEPULLERTOHOLDTHERUNNERONTHEEJECTORHALFOFTHEMOLDTHERUNNERMUSTFLEXFORTHEGATETOCLEARTHEUNDERCUTINTHEMOLDSTEELTHEGATEMAYBREAKORLOCKINTHEMOLDIFTHERUNNERISTOOSTIFFORIFTHEEJECTORPINISTOOCLOSETOTHEGATENORMALLY,THEEJECTORPINSHOULDBEATLEASTTWORUNNERDIAMETERSAWAYFROMTHEBASEOFTHEGATETHEORIFICEEDGECLOSESTTOTHEPARTINGLINEMUSTREMAINSHARPTOSHEARTHEGATECLEANLYWHENMOLDINGABRASIVEMATERIALSSUCHASTHOSEFILLEDWITHGLASSORMINERAL,MAKETHEGATEOFHARDENEDORSPECIALLYTREATEDMOLDSTEELTOREDUCEWEARALSO,CONSIDERFABRICATINGTHEGATEONANINSERTFOREASYREPLACEMENTTHEDROPANGLEANDCONICALANGLEMUSTBELARGEENOUGHTOFACILITATEEASYEJECTIONSEEFIGURE735STIFFMATERIALS,GLASSFILLEDGRADESFOREXAMPLE,GENERALLYREQUIREDROPANGLESANDCONICALANGLESATTHEHIGHSIDEOFTHERANGESHOWNINTHEFIGURETHEMODIFIEDTUNNELGATEDESIGNSEEFIGURE736MAINTAINSALARGEFLOWDIAMETERUPTOTHEGATESHEAROFFPOINTTOREDUCEPRESSURELOSSANDEXCESSIVESHEARHEATINGCURVEDTUNNELGATESPERMITGATINGINTOTHEUNDERSIDEOFSURFACESTHATAREORIENTEDPARALLELTOTHEPARTINGPLANESEEFIGURE737UNLIKEMOLD
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