Optimization of Hot Runner Systems for Large Plastic Components
Plastic injection moulding is the most common production process for the cost-effective and time-efficient manufacture of high-quality plastic parts. To reduce waste in the upcoming production, hot runner systems and nozzles at the injection points are preferred to cold runner systems. Since the injection process also has a significant influence on the filling pattern, the fibre orientation and thus on essential structural component properties, a further objective in development is the design and optimisation of a suitable gating system.
However, complex part geometries usually require very sophisticated demoulding strategies. Consequently, there are only a few options available for the installation of hot runner systems. Many possible positions do not offer sufficient space for the nozzle and cooling. It is therefore worth spending time and effort to find the best balance between the gating and demolding system. On the one hand, this provides a high-precision mould and a production process for the best part quality, and on the other hand, a lot of time and money can be saved in production.
This presentation gives a short insight into the MAHLE pre-series (development) process to find and optimize an injection and removal system for a tool. The results of both the rejected and the final variant are shown to give an overview of the development steps that have been carried out.