Build your System Overview - Milacron · PDF fileWe offer the following ways for you to build your system. 1. ... (42CD4) 1.7225 42CrMo4 (SNB7) 42 CrMo 4 2 Prehardened Steel P20 (708A30)

® Build your System

© 2014 Mold-Masters (2007) Limited. All Rights Reserved.Revised 11 August 2014

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OverviewMold-Masters is constantly striving to make it simple and easy for you to build a hot runner system for your application. We offer the following ways for you to build your system.

1. Personal Attention - a hot runner specialist will assist you through the entire process via an on-site visit and/or over the phone.

2. Online - using Merlin, you can configure a hot runner system at any time. Your order can then be sent automatically to Mold-Masters and you receive your custom system drawings via email.

In either of the above methods, the below resin, mold and hot runner design info will help in the total system design process.

Resin Properties Various resin properties and performance ratings will have a major impact on tool and hot runner designs. Reference charts are included to ensure critical factors are known.

Mold DesignMaterials and tooling steel are important factors in designing molds for injection molding processes. This section includes useful selection standards.

Hot Runner System SelectionDetails of the key components for a hot runner system are shown. Nozzles and gating selections are all based on part size. Manifold components and hot half plate options are all dependant on the inherent mold size and layout.

ControlTotal system control is critical to ensure that application parameters are carefully monitored. The selection of the correct temperature controller is critical for producing perfect plastic parts.

Before you begin this process, the “System Design Specification Sheet” (pg 02.01.400) should be completed.

To document the decisions you are making, complete the “Hot Half Design Specification Sheet”. (02.01.410)

Reference Pages:Drafting symbols and tolerances (pg. 02.01.330)Metric to imperial conversions (pg. 02.01.340)Minimum pitch spacing 3a (pg. 02.01.350)Minimum pitch spacing 3b (pg. 02.01.360)Cutaway of a “cast-in” system (pg. 02.01.370)

pg. 02.01.010

Cutaway of a “bolt-in” system (pg. 02.01.380)System design specification sheet (pg. 02.01.390)Hot half design specification sheet (pg. 02.01.400)Hot half design specification sheet cont. (pg. 02.01.410)Hot half design specification sheet cont. (pg. 02.01.420)


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Resin Properties for Injection Molding Grade Plastics

pg. 02.01.020

Plastic Class Symbol

D792 Solid Density (g/cm3)

Recom-mended Max Vent

Depth (mm)

D648 Shrink-age (%)

Processing Temp (°C)

Recom-mendedProcess-ing Temp.

(°C)

Mold Temp. (°C)

Recom-mended

Mold Temp (°C)

No Flow Temp (°C)

Amorphous

ABS 1 to 1.2 0.025 0.5 to 0.6 195 to 240 250 38 to 93 60 135 to 150

CAB 1.2 0.3 to 0.7 180 to 230 210 50 to 80 50 130 to 170

HIPS 1 to 1.1 0.02 0.4 to 0.7 180 to 280 240 10 to 85 20 130

PC 1.2 to 1.5f 0.04 to 0.06 0.4f to 0.7 270 to 325 300 80 to 110 90 195

PEI 1.3 to 1.5f .5 to .7 (0.2f) 340 to 425 370 65 to 175 100 230

PES 1.2 to 1.6f 0.3f 0.6 340 to 380 330 140 to 160 150 300

PMMA 1.1 to 1.2 0.04 0.4 to 0.8 200 to 260 240 38 to 60 60 160 to 170

PPO 1.1 to 1.2f 0.02 0.2f to 0.7 250 to 315 280 82 to 110 80 150 to 200

PS 1.0 to 1.1 0.02 0.4 to 0.7 180 to 280 225 10 to 85 20 200 to 250

PSU 1.2 to 1.6f 0.7 310 to 400 360 100 to 170 100

PVC 1.2 to 1.4 0.025 0.2 to 0.5 180 to 204 195 20 to 40 40 120

SAN 1.1 to 1.3 0.03 to 0.04 0.3 to 0.7 220 to 270 245 5 to 60 60 130 to 170

SB 225 70

TPU 1.2 to 1.3 0.8 to 2 190 to 220 208 30 to 65 30 120

Crystalline/ Semi Crystalline

PA6 1.1 to 1.4 <0.01 0.8 to 2.1 260 to 310 250 20 to 100 80 140 to 340

PA6/6 1.1 to 1.4f <0.01 1.0 to 2.2 (0.6f) 270 to 320 280 20 to 100 80 140 to 340

PBT 1.3 to 1.6f 0.01 1.5 to 2.0 (0.5f) 240 to 270 240 50 to 100 60 220 to 250

LDPE 0.91 to 0.93 <0.01 1.5 to 3 170 to 240 200 10 to 50 30 100 to 110

HDPE 0.93 to 0.97 0.015 1.2 to 2.2 200 to 280 240 10 to 70 20 120 to 130

Liquid Cryst. LCP 1.5 to 1.7 0.01 0.2 to 0.8 400 to 430 240 to 280 200 to 300

Semi-Cryst. PEEK 1.3 to 1.4f 0.1 to 1.4 370 to 400 370 160 to 220 165 370

Amor/Cryst. PET 1.4 to 1.7f 0.015 0.2 to 2 260 to 300 275 7 to 80 135 240 to 250

80% Cryst. POM 1.4 to 1.6f 0.018 0.8f to 2 180 to 230 205 80 to 100 90 160 to 170

Semi-Cryst. PP 0.9 to 0.02 0.015 1 to 2.5 230 to 275 240 15 to 65 50 170 to 180

65% Cryst. PPS 1.3 to 1.9f 0.015 0.1 to 0.5 300 to 360 320 40 to 150 135 260 to 280

*** f = Fiber Filled PSI = 145Mpa F = (C*1.8) + 32



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Plastic Classes

Max L/T Ratio (1mm Thick)

Injection Speed

Clamping (Mpa=MN/

m2)

Force (Ton/in2)

Typical Pressure (Mpa=N/

mm2)

Amorphous

30 to 150 Slow, even 62 to 93 4 to 6 120 to 140

Various 69 to 180

200 to 250 Fast 31 to 62 2 to 4 100 to 200

30 to 100 Fast 46 to 77 (93f) 3 to 5 (6f) 138 to 200

Medium, Fast 100 to 160

60 to 120 Fast 77 to 155 5 to 10 160 to 200

130 to 150 Various 39 to 46 2.5 to 3 100 to 200

Fast 39 to 77f 2.5 to 5f 120 to 180

Fast 31 to 62 2 to 4 100 to 200

Slow

100 Slow, Medium 70 to 140

Fast 35 to 140

Fast 8 to 31 0.5 to 2 70 to 140

Crystalline/Semi Crystalline

190 to 200 Fast 46 to 77 3 to 5 90 to 150

240 to 260 Fast 62 to 77 4 to 5 100 to 150

160 to 200 Medium, Fast 46 to 77 3 to 5 80 to 120

275 Fast 23 to 31 1.5 to 2 100 to 150

250 Fast 31 to 39 2 to 2.5 100 to 200

Liquid Cryst. 370 Medium 31 to 46 2 to 3 80 to 120

Semi-Cryst. 200 Fast 31 to 62 (93f) 2 to 4 (6f) 160 to 200

Amor/Cryst. 80 to 200 Slow, Even 31 to 93 2 to 6 70 to 160

80% Cryst. 100 to 200 Medium, Fast 54 to 77 3.5 to 5 100 to 170

Semi-Cryst. 200 to 300 Fast 31 to 46 2 to 3 100 to 130

65% Cryst. 150 Slow 31 to 46 2 to 3 50 to 140

Resin Properties for Injection Molding Grade Plastics - cont.

