M Gb-Hrappl PDF

Hot Runner Technology
Examples of Hot Runners in use
C P
T A
GB
All rights reserved. Errors and omissions excepted.
Illustrations simplified, schematically drawn and not to scale.

For a specific application, please consult Synventive.
Company
Technology
Products
Application
Hot Runner Technology CC PP

Examples of Hot Runners in use TT AA
What is the purpose of this compilation of examples?
The collection of practical application examples shown here is intended to help
everyone who uses the hot runner technology, wishes to use the technology or
simply wants to find out about the technology in the following way:

Broadest possible insight into hot runner technology
Supplementary aid to selecting the appropriate hot runner components
Overview of different solutions in the field of gating technology
What is shown here in detail?

All the examples are based on applications that were implemented using Synventive hot runner technology. The choice was made under the following aspects:
Different examples in order to include as many fields of application as possible
Limitation to the most important key data
Guaranteeing of data security by the use of schematic illustrations
Illustration of original parts only after approval by the manufacturer
Important copyright note

All examples and their data may only be used for their own information by persons
to whom this compilation of examples was supplied by authorised representatives
of Synventive Molding Solutions. Passing on information, in whole or in part,
requires the written approval of Synventive.
Contents
Material
Moulded Part(s)
Application
Mould Type / Remarks
1g
PP
Cap insert
Housing cover
64-cavity mould
2g
PE
Cap
Bottle cap
8-cavity mould
5g
PA 6 V0
Terminal body
Modular terminal
2-cavity mould, flame retardant
5g
7g
PS metallic
PS cust. col.
Fork
(prongs and handle)
Aircraft cutlery
16+16-cavity turntable mould

2-component moulding
8,6 g
POM
Guide wheel
Car window mechanism
4+4-cavity stack mould
15 g
PC / ABS
Lower casing
Mobile telephone
2-cavity mould
21 g
2g
POM
TPE
Chain link
(chain body & cleats)
Conveyor belt
4+4-cavity turntable mould

2-component moulding
20 g
13 g
10 g
7g
PP
PP
PP
PP
Cartridge
(housing & 3 inner rings)
Needle dispenser
2+2+2+2-cavity family mould
10
150 g
PP GF20
Fan wheel
Car air condition
2-cavity mould
11
150 g
ASA
Bumper strip
Car bumper
Single-cavity mould, cascade moulding
12
220 g
PP
C-pillar cover
Car interior
Car interior, textile moulding
13
1400 g
PP / EPDM
Wheel arch liner
Car body
1+1-cavity family mould
14
2500 g
PPO GF10
Instrument panel support
Car interior
Single-cavity mould, long glass fiber material
15
2500 g
PP LGF30
Front end module
Car body
Single-cavity mould
5000 g
PC
Car window
Car body
1+1-cavity
Rotary stack mould
GB
Weight
Page
16
2008-07-30 - All rights reserved. Errors and omissions excepted.
1 / 16
C P
T A
1 g PP
Cap insert for housing cover
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Cap insert
Housing cover
1g
PP
Multi-cavity mould
64
Customer requirements
In this particular application, it was a
question of manufacturing PP caps in a 64cavity mould with fast delivery of the
complete, pre-wired and adjusted system,
including mould plates, connection box and
connector-ready, pre-configured temperature
controller.
2005-10-14
MK-PRM.SIS. GB -A.CS0019
Solution
This application was implemented using an
externally heated, 64-cavity hot runner
system with face fit between nozzles and
manifold. The manifold system consisted of 2
block manifolds with 32 nozzles each, fed by
an H-manifold. All runners are naturally
balanced. Gating with the hot runner was
direct, in the centre of the moulded part. To
suit this system with a large number of
cavities, a mobile temperature controller was
supplied, ready to plug in.
2 / 16
Benefits
Saving of time and manufacturing

resources through the "hot half concept"
as initial stage of the finished mould half
Manufacture without sprue waste and

post-processing
Production with high number of cavities
Good gating quality regarding gate mark

