Mold Plastic Set textbook for Website

JETRO SUPPORTING INDUSTRY PROGRAM

June 2006
SET C
1. Mold design chapter
1-1 Gate method
1-2 Guidelines for steel materials and mold life
1-3 Guidelines for steel material selection intended for plastic injection
materials
1-4 Comparison table of International Standards for steel materials of mold
1-5 Heat treatment method of steel materials
1-6 General data on steel materials used for mold making
1-7 Computation of deflection on moveable side
1-8 Computing necessary thickness of side walls of rectangular shaped
cavities(if bottom surface is integrated)
1-9 Computing necessary thickness of side walls of rectangular shaped
cavities(if the bottom surface is separated from the others)
1-10 Computing necessary thickness of side wall of cylindrical cavities
1-11 Mold temperature control method
1-12 Cross sectional shape design for “runners”
1-13 Guideline for designing tunnel gate
1-14 Head shape design for pinpoint gate
1-15 Runner lock structures for Pinpoint gate
1-16 Polishing, finishing of Plastic mold parts
1-17 Outline for food container mold
1-18 Outline for medical utensils mold
1-19 Outline for blow molding
2. Plastic injection materials chapter

2-1 predrying condition of plastic injection materials

2-2 tables showing material properties of plastic injection materials
2-3 trouble shooting for rejected works (bubbles)
2-4 trouble shooting for rejected works (sink mark)
2-5 trouble shooting for rejected works (flow mark)
2-6 trouble shooting for rejected works (burn)
2-7 trouble shooting for rejected works (silver streak)
2-8 trouble shooting for rejected works (defective brightness)
2-9 trouble shooting for rejected works (short shots)
2-10 injection materials and purpose of usage (polyamide)
2-11 injection materials and purpose of usage (polyacetal)
2-12 injection materials and purpose of usage (polycarbonate)
2-13 injection materials and purpose of usage (thermoplastic elastomer)

From page 3…
 1 ‒ 1 Gate method

Gate Method
[Submarine gate (tunnel gate)]

∅d= gate tip diameter

θ= penetrating angle
α= angular aperture
l = gate land length

runner
==Characteristics==
① gates are automatically cut
when mold open
Parting surface ② gate marks are small and not
obvious
③ gating are possible on both
movable and fixed side
④ pressure keeping is difficult
to apply due to fast gate sealing
 [Tab gate]

Tab
b= gate width
l= gate length
h= gate depth

runner cavity ==Characteristics==

① gate mark is same as that of
side gate
② after staying in the tab area
Parting surface core for a moment, melted resins
will enter into cavities. This
is the reason why flow marks
tend to generate at the area.
 [Disc gate]

l= gate land length

h= gate depth

sprue ==Characteristics==
Disc gate ①gate mark appears toroidally
at the inner surface of
molded items
cavity ② it is necessary to include
cutting out process of gate
③ cylindrical filling becomes
parting surface homogeneity
core
[Film gate]

b= gate length
l= gate land length
h= gate depth

==Characteristics==
① gate mark will remain on the
side surface of the product
sprue
cavity ② it is necessary to include
runner cutting process of film
shaped gate
parting surface
core ③ it is suited to filling of
thin plate shaped products
 [Side gate]

b= gate width
h= gate depth
l= gate length

side gate cavity ==Characteristics==

① gate mark will remain on the
Runner
side surface of products
② it is necessary to include
gate cutting process
Parting surface core ③ machine fabrication of
cavities at gate areas are
easy
④ filling of resins is
relatively easy
 [Under gate]

b= gate width
h= gate depth
l= gate length
l1= inflow area
l2= gate land length
cavity l3= runner overlapping length
under gate
runner ==Characteristics==
①gate mark will remain at bottom
parting surface surface of products but not on
core side surface
②it is necessary to include gate
cutting process
③gates are done by scrive
process on the core side
④it is relatively easy to fill
resins
 [Direct gate]

∅D= gate diameter

θ= sprue removal pitch

==Characteristics==
① large gate mark will remain
at the bottom surface of
product
sprue
② it is necessary to include
cavity gate cutting process
③ it is relatively easy to
fill resins
parting surface
core
 [fan gate]
α= opening angle
l = gate land length
h = gate depth

==Characteristics==
① gate mark will remain
on the side surface of
products
runner cavity ② it is necessary to
include gate cutting
process, but cutting is
parting surface difficult
③ it is suited for thin
core plate shaped items
[Pinpoint gate]

runner lock part runner lock pin

runner plate

cavity

parting surface

core
∅d= gate diameter
l= gate land length
α= opening angle
SR= runner tip radius
θ= runner removing taper
h1= gate relief depth
h2= depth of the basin
SR = radius of basin
∅dr1= runner lock pin diameter
∅dr2= runner lock area diameter
h3= runner lock pin undercut length
h4= runner lock area depth

==Characteristics==
① one can locate gate at random area at flat surface of product
② gate mark appears small, and not obvious
③ tend to use multiple point gate
④ scrive process of gate area is relatively difficult
⑤ countermeasures for gate cutting remains must be establish
 1-2 Steel materials and mold life guidelines

electronic parts /
appliances / mass production /
Guidelines of steel general items automobile / OA optical parts
- non heat treated type
materials and mold of steel
life sample marageing steel - prehaiden steel
- age hardening type of
steel
- quenching and tempered
Hardness(HRC) type of steel

prehaiden steel

mold life(expected shots) (×10,000 shots)

 1-3 Guidelines for selecting steel materials depends on types of plastic injection
materials
Examples of Types of Forming expected expected Recom-
selecting steel Resins sample specifications specificatio mended
materials to resins n to steel
depends on
steel type
materials
types of plastic
injection
materials PP Bumpers Impact S50C
Thermo- ABS OA enclosures resistance Creping SCM440
plastic control
types of PS Lighting fixture
resins PMMA Miscellaneous design Creping SKD61
ABS goods control prehaiden
Cosmetic Mirror finish steel
containers
POM Gears Abrasion Abrasion SKD61
PA Shafts resistant resistant prehaiden
steel

PC Lens Transparency Mirror finish SUS420J2

PMMA Photo Optical easiness precipitatio
conductor transparency n hardening
types of
steel

PC CD Discs Optical Mirror finish SUS420J2

PMMA DVD Discs Transparency easiness
Light Corrosion
retractivity resistant
Gutter Heat Corrosion
PVC Pipes resistant resistant SUS

Fire TV Cabinet Heat Corrosion SUS420J2p

resistan Appliances part resistant resistant rehaiden
ce ABS
steel

PBT-GF Camera
PA-GF Enclosure resistance Abrasion SKD11
Electrical resistant prehaiden
Equipment steel

Magneti Printer rollers Mold ability Non- Nonmag-

c Sensor parts Magnetic magnetic netic steel
powder characteristic Abrasion
containi resistant
ng PA
Mg Computer Heat Heat Nonmag-
forming enclosure resistance resistant netic steel
Cellular phone Light weight Abrasion
enclosures resistant
Thermo Phenol resin Dishes Heat Heat
setting Melamine resin Ashtray resistant resistant prehaiden
type of Abrasion steel
resins resistant SKD11
Phenol resin
Switches Heat abrasion SUS420J2
unsaturated Connectors resistant resistant SKD11
polyester Fire corrosion
resistant resistant
Epoxy resin IC seal Electric Abrasion SUS420J2
Transistor insulation resistant SKD11
Corrosion
resistance
 1-4 Comparison tables of International Standards for steel materials of mold