*** f = Fiber Filled PSI = 145Mpa F = (C*1.8) + 32



pg. 02.01.030

Properties PET Oriented

PET Unoriented

PETG PVC Unoriented

HDPE LDPE PP

Clarity 5 5 5 4 3 2 2

Impact Strength 4 1 1 2 4 5 3

Scuffing Resistance 1 1 2 3 4 4 4

Stiffness 4 4 4 4 3 2 4

Maximum Hot Fill (°C) 50 60 60 60 80 65 115

Anti PermeabilityCO2 5 4 4 4 2 1 3

Oxygen 4 4 4 4 2 1 2

Water 3 3 3 3 5 4 5

ResistanceAcids 2 2 1 4.5 3 3 3

Alkalis 2 2 2 4.5 4.5 4.5 5

Alcohols 4 4 1 4.5 4.5 3 4

Min Temperature (°C) - Brittleness

-40 n/a -40 30 -100 -100 0

Melt Temperature (°C) 240 120 120 to 130 100 to 110 170 to 180

Density 1.35 to 1.40 1.35 to 1.40 1.27 to 1.35 1.35 0.94 to 0.965 0.91 to 0.925 0.89 to 0.91

Resin Properties Common Resin Comparison Chart

Legend 0 1 2 3 4 5n/a Poor Fair Good Very Good Excellent

*This chart is a guideline only. Variables such as bottle or container weight and wall thickness may have an effect on material performance. Testing is always recommended.



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Mold Design Tooling Steel Comparison Table

pg. 02.01.040

Item

No.

Mat

eria

ls

NA

UK

FR DE

JP EU

SE

Udd

ehol

m

Ass

ab

AIS

I

ISO

BS

NF

DIN JIS

W-N

r

Typ

e/Y

D E

h

SIS

1 Prehardened Steel 4140 42CrMo4 42CrMo4

(709H40)42CrMo4 (42CD4) 1.7225 42CrMo4

(SNB7) 42 CrMo 4

2 Prehardened Steel P20 (708A30) (30CD4) 1.2330 SMC

(SMC430) IMPAX 718

3Prehardened

Stainless Steel

420SS BS420S45 NFZ30CF13 1.2083 SUS420J2 2304 RAMAX

4 Carburizing Steel P5

5 Carburizing Steel P6 1.2735 (1.2764) X 19

NiCrMo 4

6 Oil Hardening O1 BO 1 90 CW 2 1.2510 SKS3 (1.2419) (105 WCr

6) 2140 ARNE DF-2

7 Air Hardening H13 40CrMoV5 BH13 X40CrMoV5

(Z40 CDV 5) 1.2344 SKD61 1.2344 X 40 CrMoV 5 1 2242 ORVAR 2 8407

8 Air Hardening A2 100CrMoV5 BA 2 X100CrMoV5

(Z 100 CDV 5) 1.2363 SKD12 1.2363 X 100 CrMoV 5 2260 RIGOR XW-10

9 Air Hardening D2 BD 2

(BD 3)

X160CrMoV12 (Z 150 CDV

12)1.2379 SKD11 (1.2601) X 160

CrMoV 12 2310 SVERK-ER21 XW-41

10 Stainless Steel 420SS BS420S45 NFZ30CF13 1.2083 SUS420J2 STAVAX

11 Maraging 250

12Maraging Stainless

Steel455M

13 High Speed Steel M2 HS 6-5-2 BM 2 HS 6-5-2

(Z 85 WDCV) 1.3343 SKH51 1.3344 S6-5-2

14 Beryllium Copper BeCu



pg. 02.01.050

Mold Design - Properties of Mold Materials Rated

Item

No.

Mat

eria

ls

AIS

I

DIN

Har

dnes

s

Wea

r R

esis

tanc

e

Toug

hnes

s

Com

pres

sive

Str

engt

h

Hea

t H

ardn

ess

Cor

rosi

on R

esis

tanc

e

The

rmal

Con

duct

ivit

y

Hob

babi

lity

Mac

hina

bilit

y

Pol

isha

bilit

y

Nit

ridi

ng A

bilit

y

Wel

dabi

lity

1 Prehard-ened Steel 4140 1.7225 30-35 2 4 2 2 1 3 1 3 3 2 2

2 Prehard-ened Steel P20 1.2330 30-35 2 5 2 2 2 3 1 3 4 3 2

3Prehard-

ened Stain-less Steel

420SS 1.2083 30-35 2 5 2 2 3 2 1 2 5 4 2

4 Carburizing Steel P5 59-61 4 3 3 3 2 2 5 5 4 4 5

5 Carburizing Steel P6 1.2735 58-60 4 4 3 3 2 2 4 5 4 4 4

6 Oil Hardening O1 1.2510 58-62 4 2 5 3 1 3 3 4 4 2 2

7 Air Hardening H13 1.2344 49-51 3 4 4 4 2 2 3 5 4 5 3

8 Air Hardening A2 1.2363 56-60 5 2 5 4 2 2 2 4 4 4 2

9 Air Hardening D2 1.2379 56-58 5 2 4 4 2 2 2 2 3 5 1

10 Stainless Steel 420SS 1.2083 50-52 3 3 3 4 4 2 2 4 5 4 3

11 Maraging 250 50-52 3 5 3 4 2 2 2 2 4 5 3

12Maraging Stainless

Steel455M 46-48 3 5 3 4 5 2 2 2 4 n/a 3

13 High Speed Steel M2 1.3343 60-62 5 5 5 5 2 2 2 2 3 5 2

14 Beryllium Copper BeCu 28-32 2 1 2 2 3 5 5 5 5 n/a 4

Legend 1 2 3 4 5

Poor Fair Good Very Good Excellent



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Mold Design - Steel Selection for Plastic Injection Mold Plates and Inserts

pg. 02.01.060

Steel Type Hardness Characteristics Resins Applications

Mold Plates

103025% greater Tensile Strength than Typical Low -carbon SteelUse of General Mold Plates

General ResinsPrototype and Low Production MoldRecreation/Toys/Sporting productsLarge parts

4130 Preharden

Prehard treated to 28-34 RcIdeal for Cavity and Core Retainer Plates, Clamping Plates, support plates in plastic molds

ABS / PPO PA / PSPE / PPPMMA

Medium Volume Production MoldConsumer ProductsElectronic/Electrical PartsMechanical Parts - Small

P20(4130 Modified) Preharden

Prehard treated to 29-36 RcHigh Toughness and PolishabilityIdeal for Cavity and Core Retainer PlatesManifold Plates in Hot Runner Molds

ABS / PPO PA / PSPE / PPPMMA

Medium Volume Production MoldConsumer ProductsElectronic/Electrical PartsMechanical Parts - Small

420SS Preharden

Prehard treated to 33-37 RcCorrosion ResistanceHigh Toughness and PolishabilityHigh Nitriding AbilityGood for humid environments

POM / PVCPET

High Volume Production MoldContainers and ClosuresFood/PackagingMedical/Dental/CosmeticPipes/CasingClean Room/ Stainless ApplicationsHumid Environments

Mold Inserts

P-20 (4130 Modified) Preharden Prehard treated to 29-36 Rc

High Toughness and Polishability

ABS / PPOPAPC

PP / PEPS

Prototype and Low Production MoldAutomotive - Large PartsIndustrial and OA EquipmentMajor AppliancesRecreation/Toys/Sporting products

420-SS Preharden

Prehard treated to 33-37 RcCorrosion ResistanceHigh Toughness and PolishabilityHigh Nitriding Ability

PCPE / PP

POM / PVCPMMA

Prototype and Low Production Mold (Special)Aircraft and Aerospace PartsConsumer ProductsMajor Appliances

BeCu Preharden

Prehard treated to 28-32 or higher (HH up to 40 Rc)Core and InsertsGood Corrosion ResistanceHigh Thermal ConductivityThin Wall Applications

General Resins

Prototype and Low Production Mold (Special)Cooling channels limitation conditionsThin Wall ApplicationsFast Cycle Time

H-13 Heat Treatment 50-52 Rc

Good Resistance to Abrasion at both Low and High TemperatureGood High-Temperature Strength and Resistance to Thermal FatigueHigh Level of Toughness and Ductility High Nitriding and Nitrocarburizing Ability