and appearance
Equal supply and filling of all cavities with

melt
Good moulded part quality from all

cavities
04C W01T
Schematic product overview

1. Manifold nozzle, face fit
Nozzle class 04 C
2. Manifold
Series VC
04
+ V
C P
T A
2 g PE
Cap for foodstuff bottle
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Cap
Foodstuff bottle
2g
PE
Multi-cavity mould
8
Customer's requirements
This application involved the production of
caps of PE for foodstuff bottles in an 8-cavity
mould.
Solution
In the implementation of this application, an
externally heated 8-port hot runner system
with face fit manifold nozzles was employed.
The manifold was in the standard manifold
form (H) and its runners were naturally
balanced. The cavity was directly gated with
the hot runner to the moulding surface via
open nozzles with torpedo.
Benefits
Production without sprue waste and

without reworking
Good gating quality with respect to

separation and appearance
Uniform supply and filling of all cavities

with melt
Good moulding quality from all the cavities
2005-04-13
CB WT M
3 / 16

1. Manifold nozzle with sliding mounting
Series CBM, Type WT, Class 07 C
2. Manifold
Series VC
07
+ V
C P
T A
5 g PA 6 V0
Terminal body for modular terminal
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Terminal body
Modular terminal
5g
PA 6 V0
Multi-cavity mould
2
modular terminals of PA 6 with V0 properties
in a 2-cavity mould.
Solution
The manifold was of standard form (I) and its
runners were naturally balanced. The cavity
was directly gated with the hot runner to the
moulding surface via open nozzles with
torpedo, whereby the gate was recessed in a
dimple.
Benefits

without reworking


with melt
2003-06-03
CB FT M
4 / 16

Series CB...M, Type FT, Class 07 C
2. Manifold
Series VC
07
+ V
C P
T A
5 g PS metallic + 7g PS custom color

Fork for aircraft cutlery
Key data
Moulded parts
Application
Part weight
Material
Mould type
No. of cavities

Fork: Prongs and handle

Aircraft cutlery
5g+7g
PS: metallic & cust. colour
Turntable mould
16 + 16
forks of PS for aircraft cutlery using the 2component process with a 16+16-cavity
turntable mould. The plastic cutlery is to
replace the metal cutlery used to date.
System 1
PS metallic
System 2
PS custom color
2004-08-13
Solution
In the implementation of this application, two
identical externally heated 16-gate hot runner
systems with nozzles sliding on the manifold
were employed. The runner systems each
consisted of two T-shaped runners linked by
an I-shaped runner. The cavity was directly
gated with the hot runner to the moulding
surface via valve gate nozzles with 4 nozzles
being actuated by one actuator. The system
was supplied as hot half, i.e. including mould
plates, ready installed and adjusted as well
as wired ready for plugging in and with the
necessary hose connections.
5 / 16
Benefits
Savings in time and costs thanks to the

hot half concept as the preliminary stage
to the finished mould side

without reworking
Production with a large number of cavities
Good gating quality

with melt

Series N CB...M, Type WV, Class 07 C
2. Manifold
Series VF
3. Actuator, pneumatic, in mould plates
Series LCP 4008 02
N CB W M
07
+ V
C P
T A
8.6 g POM
Guide wheel for car window mechanism
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Guide wheel
Car window mechanism
8,6 g
POM: Hostaform C9021
Stack mould
8
guide rollers of POM for the car window
mechanism with the largest possible number
of cavities on an existing, relatively small
injection moulding machine. The cavities
were to be gated directly with the hot runner
and at several points around the perimeter of
the moulding in order to ensure good
concentricity.
Solution
with mutli-tip face fit manifold nozzles was
employed. The runner was designed in an H
shape and had a long gating neck due the
stack design of the mould. The nozzles were
positioned on both sides of the runner. The
cavity was directly gated via open multi-tip
nozzles with torpedo at 3 points on the side
surface of each moulding.
2003-10-06
Benefits
Production with a relatively large number