Comparison tables of Standards for steel materials of mold in different countries

BS 970 DIN 17210, NFA35-551 ΓOST ISO
JIS AISI SAE AISI ASTM Part 1.3 17220 NF EN10083- 14959, 683/1,10
1,2 4543 ,11
S10C 1010 040A10 CK10 XC10 C10
040A10 C10
040M10
S12C 1012 040A12 XC12
S15C 1015 055M15 CK15 C15E4
C15 C15M2
S17C 1017 XC18
Carbon
S20C 1020 070M20 CK22 1C22
steel C22 2C22
for 3C22
mecha S22C 1023
nical S25C 1025 CK25 1C25 C25
structu C25 2C25 C25E4
res 3C25 C25M2
S28C 1029
S30C 1030 080A30 CK30
080M30 C30
S33C
S35C 1035 CK35 1C35
C35 2C35
3C35
S38C 1038
S40C 1039 080M40 CK40 1C40
1040 C40 2C40
3C40
S43C 1042 080A42
1043
S45C 1045 CK45 1C45
1046 C45 2C45
3C45
S48C 080A47
S50C 1049 080M50 CK50 1C50
C50 2C50
3C50
S53C 1050
1053
S55C 1055 070M55 CK55 1C55
C55 2C55
3C55
S58C 1059 CK60 1C60
1060 C60 2C60
3C60
S09CK 045A10 CK10 XC10
045M10
S15CK CK15 XC12
S20CK CK22 XC18
 SK1 Y13 TC140
Carbon SK2 W1-11 1/2 Y12 TC120
tool SK3 W1-10 Y11 TC 105
steels SK4 W1-9 Y10 TC 90
SK5 W1-8 Y9 TC90
TC80
SK6 Y8 TC80
TC70
SK7 Y7

JIS AISI AISI BS DIN NF OST ISO

SAE ASTM
SKH2
High SKH3
speed SKH4
tool SKH10
steel SKH51
SKH52
SKH53
SKH54
SKH55
SKH56
SKH57
SKH58
SKH59
 SKS11 F2
SKS 2 105WCr6 105WC13 XB4 105WCR1
SKS21
SKS 5
SKS51
SKS7
SKS8
SKS4
SKS41
SKS43
SKS44
Alloy
SKS3
tool
SKS31
steel
SKS93
SKS94
SKS95
SKD1
SKD11
SKD12
SKD4
SKD5
SKD6
SKD61
SKD62
SKD7
SKD8
SKT3
SKD4
JIS: Japan Industrial Standards
AISI: American Iron and Steel Institute
SAE: Society for Automotive Engineers
ASTM: American Society for Testing Material
BS: British Standards Institution
DIN: Deutche Industrie Normen
NF: Normes Francaises
Гost:
ISO: International Organization for Standardization

(Reference literature) JIS Handbooks

 1-5 Heat treatment methods of steel materials

Heat treatment methods of mail steel materials

Types Heat tempering

Quenching method Heat tempering method hardness (reference)
of steel

Standard quenching

Tempering
Oil quenching ℃
none

Air cooling

marquenching

air
cooling
Standard quenching Standard tempering

Air
Tempering
air cooling cooling
℃
none
preheat preheat

marquenching High temperature tempering

Air
cooling
cool down

preheat preheat
air cooling
 Tempering
℃
none

Air
cooling
Secondary Air
preheat cooling
Primary Cool down
preheat Main
temperature
 1-6 General data on steel materials used for mold making

General data on steel materials used for mold making

Specific modulus of modulus ofmaximum YP (yield Specific coefficient thermal

longitudinal transverse elasticity point) ultimate strength gravity of linear conductiv
ation elasticity elasticity expansion ity
tension com shear
(Young's press
Material modulus) ing
quality E G
Kgf/cm2 Kgf/cm2 S
mild 210 x 104 81 x 104 (1800) (1900) 3400 1900 2900 11.7
steel 7.85 39
4500 3800
S55C 210 x 104 81 x 104 (2500) (2800) 6600 (2800 (4000 7.86 11.7 (39)
) )
SKD11 210 x 104 81 x 104 7000 8500 7.85 11.7
10000
12000
prehaiden 210 x 104 10800 7.80 11.5 (25)
steel
(SCM440)
nickel 209x104 84x104
steel
(2~3%
Ni)
215x104 83x104 (2000) (2100) 3500- (2800) (4000) 7.85 (11.7)
Cast steel 7000
210x104 84x104 8000 9000- 7.75 17-18
Ni-Cr-Mo – 12000
steel 10000
75- 27- 1200- 7000 - 1300 7.30
Cast steel 105x104 40x104 2400 8500 –
2600
Brass 63x104 24x104 1500 1500 8.50 18-23
(rolling)
Copper 105x104 420 - 1250- 8.88– 16.5
(Casting) 620 1800 8.95
Aluminum 68x104 26x104 930 2.56 (23) 197
(casting)
extra super 73x104 27.5x104 5100 2.80 23.4 (202)
duralumin
(Alcuin300)
Zinc alloy 13x104 2600 6.9 27.4 (97)
third type
(ZAS)
68x104 8500- 8800- 4.51 8.2
Titanium 12500 15000
( ) indicates reference value
Computation of deflection on moveable side

Cavity

Projected area

Cavity

mold plate

Backing plate

spacer block

Attachment plate
on movable side
B: width of mold plate (mm)
L: space inside spacer block (mm)
h: thickness of backing plate (mm)
l: length of part that receives internal pressure(p)of the cavity
b: width of part that receives internal pressure(p)of the cavity
p: internal pressure of cavity (Kgf/㎠)
E: modulus of longitudinal elasticity of materials (Young's modulus) (Kgf/㎠)
δmax ： max deflection of backing plate (mm)
<Computation sample>

Question: How thick must be bottom part(h) for the following

movable side plate using carbon steel used in
mechanical structure(S55C)?
Based on Table1

A : E of S55C is E=210 ×10 kgf/㎠

Therefore
h=3√⎯5x500x30x1144
32x210x104x250x0.01
= 42.2 (mm)

Answer : at least 42.2mm is needed

In case one allows up to σmax=0.025

h=3√ 5x500x30x1144
32x210x104x250x0.025 =31.1 (mm)

In this case, at least 31.1mm is needed

[Simplified computation when we assume l= L]

δmax = 5.p.b.L4
32.E.B.h3 (mm)

h =3√5.p.b.l4
32.E.B.δmax (mm)
 Table 1. List of value “E”

material E (kgf/ cm2)

mild steel 210x104
prehaiden steel 230x104
(SCM440system)
(75-105)x104
extra super 73x104
duralumin
Table 2. rule of thumb for cavity internal pressure(p)

mold P (kgf/ cm2)

condition
lower setting 200 - 400
of injection
pressure
higher setting 400 – 600
of injection
pressure
Table 3. rule of thumb for maximum permissible deflection considering
parting burrs

molding maximum
materials permissible
deflection σmax
(mm)
good flow 0.025
ability (such as
PA,PP etc.)
those which 0.03 – 0.05
with general
flow ability
products which 0.1 – 0.2
are not affected
by burr
generation
[Variation of maximum deflection by insertion of supporting blocks]