ABS / PPOLCP

PA / PCPBT

PPS / PSSAN

Flame Proof Resins

Building and Construction Parts - Small Consumer ProductsElectronic/Electrical PartsFurniture and FixturesHousehold and OA EquipmentMechanical Parts - SmallRecreation/Toys/Sporting productsTools and OA Equipment

420-SS Heat Treatment45-54 Rc

Corrosion ResistanceHigh Surface FinishStaining ResistanceWear Resistance

PE / PPPET

PMMAPC / PMMAPOM / PVC

PSSAN

Flame Proof Resins

Containers and closuresFood/PackagingMedical/Dental/CosmeticOptical LensPipes/CasingClean RoomHumid EnvironmentsStainless Applications

HOTVAR Heat Treatment54-58HRC

High resistance to thermal fatigue, hot wear and plastic deformationVery good performance in tooling up to 1200°F (650°C)

ABSPC

SANPMMAPES

Automotive partsElectrical appliance partsCookware componentsConsumer products

A2 Heat Treatment56-60 Rc

Best Compressive StrengthBest Wear Resistance“Universal” Cold Work Steel

ABS + GFPC +GFPA + GF

PBT + GFFiber Filled Resins

Electronic Components - MiniMechanical - MiniInsert Molding ApplicationsGlass Fiber Filled Applications **GF: Glass Fiber Filled

S7 Heat Treatment54-58HRC

Excellent combination of toughness and wear resistanceExtremely clean and high surface finish capability

ABSPC

SANPMMAPES

Display windowsElectronic / electrical componentsCosmetic productsMedical applications



Product Size Selection

Choose the nozzle product according to the weight of your part. If you are using more than one nozzle to fill your part, use the weight per nozzle to select the right nozzle size.

pg. 02.01.070

Product size Part size Shot weight per gate

Runner Diameter (mm)

Tip / Sprue Valve

*Femto-Lite Small Up to 5 grams 3.5 x

Femto Small Up to 10 grams 5.0 6.0

Pico Medium Up to 20 grams 5.0 7.0

Centi Medium 15 To 50 grams 6.0 8.0

Deci Large 50 To 500 grams 8.0 11.0

Hecto Large 500 To 3500 grams 12.0 16.0

* Femto-Lite should be used when gating into a space-restricted area



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Please note, for cylindrical and Accu-Valve gate styles only, it is recommended that the nozzle well area be made of steel with a hardness of HRC 54. For sprue, tip and valve gates other than cylindrical and Accu-Valve, it is recom-mended that the nozzle well area be made of AISI-H13 steel (DIN 1.2344) steel with a hardness of 46-48.

Gating

Select the best gating method appropriate for your ap-plication and for the material to be molded.

Mold-Masters offers four types of gating that cover all your hot runner requirements: tip gates, sprue gates, valve gates and edge gates.

To select the right gating method, you must take into account:

1. The desired gate appearance

2. Your material type (crystalline or amorphous)

The following table highlights the gating methods and the nozzle product line sizes that support each method. In the catalog section of the Resource Guide, each of these gating methods/nozzle combinations have a supporting catalog page.

pg. 02.01.080

Femto-Lite Femto Pico Centi Deci Hecto

Tip Gates E-Type torpedo √ √ √ √ √ √ Extended E-Type torpedo √ F-Type torpedo √ √ √ √ √ √ Spiral Hot Tip √ √ √ Sprint Hot Tip √ √ Melt Disk √ √ Melt Cube √Sprue Gates C-Sprue √ √ Bi-Met C-Sprue √ √ √ √ Hot Sprue √ √ √ √ √ √ Extended Hot Sprue √ √ √ √Valve Gates C-Valve √ Bi-Met C-Valve √ √ √ √ Hot Valve √ √ √ √ √ Accu-Valve CX/EX/MX √ √ √ √ Sprint Valve Gate √



E-Type Torpedo

The E-Type Torpedo is the most versatile of tip gating methods. It is suitable for processing most materials, and because it runs cooler in the gate area it is particularly suitable for amorphous and crystalline resins. The E-Type Torpedo provides excellent color change and leaves a very small gate vestige on the molded part.

F-Type Torpedo

The F-Type Torpedo is essentially an E-Type Torpedo with an integral, replaceable gate. Generally, offering all the benefits of the E-Type Torpedo with the added advantage of having a replaceable gate. The F-Type Torpedo runs slightly warmer than the E-Type, making it more suited to the crystalline and filled material grades.

Gating - Tip Gates

The tip gate is the most commonly used gating method. Acceptable for crystalline and amorphous materials, this gat-ing method relies on gate diameter, gate area cooling, and temperature control at the tip to optimize the part quality. Tip gating leaves a small mark on the molded part surface (gate vestige).

The size of this mark is directly related to the gate geometry and material properties. The less notch sensitive the thermoplastic, or the larger the gate diameter, the more the vestige will protrude. For this reason, the gate is often sunk into a spherical depression (referred to as a ‘technical gate’) so that the mark does not protrude above the part surface. Tip gating is generally not suitable for shear sensitive and highly filled materials due to the high temperature/high shear effects of the relatively small gate.

pg. 02.01.090

E-Type Torpedo

F-Type Torpedo



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Gating - Tip Gates cont.

Spiral Hot Tip

The Spiral Hot Tip utilizes a thermally conductive torpedo placed in the melt stream and features a wear resistant alloy tip. The conductive torpedo serves to remove gate area heat during part solidification while maintaining melt temperature behind the gate. The Spiral Hot Tip’s slender construction allows close spacing of gates, and permits the tip to plunge deeper into complex part geometry and mold cores. This also permits optimum positioning of cooling while realizing maximum tool rigidity.

Sprint Hot Tip

The Sprint Hot Tip is purpose engineered for ultra fast closure molding. Sprint is optimized for high performance at fast cycle times through high injection velocity and lower pressure drops. The special tip design provides fast color changes and optimized decompression for a very high quality gate vestige. The gate seals are designed to fit industry standard gate bubbles for easy retrofits.3-hole and 6-hole torpedos are designed for lowest possible pressure. The tips have demonstrated very good tip wear (5M cycles) and for even more exceptional tip wear (10M cycles) they can be ordered with a hardened tip.

Melt-Disk™

The Melt-Disk provides hot tip performance for edge gate applications. One of the distinct advantages of the Melt-Disk over an edge gate is that the cold slug is eliminated, allowing it to be used to gate thinner wall parts. The Melt-Disk offers direct gating with up to eight gates per nozzle in close proximity. It is also available in horizontal and angled configuration (at 15°, 30°, 45° and 60° positions). This gat-ing method proves to be cost effective in certain applica-tions since only one nozzle and temperature control zone is used for multiple gates. The compromise in individual gate control enables consistency between gate geometry and cooling to operate effectively.

pg. 02.01.100

Melt Disk

Spiral Hot Tip

Sprint Hot Tip



Gating - Tip Gate cont.

Melt-CUBE

Melt-CUBE technology provides precise cavity-to-cavity balance, excellent vestige control, easy servicing and low injection pressures for a variety of crystalline and amorphous side gating applications. The Melt-CUBE product is perfect for deep draw parts such as pipettes, syringe barrels, needle shields or smaller parts where only side gating is permitted. Melt-CUBE designs are available in horizontal or angled tips (15, 30, 45 and 60 degrees) and simultaneous gating from 2 to 16 cavities per cube. With Melt-CUBE it is possible to achieve 20% higher pitch density than circular systems. Melt-CUBE

Gating - Sprue Gates

Sprue gates use an “open” gate, characterized by a small cold sprue that remains on the surface of the molded part, where the cosmetic appearance of the gate is less critical. The sealing of the gate is accomplished by solidification during the cooling phase of the cycle, and is affected by gate diameter and gate cooling. The relatively large gates, although not suitable for very “stringy” materials, permit good packing with reduced part stresses. Applications include technical components where gate appearance is not critical and when gating onto cold sub runners.