of cavities on the existing machine
Good concentricity of the mouldings

without reworking

Uniform supply and filling of the mould

cavities
6 / 16
M CB WT M

Series M CB...M, Type WT, Class 07 C
2. Manifold
Series VC
07
+ V
C P
T A
15 g PC/ABS
Lower casing for mobile telephone
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Lower casing
Mobile telephone
15 g
PC/ABS
Multi-cavity mould
2
lower casings for mobile telephones of
PC/ABS. The cavities were to be directly
gated via the hot runner to the moulding
surface in a spherical dimple.
Solution
The cavity was directly gated with the hot
runner to the moulding surface via open
nozzles with torpedo, whereby the gate was
recessed in a spherical dimple.
Benefits

without reworking


with melt
2005-03-31
CB WT M
7 / 16

1. Manifold nozzle with sliding mounting
Series CB...M, Type WT, Class 07 C
2. Manifold
Series VC
07
+ V
C P
T A
21 g POM + 2 g TPE
Chain link for conveyor belt
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Chain link
Conveyor belt
21 g POM + 2 g TPE
POM + TPE
Turntable mould
4+4
chain links of POM and TPE for conveyor
belts in a 4 + 4-cavity turntable mould using
the 2-component process.
System 1
POM
System 2
TPE
GA KN E
N CB X M
2004-04-28
Solution
In the implementation of this application, a
single nozzle was used for the POM
component and a 4-gate runner system with
valve gate nozzles with face fit to the
manifold for the TPE component. The
cavities were directly gated on the one hand
via a cold sub-runner (POM) and on the
other with valve gate nozzles directly to the
moulding (TPE). The system was supplied as
a hot half, i.e. including mould plates, ready
installed and adjusted as well as wired ready
for plugging in and with the necessary hose
connections.
8 / 16
Benefits
Savings in time and costs thanks to the

hot half concept as the preliminary stage
to the finished mould side

without reworking
Production with a large number of mould

cavities


with melt

1. Single nozzle
Series GA...E, Type KN, Class 12 S
Series N CB...M, Type XV, Class 07 C
3. Manifold
Series VC
4. Actuator, pneumatic, in mould plate
Series LCP 4008 02
12
07
+ V
C P
T A
20 g + 13 g + 10 g + 7 g PP
Components for needle dispenser
Key data
Moulded parts
Application
Part weight
Material
Mould type
No. of cavities

Housing + 3 inner rings

Needle dispenser
20 g, 13 g, 10 g, 7g
PP
Family mould
2+2+2+2
This application involved the production of a
four-piece module of PP, a housing and three
inner rings. They formed the heart of a
cartridge housing. The components were to
be produced in a family mould with which two
complete modules could be produced in one
shot.
03 C01 W01T
Solution
In the implementation of this application, a
rheologically balanced, externally heated 7port hot runner system with face fit manifold
nozzles was employed. Manifold form and
nozzle lengths were specially adapted to the
part contour and the required injection points.
The cavities were gated via cold sub-runners
that were fed by open nozzles with torpedo.
The outstanding feature of this system lies in
the combination of nozzles of three different
sizes on one manifold, whereby the largest of
the nozzles feeds two cavities.
2006-06-26
04 C01 W01T
9 / 16
Benefits
Two complete modules in one shot

with one mould on one machine
Assembly of the modules directly at

the machine without long transport
routes or complex logistics
Good, uniform moulding quality from

all the cavities
High productivity
CB XT M

1. Manifold nozzles, face fit
Series 03 C01, Type WT, Class 03 C
Series 04 C01, Type WT, Class 04 C
Series CB...M, Type XT, Class 07 C
2. Manifold
Series VC
X
03
04
07
+ V
C P
T A
150 g PP GF20
Fan wheel for car air condition
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Fan wheel
Car air condition
150 g
PP GF20
Multi-cavity mould
2
fan wheels for car air conditioning systems
with a 2-cavity mould. Until now the fan
wheels had been produced with a singlecavity mould to ensure the necessary
precision. The demand on the production
with a multi-cavity nozzle was that at least
the same precision in dimensions and
concentricity be achieved.
Solution
with face fit manifold and melt pressure
control was employed. The runner was
designed in the standard form (I). The cavity
was gated via cold sub-runners that were fed
by valve gate nozzles. A pressure-controlled
melt valve was installed upline of each
nozzle with which the flow cross-section in
the runner could be varied dynamically and
infinitely online and in real time or could be
held constant. This permitted not only gentle
opening and closing but also the generation
of individual pressure profiles and hence
individual filling conditions during the filling
and holding pressure phases for each
individual nozzle.
2004-12-08
Benefits
Optimised and variable filling conditions