Position of supporting block Maximum deflection σ

σ1 generates when position
is X= 0.421 × L/2

One portion at
the center for ※ δmax = maximum
supporting deflection when there is no
block supporting blocks

(Note) above computation may applied when supporting block is inserted with the
width equivalent to mold plate width B. On the other hand, above computation will
not applied once there is (are) insertion of supporting pins
Supporting
Supporting block
pin

Diagram 1 Case that above Diagram 2 Case that above

computation applies computation will NOT apply
 Altered condition Maximum deflection σ

Once one creates 1/2 of

inner support block space

once backing plate

thickness h become h1
Computing necessary thickness of side walls of rectangular shaped cavities (if
bottom surface is integrated)

core

cavity
l/a C
1.0 0.044
1.1 0.053
1.2 0.062
1.3 0.070
1.4 0.078
1.5 0.084
1.6 0.090
1.7 0.096
1.8 0.102
1.9 0.106
2.0 0.111
3.0 0.134
4.0 0.140
5.0 0.142
p: cavity internal pressure (kgf/㎠)
l: cavity inner length (mm)
h: thickness of cavity side surface (mm)
a: sidewall height of cavity internal pressure (p) receiving area (mm)
E: modulus of longitudinal elasticity(Young's modulus) (kgf/㎠)
c: constant derived from l/a ratio
σmax: maximum deflection (mm)
<Computation sample>

Question: How much should be a minimum cavity side wall thickness

“h”for the following bottom surface integral hard steel mold?
380 From Table 1. E= 220 × 10⁴kgf/㎠
381 yh, l/a value is considered as modulus of longitudinal elasticity of
hard steel

382 l/a= 40/10 = 4

from the table it becomes

384 therefore

385 Answer : at least 2.95 is needed

386 at least approx.5mm is needed including over design thoughts

Computing necessary thickness of side walls of rectangular shaped cavities (if the
bottom surface is separated from the others)

Core

Cavity
Bottom bushing

p: cavity internal pressure (kgf/㎠)

l: cavity inner length (mm)
h: thickness of cavity side surface (mm)
a: sidewall height of cavity internal pressure (p) receiving area (mm)
b: cavity height (mm)
E: modulus of longitudinal elasticity(Young's modulus) (kgf/㎠)
σmax: maximum deflection (mm)

h = 3√12.p.l4.a
384.E.b.σmax

(note) this formula does NOT apply if it is bottom attached type of cavity
 Table 1 Table for value “E”

Materials E (kgf/cm2)
mild steel 210x104
hard steel 220x104
prehaiden steel 230x104
(SCM440system)
cast steel (75-105)X104
extra super
duralumin 73x104
Table 2 Guidance for cavity internal pressure (reference value)

forming condition
lower injection
pressure setting 200 – 400
higher injection
pressure setting 400 - 600

<Computation sample>
Question: How much minimum thickness “h”do you have to provide on the side wall of
hard steel cavity which the bottom surfaces are divided as drawing?
A: if the maximum deflection of cavity side wall is σmax= 0.01mm, we will know
the modulus of longitudinal elasticity of hard steel is
E = 220 × 10⁴kgf/㎠ based on Table 1.

Therefore

at least 7.83mm is needed

hopefully 10mm is given including some allowance purpose

Computing necessary thickness of side wall of cylindrical cavities

p: cavity internal pressure (kgf/㎠)

R: cavity external radius dimension (mm)
r: cavity internal radius dimension (mm)
σℷ：tangential allowable stress of cavity
(kgf/㎠)
 Table 1. value ofσℷ

material quality
mild steel 900 ‒ 1500
hard steel 1200 ‒ 1800
cast steel 500 ‒ 750
<Computation sample>
Question: How much external radius of the following cylindrical
cavity shape made of SKD11 is needed?
Answer : SKD11 is hard steel materials, and therefore value of σ ℷ from
Table1.becomesσ₁= 1200 ∼ 1800 kgf/㎠. Just to give allowance on the
computation, we use smaller value to setσℷ= 1200 kgf/㎠.

430 therefore

Answer: At least 7.07mm is necessary. Giving some extra space, we will make it
10mm.
 1-11 Mold temperature control method

Some of the engineering plastic and super engineering plastic generate

cavity temperature over 100 .
It is difficult to raise the cavity temperature by water temperature control,
once cavity surface temperature exceeds 90 .
Following methods are used generally for countermeasure.

1. Oil temperature control

Temperature is kept constant by oil exhaled from recycling pump passes

channels in mold and cavities, passes joint hose and circulate. Once
temperature will raise up to setting temperature, it is relatively easy to
sustain stable temperature.
But the weak point is, it takes time to startup temperature.
Also, there are other concerns like potential danger of burns, and difficulties
of post treatment.

2. Electric heater

Electric heater (cartridge heater) temperature control may be done with

temperature sensor (thermo-couple etc.) so that temperature will be kept
constant.
Since the heat capacity is big, startup temperature is fast.
Difficulty is that heater surroundings become high temperature, but low
temperature at isolated area from heater which means keeping heat
distribution constantly.
Heaters have product life, and therefore we must replace heater periodically.
For the heater attachment, it is important to provide right clearance at
attachment hole. Too big clearance will cause a situation like boiling without
water, and reduce heater life.
MISUMI M-HTM3021 (Temperature controller for cartridge heater) can
control temperature by PID control method, therefore quite stable
temperature control than “ON-OFF type controller” is possible.
It is recommended to provide heat intercepting board in between platen and
mold attachment plate of injection machine. It is further recommended to
provide heat intercepting board surrounding mold plate.
[Table] Example of molding materials with high cavity surface
temperature

Name of plastic cavity surface temperature( )

PPS Glass fiber 30%

(polyphenylene sulfide) 130∼150

LCP Glass 40%

(Liquid crystal polymer) 70∼110

PET
(polyethylene terephthalate) 130∼150

PA 46
(Polyamide/46 Nylon) 80∼120

PC
(Polycarbonate) 80∼120

heat resistant PLA

(heat resistant polylactic acid) 110∼120

PEEK
(polyether ether ketone) 120∼160

PI
(polyimide) 170∼200
In injection molding of PPS resins and liquid crystal polymer, one need to
maintain the cavity surface temperature above 100 . Therefore it is
necessary for one to control temperature thru oil or cartridge heater.
Commercially available “Cartridge heater” utilize [ON-OFF control] by power
ON and OFF to control temperature.
“ON-OFF Control” is simple structure to shift switch that the cost is cheap.
On the other hand, it has weakness like,
(ア) cavity surface temperature gap is big
(イ) instability
Instability cavity surface temperature will cause defects such as shrinkage
of dimension, unevenness of surface brightness on precision products.

To stabilize cavity surface temperature, we use “PID control”.

PID control is
P: Proportional
I: Integral
D: Derivative

PID control applies above to reduce lead time to stabilize temperature.

Heat intercepting board is very important parts considering that it stabilizes

temperature of injection mold, materialize energy conservation while
keeping the temperature.

Heat intercepting board has following usage

1. fixed to platen of injection mold machines and use

2. fixed to back of attachment plate of mold and use
Following are selection standard of Heat intercepting board.

1. Heat resistant temperature

Following are recommended working temperature as guidance

● recommended working temperature below 100

● recommended working temperature below 180
● recommended working temperature below 220
● recommended working temperature below 400
● recommended working temperature below 500

2. Material
Materials are related to recommend working temperature and crushing
strength.
There are following types of materials.