Bi-Metallic C-Sprue / C-Sprue

The Bi-Metallic C-Sprue provides superior thermal separa-tion in the gate as needed for amorphous thermoplastics. The processing temperature is maintained behind the gate by a highly conductive insert while the mold contact is achieved with a less thermally conductive transfer seal. An insulating material layer between the two components provides the necessary thermal barrier.

There is also a C-Sprue design that utilizes a smaller mate-rial insulation layer in a one-piece seal design. The one-piece seal facilitates a more compact design as required for the smaller nozzles. i.e. Femto-Lite and Femto.

Bi-Metallic C-Sprue



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Gating - Sprue Gates cont.

pg. 02.01.110

Hot Sprue / Extended Hot Sprue

For crystalline and filled thermoplastics with rapid so-lidification characteristics, the tip of the Hot Sprue nozzle conducts heat into the gate area to prevent premature gate solidification. Both the gate size and the gate seal length are normally supplied unfinished to permit nozzle profiling and length adjustments by the mold maker. As the Hot Sprue has a removable gate seal that forms the actual gate, it also provides the advantage of a replaceable gate.

The Extended Hot Sprue is used for applications where the Hot Sprue is appropriate but where extra stock on the gate seal face is required. This extended version of the Hot Sprue is useful when differing molding elevations are necessary to reach the molding surface. Hot Sprue

Gating - Valve Gates

With this gating method, the valve pin tip mechanically closes the gate on completion of the holding pressure time. Since pin closing occurs before the gate solidifies, valve gates frequently offer decreased cycle times when compared to open gating methods. Unlike the other gating methods, valve gating creates no gate vestige, but leaves only a barely visible ring. For this reason, it is the best solution for all parts where surface quality is critical.

Due to the unrestricted gate opening, reduced shear heat and pressure drop is realized with this gating method. As a result, valve gating imparts lower mold filling stresses and gives a wide processing window suitable for even the most difficult thermoplastics that contain sensitive additives. With all materials, valve gating results in better part characteristics, especially with higher shot sizes and injection speeds.

For stringy materials, this gating method eliminates the possibility of drooling entirely. Although normally oriented perpendicular to the part surface, valve gates can also gate onto inclined or profiled surfaces.

Mold-Masters offers several types of valve gates to accommodate the varying solidification rates of different thermoplastics.



Bi-Metallic C-Valve

Although a valve gate is mechanically opened and closed, the temperature of the material in the gate area is still very important. Using different metals in our gate seal construction facilitates this. The Bi-Metallic C-Valve uses a conductive liner to maintain melt temperature to the gate without heating the mold steel in the gate. A second less conductive steel is em-ployed to thermally separate the liner from the mold steel and provide a leak proof seal between the gate well and the mold. An insulation layer of plastic is formed between the liner and the gate seal, further enhancing thermal isolation of the gate area. Bi-Metallic C-Valve is best suited for amorphous and semi-crystalline materials (materials with slow solidification rates).

Hot Valve

For thermoplastics with a rapid solidification rate, the Hot Valve eliminates premature gate sealing by allowing greater heat conduction into the gate area. This gating style maintains an open gate to permit sufficient packing prior to valve pin closing. It is designed and suitable for crystalline materials. As the Hot Valve has a removable gate seal that forms the actual gate, it also provides the advantage of a replaceable gate.

Sprint Valve

The Sprint Valve Gate is a true cylindrical Valve Gate solution for fast cycling molds running as fast as 2.5 second cycles. It provides fast color changes and superior fill balance on high cavity tools. In addition the Sprint Valve Gate allows optimum gate cooling and top panel cooling in front of the nozzle and is designed for effective mold decompression. Sprint Valve Gates are available with pneumatic actuation or E-Drive systems.

Gating - Valve Gates cont.

pg. 02.01.120

Bi-Metallic C-Valve

Hot Valve

Sprint Valve



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Gating - Valve Gates cont.

Accu-Valve CX/MX/EXOur premier cylindrical valve gate, the Accu-Valve, finds its uses when optimum gate appearance and longevity is paramount to your application. Similar to the Bi-Metallic Cylindrical Valve in that the straight pin is guided into the gate, the Accu-Valve ensures optimum alignment between the pin and gate by progressively guiding the pin in non-critical areas of the gate well ensuring precise final mating of the pin and gate.

Unlike the Bi-Metallic C-Valve, which utilizes a tapered shut-off profile on the pin and gate land, the Accu-Valve

pin and land have a straight profile. A highly conductive, wear resistant gate seal liner guides the pin into the gate, preventing damage and ensuring excellent gate cosmetics.

Accu-Valve is available in three different designs:

Accu-Valve CX

• For commodity resins, e.g. PP, PS, TPE, ABS.

• With precise flow channel in the liner eliminating dead spots, perfect for color changes.

Accu-Valve MX

• For both commodity and engineering grade resins, e.g. PP, ABS, PC, POM.

• Robust double Valve Pin guidance maintaining exact alignment between the pin and cavity which ensures long lasting gate quality.

• Provides a long lasting cosmetics gate appearance.

Accu-Valve EX

• For engineering grade resins, e.g. PC, POM.

• This design provides pressure gate area thermal condition to ensure no pin resistance to closing while still maintaining exact alignment between pin and cavity.

pg. 02.01.130

Accu-Valve CX

Accu-Valve EX

Accu-Valve MX



Gating - Material Suitability Chart

Use this chart to confirm that your preferred gating method is suitable for the material to be molded.Gating Type Tip Sprue Valve Edge

Gating Method

E-Ty

pe T

orpe

do

F-Ty

pe T

orpe

do /

Ext

. F-T

ype

Torp

edo

Spira

l Hot

Tip

Sprin

t Hot

Tip

Mul

titip

C-S

prue

B-M

etal

lic C

-Spr

ue

Hot

Spr

ue /

Ex

t. H

ot S

prue

C-V

alve

Bi-M

etal

lic C

-Val

ve

Hot

Val

ve /

Ex

t. H

ot V

alve

Acc

u-Va

lve

CX

Acc

u-Va

lve

MX

Acc

u-Va

lve

EX

Sprin

t Val

ve G

ate

C-T

ype

Tit E

dge

E-Ty

pe T

it Ed

ge

Mel

t-Dis

k

Mel

t-CU

BE

amorphous materials

PPO √ ∆ √ x √ √ √ x √ √ x ∆ √ √ x √ ∆ √ xPPO + Glass Fiber ∆ √ x x ∆ ∆ ∆ √ x *∆ √ x *∆ *∆ x x x ∆ x

PEI ∆ √ ∆ x ∆ ∆ √ ∆ √ ∆ ∆ x √ √ x √ x ∆ xPEI + Glass Fiber ∆ √ x x ∆ ∆ ∆ √ x *∆ √ x *∆ *∆ x x x ∆ x

PMMA √ ∆ √ x √ √ √ x √ √ x ∆ √ √ x ∆ √ √ √ABS √ ∆ √ x √ √ √ x √ √ x √ √ √ x ∆ √ √ √

ABS + Glass Fiber ∆ √ x x ∆ √ √ √ x *∆ x x *∆ *∆ x x x ∆ xSAN ∆ √ √ x ∆ √ ∆ x √ ∆ x x √ √ x ∆ x ∆ √

PS √ ∆ √ √ √ √ ∆ x √ √ x √ √ √ √ √ x √ √SB √ ∆ √ x ∆ √ ∆ √ √ ∆ √ ∆ √ √ x √ x √ ∆

PES √ ∆ √ x ∆ √ ∆ ∆ √ x ∆ x √ √ x ∆ x √ xPSU √ √ √ x √ √ √ x √ √ ∆ x √ √ x ∆ x √ xPVC ∆ ∆ ∆ x ∆ √ ∆ ∆ ∆ ∆ x x ∆ ∆ x x ∆ ∆ x

PVC-P ∆ ∆ ∆ x ∆ √ ∆ ∆ ∆ ∆ x x √ √ x x ∆ ∆ xPC √ ∆ √ x ∆ √ ∆ ∆ ∆ √ ∆ x √ √ x √ ∆ √ ∆

