Gastrow Injection Molds

Contents

1 Principles of Mold Design

1.1 Types of Injection Molds

1.2 Types of Runners and Gates

1.2.1 Solidifying Systems

1.2.2 Hot Runner Systems

1.2.3 Cold Runner Systems

1.3 Temperature Control in Injection Molds

1.4 Types of Ejectors

1.5 Types of Undercuts

1.6 Special Designs

1.6.1 Molds with Fusible Cores

1.6.2 Prototype Molds of Aluminum

1.6.3 Prototype Molds Made of Plastics

1.7 Status of Standardization for Injection Molds

1.7.1 Standardized Mold Components (as of Mid-2005)

1.7.2 Standardized Electrical Connections for Hot Runner Molds

1.7.3 Terminology Standards for Injection Molds

1.7.4 DIN ISO 16916 "Tools for Molding - Tool Specification Sheet for Injection Molds"

1.8 Standard Mold Components

1.9 Injection Mold for Producing Test Specimens from Thermoplastic Resins

1.10 Materials Selection

1.10.1 General Requirements for Materials

1.10.2 Tool Steels

1.10.3 Non-Ferrous Metals

1.10.4 Anorganic Nonmetallic Materials

1.10.5 Surface Treatment Methods

1.11 Materials Properties under Mechanical Stress

1.11.1 Notch Effect under Static Stress

1.11.2 Notch Effect under Dynamic Stress

1.12 Thermal Insulation and Reflector Plates

References in Chapter 1

1.13 Further Reading on Injection Mold Construction

2 Special Design Features of the Example Molds

3 Examples

3.1 Single-Cavity Injection Mold for a Polyethylene Cover

3.2 Two-Cavity Injection Mold for Elbow Connector Made from PA 66

3.3 Injection Mold for the Body of a Tape-Cassette Holder Made from High-Impact Polystyrene

3.4 Five-Cavity Injection Mold for Tablet Tubes Made from Polystyrene

3.5 Four-Cavity Injection Mold for a Polyamide Joint Element

3.6 Mold Base with Interchangeable Inserts to Produce Standard Test Specimens

3.7 Two-Cavity Rotary Core Mold for a Polyacetal Pipe Elbow

3.8 Hot Runner Injection Mold for Car Front Fender

3.9 Injection Mold for Magnifying Glass Frame with Handle

3.10 16-Cavity Hot-Runner Mold for Cover Caps with Segmented Internal Contours Made from Polypropylene (PP) or Polyethylene (PE)

3.11 Four-Cavity Injection Mold for a Housing Made from Acrylonitrile-Butadiene-Styrene (ABS)

3.12 Four-Cavity Injection Mold for a Nozzle Housing Made from Polyamide

3.13 Single Split Cavity Mold for a Threaded Plug Made from Polyacetal (POM)

3.14 Demolding a Polyethylene Container with External Undercuts

3.15 Injection Mold with Reduced Opening Stroke for Milk Crates from Polyethylene

3.16 Two-Cavity Injection Mold for Recessed Refrigerator Handles Made from Polyamide

3.17 Injection Mold for a Grass Catcher Made from Polypropylene

3.18 Injection Mold for Hose Connectors Made from Polyamide 6.6

3.19 Two-Cavity Injection Mold for the Coil Form of an Auxiliary Relay

3.20 Single-Cavity Hot-Runner Mold for Business Card Boxes Made from Polypropylene

3.21 8-Cavity Injection Mold for Threaded Rings Made from Polyacetal (POM)

3.22 Mold for a Pump Housing and Pump Piston Made from Polyacetal

3.23 Hot-Runner Injection Mold for Two Film Spools Made from High-Impact Polystyrene

3.24 Injection Mold for an Angle Fitting from Polypropylene

3.25 Mold for Bushings from Polyamide with Concealed Gating

3.26 Injection Mold for the Valve Housing of a Water-Mixing Tap Made from Polyacetal

3.27 Mold for a Lid with Three Threads Made from Polyacetal

3.28 Two-Cavity Injection Mold for Coupling Sleeves Made from Polyamide

3.29 Injection Mold for the Housing of a Polypropylene Vegetable Dicer

3.30 Two-Cavity Injection Mold for a Polypropylene Toy Tennis Racket

3.31 Two Injection Molds with Two-Step Ejection Process for Housing Components from Polycarbonate

3.32 Injection Mold for a Polypropylene Container with a Threaded Neck

3.33 Three-Plate Injection Mold with Stripping Device for a Precision Magazine

3.34 6-Cavity Metal-Powder Injection Mold (MIM) for Transport Fasteners

3.35 Mold for a Polyamide V-Belt Pulley

3.36 2 x 8-Cavity Hot-Runner Stack Mold for Yoghurt Cups Made from Polypropylene

3.37 2 x 2-Cavity Stack Mold for Covers Made from Polypropylene

3.38 2 x 5-Cavity Stack Mold for Cases Made from Polypropylene

3.39 16-Cavity Hot-Runner Mold for Packaging of Medical Parts made from Polypropylene