● cotton cloth ＋ Phenol resins(bakelite)

● craft paper ＋ Phenol resins(bakelite)
● Glass fiber ＋ silicate binder
● Glass fiber ＋ super heat-resistant epoxy resin
● Glass fiber ＋ phosphate binder
● Glass fiber ＋ borate binder
1-12 Cross sectional shape design of runner

Runner is channel to let molted resins to flow from sprue to product.

Selection of cross sectional shape of runner depends upon product size,
resin types, expected molding condition etc.
Following are basic standard for the selection of runner cross section shape.

[Diagram] shows main runner cross section shape

parting surface fixed side

movable side angle
angle inscribed circle
thin
One may select runner from following 3 types
1) carve on movable side
2) carve on fixed side
3) carve on both movable and fixed side

Selection depends on shape restriction and mold parting position.

Symbols such as ◎: excellent , ○: proper, ×: inadequate

Important roll of runner is to let molten resin flow under minimal pressure
loss condition. Unnecessary large sized runner will increase scraps, worsen
material costs, prolonged molding cycle, and increase volume of disposing
waste.

Index to indicate runner efficiency is “inscribed circle diameter area” at

cross sectional shape. The bigger the space of inscribed circle, wider the
area that hot resins will flow, and therefore one can expect better flow of
molten resins.
So the ideal is the runner on round cross section shape. But cost wise this
becomes more expensive for mold cost because one must carve runner on
both movable and fixed side.
To comply on such nonconformity, further biting of trapezoidal shape or
semicircle cross section are utilize.

It is better to provide angles on the side of runner so that mold release

becomes better. On the other hand inner surface of runner must be polished
by rubber wet stone or rapping to avoid pressure loss.
 1-13 Guideline of tunnel gate design

Tunnel gate (submarine gate) is widely used gate method where the
product and gate are automatically cut every time parting surface opens
and close.
It is necessary for one to know the basics such as shapes and dimension to
design tunnel gate. But for this time, we are introducing to you the basic
variation of molded products and gate, runner relation.
In the [Diagram], shows basic patterns of tunnel gate.
Put parting surface between, there are 4 patterns of gate-runner
combination on fixed side and moving side.
 Fixed side tunnel gate Fixed side tunnel gate
Fixed side runner Movable side runner

Movable side tunnel gate Movable side tunnel gate

Movable side runner Fixed side runner

Movable side tunnel gate

Arrangement for hub
Fixed side runner
In case if tunnel gate is provided on the fixed side, cutting of product and
gate will be done while parting surface opens. Therefore, gate cutting
condition varies depending on mold opening speed.
On the other hand, in case if tunnel gate is provided on the fixed side,
cutting of product and gate will be done when runner ejector pin pushes
runner. This means, gate cutting condition depends on protruding speed of
runner ejector pins.
In case runner is provided on the fixed side, it is necessary to make
structure that the lock pins will pull runner toward movable side, because
there is a chance that runner itself may be left on fixed side.
In case runner is provided on the movable side, we must set ejector pin to
push out runner properly.
In special case, there are times that boss-shaped (sharpen up ejector pin)
tunnel gate is provided on the movable side, and fill resins from back
surface of top panel.
In actual practice, we must decide what type of gate and runner to use on
mold design based on product characteristics, and material properties.

If specification prohibits any trace of gate mark on side panel or top panel,
we rarely have to provide gate on back surface of products.
In such a case, “Curved tunnel gate” is rarely used.
Runner Curved tunnel gate

Cavity

Ejector pin

Gate holding hub

Ejector pin
In the structure of curved tunnel gate, bulging gate shape extends from
parting surface to inner movable core. Therefore, gate opening locates at
top plate of core.
Ejector pins are provided on runner near the gate area, and boss is
provided at the top part of pin part to hold gate. Overall length of boss is
“H”. During the ejection, so as to undergo smooth gate cutting, it will hold
gate until product will be cutout from core completely.

Final shape of bulging part is usually corrected after several trial-and-error.

It is wise to set nested split type structure from very beginning, so that the
correction of mold become easy.

Gate passage is always affected by mold cooling time and pressure keeping
time. Try several variation as sample for prototype.

Whichever method one may choose, cutting condition at cutting area and
scum become common problem upon cutting product and gate.

Following factors may affect cutting condition

1. Gate tip shape design
2. gate size (cross-sectional shape)
3. distance from gate cutting part to runner lock part
4. acting condition of pressure keeping
5. orientation of high molecules at gate part
6. cutting timing of gate and products

Careful analysis must be made before entering into preparing mold for
precision mold and multi-cavity mold.
 1-14 Pinpoint gate tip shape design

Following are potential problems on pinpoint gate structure.

1) Gate tip portion protrude and remain on the product surface, or pluck off
part of product
2) In comparison to high filling pressure and keeping pressure, filling cant
be done smoothly

Above are common problems and headaches of mold designer upon using
“Pinpoint gate”.
Following are technical trouble shooting.

[Diagram1.] Shows general pinpoint gate structure. Gate design without

any consideration usually looks like this.
On the other hand, [Diagram2.] shows contrive design to minimize above
problems.
 2. Gate

Opening angle
3. thickness relief
1. gate land
Length

4. Dimple
(basin)
Point 1 Gate land length L

If the gate land is unnecessary long length, it may remain as protrusion,

because gate will be cut in the middle portion.
From the study, we recommend that Gate length(L) size be 1∼2 times the
diameter of gate tip.

Point 2 Gate open angle A

One must provide tapering to open angle and create cone shape. As long as
it is cone shape, strong chance that contact point of minimal cross section
gate area and product shall be the cutting point.
Mold release becomes easy too. Value A is usually 15°∼30°. Bigger the
value, more assurance on cutting, but wearing out at the tip portion tends
to become faster.
Point 3 Slot

Once “Slots” are provided, they will encroach 1 step into the surface of
molded products. Because of this, protrusion will not exceed the surface
level of products even if it remains at cutting area.
One must first acquire “Approval” of product designer in prior to set slots on
the drawing.

Point 4. Dimple

Dimples are spherical shape concave provided at the opposite side of the
gate which has almost same wall thickness to product, so that molten resin
will flow stable when slots are created.
One must also first acquire “Approval” of product designer in prior to set
dimples on the drawing.
457 1-15 Runner lock structures for Pinpoint gate

Runner lock shapes in pinpoint gate structures have several patterns,

however usually applied pattern is indicated in Diagram 1.

Diagram 1.
Gate
Product

Runner
Fixed side mold plate +
Cavity Narrow

Runner

Runner plate Runner lock pin

Fixed side attachment plate

In the [Diagram1.], locate runner lock pin which has undercut shape at the
head area into the runner foundation. When fixed side of mold plate and
runner plate create a space, they will compulsively separate runner and
gate.

Runner lock pin will be engage by clearance fit to runner plate, and fixed to
fixed side attachment plate by plate and screw plug.
In this method, if one will work on thin product or resin with higher
pressure loss, channel within runner from the head portion of runner lock
pin becomes narrower. In this case, it is necessary for one to provide higher
filling pressure or pressure keeping as molding condition.

In this case, as indicated in [Diagram2.], one may set lock area one step
lower within runner plate. In this manner, one is necessary to create
coniform curving on top of runner plate. For this process, mold cost may
become higher, but be able to improve pressure losses during molding.