PC + Glass Fiber ∆ √ x x ∆ x ∆ √ x *∆ √ x *∆ *∆ x x x ∆ xCAB √ ∆ √ x √ √ √ x √ √ x ∆ √ √ x ∆ √ √ √COC √ ∆ √ x √ √ √ x √ √ x ∆ √ √ x ∆ √ √ √

TPU-A ∆ x ∆ x ∆ ∆ √ x √ √ x x √ √ x x x ∆ xTPE-A ∆ x ∆ x ∆ ∆ ∆ x √ √ x √ ∆ ∆ x x x ∆ xTPE-B ∆ x ∆ x ∆ ∆ ∆ x √ √ x ∆ √ √ x x x ∆ xEPDM ∆ x ∆ x ∆ ∆ ∆ x √ √ x √ ∆ ∆ x x x ∆ xSEBS ∆ x ∆ x ∆ ∆ ∆ x √ √ x √ ∆ ∆ x x x ∆ x

PC-ABS √ ∆ ∆ x √ √ √ x √ √ ∆ ∆ √ √ x ∆ √ √ √PC-SAN √ ∆ ∆ x √ √ √ x √ √ x ∆ √ √ x ∆ √ √ √

MABS √ ∆ ∆ x √ √ √ x √ √ x ∆ √ √ x ∆ √ √ √PET √ x ∆ x √ √ √ x √ √ x ∆ √ √ x ∆ √ √ x

PCTG √ x ∆ x √ √ √ x √ √ x ∆ √ √ x ∆ √ √ x

Legend√ = Recommended ∆ = Application Dependent x = Not Recommended * = <10%

pg. 02.01.140



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Gating - Material Suitability Chart

Use this chart to confirm that your preferred gating method is suitable for the material to be molded.Gating Type Sprue Valve Edge

Gating Method

E-Ty

pe T

orpe

do

F-Ty

pe T

orpe

do /

Ext

. F-T

ype

Torp

edo

Spira

l Hot

Tip

Sprin

t Hot

Tip

Mul

titip

C-S

prue

B-M

etal

lic C

-Spr

ue

Hot

Spr

ue /

Ex

t. H

ot S

prue

C-V

alve

Bi-M

etal

lic C

-Val

ve

Hot

Val

ve /

Ex

t. H

ot V

alve

Acc

u-Va

lve

CX

Acc

u-Va

lve

MX

Acc

u-Va

lve

EX

Sprin

t Val

ve G

ate

C-T

ype

Tit E

dge

E-Ty

pe T

it Ed

ge

Mel

t-Dis

k

Mel

t-CU

BE

crystalline materials

HDPE √ x √ √ √ ∆ ∆ x √ √ x √ √ √ √ √ x √ √

LDPE √ x √ x √ ∆ ∆ x √ √ x √ √ √ x √ x √ √

PP √ x √ √ √ x x x √ √ x √ √ √ √ √ x √ √

PP engineering (ex. Nucleated) ∆ x ∆ x ∆ ∆ ∆ x √ √ x ∆ √ √ x √ x √ √

PP + Glass Fiber √ √ ∆ x *∆ ∆ *∆ √ ∆ ∆ √ x *∆ *∆ x x x ∆ xLCP √ √ ∆ x ∆ x ∆ √ x x √ x x x x ∆ √ x xPET ∆ ∆ ∆ x ∆ ∆ ∆ ∆ ∆ √ ∆ x √ √ x ∆ √ √ xPBT ∆ √ ∆ x ∆ x ∆ √ ∆ √ ∆ x ∆ ∆ x ∆ √ √ x

PBT + Glass Fiber ∆ √ x x x x *∆ √ x *∆ √ x *∆ *∆ x x *∆ ∆ xPPS + Glass Fiber ∆ √ x x ∆ x *∆ √ x *∆ √ x *∆ *∆ x x x x x

PEEK ∆ √ ∆ x x x ∆ √ x ∆ √ x √ √ x ∆ √ x xPEEK + Glass Fiber ∆ √ x x x x *∆ √ x *∆ √ x *∆ *∆ x x x x x

PA (4.6, 6, 6.6, 6.10, 6.12, 11, 12) √ √ ∆ x ∆ x ∆ x ∆ ∆ √ ∆ √ √ x ∆ √ ∆ ∆

PA + Glass Fiber ∆ √ x x x x *∆ √ x *∆ √ x *∆ *∆ x x *∆ ∆ xPOM √ √ √ x ∆ x x √ ∆ ∆ √ x √ √ x ∆ √ √ ∆

POM + Glass Fiber ∆ √ x x x x *∆ √ x *∆ √ x *∆ *∆ x x *∆ ∆ xLCP + Glass Fiber ∆ √ x x x x *∆ √ x *∆ √ x *∆ *∆ x x *∆ ∆ xPET + Glass Fiber ∆ √ x x x x *∆ √ x *∆ √ x *∆ *∆ x x *∆ ∆ xPAA + Glass Fiber ∆ √ x x x x *∆ √ x *∆ √ x *∆ *∆ x x *∆ ∆ x

Legend√ = Recommended ∆ = Application Dependent x = Not Recommended * = <10%

pg. 02.01.150



Gating - Optimum Gate Size

The first step in establishing the proper gate diameter is to assess whether your application requires a small, medium or large gate size. Review the Gate Sizing Tables shown below. Since different considerations may suggest a different optimum gate diameter, a compromise for each application is normally required. Without reason small gates should be avoided when possible as they restrict flow and induce higher pressure losses.

pg. 02.01.160

Material Consideration

Structure

Molecular Weight

Melt Flow Index

Reinforcements, Fillers

Additives, Flame Retardants

Heat, Shear Sensitivity

Solidification Rate Of Material

Part Considerations

Shot Weight

Wall Thickness / Flow Length

Tolerances

Gate Mark, Gate Vestige

End Use

Process Considerations

Temperature Window

Injection Speed

Pressure Drop Created

Effect Of Holding Pressure

Amorphous

Low

High, Lubricants

None

Without

Not Feasible

Slow

low

small

wide

excellent

consumer-cosmetic

wide

low

high

less

part Crystalline

Medium

Medium

Low Percentage

Acceptable

Medium

medium

medium

average

good

medium

medium

normal

crystalline

high

low

high

with

feasible

fast

high

large

tight

fair

technical

narrow

high

low

more

Gate sizing

Small Medium Large



www.moldmasters.com

pg. 02.01.170

Gate Diameter

The available gate diameter range (small, medium, large) is shown in the table below. If a row contains an arrow, then the gate size can be any value in that range.

Femto-Lite

Gate size (mm)

Small Medium Large

E-Type Torpedo 0.6 0.8 1.0

Extended E-Type Torpedo

0.6 1.0

F-Type Torpedo 0.6 0.8

C-Sprue 1.0 1.5

Hot Sprue 0.6 1.0 1.5

Femto

Gate size (mm)

Small Medium Large


F-Type Torpedo 0.8 0.9 1.0

C-Sprue 1.0 1.5

Hot Sprue 0.6 1.0 1.5

C-Valve 1.0 1.5

Hot Valve 1.0 1.5

Accu-Valve CX 1.4

Accu-Valve EX 0.8 1.0

Pico

Gate size (mm)

Small Medium Large



Bi-Metallic C-Sprue 1.0 1.5 2.0

Hot Sprue 1.0 1.8 2.5

Ext. Hot Sprue 1.0 1.8 2.5

Bi-Metallic C-Valve 1.0 2.0

Hot Valve 1.5 2.0

Accu-Valve CX 1.8

Accu-Valve EX 1.0 1.51 2.4

Spiral Hot Tip 0.6 1.0 1.6

Centi

gate size (mm)

Small Medium Large




Hot Sprue 1.0 1.8 2.5



Hot Valve 1.5 2.0

Accu-Valve CX 2.5



Sprint Hot Tip 0.6 0.75

Deci

Gate size (mm)

Small Medium Large




Hot Sprue 1.5 2.5 4.0


Bi-Metallic C-Valve 2.0 2.5 3.0

Hot Valve 2.0 2.5 or 3.0 4.0

Accu-Valve CX 1.5 3.0 3.95



Sprint Hot Tip 0.6 0.75

Hecto

Gate size (mm)

Small Medium Large




Hot Sprue 1.5 3.0 5.0


Hot Valve 4.0 5.0




Nozzle

Choose an Appropriate Nozzle Length

All Master-Series nozzle sizes are available in a number of standard lengths. When selecting the nozzle length consider the following:

• The nozzle flange (insulation ring) should be seated in the manifold plate.

