Top Tools for Injection Molding

Rapid leak detection in press nozzles and manifolds.

Image courtesy PCS Co.

The new Airtect Plastic Leak Detection System from PCS Co. is designed to provide 24/7 protection of injection molding machine nozzles and manifold systems, reducing downtime and costly repairs. 

The system sends tiny volumes of low-pressure air through robust stainless-steel sensor tubes to quickly detect most leaks thanks to a self-teaching algorithm, said PCS. 

The starter kit comes with a small controller, an air regulator, silicone tubing, stainless-steel tubing, and polyurethane tubing. Users can build onto the starter kit with additional accessories that make it possible to perform full hot-runner manifold leak detection. 

“The Airtect Plastic Leak Detection System is an essential tool that can be installed directly onto the injection molding machine nozzle or hot runner manifold system," said PCS VP of sales Derrick Jones. “It quickly alerts users of leaks in the form of an alarm and/or the suspension of production, enabling faster operator response and repair. The system can be adapted to any hot runner system, either new or retrofit.”

Granulator cuts large molded parts down to size.

Image courtesy of Wittmann.

Wittmann’s new beside-the-press blade granulator is suited for grinding large injection molded parts up to 500 x 200 mm (19.7 x 7.9 in.) in size.

Because of its compact footprint, performance, and maximum material throughput of 100 kg per hour, the G-Max XL can be used as a beside-the-press granulator for inline recycling of sprues and reject parts during machine startup. It can also be used as a central granulator.

The open design of the three-blade cutting rotor makes the G-Max XL ideal for grinding heat-sensitive materials that still retain heat from processing, according to Wittmann. Open spaces between the blades and rotor shaft ensure ventilation, and the knives can be easily changed. The rotating and fixed blades, which are angled in opposite directions, ensure a clean scissor cut.

No tools are required to access the cutting chamber or the screen fixture, which also facilitates cleaning and maintenance operations. Even material and color changes can be carried out very quickly, further increasing productivity.

Precise temp control for hot-runner molding.

Image courtesy of Oerlikon HRSflow.

New T-Flow HRS control units from Oerlikon HRSflow increase the precision and reliability of temperature control in hot-runner injection molding. Modular in design, three models are configurable to multiples of six zones.

The combination of integrated touchscreen, clear text display, smart navigation, and guided operation results in a particularly user-friendly concept without the need for instruction or prior knowledge, according to Oerlikon HRSflow. Recipes and test reports can be installed and transferred quickly and efficiently via the integrated USB port. Data is exchanged with the injection molding machine via the OPC UA interface in accordance with the new Euromap 82.2 standard protocol for hot-runner controllers. The integrated VNC server also enables convenient operation via notebook, tablet, or smartphone.

T-Flow HRS precisely controls the nozzle temperatures, allowing universal use, even in demanding high-performance applications with compact nozzles. Several heating options are available, and different recipes can be saved, stored, compared, and quickly called up.

Die changing system enables single person to move five-ton loads.

Image courtesy of Roemheld.

A new rail-guided die changing table for transporting heavy dies and molds is available in three versions for loads up to 15, 25, or 40 tonnes per die. The electric RWS system from Roemheld is equipped with two different pull-push mechanisms for the safe, automatic transport of dies to set-up presses. It is compatible with most machines.

The RWS system, for example, can help car manufacturers integrate numerous individual parts into increasingly large castings, which are processed with heavier dies in larger presses and punches.

The die changing table travels on floor-level round rails, with a rolling resistance so low that up to five-ton loads can be moved manually by one person. In addition, the rails are designed to facilitate precise carriage guidance and to prevent dirt deposits and tripping hazards in the floor.

The integrated pull-push mechanism moves dies on and off the press bed via the roller rails. A safety device ensures that loads can only be moved when the RWS die changing table is firmly attached to the press or storage space.

A standardized base plate accepts dies of various sizes, and the integrated control system enables semi- and fully automatic die changes and precise positioning to within ±0.3 mm. 

Ejector pins fit into crowded cavities.

Image courtesy of Progressive Components.

Progressive Components has expanded its line of TI pins, which now include 267 new standard sizes in longer lengths.  

Unlike stamping punches, which are sometimes used as core pins in molds, the heads of TI pins are precision ground to mold tolerances. Also, rather than beginning with a fractional-diameter core pin, step grinding can be eliminated with mold inserts fabricated to the molded part diameter via wire electrical discharge machining. The TI pins only need to be cut to the finished length.

Designed to fit into small, crowded cavity and core inserts, the pins are manufactured with hardened M-2 steel and are available in diameters from 0.060 to 0.320 in. and in 2.5- and 5.5- in. lengths. Cut-to-length and custom options are also available.