The development of advanced hot runner nozzles and controls never stops.Here’s news about these and other tool products at the show.
Männer’s new Edgeline valve gate nozzles are used for lateral injection of long, narrow tubular parts such as syringe barrels.Each nozzle is available in 1, 2 and 4 drops for a compact high cavitation layout.
MHS Hot Runner Solutions introduces a larger size Rheo-Pro Black Box pneumatic valve gate actuator that handles materials such as PEEK, LCP, PSU, PEI and PPS and 200 C ( 392 F) in molds without water cooling.
Another passive cooling system for valve actuators is Synventive’s new SynCool3.The corrugated aluminum conductor contacts the top plate or pressure plate.No water cooling required.
Water flow and temperature monitoring are new options for the Gammaflux G24 temperature controller.This is a recommended safety feature to ensure that the water and valve seals are protected from adequate cooling.
Mold-Masters’ new Summit line of premium hot runner systems are stainless steel with built-in heaters embedded in copper.It is especially targeted for medical applications and has an unusual thermal uniformity for trouble-free handling of sensitive resins through a valve or thermal gate.
Husky’s new Ultra Helix servo-actuated valve gate nozzles reportedly offer least gate residue, longest life and easier mold integration than ever before
ToolingDocs’ new tool room product line includes a standardized mold repair station with optional utility and mold storage space, as well as magnetic mold status labels and light bars.
From hot runners to self-cleaning PET preform molds to 3D printed plastic cavity inserts, a plethora of cutting-edge tooling technologies were showcased at NPE2015 in Orlando, Florida in March.In hot runners, key topics are data storage in the “cloud”, individual adjustability of valve gate opening and closing, and multi-head nozzles for molding long, thin tubular products such as medical pipettes and syringes.Valve gate actuators without water cooling also make their debut.Here’s more news on these topics, complementing those published in previous issues.
Hot Runner News Alba Enterprises introduces to the US a tri-tip nozzle from Thermoplay, Italy, which provides radially balanced fill for long tubular components such as syringe barrels.
As we reported in our March preview, Athena Controls showed off a new version of its Bedros controller with 8 to 64 zones and “cloud”-enabled software.New cloud-based Ion and Pulse controller software from Fast Heat was also reported in March.Wireless remote access to controllers and the ability to predict failures before they occur are key features.Also new are CableXChecker and MoldXChecker, special diagnostic devices that quickly identify bad cables and thermocouple or heater shorts, respectively, before the mold enters the press.
Ewikon Molding Technologies uses an unusual “variable pitch” manifold with hinged arms (HPS III-FleX) for two-chamber prototypes and short runs.Also on display was the MWB 100 Micro Fluidized Bed Cleaning Furnace for nozzle tips (see January Fakuma Close Up for details).
Gammaflux has introduced two new options that can be added to its G24 temperature controller.The water flow monitor uses dual output flow and temperature sensors to ensure proper water flow throughout the mold.Adequate mold cooling is essential to prevent overheating and potential leakage of water and valve gate seals.Consistent cooling is equally important for consistent part quality.The monitor supports 16 analog channels (8 dual output sensors) and has data logging capabilities.An optional second module will double the number of monitored channels.
The second new G24 option is a machine mount bracket that removes the controller from the floor, saving floor space and especially useful in cleanrooms.
Germany’s Heitec, represented by Technoject Machinery Corp., demonstrated a new two-drop valve gate system with a linear motorized Visio-NV-Drive that delays valve opening in adjustable 0.01 second increments, And the valve-pin end position can be set in 0.01mm increments.
HRSflow Italy announced that its Flexflow servo-electric valve gating system has been integrated into Autodesk Moldflow simulation software.Moldflow can now simulate the gradual opening and closing of nozzles whose speed, force and position can be individually programmed.Flexflow targets large thin-walled automotive parts.
Tests using a seven-drop rear spoiler tool equipped with an additional pressure sensor verified Moldflow’s prediction that progressive valve opening and closing produces lower holding pressures and lower holding pressure compared to traditional “cascading” hot runner molding more even.The part is a 4mm thick TPV with 20% talc.Benefits include better surface appearance, lower stress and warpage, and up to 20% higher clamping force requirements.To demonstrate the value of Flexflow, HRSflow installed spoiler tools for demonstrations at its facilities in Italy, China and Grand Rapids, Michigan.
Husky Injection Molding Systems’ main hot runner new product is the Ultra Helix nozzle.According to the company, this servo-driven valve gate reportedly allows direct gated parts to have gate marks so slight that they are “often unmeasurable,” and the company also claims that “this level of gate quality can last for several days.” Million Cycles – Longer than any other” valve gate currently available.Husky said testing showed 65% of parts had an average gate residue of 0.0mm, with a maximum residue of less than 85% of parts molded with other valve gates, including earlier Husky models. Hess Base asserts that the nozzle will require no replacement parts for over 5 million cycles.