• Ensure sufficient steel between the nozzle flange and the A plate/cavity insert. Refer to the appropriate catalogue page for guideline.

• Choose a nozzle length “L” that will give you the molding elevation you require. Molding elevation is the distance from the bottom of the manifold plate to the gate level on the part.

• Choose the shortest length possible, considering the previous points.

pg. 02.01.180



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First, determine the number of nozzles you require.• Establish the configuration or layout you require,

e.g. a four-nozzle system can be laid out in an ‘X’, ‘H’ or ‘4-in a-row’ configuration.

• Sub-manifolds are available for up to 16 nozzles (for the smaller shot weight systems).

• Determine your required gate to gate spacing. Refer to “Minimum Pitch Spacing” (Reference Page #7).

• Go to the manifold section of the product range you previously established and find the appropri-ate catalog page for your manifold configuration.

• The manifold with nozzle (gate to gate) spacing greater than your minimum permissible cavity spacing.

Note: MasterSPEED does not support the following: Femto-Lite, Melt Disk, Accu-Valve, water cooled gate inserts and certain valve actuators.

Selecting a MasterSOLUTION System

A MasterSOLUTION manifold is available if the mani-fold shape or size that you require is beyond the range of the MasterSPEED configurations. These include bridged systems and totally custom manifolds.

main manifoldsMain manifolds (or bridge manifolds) are used to bridge one or more sub-manifolds. The ability to connect sub-manifolds increases the cavitation possible with your hot runner system and increases flexibility for spacing groups of cavities.

Example shown uses two XX sub-manifolds and a 2-in-a-row main manifold.

Manifolds

Select a Manifold Configuration

For 1 drop tip/sprue applications Mold-Masters offers the single nozzle systems. For one drop valve gate applica-tions, we offer Accu-Line systems. For a multi-drop system, a manifold is required. Mold-Masters offers two distinct programs for selecting a manifold:

• MasterSPEED system: based on the nine configura-tions that are presented in the catalog section of this Resource Guide.

• MasterSOLUTION system: a vast range of sub-man-ifolds and main manifolds that can be utilized to build virtually any hot runner system you might need.

Selecting a MasterSPEED System

Our MasterSPEED program offers many standard con-figuration sub-manifolds from single drop offset entry to 16 matrix manifolds for small to medium shot sizes. Each configuration of manifold accommodates a range of drop locations with infinite variability within the range.

You can select from the following MasterSPEED mani-folds for the Femto, Pico, Centi, Deci & Hecto product lines.

Note: Some configurations shown are not available with all product lines, with all manifold pitches, or with valve gating.

To incorporate a Mold-Masters MasterSPEED manifold into your mold design:

pg. 02.01.190

*Only available in Femto, Pico and Centi

1 drop offset

2 drop in-line

2 drop “T”

4 drop in-line

4 drop “X”

4 drop “H”

8 drop “XX”

12 drop Matrix*

16 drop Matrix*



Note: Some combinations shown are not available with all product lines, with all manifold pitches, nor with valve gating. Consult your Mold-Masters representative for availability.

pg. 02.01.200

Manifolds

Some typical standard main and sub manifold combinations are illustrated below.



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Manifolds

MasterSOLUTION Manifold Styles

Although most systems are designed, when possible, with our cast-in heater technology, this is sometimes not feasible for very large or complex designs.

pg. 02.01.210

In these cases, external heater plates provide optimal heat profile and control for very large manifolds. Please contact your Mold-Masters representative to confirm the feasibility of the design you require.

See cutaway of a cast-in system (reference page #4) and cutaway of a bolt-in system (reference page #5) for more detailed information.



Manifold Center HeatersFor all applications processing crystalline and high temper-ature amorphous materials. See catalog pages 09.01.080, 09.01.150 and 09.01.160.

Inlet ExtensionsFor valved applications. See catalog pages 09.01.120, 09.01.130 and 09.01.140.

Locating Rings

Standard inch and metric locating rings are available for all machine nozzle pads (backplates) and inlet exten-sions. Locating ring catalog pages indicate which inlet components they are compatible with. See catalog pages 09.01.010 to 09.01.070.

Water-cooled Gate Inserts

Designed to provide effective cooling to quickly extract heat from the gate area.

• Provides highly effective cooling to the gate area to help ensure that gate cooling does not limit the overall cycle.• Allows productivity from high volumes to be optimized.• Achieves efficient gate cooling for those applications where the gates are difficult to access with conventional cooling techniques.

pg. 02.01.220

Hot Runner Components

Your hot runner system may require the following components:• Valve components• Inlet components• Locating rings• Water cooled gate inserts

Valve Components (for valve-gated systems)

If you have chosen a valve gate in step 2, you will require valve actuators. In most cases you will have the option to choose a hydraulic or a pneumatic unit and in some cases the same actuators can be both hydraulically and pneumatically operated. There are three different types of actuators:

Individual hydraulic - Oil operated, with each nozzle having its own actuator.

Individual pneumatic - Air operated, with each nozzle having its own actuator.

Syncro-plate technology (hydraulic or pneumatic) - In certain situations, specifically smaller systems, a syncro valve actuator unit may be employed, where all of the pins are mounted in a single plate and are actuated as a single unit.

Page 11.01.010 references valve actuation units avail-able for each product range size and valve gating method.

Inlet Components

There are four types of inlet components available with Master-Series systems. Correct component selection is dependent on the application and type of system being utilized.

unheated machine nozzle pads (backplates) For non-valved applications processing commodity resins. See catalog pages 09.01.090 and 09.01.100.

heated machine nozzle pads (backplates)For all applications processing crystalline and high temperature amorphous materials. See catalog pages 09.01.110.



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Hot Half Information

Mold-Masters offers two distinct programs for selecting a hot half:

• MasterSPEED hot half: available for any hot runner system that utilizes a MasterSPEED hot runner system.

• MasterSOLUTION hot half: If your hot half requirements do not fall under the MasterSPEED program we can build a hot half to your specifications. Simply submit a set of mold prints or an electronic version of the same. Use the Hot Half Specification Sheet (pg 02.01.410) to verify that the required integration information is detailed in your mold design. This is located in the Reference Section at the end of this section.

The following steps outline how to specify your MasterSPEED hot half. To document the decisions you are making, complete the MasterSPEED System Design Specification Sheet (pg 02.01.400).

1. Specify plate size, i.e. length x width. (L x W).

2. Choose the manifold layout in the hot half.

3. Select your cooling line preference.

4. Specify whether an insulation plate is required or not.

5. Specify molding elevation.

6. Specify leader pin size and locations.

7. Specify the offset leader pin location.

8. Specify A-screws size and locations.

pg. 02.01.230



Hot Half Information

1. Specify plate size, i.e. length x width. (L x W).

Note: The clamp slot consists of three dimensions, the width, the depth and the thickness. The default geometry is 16 x 22.2 x 22.2mm respectively.

2. Identify the correct manifold layout (A or B) in the hot half. Please see the two drop in-line example below.

Note: The hot runner systems wiring sequence is, nozzle, manifold, and inlet.

pg. 02.01.240

3. Select your cooling line preference (1 or 2) from the images below.

Standard water fittings are DME JP-352.

Cooling Line 2

1 drop offset

2 drop in-line



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2 drop “T”

4 drop in-line

pg. 02.01.250



pg. 02.01.260

4 drop “X”

4 drop “H”

8 drop “XX”



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16 drop matrix

pg. 02.01.270

12 drop matrix



4. Specify whether an insulation plate is required or not.

An insulation plate is recommended if the mold temperature will be over 100ºF (38ºC).