Place runner
locks one step
down
If incase one wish to reduce the molding cycle, create a pointed conifom
shape at tip of runner lock pin shown in [Diagram3.], which will also act
as slot like lock shape. In this way, excess materials at the runner
center will be reduced, therefore more efficient cooling is done, then
contribute to reduction of cycle.
But one must take care of coniform shape portion balance, because
poor balance at the area will cause fracture of cuneiform shape from the
base. One can also provide corner radius to improve strength.

One must select proper runner lock, by first determining expected roll of
runner lock in prior to design mold.

Encroach into inner side

also for the purpose for
relief thickness
 1-16 Polishing finish of plastic mold parts

Cavity surface of plastic injection mold undergo mainly hand polish or

machine polishing after milling, EDM, wire cut process to smoothen the
surface.
Transcription surface for products be dull, and surface quality may
become poor if polishing condition is not good.
凹凸 surface may become potential undercut upon separating product
from cavity, and cause defective mold release.

Hard wetstone and abrasive grain are utilized for cavity polishing. You
may use rough mesh number (larger grain) to finer mesh number. Use
grinding fluid while making sure that clogging and galling will not take
place.
Polishing is not only done one direction but relative position and
circumferential direction so that polishing surface will be uniform.

Following are main polishing materials.

Natural polishing agent - silica group (agate, alcansas)

- Corundum group (emery, garnet)
- Diamond powder

Synthetic polishing agent - alumina (Al2O3)

- Silicon carbide (SiC)
- Boron carbide (BC)
- Synthetic diamond

Grain size of polishing materials ranges from #10∼#20000. Smaller the

value, rougher the mesh.
(Ex. Using #10∼#30 polishing results rough finish, but #1000∼#2000
polishing results finer finish)

In case one will use fine abrasive grain, we mix olive oil or vegetable oil
into maple, pine, willow, balsa like trees and polish.
 1-17 Food container mold overview

Many plastics are used as food container. PET bottles, food cups,
wrappings are mostly plastics.
It is necessary to give extra care on food container quality, so that man
can enjoy foods not worrying hygienics, at the same time not to
damage lips and tongues by burrs.
Any pores or cracks on plastic will allow bacteria to infiltrate into foods
and spoil them. Such quality defects are not allowed too.

There are following major food containers

● margarine container : PP
● ice cream container : HIPS, HDPE
● lactic acid bacteria beverage : HIPS
● pudding container : PS, PP
● confectionary container : HIPS, PP, HDPE
● soft drink container : PET

Necessity of function depends on food purposes such as thermostability

(for foods necessary to heat up), low thermal resistant(for food
necessary to freeze, refrigerate), gas barrier(for those foods that can
not be exposed to oxygen).

For food containers, sales of the foods will also depends on product
design(beautiful finish), which means 3 dimensional curved surface
shape and design become significant. Therefore, in product design and
mold design, one needs 3 dimensional solid data.
There are always chances of burrs to generate at parting surface,
therefore location of parting surface must be paid attention.
This is same for gate position and method.

Cavities, and cores must be fabricated by corrosion resistance steel

materials. It is better that one will not apply grease nor slide promoting
oil. This means non lubricating mold mechanism is recommended.
Electric injection machines are ideal, further ideal to work inside clean
rooms.
Its worth trying using valve gate and hot runners. If mass production is
expected, one can also use scrap press effects and high cycling.
 1-18 Medical utensils mold overview

Many plastics are used in medical utensils. In many cases, injection

molding method is used for production.
This means many parts of medical utensils have been produced thru
mold making.
There are following major plastic medical utensils.

1. syringe (syringe body) : PP, PE

2. piston of syringe : PP
3. pipet chips : PP
4. catheter : PVC, PC
5. blood collecting test tubes : PC
6. dish for culturing : PS

For plastic medical utensils materials, only those which are allowed by
drug legislation and quality standard prescribed by Ministry Of Labor
and Health can be utilize. Those materials must withstand exposures of
UV lights and gamma rays used for sterilization, at the same time
passed the clinical test for blood coagulation reaction, allergies etc.
Basically, medical utensils are disposable. Therefore those materials
must be environmental friendly upon incineration.

It is recommended that mold materials shall be non rusting type. This is

the reason why many cases, medical utensil molds are made of
stainless, ion plating film, hard chrome plating so as to prevent
corrosion of core, cavity.
Valve gate molds are used in mass production items.

Needless to say that burrs for products are defects, therefore use
precision guide to locate movable side and fixed side, and also try to
apply contraption preventing the abnormal worn out of core pins of
centering location structure.

There must be delicate temperature setting for cavities and cores to

produce stable quality products. For this point, one must pay attention
to the structure of cooling circuit and heat pipes.
Cooling structure in core becomes very important for cylinder body of
syringe.

Removal of gases and resins on the mold surface is related to quality.

Gas vent settings and enforced ventilation structures are applied.
 1-19 Blow molding mold overview

Blow molding method is usually applied to pet bottle containers for

juices (PET : polyethylene terephthalate resin) which blow methods are
used.
It is familiar in all over the world because it is used as shampoo
container, soy sauce and other seasoning container, detergent container
etc.
Polyethylene terephthalate, polypropylene, PVC, nylon, polycarbonate
may be used for blow molding method.

Exclusive blow machine is used for blow molding. In the mold, there is
only cavity on female mold, but no core on male mold.
Instead, there is a nozzle prepared to blow air. Balloon like performing
shape part called “Parison” blows, stick to cavity and transcribe shape.

Generally speaking, soft metal materials are used for cavities in blow
molding. These are aluminum alloy, bronze, and special steels.
Usually beautiful brightness surface is required to product, therefore
polishing of inner cavity surface must be done properly.

In beverage containers blowing, multi-cavity moldings are practice

generally which means contraption on cooling and temperature control
are important to comply high-cycle operation.

Also design of products that incorporated recycle is important, because

most of those blow items will be disposed after the consumption.
 2-1 pre-drying condition of plastic molding materials

Usually, plastic molding materials comes in pellet form in the paper bag
upon their delivery.

Pellets absorbs moisture in the air, therefore hydrolysis may take place
on some resins in the process of molding if pellet still contains moisture,
or degrade physical properties of materials. There are also cases that
silver streak may appear on the surface of product, or short shots may
occur due to gases, and burns may be generated too.

Many cases, materials are first placed into box shape pre-drying device
before placing them into the hopper dryer.