Additionally, Husky says the Ultra Helix simplifies cold semi-machining requirements to integrate hot runners.That’s because “all the complexity is inside the nozzle,” said Dave Morton, Husky’s vice president of hot runners and controls for the Americas.He also noted that new manufacturing techniques ensure the concentricity of the valve stem and gate, virtually eliminating mechanical wear on these components.Ultra Helix also has a highly consistent heat distribution, so molders don’t have to worry about changing the balance between cavities after replacing replaceable heaters.
Other news from Husky nozzles includes the introduction of the Ultra Side Gate for stack molds at NPE 2012.The sloped tip helps keep more customers away from cold runners, Husky said.
In addition, Husky’s new Unify pre-assembled manifold system marks the company’s renewed foray into automotive technical components – precision molding of engineering resins.
On the control side, Husky showed the latest enhancements to its Altanium Matrix2, a high-end system for high-cavity molds (up to 254 zones).Measurement and control accuracy is said to be even better than before, while the new H-series circuit cards offer more functionality in a smaller footprint.Added safety features enhance diagnostics and fault mitigation.
Husky’s big news in control, however, is the Altanium Servo Control, which Husky calls “the first integrated temperature and servo controller.”It controls all servo axes in the mold – not just valve gates, but also collapsible cores, slides, unscrewing, stack rotation and imprint movements.
Incoe announces the new GSC Micro Valve-Gate Sequencer.It is a simple, low-cost device that provides timer-based pneumatic control of up to eight zones.Incoe also demonstrated a compact HEM hydraulic cylinder for valve gates and demonstrated the value of its SoftGate valve-gate speed controller.The chrome layer of the Audi grille is blistered, which is caused by tiny air bubbles under the surface of the ABS components.This problem is solved by using SoftGate to control the opening of the control gate.
Edgeline is a new generation of side jet valve nozzles from Männer, Germany.It targets long, narrow tubular parts such as syringe barrels.The valve pin moves at right angles to the mold parting line.Available in 1-drop, 2-drop and 4-drop per nozzle, it enables a compact high cavitation layout (see image).The multi-drop nozzle has a pneumatic pin that opens and closes all gates simultaneously, but the temperature is individually controlled.Edgeline is said to perform well with resins such as COP, COC, PMMA, PC and TPE.
Another new product from Männer is its smallest Slimline nozzle for engineering resins with a diameter of 8 mm.and 16 mm spacing.(This size is already available for polyolefins.) The improved temperature distribution allows these small nozzles to be as long as 164 mm.
Männer’s third new development is the MCN-P valve gate nozzle for thin-walled packages molded at high injection pressures and high speeds.Available in lengths from 79 to 404 mm (previously up to 304 mm), it has a screw-in tip with an improved temperature profile, a highly wear-resistant design, and an additional guide ring for under the pin Nozzle tip available Excellent gate quality.
MHS Hot Runner Solutions introduces a larger size Rheo-Pro Black Box pneumatic valve gate actuator that handles materials such as PEEK, LCP, PSU, PEI and PPS and 200 C ( 392 F) No cooling required in mould.The original smaller version was introduced at the K in 2013.
As reported in March, MHT Mold & Hotrunner Technology showcased a cavitation upgrade kit and new prefabricated manifold system for Husky HyPET preform molds for fast delivery and moderate cost.
Topping the list of new products from Milacron LLC is the Mold-Masters Summit series of premium hot runner systems.The nozzle and manifold feature cast heaters surrounded by copper for good heat transfer, sandwiched between a stainless steel core and jacket for chemical resistance.Specifically targeted for medical and personal care applications, it has less than ± 5% thermal variation, which is important for running sensitive resins such as PC, COP, COC, PBT and acetal.At the show, the Summit Series also used Eastman’s Tritan copolyester in a 32-cavity mold for medical luer fittings.
The Summit series is available in valve-style versions with servo-controlled pin actuators that use compact stepper motors for individual speed, time and position control.Synchronized plate drives for all pins (pneumatic, hydraulic or servo) are also available.Summit series valves feature a new expanded ceramic disc for thermal insulation and improved guidance and leak resistance.The popular version comes with a ceramic EcoDisk for thermal insulation.
The collection is available in three sizes – femto, pico and centi.The manifold uses iFlow technology – curved flow channels instead of straight gun drilled channels.The full hot half has a special coating on the front of the valve stem for corrosion resistance and durability.
Other hot runner news from Milacron includes a new optimized dual gate solution for the Mold-Masters Melt Cube.It feeds long, hollow parts such as pipettes and syringe barrels from both sides.Previously, each Melt Cube contained one nozzle for each part, but now it contains two nozzles facing in opposite directions.It is said to result in lower capital investment.
Osco Inc. demonstrated its new Micro Valve-Gate Sequencer for up to 8 zones.It is pneumatic and time based.Also new last year was the Quick Set mini hot half, a drop-in manifold with standard off-the-shelf components.Osco also demonstrated mixing applications for its MGN multi-gate nozzles.It combines two Osco systems: its MGN multi-gate nozzle body is used for the manifold, and the CVT-20 series of externally heated nozzles are used for droplets instead of using nozzles embedded in the MGN manifold.This provides design flexibility and longer nozzle lengths for applications with tight spacing requirements.