for each individual cavity
Twice the productivity in the same time
Increased production quality
Constant quality shot for shot
10 / 16
12 E01 W01V
W
1
Series N GA...M, Type WV, Class 12 C
2. Manifold
Series VE
3. Melt valve block DFTB with pressure
transducer
4. Actuator, hydraulic, bolted
Series HYC 4520M 01
5. Servo valves (and pressure generator)
6. PID controller DFC
7. Start signal from the injection moulding
12
+ V
+
Dynamic Feed
p
t
START
C P
T A
186 g + 92 g PP
B-pillar cover for car interior
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Shell, inner support

Car interior
186 g, 92 g
PP
Family mould
1+1+1+1
covers for B-pillars with a family mould. The
cover consisted of the outer shell and the
inner support. Both parts were to be mounted
together after being moulded. Due to qualitiy
and stability reasons both parts had to be
made from the same material and produced
under the same conditions.
Solution
with face fit manifold and melt pressure
control was employed. The runner was
designed in the standard form (I). The cavity
individual nozzle.
2004-12-08
Benefits
Optimised and variable filling conditions

for each individual cavity
Increased production quality
Constant quality shot for shot
10 / 16
T 20 - CV10
CV 10
1
Series N GA...M, Type WV, Class 12 C
2. Manifold
Series VE
3. Melt valve block DFTB with pressure
transducer
Series HYC 4520M 01
20
+ V
+
Dynamic Feed
p
t
START
C P
T A
150 g ASA
Decorative strip for car bumper
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Bumper strip
Car bumper
150 g
ASA
Single-cavity mould
1
decorative strips for the front bumper of a
car. The mould was to be filled in a cascade,
avoiding flow lines and marks on the
mouldings.
Photo: Ford
2004-04-08
Solution
with valve gate nozzles screwed into the
runner and melt pressure control was
employed. Manifold form and nozzle lengths
were specially adapted to the part contour
and the required injection points. The cavity
individual nozzle.
11 / 16
Benefits
Pressure-controlled cascade filling from

the middle of the moulding
Gentle and infinitely variable opening of

individual nozzles
Roughly identical melt front velocity over

the whole moulding length
High surface quality, no flow lines
High dimensional accuracy and form

stability
16 E01 L01V
L
1
1. Manifold nozzle, screw fit
Series 16 E01, Type LV, Class 16 E
2. Manifold
Series VF
3. Melt valve block DFTB
with pressure transducer
Series HYC 4520M 01
16
+ V
+
Dynamic Feed
p
t
START
C P
T A
220 g PP + PES
C-pillar cover for car interior
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

C-pillar cover
Car interior
220 g
PP + PES
Family mould
1+1
textile-lined covers for car C-pillars using the
textile moulding process. The main body of
the cover was to be of PP, the textile surface
of PES. The mould filling had to be
correspondingly gentle and uniform, in a
cascade without flow lines. The cover for the
right-hand side was to be produced in a
family mould together with the cover for the
left-hand side.
2006-06-26
Solution
externally heated 10-port runner system with
long, narrow screw fit valve gate nozzles was
employed. The form of the manifold was
adapted specially to the contour of the part
and the respective required injection points.
The cavity was directly gated with sprue to
the rear of the moulding via valve gate
nozzles.
12 / 16
Benefits
Gentle back-filling of the textile
Adequate space in the mould thanks to

the narrow design of the nozzles
Deep insertion into the mould and

connection at the optimum points
Good, uniform moulding quality from all

the cavities
Moulding production and surface

lamination in a single step
16 E02 L01V

1. Manfiold nozzle, screw fit
2. Manifold
Series VE
Series HYC 4018M 01
16
+ V
C P
T A
1400 g PP LGF10
C-pillar cover for car interior
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