It is recommended that proper drying temperature and time are take

into consideration. Moisture can not be eliminated completely even
placed for long period, if drying temperature is below the proper setting.
Quick consumption of materials after pre-drying is recommended. If
there will be any left over of materials in a daily production, you must
undergo pre-drying again before usage.
Pre-drying temperature of plastic molding materials

Name of materials symbol predrying temperature℃ drying time(H)

Liquid crystal polymer LCP 110 – 150 4-8

Polyetherimide PEI 120 – 150 2-7

polyamide imide PAI 150 – 180 8 - 16

thermoplastic elastomer TPE 120 3-4

polyether ether ketone PEEK 150 8

polyphenylene sulfide PPS 140 – 250 3-6

polyalylate PAR 120 – 150 4-8

polysulfone PSU 120 – 150 3-4

ABS resin ABS 70 – 80 2-3

Acryl PMMA 70 – 100 2-6

Polycarbonate PC 120 4-6

Nylon 6 PA6 80 8 - 15

Nylon 66 PA66 80 8 - 15

Nylon 11 PA11 70 – 80 8 - 15

Nylon 46 PA46 80 8 - 10

Polyacetal POM 110 2-3

PBT PBT 120 4-5

Pellets of Plastic molding materials usually absorbs certain degrees of

moisture in the air. If there will be too much moisture absorption,
hydrolysis may take place (some resins cause chemical decomposition
by water) in the cylinder of injection machine during molten and
kneading process. Sometimes, silver streak, bubbles, defective
brightness, defective transcription may occur during injection.
To avoid above problems, we must first place the pellets in the drying
machines to remove water content.
Variation of flow of materials, degrading physical properties, defective
molding may happen if we do not give out predrying properly.
 2 – 2 Tables showing material properties of plastic molding materials

Main plastic material physical properties list

Thermoplastic type of Plastic

Resin name ABS resin

High steel
Grade ability Heat resistance
Glass fiber
A.S.T.M. Filling materials 20 – 40%
JIS testing Testing
method method Abbreviation ABS

Drying temperature 70~80 70~80 70~80

Drying time 2 2 2
Injection mold cylinder
temperature 200~260 250~300 200~260

Injection mold temperature 50~80 50~80 50~80

Injection molding pressure 560~1760 560~1760 1050~2810

Compression mold
temperature 160~180 160~260

Compression mold pressure 0.7~506 0.7~5.6

Mold contraction rate 0.4~0.9 0.4~0.9 0.1~0.2

Mold K6911.
ability K7112 D792 Specific gravity (density) 1.03~1.06 1.05~1.08 1.22~1.36

K6911.K7113 D638 Tensile strength 400~530 400~560 570~740

Elongation percentage 3.0~20.0 5.0~25.0 2.5~3.0

Compression strength 127~879 505~702 844~1550

Bending strength 773~914 703~1050 1120~1900

Mecha-
nical
properties Impact strength (Izod) 10.9~33.7 10.9~35.4 5.4~13.1

Hard ness (Rockwell R107~115 R100~115 M65~100

Heat resistance (continuos) 71~93 88~165 93~110

Heat distortion (℃) a)bending
stress 101~112 85~107
Thermal
Charac- K7206.
teristic K7207 b) bending stress 99~108 107~122 93~119
 Thermoplastic type of plastic
Etylene-vinyl
AS Resin acetate Polyamide (Nylon)

General Nylon 6 Nylon 66 Nylon 11.12

Glass
fiber 20 – Glass fiber Glass fiber
30% - 30% - 30%

SAN EVA PA6 PA66 PA11.12

85 85 80 80 80 80 70~80

2~4 2~4 8~15 8~15 8~15 8~15 8~15

200~260 200~260 120~230 240~290 240~290 260~300 260~300 190~270

50~80 50~80 20~60 40~120 40~120 40~120 40~120 20~100

710~2320 1050~2810 562~1410

150~200 90~150

70.3~703 0.04~1.76

0.2~0.7 0.1~0.2 0.7~1.2 0.5~1.5 0.4~0.6 0.8~1.5 0.5 0.3~1.5

1.07~1.10 1.20~1.46 0.92~0.95 1.12~1.4 1.35~1.42 1.13~1.15 1.38 1.03~1.08

600~840 600~1440 95~200 700~850 1650 770~850 1850 530~550

1.5~3.7 1.1~3.8 500~900 200~300 3~6 150~300 3 300~500

984~1200 1550 914 1340 1050 2070

984~1340 1550~1830 1270~2320 429~1200 471~1260

Non
destructive 3.3~5.4 16 4.3~5.4 12 10~30

M80~90 M100~E60 D17~45 R119 M101 R120 M100 R106~109

60~96 93~104 82~121 93~149 82~121 82~121 82~149

88~104 88~110 33.7 88.1 210 74.8 77 54.2

101~115 77~80 203 239 208 236~239 167

 Thermoplastic type of Plastic
Methacrylate
resin (acryl) Polyacetal
High Thermos
General General General impact ability
Glass fiber Glass
- - 20% - Fiber 40%

PMMA POM PP PS HIPS PS

70~100 110 110

2~6 2 2

190~290 180~230 180~230 200~300 200~300 170~280 190~280 199~280

40~90 60~120 60~120 20~90 20~90 20~60 10~80 20~80

703~1410 703~1410 703~1410 703~1410 703~1410 703~2110 703~2110 703~2110

149~218 171~288 171~288 129~204 121~204 129~204

141~703 0.35~0.70 0.35~0.70 70.3~703 70.3~703 70.3~703

0.1~0.4 2~2.5 0.4 1.0~2.5 0.2~0.8 0.4~0.7 0.4~5.7 0.2~0.6

1.07~1.20 1.41~1.42 1.61 0.90~0.91 1.22~1.23 1.03~1.05 1.03~1.06 1.05~1.09

470~770 580~800 1250~1300 210~400 560~1000 350~840 200~350 350~530

2~10 25~75 3 100~800 2~4 3~4 13~50 2~60

844~1270 1270 1200 260~562 387~492 809~1120 281~633

914~1340 991 1970 352~492 492~773 562~984 211~844

1.6~2.7 5.4~13 10 2.2~110 7.6~11 1.4~2.2 3.3~20 2.2~19

M85~105 M78~94 M79 R50~111 R102~75 M60~75 M10~80 M70

59.8~93 90 104 88~115 121~138 65.3~76.5 59.3~79.2

73.7~99 124 110 45.9~59.8 59.8~93 104 90 90

79.2~107 170 158 103~130 117~161 82~110 82~104

 Thermoplastic type of Plastic
polybutylene
Polycarbonate Polyethylene terephthalate
Low Moderate High
General density density density
Glass fiber
less than Glass Fiber Glass fiber
10% 10 – 40% 20 – 30%

PC LDPE MDPE HDPE PBT

120 120 120 120 120

>4 >4 >4 4 4

270~380 270~380 270~380 150~270 200~300 200~300 230~280 230~280

80~120 80~120 80~120 20~60 10~60 10~60 40~80 40~80

700~1410 700~1410 1050~2810 562~2110 562~2110 703~1410 562~1800 562~1800

249~326 135~176 149~190 149~232

0.7 7.03~56.2 7.03~56.2 0.35~0.56

0.5~0.7 0.2~0.5 0.1~0.2 1.5~5.0 1.5~5.0 2.0~6.0 1.5~2.0 0.2~0.8

1.19~1.20 1.27~1.28 1.24~1.52 0.91~0.925 0.926~0.940 0.941~0.965 1.31~1.38 1.52

550~700 630~675 840~1760 42~161 84~246 218~387 550~540 110~1340

100~130 5~10 0.9~5.0 90~800 50~600 20~130 50~300 2~4

844 984 914~1480 190~253 605~1020 1270~1650

949 1050 1200~2250 337~492 844~1170 1830

Non
75~100 5.5 11 destructive 2.7~87 2.7~110 4.4~5.4 7.0~8.7

R115~125 M75~85 M88~95 D41~50 D50~60 D60~70 M68~78 M90

121 135 135 82~100 48.7~121 121 49.8~121 115~176

129~140 142 143~149 40.3~48.7 40.3~48.7 43.1~54.2 49.8~85 220

132~143 146 149~154 48.7~73.7 48.7~73.7 59.8~88 115~193 225

 Thermoplastic type of plastic

Polystyrene Polyvinyl chloride Fluororesin Polyphenylene chloride Crystal liquid polymer