5. Specify molding elevation

Molding elevation is defined as the distance from the bottom of the manifold plate to the gate level on the part.

pg. 02.01.280

6. Specify leader pin size and locations.

Leader pins are available in diameters from 0.750” to 1.500” and lengths from 4.250” to 15.750”.



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8. Specify A-screw size and locations.

A-screw sizes are available in the following sizes:

M12 x 1.75 M16 x 2.0

A-screws are placed around the perimeter of the hot half. This diagram illustrates their locations. You may move the screws located within the center of the hot half.

7. Specify the offset leader pin location.

Typically the Top, Non-Operator pin location is the offset leader pin.

pg. 02.01.290

A-screw locations



Temperature Controller

Select a Temperature Controller

Now that you have specified your hot runner system, you will need to establish the temperature control requirements for that system.

Mold-Masters recommends that each heated component of the hot runner be independently controlled. Thermocou-ple control is also recommended. To specify your temperature controller you will first need to establish how many zones of control will be required, i.e. how many electrically powered heaters are comprised in the hot runner system.

Each nozzle will require one zone of control. Each manifold will require at least one zone of control. Some larger cast-in heat manifolds have two heaters, and will require two zones of control, e.g. 12 matrix and 16 matrix manifolds. Bolt-in style manifolds that utilize heater plates will typically require two or more zones of control.

All inlet components, except unheated backplates, require a zone of control.

If you are having difficulty establishing how many zones of control are required for a hot runner system, please contact your local Mold-Masters representative.

Now that you have established the number of control zones required for your hot runner system you can select a temperature controller. Refer to the temperature control section in the catalog for detailed specifications on avail-able models.

Comparison ChartXL XL-2 XL-4 XL-6 MZ-LT MZ-MG MZ-G MZ-MDM MZ-LTD

zone range

1-9 2-18 4-48 6 4-60 24-60 24-240 4-24 4-24

display LED LED LED LED touch screen5.2” color

touch screen8.4” color




mountingoptions

heavy dutystand, table

top

heavyduty

stand,table top

heavy duty stand

stand alone

heavy duty stand,

slim stand, direct mount,

table top, integrated

stand

integrated stand

integrated stand

machine direct mount

table top

pg. 02.01.300



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XL:

Our basic small controller for 1 to 9 zones

• Simple closed loop control• Single point control (each module controls one heater)• Modular construction, available in 2 zone, 6 zone and 9 zone cabinets• Accurate Digital Control• Plug and Play• Easy maintenance and service

XL-2:

4 to 18 zone controller utilizing dual zone per card technology

• Innovative cards control two zones each• Reduction in size and cost, perfect for low cavitation applications• Three sizes of compact cabinets that are easily expandable• Accurate auto-tuning control with open and closed loop operation• Simple four button control• Minimal maintenance and no calibration required

XL-4:

Innovative internal cards control 4 zones each

• Easy operation for a variety of configurations up to 48 zones• The perfect cost-efficient solution for your low cavitation applications• Compact cabinets come fully wired for ease of expansion including accessible fuses and integral ventilation fans for all industrial environments• Superior Mold-Masters proprietary PID2 auto-tuning control algorithm with closed and open loop operation• Fully automatic system with no calibration or maintenance required; reducing downtime

XL-6:

Controls up to 6 zones

• Simple five-button user control• Very compact, free standing design 300 x 400 x 100 mm / 12 x 16 x 4 in (WxLxH)• Auto-calibration and maintenance feature increases uptime• Special control structure minimizes control deviations or over-swing of set

temperature • Modular based system with minimal spare parts

pg. 02.01.310



pg. 02.01.320

MZ-LT:

Up to 60 zones of control using Mold-Masters PID2 auto-tuning control algorithm

• 5.2” color touch screen STN interface provides complete viewing with access to graphs, drawings and photos • Available in five different mounting options including the slim stand (shown)• The slim stand features a rotating display, easy to access controller cards and has a 50% smaller “footprint”, reducing floor space requirements • Fully automatic system with no calibration or maintenance required • Perfect low-cost control for high cavity hot runner applications

MZ-MG:

24 to 60 zones with LCD Graphical User System touch screen control

• Same key features as MZ-L• 8.1” VGA, TFT color touch LCD Graphical User System• Compact flash media kit and wireless communication networking• Additional features: 3D graphic rotating display, historical display, live mini-panels attached to real me mold settings, stores and display drawings or photos, unlimited tool stores via compact flash, export to Excel, online help, multi language and auto tool configuration

MZ-G:

24 to 240 zones touch screen graphic user systemwith the most capabilities

• All the features of MZ-L and MZ-MG • Full Graphical User System (G.U.S.) in a 12.1” SVGA, TFT color touch screen control• Uses the same control card - QMOD in all slots - modular construction, 80 zones per rack• G.U.S. can be mounted on a desktop or swing arm• Additional features: Standard LAN network, SPI communication, identical foot print of the MZ-L, 60 zone unit, heavy duty power distribution system



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pg. 02.01.330

reference page 1

For parallel dimensions, the following convention is used:

This signifies that the top surface must be parallel to surface B within 0.01mm.

tolerances

surface finish parallelism

concentricity

For concentric bores, the following convention is used:

This signifies that the bore dimensioned with the upper symbol must be concentric to the bore marked with the lower symbol to within 0.02mm.

The North American third angle projection is used throughout this design guide as illustrated below:

A

B 0.01

B

Drafting Symbols And Tolerances

The following tolerances and drafting conventions are used throughout this design guide. Only the metric system is used, but the units of measure may be converted to the Imperial system by using the conversions given on refer-ence page 2.

In order to improve readability of the design pages, uncommon drafting scales are sometimes used. When this occurs, the scale used will be shown in the bottom corner of the design page.

projections

Unless otherwise specified, the following tolerances are used for all design pages:

1 decimal place = ±0.10mm2 decimal places = ±0.05mmAngular dimensions = ±0.25°

The following convention is used to designate surface roughness:

0.02 A

0.80µm (32µ in.)0.40µm (16µ in.)



pg. 02.01.340

reference page 2

Metric To Imperial Conversions

All linear dimensions in this design guide are in millimetres unless otherwise stated. The metric system is used throughout and may be converted to Imperial using the conversions given below.

Multiply by

0.03937008

14.50377

.03527

1.8 and add 32

3.41214

0.06102

0.7375621

Given

millimeter (mm)

bar (105 N/m2or Pa)

gram (g)

°C

watt (W)

centimeter3 (cm3)

Newton-meter (NM)

To obtain

inch

pound/inch2

ounces [avoirdupois]

°F

BTU per hour

inch3

pound-foot

length

Pressure

Mass

Temperature

Power

Volume

Torque



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pg. 02.01.350

reference page 3a

“other” manifolds

See the table below for minimum pitch “P” for manifold configurations that do not have all nozzles in a row.

Minimum Pitch Spacing

Minimum pitch dimensions (space between nozzle tips) for the Master-Series Femto-Lite, Femto, Pico, Centi and Deci nozzles are provided below.

Tip & Sprue Gating“in-line” manifolds

See the table below for minimum nozzle pitch for manifold configurations that have all nozzles in a row (e.g. 2 in-line, 4 in-line). The flange diameter is shown for reference.

Minimum pitch (P) First nozzle spacing (P1)Product line

mm inch mm inch

Femto-Lite

Femto

Pico

Centi

Deci

20.0

23.0

32.0

33.0

41.0

0.787

0.906

1.260

1.299

1.614

23.0

25.0

29.5

30.0

34.0

0.906

0.984

1.161

1.181

1.339

Flange diameter (F)

mm inch

18.0

21.0

30.0

31.0

39.0

0.709

0.827

1.181

1.220

1.535

Femto-Lite

Femto

Pico

Centi

Deci

19.0

22.0

32.0

33.0

41.0

0.748

0.866

1.260

1.299

1.614

18.0

21.0

30.0

31.0

39.0

0.709

0.827

1.181

1.220

1.535

Minimum pitch Flange diameterProduct line

mm inch mm inch



pg. 02.01.360

reference page 3b

Minimum Pitch Spacing Valve Gatingindividual actuation

Valve Gating Syncro-Plate Actuation

In some valve gating applications, the pitch can be reduced with Mold-Masters’ synchro plate technology which eliminates the need for an individual actuator for each nozzle. With a syncro plate valve actuator, all of the actuators are linked together and are centrally controlled to move in sync.