C-pillar cover
Car interior
220 g
PP + PES
Family mould
1+1
textile-lined covers for car C-pillars using the
textile moulding process. The main body of
the cover was to be of PP, the textile surface
of PES. The mould filling had to be
correspondingly gentle and uniform, in a
cascade without flow lines. The cover for the
right-hand side was to be produced in a
family mould together with the cover for the
left-hand side.
2006-06-26
Solution
long, narrow screw fit valve gate nozzles was
employed. The form of the manifold was
adapted specially to the contour of the part
and the respective required injection points.
The cavity was directly gated with sprue to
the rear of the moulding via valve gate
nozzles.
12 / 16
Benefits
Gentle back-filling of the textile
Adequate space in the mould thanks to

the narrow design of the nozzles
Deep insertion into the mould and

connection at the optimum points
Good, uniform moulding quality from all

the cavities
Moulding production and surface

lamination in a single step
22 E01 V01V
1

1. Manfiold nozzle, screw fit
2. Manifold
Series VE
Series HYC 4018M 01
22
+ V
C P
T A
1400 g PP/EPDM
Wheel arch liner for car body
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Wheel arch liner

Car body
1400 g
PP/EPDM
Family mould
1+1
wheel arch liners for car bodies. The wheel
arch liner for the right-hand side was to be
produced in a family mould together with the
wheel housing liner for the left-hand side.
2002-10-09
Solution
with screw fit valve gate manifold nozzles
and melt pressure control was employed.
Manifold form and nozzle lengths were
specially adapted to the part contour and the
required injection points. The cavity was
directly gated with hot runner to the surface
of the moulding via valve gate nozzles or
with sprue via valve gate nozzles. A
pressure-controlled melt valve was installed
upline of each nozzle with which the flow
cross-section in the runner could be varied
dynamically and infinitely online and in real
time or could be held constant. This
permitted not only gentle opening and
closing but also the generation of individual
pressure profiles and hence individual filling
conditions during the filling and holding
pressure phases for each individual nozzle.
13 / 16
Benefits
Differentiated, optimum filling of the

different cavity areas
Avoidance of overfilling in part-areas of the

cavity
Reduction in cycle time and reworking
Increased productivity during series

production of more than 30%
Good, uniform moulding quality from all the

cavities
16 E02 V01V
1
Series 16 E02, Type V V, Class 16 E
2. Manifold
Series VF
3. Melt valve block DFTB
with pressure transducer
Series HYC 4520M 01
16
+ V
+
Dynamic Feed
p
t
START
C P
T A
2500 g PP LGF30
Front end module for car body
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Front end module

Car body
2500 g
PP LGF30
Single-cavity mould
1
plastic front end modulse of long glass fibrereinforced PP for use in car bodies. The
cavity was to be filled sequentially.
2004-08-13
Solution
long, narrow screw fit valve gate manifold
nozzles was employed. Manifold form and
nozzle lengths were specially adapted to the
part contour and the required injection points.
The cavity was gated both directly with hot
runner to the moulding surface and via cold
sub-runners. Both were equipped with valve
gate nozzles. The hot runner system was
correspondingly optimised and equipped for
the processing of long glass fibre-reinforced
material.
14 / 16
Benefits
Gentle processing and minimised glass

fibre shortening thanks to optimised and
runner and correspond equipment of the
hot runner system
Optimisation of the mould cavity filling by

temporally offset opening and closing of
the needles
Optimum positioning of the gates for filling

thanks to runner form and nozzle lengths
adapted to the moulding contour
Production with minimised sprue waste

2. Manifold
Series VF
Series HYC 4018M 01
22 E01 V01V
22
+ V
C P
T A
2500 g PPO GF10

Dash board for car interior
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Dash board
Car interior
2500 g
PPO GF10
Single-cavity mould
1
dash boards of PPO with 10% glass fibre
content for the car interior using the cascade
process.
Solution
screw fit nozzles was employed. Manifold
form and nozzle lengths were specially
adapted to the part contour and the required
injection points. The cavity was gated directly
with hot runner to the surface of the moulding
via needle valve nozzles.
a) Original delivery condition, previous series
components
b) Current situation, current series
components
a)
2001-10-20
Benefits

without reworking
Direct gating of the demanded injection

points

Possibility of influencing the mould cavity

filling thanks to the valve gate nozzles
operating in a cascade
15 / 16
N EZ L G
VHYZ
b)
16 E02 L01V
HYC 4018M 01