Flexible rigid
Glass fiber Glass fiber Glass
20 -30% - - 40 % fiber 40%

PS SPVC HPVC FEP PPS LCP

120~140 120~140 140~160 140~160

3~5 3~5 4 4

170~280 160~190 170~210 370~430 315~330 315~360 250~310 250~310

20~80 10~20 10~60 95~230 130~150 130~150 70~110 70~110

1050~2810 562~1760 703~2810 352~1410 300~1000 300~1000 150~500 150~500

140~176 140~204 315~399

35.2~141 52.7~141 70.3~140

0.1~0.3 1~5 0.1~0.5 2~3 0.6~0.8 0.2~0.4 0.1~0.8 0.1~0.55

1.20~1.33 1.16~1.35 1.30~1.58 2.15~2.17 1.3 1.60~1.67 1.35 1.7

633~1050 100~240 400~500 180~210 630 1500~1550 1060~1335 900

1~2 200~450 40~80 250~330 1~2 0.9~4 1.3~4.5 1.8

949~1270 63~120 562~914 155

738~1410 703~1120
Largely Non
1.4~2.2 2.2~100 change destructive <2.7 5~8 13~21 8.7

M70~95 A50~100 D68~85 D60~80 R123 R123 R60~63 R79

82~93 54.2~79.2 204

90~104 59.8~76.5

97~110 57.0~82 69.8 135 250~265 332~335 319

 2-3 Countermeasure on defective molding

“Bubble” “Void” are phenomenon where air bubbles are generated within
molded products. These bubbles or voids will be considered rejected on a
product such as lens, prism because appearance and optical characteristic
be disturb by such defect. It will also reduce strength and become cause of
destruction of machine once those defective items are used as machine
parts.

There are 2(two) major cause of bubbles.

One cause is that, air was mixed into molten plastic. This is called bubbles.

Other one is caused in the process of shrinkage of molded articles known as

“Void”. In the void, insufficient pressure keeping was applied to thick wall
area, and this caused abnormal shrinkage just like this happened in the
process of generation of “Sink mark”.

Following can be possible countermeasures for above problems.

Countermeasures for bubbles

1. Countermeasures related to mold

1. There are no air vent or lack of numbers of air vent

2. There is no cold slag well, or it may be too small
2. Countermeasures related to injection molding condition

1. too fast screw rotational speed

2. too high cylinder temperature
3. too fast injection speed

3. Countermeasures on product design

1. insufficient predrying of mold materials

Countermeasures on void

1. Countermeasures on molds

1. There is no air vent, or lacking

2. There is no cold slag well, or it is too small
3. too small sprue, runner
4. too small gate
2. Countermeasure related to injection mold condition

1. Too high cavity surface temperature

2. Too low pressure keeping
3. lack of pressure keeping time

3. Countermeasure on product design

1. insufficient predrying of molding materials

2. too thick molded product wall thickness
 2-4 Countermeasures on defective molding (sink mark)

“Sink mark” is a phenomenon which generate slight concave due to

shrinkage of product surface.
It may become defective quality in case product used for surface
appearance.
There are following methods to control sink mark.

1. Countermeasures related to mold

1. Set the cavity surface temperature slight lower

2. Make gate size bigger
3. Make runner size larger
4. Use larger sprue
5. Review cooling channels of mold to improve cooling efficiency
6. Improve the structure where difficult cooling area to become easier
to cool. (Ex. Baffle plate structure, cooling pipe structure, heat pipe,
non-ferrous bushing)
7. Increase the number of gate
8. Relocate gate position to thick wall area
2. Countermeasures related to injection mold condition

1. Set pressure keeping time longer

2. Set pressure keeping to higher setting
3. Set the injection speed faster
4. Set nozzle temperature lower
5. increase indiscrete value
6. Increase cushion volume
7. Change the injection mold machine
8. Exchange the “backflow prevention ring” of injection unit

3. Countermeasure on product design

1. remove the thick wall area of products

(Ex. Material relief shape, alter into another parts)
2. apply amorphous resins
 2-5 Countermeasure for defective molding (flow mark)

“Flow mark” is a phenomenon where melted resin flowing marks remains

on the surface of products. This may become a cause of reject depends
upon degree of such mark appearance. Products such as electric appliances
or cosmetic product casing are particular about such appearance.

Flow mark is generated in the process that molted resins contact metal
surface in the mold will encounter different degree of cooling at the tip of
resins.

Following methods are considered to improve the flow mark.

1. Countermeasures related to molds

1. set the cavity surface temperature lower

2. expand the size of the gate
3. enlarge the size of the runner
4. secure enough cold slag well

2. Countermeasures related to injection molding condition

1. set the injection pressure higher

2. set the injection speed faster
3. secure enough measurement to increase the cushion volume
4. set the pressure keeping time longer
5. set the resin temperature higher
6. enlarge the nozzle tip diameter larger

3. Countermeasures related to molded article design

1. set the variation of wall thickness of molded articles smaller

 2-6 Countermeasures on defective molding (Burn)

“Burn” is a phenomenon where black burning materials are generated on

the surface of molding articles. Air which remained in the cavity while
compressed will generate heat, and this heat burns the plastics when
molten plastics are filled into cavity.

Burn can be appearance defect, causing missing parts, and decreasing

material properties.

Following are considered countermeasures on burns.

1. Countermeasures related to mold

1. provide the air vent

2. prepare deeper air vent and secure enough vent passage
3. dismount mold and wash give out maintenance to air vent
4. use insertion mold structure or bushing structure so that air will escape
from parting surfaces
5. Use vacuum aspirator device
6. change the gate position

2. Countermeasures related to injection molding condition

1. set the injection speed slower

2. set the cylinder temperature lower
3. make smaller measurement
4. avoid staying of resins in the cylinder

3. Countermeasures related to molded article design

1. try to apply design that avoids thinner wall areas of molded articles
2. change the wall thickness of molded articles, and flow of plastics
3. alter the design that allows air to stay
 2-7 Countermeasures on defective molding (Silver streaks)

Silver streak (silver film) is a phenomenon where shinny stripe marks are
generated on the surface of molded articles. This may become potential
rejects as an exterior parts for electric appliances, automobile, bicycle for its
defective appearance quality.

Silver streaks occur because the air and volatile gas in the molding
materials come out on the surface of products.

Following are potential countermeasures on silverstreaks.

1. Countermeasures related to mold

1. improve the functions of air vent

2. enlarge the gate size
3. enlarge the cold slag well

2. Countermeasures related to injection molding condition

1. confirm the preheating condition(temperature, drying time) of

molding materials and apply proper drying.
2. set the injection speed slower to slower filling
3. set the cylinder temperature lower
4. reduce the screw rotation speed
5. avoid staying in the cylinder

3. Countermeasures related to molded article wall thickness

1. prepare as much as possible the uniform wall thickness

 2-8 Countermeasures on defective molding (defective brightness)

Ideal surface of molded articles must be the transcribed surface appearance

of cavities, but there are times that surface of molded articles exhibit
obscured or uneven brightness surfaces.

This may become major defect cause on the product exterior surface which
the appearance quality is considered significant.

Following are potential countermeasures on defective brightness.