3.40 Hot-Runner Stack Mold for a Water Distribution Block Made from Polypropylene

3.41 2 x 8-Cavity Stack Mold for Lozenge Box Made from Polystyrene

3.42 Two-Cavity Injection Mold for a Tail Light Housing Made from ABS

3.43 2 x 2-Cavity Stack Mold with a Hot-Runner System for Runnerless Molding of Polystyrene Container Lids Using Direct Edge Gating

3.44 2 x 4-Cavity Hot-Runner Stack Mold for Dessert Cups Made from Polypropylene

3.45 Hot-Runner Mold for Bumper Fascia Made from Thermoplastic Elastomer

3.46 Four-Cavity Hot-Runner Mold for Threaded Covers Made from SAN

3.47 Two-Cavity Hot-Runner Mold for Trim Bezels Made from ABS

3.48 Four-Cavity Hot-Runner Mold for Control Flap Made from Polyacetal Copolymer

3.49 64-Cavity Hot-Runner Mold for Seals Made from Thermoplastic Elastomer (TPE)

3.50 Eight-Cavity Hot-Runner Mold for PP Toothpaste Dispenser

3.51 2-Cavity Hot-Runner Mold for Polyethylene Jars

3.52 Two-Cavity Hot-Runner Mold for Production of Connectors Made from Polycarbonate

3.53 Four-Cavity Hot-Runner Unscrewing Mold for Cap Nuts Made from Polyacetal (POM)

3.54 Four-Cavity Hot-Runner Mold with a Special Ejector System for a Retainer Made from Polypropylene

3.55 Example 55, 2 x 16-Cavity Two-Component Injection Mold for Microswitch Covers Made from Polyamide and Thermoplastic Elastomer

3.56 32-Cavity Hot-Runner Mold for Production of Packings Made from Polyethylene

3.57 12-Cavity Hot-Runner Mold with Edge Gates for Bushings Made from Polyacetal Copolymer

3.58 Single Injection Mold for Sleeves Made from Glass-Fiber and Talcum Reinforced PA 66

3.59 Two-Component Injection Mold for Drink Can Holders Made from Polypropylene and Ethylene-Propylene Terpolymer

3.60 Hot-Runner Mold for Polypropylene Clamping Ring with Internal Undercut around the Circumference

3.61 Injection Mold for Compact Discs Made from Polycarbonate

3.62 Single-Cavity Injection Compression Mold for a Cover Plate Made from Unsaturated Polyester Resin

3.63 Two-Cavity Injection Compression Mold for a Housing Component Made from a Thermosetting Resin

3.64 Injection Compression Mold for a Plate Made from Melamine Resin

3.65 Five-Cavity Unscrewing Mold for Ball Knobs Made from a Phenolic Resin

3.66 Four-Cavity Injection Mold for a Thin-Walled Housing Made from a Phenolic Resin

3.67 Thermoset Injection Mold for a Bearing Cover Made from Phenolic Resin

3.68 6-Cavity Hot-Runner Mold for Coffee Cup Covers Made from Polypropylene

3.69 Two Injection Molds for Overmolding of Polyamide Tubing for Automobile Power Window Operators

3.70 Single-Cavity Injection Mold for a Housing Base Made from Polycarbonate

3.71 Connector with Opposing Female Threads Made from Glass-Fiber-Reinforced Polyamide

3.72 Cylindrical Thermoplastic Container with Reduced-Diameter Opening – A Study in Part Release

3.73 Single-Cavity Injection Mold for a Lighting Fixture Cover Made from Polymethylmethacrylate (PMMA)

3.74 Injection Mold for a Housing with a Thread Insert Made from Polycarbonate

3.75 Mold for Long, Thin, Tubular Parts Made from Polystyrene

3.76 Insulated Runner Mold for Three Specimen Dishes Made from Polystyrene

3.77 Single-Cavity Injection Mold for a Polypropylene Emergency Button

3.78 Eight-Cavity Injection Mold for Battery Caps with Undivided External Thread and Sealing Cone Made from Polypropylene

