2 Sprue Bushing

Sprue
Mold Parts Gate

ž Sprue Bushing Cavity

— Cold sprue
— Sprue puller Runner
2 Sprue Bushing
Mold Parts
ž Sprue Bushing
— Cold sprue
— Sprue puller
2 Runner System Construction

Sprue
sprue will contact first time with melt plastic, at the
injection process, sprue always contact with nozzle
from the injection machine, so consider when design
the sprue consider the ball radius of nozzle, make
sure it isn't make undercut on sprue.The dimensions
of the sprue depend primarily on the dimensions of
the molded part in particular the wall thickness, too
little sprue will make sprue cold faster and make
insufficient flow.

Main Runner
First time when design runner system, determine
number of cavities, shape and gate types, then
arrange the cavity layout,at the multi cavity of mold
balancing of runner is important, balancing ensures
virtually equal flow of plastic trough each gate. To
achieve balancing runner layout must be though,
2 Runner System Construction

Consider computerized moldfilling Analysis to adjust gate locations and/or runner

section lengths and diameters to achieve balanced flow to each cavity. Naturally
balanced runners provide an equal flow distance from the press nozzle to the gate on
each cavity. Spoked-runner designswork well for tight clusters of small cavities.
However they become less efficient as cavity spacing increases because of cavity
number or size.
2 Runner System Construction
Su
Sub
u Runner
this part will continues flow from main runner until the gate, the dimension of sub
runner and how much sub runner system will be, is very depending on how much
cavity of the mold, and how the layout, what the layout use herring bone, H type, or
star type. at the picture above use H type runner layout.

Cold Slug
when runner layout bent, clod slug may be required to continue plastic flow of better
quality to the cavities.The cold slug well helps the flow of material through the runner
system by stopping colder, higher viscosity material moving at the forefront of the
molten mass entering into the cavity.The length of the well is usually equal to or
greater about 1,5-2 time than the runner diameter.

Gate
Basic purpose of the gate is to limit the flow of the melted plastic, but it must allow
that melted plastic flow and fill the cavity easily.
considering the fluidity of the material, gate should be made near the center of
gravity of molding or the line to make flow uniform and melted material even, then
make the gate thick but still considering melted plastic material, becouse thin part will
cooled easily and faster.
22 Runner System Construction
Runner layout
R
Ru
In general they are three type of runner
layout
1. "H" bridge (branching) runner system
2. Standard (herringbone) runner
system (conventional runner)
3. Radial (star) runner system
2 Runner System Construction
Three-plate
Th runners usually
require sucker pins or some other
feature to hold the runner on the
stripper plate until the drops clear
the center plate during mold
opening. Be sure these features do
not restrict flow. Artificially
balanced runners provide
balanced filling and can greatly
reduce runner volume. Artificially
balanced designs usually adjust
runner-segment diameters to
compensate for differences in
runner flow length. For instance, in
ladder runners, the most common
artificially balanced runner design,
a primary runner feeds two rows of
cavities through equal-length
secondary runners.
The diameters of these secondary runners are made progressively smaller for the
avities with shortest runner flow distance. These designs require enough secondary
runner length to flow balance using reasonable runner diameters.
2 Runner System Construction
Mold Parts
ž Runner
— Layout
Conventional Improved Balanced “H” Circular
2 Runner System Construction
Mold Parts
ž Runner
— Layout
Conventional Improved Balanced “H” Circular
2 Runner System Construction
Mold Parts
ž Runner
— Cold well
2 Runner System Construction
Mold Parts
ž Runner
2

Runner dimensions
The diameter of a
runner depends on its
length in addition to the
part volume, part flow
length, injection
machine capacity, and
gate size, Generally
runner must never be
smaller than the largest
wall thickness of the
product, it's usually
make from 3 mm until
15 mm.)
2 DIE
To compare runners of
T
different shapes, the flow
efficiency L of the melt
through a runner, which is
an index of flow resistance,
is employed. The higher
the flow efficiency of the
melt through the runner,
the lower the flow
resistance is. Flow
efficiency can be defined
as:
L= A/P

L = flow efficiency of the

melt through a runner,
A = cross section area,
P = perimeter.
2 DIE

Diameter
to determine the diameter,
based on the type of
material and wall thickness,
the following chart can help,
for similar materials PP, PA,
POM, PC, PE can use the
following graph, first select
the appropriate thick wall
thickness and look heavy
parts, and then pull the line
down, the approximate
diameter required will be
obtained
2 T high shear gates reach a size limit based on the frictional heat that is
The
generated when the polymer chains are forced through the gate. If the shear rate
g
is too high then thermal degradation of the polymer occurs. The chain scission
that follows can result in discolouration of the material and may cause a loss of
physical properties. As a guide the maximum shear rate of 60,000 sec-1 is used in
determining the minimum gate size.

The low shear gates on the other hand are more concerned with maintaining
laminar flow as the material exits the gate because the turbulence will cause
visual gate defects. In this case we want to maintain a laminar flow so a maximum
shear rate of 10,000 sec-1 is recommended.

At this point it must be stressed that these guidelines are for the minimum gate
size that should be used and is a recommended starting point. The gate size may
need to be increased to allow sufficient pack out of the cavity. In rearranging the
formulas to calculate the gate size;