1. Countermeasures related to mold

1. there might be NO air vent or lack of air vent

2. small gate
3. small and narrow sprue and runner
4. cavity plating is NOT good condition
5. cavity surface polishing is NOT good condition
6. deposits are attached to the surface of cavity

2. Countermeasures related to injection mold condition

1. lack of measurement
2. too short cushion surface
3. too low pressure keeping
4. too short pressure keeping time
5. low cavity surface temperature
6. insufficient predrying of molding materials
 2-9 Countermeasures on defective molding (Short shots)

Short shot is a phenomenon where incomplete filling takes place at the part
of molded articles.

There are 2(two) potential cause of short shots.

First cause is, cooling down and solidifies of tip of materials while molten
resins flow.
Second cause takes place in the process of flowing. Because air traps are
generated depends on the flowing condition.

To take countermeasures on short shots, one must first find out the cause
of problems from the above cause.
 ■ Short shots caused by flow tip solidification

1. Countermeasures related to mold

1. Expand further the gate size

2. Expand further the runner size
3. use the larger sized sprue
4. too small cold slag well
5. provide heat insulating plate at bottom surface of mold plate
6. increase the number of gate
7. alter the location of gate

2. Countermeasures related to injection mold condition

1. set the resin temperature higher

2. set the cavity surface temperature higher
3. increase the filling pressure
4. set the pressure keeping higher
5. set the pressure keeping time longer
6. increase the measurement value
7. increase the number of cushon
8. change the injection machines
9. exchange the backflow prevention rings of injection unit
10.exchange the injection nozzle tip diameter of injection machine larger
3. Countermeasures related to molded article design

1. increase wall thickness of molded articles

2. provide ribs at the area where there is poor flowing

■ Short shot due to air trap

1. Countermeasures related to mold

1. provide an efficient air vent at air trap generating areas

2. change the gate position
3. change the runner balance
4. review and improve the structure into heatup possible structure where
there is poor flow
5. change the structure to insertion or bushing structure where there is
poor flow
2. Countermeasures related to injection mold condition

1. change the injection speed, to change the flowing patterns

2. relayout the position of screw speed pressure exchange position
3. set the injection speed slower
4. set the cavity surface temperature higher
5. set the mold clamping pressure slight lower

3. Countermeasures related to mold article design

1. review and apply uneven wall thickness of molded articles

2. increase the wall thickness of molded articles
 2-10 Molding materials and its usage (polyamide)

Polyamide is also known as “Nylon(trademark)”. There are PA6,PA66,PA46,

and aromatic polyamides.
Characteristics of polyamide are that it is outstanding in friction abrasion
character. Because of this characteristics, materials will not cause much
noise, stable sliding. Its also has superior resistant character to organic
solvents and oils.
On the other hand, it has great water permeability and hygroscopic property.
This means, one can expect dimensional change of products,
There will be an improvement of heat resistant and strength by filling glass
fibers.

Following are main usage:

■ Automobile parts
● throttle cam ● throttle body housing
● intake control valve ● shifting lever set
● door mirror bracket ● engine cover
● electric oil sensor
● intake manifold

■ electric / electronics parts

● FPC connector
● Coil bobbins
● Relay
● Switch parts

■ electric appliances / residential related

● surfing board
● electric shaver moving parts
● residential window handle levers
● electric tool housing

■ others
● fastener
● chair legs
 2-11 Molding material and its usage (polyacetal)

POM resins (Polyacetal, polyoxymethylene) are superb in mechanical

specification like breaking strength, and worn out resistance property so
they are known as engineering plastics.
In POM, there are “homopolymer” and “copolymer”.
There are differences in strength, thermal resistance, molding condition
between homopolymer and copolymer.
Biggest feature of “POM Resins” are self-lubrication. It is valued functions
when its applied as gear, bearing like parts where there are always facing
frictions.
Crystallinity is high, therefore is shows good result in strength and thermal
resistance.
In injection molding, one must take care not this materials to stay long
period in the cylinder, because they will undergo thermal decomposition.
Followings are main usage.

■ Automobile parts
● fuel gauge
● fuel chamber
● door mirror warm gear
● mirror stay
● fuel pump
● radiator drain cock

■ Electric / Electronics parts

● CD pickup unit
● Switch stem
● DVD drive unit / pulley. Cum
● Magnetic memory device roller

■ precision parts
● watch gears
● bearing

■ others
● shower bib
● fastener
● gas meter parts
● flushing toilet parts
 2-12 Molding material and its usage (polycarbonate)

Polycarbonate is a transparent strong thermal resistant material applied in

diverse areas.
Recently alloy type of usage of polycarbonate by mixing it with ABS resins
and used for industrial purposes.
It is amorphous and exhibit good light transmittance therefore applied as
lens and cover materials. It also exhibits outstanding strength especially
shock resistance among other plastics.
However it will be corroded by organic solvents. This is the reason why one
must pay great attention, if ever grease group of chemicals and solvents
are applied on the material.
In injection molding, this material exhibits poor liquidity. Therefore filling
pressure must be set higher. One shall also necessary to increase the
temperature up to approx 80 .
Following are usage of the materials.

■ Automobile parts
● meter panel
● head lamp lens
● door handle
● sun roof
● instrumental panels
● wheel cover

■ Electric / Electronics
● cellular phone case
● memory sticks
● CD disc
● DVD disc
● Digital camera case
● Printer chassis
● PC casing

■ optical components
● camera lens
● aspheric surface lens
● prism
● light conductor
● protection goggle
● dome shape roofing
● window glasses
 2-13 Molding material and its usage (Thermoplastic elastomer)

Thermo plastic elastomer (TPE) is a synthetic resin which has rubber like
properties.
Automobile tire is one good example of rubber, but those rubbers are
solidify thru chemical reaction and therefore generally speaking it is not
possible to fabricate by injection process.
On the other hand, TPE can fabricate thru injection molding. It is
thermoplastic and therefore one can fabricate without burrs under relatively
fast cycle time.
In many cases now, this material is applied to products such as sticker parts,
sports items, toys, writing materials. 1.43M tons(2001) has been consumed
in the world.

TPE shows rubber like flexible hypertrophic properties because it contains

soft segments and hard segments.

There are following types of TPE available, and being used accordingly.

(1) SBC (styrenic TPE)

Sole, automobile parts, food container, writing material grip, sports
items

(2) TPVC (vinyl chloride TPE)

Electric wire coating, automobile parts, electric appliance
(3) TPO (olefine TPE)
Automobile parts, construction/civil work parts, electric appliance
(4) TPE (Polyurethane TPE)
Watch band, sole, automobile parts. etc
(5) TPEE (polyester TPE)
Automobile parts, electric appliance, industrial materials. etc.
(6) nitryl TPE
(7) TPAE (polyamide TPE)
(8) Fluoro-chemical TPE
(9) Silicone TPE
 <reference/citation list>

1) c Michio Komatsu : “Molds for beginners. Introduction to plastic injection

mold, molding technology.” Mold technology
April 2004, special issues, [Daily industrial journals]2004

2) c Michio Komatsu : “Plastic injection molding design manual, pin gate

structure” mold technology. March 1998 special issue, Daily industrial
journals 1998

3) c Michio Komatsu : “Plastic injection design manual” Daily industrial

journals (1996)

4) “Plastic mold standard parts 2005.6 ∼2007.4”MISUMI Inc. (2005)

5) Technology course, MISUMI online, MISUMI Inc, www.mol.ne.jp