Plastics Engineering and Technical Services introduces the EvenFlow variable speed programmer for valve gates (see April Update for details).Polyshot Corp. demonstrated its new single-nozzle valve gate.
Synventive Molding Solutions introduces nuGate and hGate controls (pneumatic and hydraulic, respectively) for full control of valve gate pin speed, acceleration and opening and closing travel.These complement its eGate electric version.A new line of modular plug-and-play actuators for pre-installed, pre-wired and pre-tested valve gates was also reported in March.The third new product is SynCool 3 passive cooling for Synventive’s new hydraulic and pneumatic valve actuators.
Unlike SynCool 1 and 2, it does not use a water cooling plate, thus improving both manifold temperature control and eliminating seal failures caused by clogged cooling circuits.This patent-pending system uses aluminum heat conductors with a wavy geometry, in contact with the top plate or platen.In addition, the titanium support inhibits heat transfer to the cylinder (see image).It targets polyolefin applications up to 250 C (482 F).
Hasco America showcased its latest and improved Z3281 version of the Multimodule for mounting multiple nozzles in a circular manifold block.It now accepts screw-in TechniShot Series 20 nozzles for leak-free operation.The temperature of each nozzle is individually controlled.Nozzle lengths range from 50 to 125 mm with pitch diameters from 17 to 42 mm.
Yudo in Korea has recently started using welding to make complete hot halves.This method combines two separate plates and allows the runners on both plates to be polished so there are no dead spots, which helps in faster color changes.Likewise, Yudo has begun using brazing to produce core and cavity inserts by bonding the two pieces together.This enables cooling channels to be introduced into locations not possible with conventional gun-drill channels.
Moulds and Components Interesting news for PET preform formers is Husky’s self-cleaning moulds.As we reported in our May showcase feature, controlled flashing of the neck ring area removes mold deposits in one cycle, saving hundreds of hours of maintenance each year.
Two exhibitors used Stratasys Polyjet machines to demonstrate the use of 3D-printed prototypes or short-run builds of cavity inserts made from modified ABS.The insert is said to be durable enough for 500 shots, but relatively long cycles due to limited heat transfer.Milacron shows how a cavity can be printed in under 5 hours, then cleaned, inspected and loaded into a quick-change DME MUD die set running on a 17-ton Roboshot all-electric press.The cycle time is approximately 100 seconds.
Toshiba also molds parts in 3D printed cavities.What’s more, it uses a six-axis robot to switch plastic and steel cavities in a quick-change mold base.
While nothing new, Mitsubishi Heavy Industries demonstrated an interesting technique called Sequential Cavity Separation (SCS), which uses valve gates in family molds to sequentially inject two similar or different parts.This “shared tonnage” method uses less clamping force than when two parts are injected at the same time.At the show, a 720-ton ME2+ was fully motorized to a 16-inch diameter.PC spice pans use no more than 400 tons of force to do a job that would normally require 900 tons.SCS can allow independent injection profiles for each cavity.According to MHI, even if the two parts are identical, SCS is valuable for weight-critical applications, such as fan blades, because individual injection provides tighter injection control for each part.
A technology Milacron is developing called SmartMold will be released in the third or fourth quarter.It will reportedly be able to provide a wider range of information about molds than before – non-contact wet cycle counts, overpressure, overheating, over-tonnage and mold abuse, such as violent shutdowns.SmartMold will be able to communicate with presses, dryers and coolers; it will allow remote monitoring of molds via “cloud” reporting to automatically notify users and suppliers of pending needs for parts or services.
Several new standardized die assemblies from Hasco America were reported in the March Keeping Up, new assemblies from DME, Quick Change Die Clamps from Lenzkes Clamping Tools, Unscrewing Unit from Superior Die Set Corp. and Die Rust Prevention from MetalRustGuard The agent, , is displayed by the DMS component.Cumsa USA showcases a new air poppet valve for parts release, as reported in Keeping Up in February.Kistler presents new sensors with replaceable cables or no cables at all.
Alba Enterprises presented several new hydraulic cylinders for die action/slides from Vega, Italy:
• There is a new option for the V450CM compact heavy duty cylinder with a mechanical switch built into the cylinder.They send a signal to the machine so the machine knows where they are.These units can withstand temperatures up to 320 F and pressures up to 6500 psi.
• The internal self-locking cylinder on the stationary side of the mold is also new.More compact than competing units, the smallest can hold 10 tons and the largest can hold 70 tons, with pneumatic or hydraulic drive.
• A new waterproof connector plate is inserted into all cylinders on the mold.Indicator lights show the position of each cylinder, solving the problem of identifying which cylinder is out of position and preventing circulation without the need for a skilled electrician.
• There is also a new electric cylinder for all-electric machines.Another alternative to hydraulic actuation is high pressure air.
Post time: Jan-19-2022