2. Manifold
Series VF
Series HYC 4018M 01
16
+ V
C P
T A
5000 g PC
Car window for car body
Key data
Moulded part
Application
Part weight
Material
Mould type
No. of cavities

Car window
Car body
5000 g
PC
Rotary stack mould
1+1
windows of PC for cars. The transparent
base element of the window was to be
produced using the injection-compression
moulding process and then surrounded with
a dark edge in the 2-component process.
The mould for this process was designed as
a turning platen mould.
Solution
externally heated 1-port runner system with a
screw fit manifold nozzle was employed for
the production of the base element. The
cavity was gated made via a film gate with
sprue that was fed by an open nozzle. For
the dark edge of the window, an externally
heated 11-port runner system with long,
narrow screw fit valve gate manifold nozzles
was employed. Manifold form and nozzle
lengths were specially adapted to the part
contour and the required injection points. The
cavity was gated directly with hot runner to
the surface of the moulding via valve gate
nozzles.
Photo: Webasto
System 1
PC transp.
System 2
PC black
16 E01 V01V
22 E01 K01N
2006-06-26
Benefits
Gentle and clean melt transport
Direct connection of the demanded

injection points

separation and/or appearance
16 / 16

2. Manifold
Series VF
Series 22 E01, Type KN, Class 22 E
Series HYC 4018M 01
22
22 E02 V01V
+ V
16
+ 22
+ V
C P
www.synventive.com
T A
GB

MK-PRM.BRM. GB .P.HRAPPL 2008-07-31


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Hot Runner Technology

Examples of Hot Runners in use

All rights reserved. Errors and omissions excepted.

Illustrations simplified, schematically drawn and not to scale.

Hot Runner Technology CC PP

Illustrations simplified, schematically drawn and not to scale.

Broadest possible insight into hot runner technology

Supplementary aid to selecting the appropriate hot runner components

Overview of different solutions in the field of gating technology

What is shown here in detail?

Different examples in order to include as many fields of application as possible

Limitation to the most important key data

Guaranteeing of data security by the use of schematic illustrations

Illustration of original parts only after approval by the manufacturer

Important copyright note

Mould Type / Remarks

2-cavity mould, flame retardant

16+16-cavity turntable mould

Car window mechanism

4+4-cavity stack mould

4+4-cavity turntable mould

2+2+2+2-cavity family mould

Car air condition

Single-cavity mould, cascade moulding

Car interior, textile moulding

Wheel arch liner

1+1-cavity family mould

Instrument panel support

Single-cavity mould, long glass fiber material

Front end module

All rights reserved. Errors and omissions excepted.

2008-07-30 - All rights reserved. Errors and omissions excepted.

For a specific application, please consult Synventive.

Illustrations simplified, schematically drawn and not to scale.

All rights reserved. Errors and omissions excepted.

Saving of time and manufacturing

Manufacture without sprue waste and

Production with high number of cavities

Good gating quality regarding gate mark

Equal supply and filling of all cavities with

Good moulded part quality from all

Schematic product overview

Illustrations simplified, schematically drawn and not to scale.

Production without sprue waste and

Good gating quality with respect to

Uniform supply and filling of all cavities

Good moulding quality from all the cavities

All rights reserved. Errors and omissions excepted.

Schematic product overview

Illustrations simplified, schematically drawn and not to scale.

Production without sprue waste and

Good gating quality with respect to

Uniform supply and filling of all cavities

Good moulding quality from all the cavities

All rights reserved. Errors and omissions excepted.

Schematic product overview

5 g PS metallic + 7g PS custom color

Illustrations simplified, schematically drawn and not to scale.

Fork: Prongs and handle

All rights reserved. Errors and omissions excepted.

Savings in time and costs thanks to the

Production without sprue waste and