3.79 Injection Mold for a Curved Pouring Spout Made from Polypropylene

3.80 Injection Mold for an ABS Goggle Frame

3.81 4-Cavity Hot Runner Mold for an ABS-PC Front Ring

3.82 Two-Cavity Two-Component Injection Mold for a PC/ABS Bezel with a PMMA Window

3.83 Two-Cavity Injection Mold for Runnerless Production of Polycarbonate Optical Lenses

3.84 Injection Mold with Hydraulic Core Pull for a Cable Socket

3.85 Four-Cavity Injection Mold for Pipets Made from PMMA

3.86 Two-Cavity Mold for Water Tap Handles Made from PMMA

3.87 Two-Cavity Injection Mold for the Automatic Molding of Conveyor Plates onto a Wire Cable

3.88 20-Cavity Hot-Runner Mold for Producing Curtain-Ring Rollers Made from Polyacetal Copolymer

3.89 Injection Mold with Attached Hydraulic Core Pull for Automatic Measuring Tubs Made from PC

3.90 48- and 64-Cavity Hot-Runner Molds for Coating Semi-finished Metal Composite with Liquid Crystalline LCP Polymer (Outsert Technology)

3.91 24-Cavity Hot-Runner Injection Mold for Polyacetal Spool Cores

3.92 Two-Cavity Hot-Runner Mold for Loudspeaker Covers Made from Polyacetal

3.93 Injection Mold with Air Ejection for Polypropylene Cups

3.94 Molds for Manufacturing Optical Lenses Made from PC

3.95 Two-Cavity Injection Mold for a Polycarbonate Steam Iron Reservoir Insert

3.96 Injection Mold with Pneumatic Sprue Bushing for a Headlight Housing Made from Polypropylene

3.97 Injection Mold for a Mounting Plate (Outsert Technique)

3.98 Twelve-Cavity Hot-Runner Mold for a Polyphthalamide (PPA) Microhousing

3.99 Two-Cavity Injection Mold for Handle Covers Made from Glass-Fiber-Reinforced Polyacetal

3.100 Four-Cavity Injection Mold for Thin-Walled Sleeves Made from Polyester

3.101 Injection Mold for a Microstructure Made from POM

3.102 Injection Mold for Production of Adjustable Climate Control Vents via 3-Shot Molding

3.103 Two-Cavity Hot-Runner Injection Mold for an ABS Cover

3.104 Six-Cavity Injection Mold for Retaining Nuts Made from Polyamide with Metal Inserts

3.105 Single-Cavity Injection Mold for a Switch Housing Made from Polyacetal

3.106 Single-Cavity Injection Mold for a Snap Ring Made from Polyacetal

3.107 Single-Cavity Hot-Runner Injection Mold for High-Density Polyethylene (PE-HD) Trash Can Lids

3.108 Single-Cavity Hot-Runner Injection Mold for an Air Vent Housing Made from Acrylonitrile Butadiene Styrene (ABS)

3.109 Single-Cavity Hot-Runner Injection Mold for an ABS Housing

3.110 Single-Cavity Runnerless Injection Mold for a Polystyrene Junction Box

3.111 Four-Cavity Hot-Runner Injection Mold for a Polyamide 6,6 Joining Plate

3.112 2 x 4-Cavity Hot-Runner Stack Mold for Hinged Covers

3.113 16-Cavity Mold with Cold-Runner System for Liquid Silicone Rubber (LSR) Caps

3.114 Two-Cavity Injection Mold for a Styrene-Acrylonitrile Safety Closure

3.115 Four-Cavity Unscrewing Mold for Threaded Polypropylene Closures

3.116 Four-Cavity Injection Mold for Polyester Dispenser Heads

3.117 Two-Cavity Injection Mold for PMMA Lighting Fixture Cover

3.118 Two-Cavity Injection Mold for Polyacetal Hinges

3.119 Eight-Cavity Injection Mold for PE-HD Threaded Caps

3.120 4-Cavity Hot-Runner Mold for Connectors Made from Polystyrene

3.121 Single-Cavity Mold for a Polypropylene Cutlery Basket

3.122 Two-Cavity Injection Mold for Cover Plates Made from Polyacetal

3.123 Single-Cavity Injection Mold for a Joystick Baseplate Made from PA 66

3.124 Single-Cavity Injection Compression Mold for Thermoset V-Belt Pulley (Injection Transfer Mold)

3.125 16-Cavity Hot-Runner Mold for Paperclips Made from ABS

3.126 Single-Cavity Injection Mold for a PE-HD Clothes Hanger Produced via Gas-Assisted Injection Molding

3.127 Single-Cavity Injection Mold for a Syringe Shield Produced via Metal Injection Molding (MIM)

3.128 Three-Station Mold for a Handtool Handle Made from PP/TPE

3.129 Four-Cavity Injection Mold for Couplings Produced via Metal Injection Molding (MIM)