In most syncro plate applications, the minimum pitch can be reduced to the level that can be achieved for an equiva-lent tip & sprue gated system.

Measurements include valve disc dimensions

36.0

40.0

36.0

40.0

41.0

50.0

54.0

65.0

54.0

65.0

N/A

N/A

N/A

N/A

N/A

N/A

48.0

50.0

FemtoActuators

mm inch

P

P1

P

P1

P

P1

P

P1

P

P1

P

P1

P

P1

P1

P1

P

P1

1.417

1.575

1.417

1.575

1.614

1.968

2.126

2.559

2.126

2.559

N/A

N/A

N/A

N/A

N/A

N/A

1.890

1.968

HY550X*

HY550X*L

HY5500*

HY650X*

HY710X*

HY6500*

HY6600*

HY6700*

HY7100*

HY8400*

HY8500*

PN2300*

36.0

40.0

36.0

40.0

41.0

50.0

54.0

65.0

54.0

65.0

60.0

65.0

60.0

65.0

65.0

65.0

48.0

50.0

Pico

mm inch

1.417

1.575

1.417

1.575

1.614

1.968

2.126

2.559

2.126

2.559

2.362

2.559

2.362

2.559

2.559

2.559

1.890

1.968

36.0

40.0

40.0

40.0

41.0

50.0

54.0

65.0

54.0

65.0

60.0

65.0

60.0

65.0

65.0

65.0

48.0

50.0

Centi

mm inch

1.417

1.575

1.575

1.575

1.614

1.968

2.126

2.559

2.126

2.559

2.362

2.559

2.362

2.559

2.559

2.559

1.890

1.968

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

60.0

65.0

60.0

65.0

65.0

65.0

N/A

N/A

Deci

mm inch

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

2.362

2.559

2.362

2.559

2.559

2.559

N/A

N/A



www.moldmasters.com

pg. 02.01.370

9 pressure disk

10 gate seal

11 valve actuator

12 valve disk

1 air gap

2 inlet extension

3 locating ring

4 machine nozzle pad (backplate)

5 manifold locating cam

6 manifold locator

7 “cast-in” manifold

8 nozzle

Cutaway Of A “Cast-In” System

This illustration of a typical Mold-Masters “cast-in” hot runner system is divided into two halves (valve side and non-valve side). The terminology associated with the various components and features are listed below.

reference page 4

Valved Non-Valved

Hot Half - Cast In Arrangement


Valved Non-Valved

Hot Half - Bolt In Arrangement


pg. 02.01.380

1 air gap

2 manifold locating cam

3 bolt-in manifold

4 gate seal/gate insert

5 heater plate

6 inlet extension

7 locating ring

8 machine nozzle pad (backplate)

9 manifold locator

10 nozzle

11 valve actuator

12 valve bushing

Cutaway Of A “Bolt-In” System

This illustration of a typical Mold-Masters “bolt-in” hot runner system is divided into two halves (valve side and non-valve side). The terminology associated with the various components and features are listed below.

reference page 5



www.moldmasters.com

pg. 02.01.390

System Design Specification Sheet

reference page 6

Number of Cavities*: _________________________ Gate Size*: _____________________________

Sub-Runners*: Yes No Molding Elevation*: ______________________ (Req’d Nozzle Length)

Optional Considerations (please provide the following data if there are related potential molding concerns, such as):

1. Gate cooling (please provide mold prints to show the layout).2. Cycle time (if there is need for special consideration).3. Sequential valve gating, etc.

Please e-mail us the cavity and drop layout design details for review, or sketch the layouts in the box below and clearly indicate the view:

Company Name: ________________________

Contact Name: ________________________

Contact E-mail: ________________________

Mold-Masters Quote #:_____________________

Customer P.O / Ref #: _____________________

Contact Telephone #: _____________________

Please complete and return this specification sheet as the information is required to proceed with your order. Failure to complete the mandatory fields (marked *) will result in a delay. If you are supplying a part drawing, please ensure all this information is indicated on the drawings.

Plastic Part: Plastic Material:

Name:

Number: Industry: ________________________________

Weight*:

Gate Wall Thickness*:

Average Wall Thickness*:

Type*:

Material Grade:

Reinforcement*:

Colour Change*:

Processing Temperature*:

Mold Temperature*:



pg. 02.01.400

reference page 7

Hot Half Design Specification Sheet

Company Name: _________________________

Contact Name: __________________________

Contact E-mail: __________________________

Mold-Masters Quote #:________________________

Customer P.O / Ref #: _______________________

Contact Telephone #: _______________________

Mandatory fields are indicated with a (*).

1. Top of mold / operator side shown on mold print?* Yes No Vertical Press2. Mold bolted / clamped to platen?* Bolted Clamped3. Machine nozzle radius 1/2” 15.5 3/4” 40.04. Insulator plate required? Yes No5. Gate locations: clearly dimensioned X & Y co-ordinates* Yes No6. Leader pin type? DME HASCO Other7. Number of leader pins?*8. Offset or off size leader pin (See sheet 2 for details)* LP1 LP2 LP3 LP4 N/A9. Off size leader pin diameter* N/A10. “A” screw locations clearly specified on mold prints* Yes No MM Specify11. Number of “A” screws?*12. “A” screw from (See sheet 2 for details)* Cavity plate Clamp Plate13. “A” screw size:* 1/2” 5/8” M12 M16 Other14: Cooling line fittings type (Specify size) NPT BSPT Other Size:15. Cooling line fittings location? Bot Non-op Op Top16. Cooling line fittings recessed? Yes No17. Hydraulic or pneumatic line fittings type? (Specify size) NPT BSPT Other Size:18. Hydraulic or pneumatic line fittings location? Bot Non-op Op Top19. Hydraulic or pneumatic line fittings recessed? Yes; Counter Bore Size: No

20. Mold-Masters controller used? Yes No21. Maximum number of zones allowed? MM Specify22. Mold plug specification (for temperature controller interface). If other, please specify*

MPLUG06 MPLUG08 MPLUG12

PIC5 / MTC5 PIC8 / MTC8 PIC12 / MTC12

16 Pin 24 Pin

Other23. Maximum Amp limitation? If yes, please specify (Mold-Masters standard is 15 Amps per zone)

Yes; Max Amp: No

24. Mold-Masters standard electrical box will be supplied unless otherwise specified

Use Mount Plate: Yes Use Elec. Box: Yes; Box #:

No No

25. Wiring sequence required (zone layout) On mold prints MM standard26. Strap clamps / mold feet shown on mold prints* Yes No27. Front mount thermocouples required?* Yes No28. Special attention required for front mount thermocouple slot locations?*

Yes; Please specify on mold print No



www.moldmasters.com

*Please use this page for reference, for an electronic version, please go to www.moldmasters.com, or fill out the copy that was attached to your quote. Print notes are found on the following page.

pg. 02.01.410


reference page 8

233 Armstrong Avenue • Georgetown, Ontario, Canada • L7G 4X5 • Telephone 905-877-0185 • Fax 905-873-2818 Form #SLS226 Page 2of 2




pg. 02.01.420


reference page 9

Notes: 1. Clearly indicate gate location coordinates on mold print (4 decimals in imperial & 3 decimals in metric).2. Clearly indicate hot runner leader pin location coordinates on mold print (4 decimals in imperial & 3 decimals

in metric).3. Clearly indicate A-screw location coordinates on mold print (3 decimals in imperial & 2 decimals in metric).4. Must exceed gate height; lengths are in 12.7 mm (0.500 in) increments.

Comments:

MML Quote#/ P.O./Ref#:

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