BDD 40903

INJECTION MOLD
DESIGN
BDD 40903 Prepared by : Mohd Hilmi Othman 1
 CHAPTER 6
Ejector Design(4 hours)
1. Ejector system design process
a) Identify mould parting surface
b) Estimate ejection force
c) Ejector push area and parameter
d) Type, number and size of ejector
e) Ejectors layout
2. Ejector system analyses and designs
a) Ejector pin
b) Ejector blade
c) Ejector sleeve
d) Ejector plate

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Ejector Design ( Part 1)
Ejector System Design Process

• Identify mould parting surface

• Estimate ejection force
• Ejector push area and parameter
• Type, number and size of ejector
• Ejectors layout

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Ejector Design

What is the
different between
Inject and Eject?

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Ejector Design

Eject

Before After

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Ejector Design
Ejector Component List

1. Ejector plate, place for ejector and ejector guide bush, shoulder bolts and return pin.
2. Ejector Backing Plate, place for clamping the ejector and push back the ejector.
3. Return pin, push the ejector plate and ejector backing plate to first position.
4. Spring in return pin, to make sure and holds the ejector plate so it's always in back position, when in
assembling process, it can lift up the ejector pin, and ejector plate so the position always in back, give the
little preloads to ejector plate to make sure the ejector plate position.
5. Shoulder bolts, first time lock in assembling molds
6. Ejector pin, eject and push the product from core.
7. Ejector guide pin, guide the moving of ejector plate.
8. Ejector guide pin bush, to make sliding and prevent large contact when moving.
9. Support pillar, to prevent large deflection of core plate when injecting the plastic material process held.
10. Ejector rod, contact with rod in injection machine, this also passing force from injection machine to ejector
plate.
11. Ejector bolts, to tie up between ejector plate and ejector backing plate.

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Ejector system design process
Ejector working system
1. After cavity of mold injected with plastic material, and cooled mold
base will open, and product have to eject from the core insert.
2. After mold base in open condition, the rod from injection
machine will push the ejector rod, because ejector rod connected
to ejector plate, ejector plate will move forward.
3. The ejector guide pin will guide those moving, to prevent scratch
and guide the moving more easily use ejector guide bush, ejector
pin and ejector guide bush will have little friction.
4. The ejector pin clamped between two ejector plate, because that
ejector pin will also move forward push the product.
5. After product take it out from cavity, mold base will moving close
again.
6. Because at the return pin have spring, spring and closing mold will Ejector pin for mold and tool
guide ejector back to the position (1).

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Identify mould parting surface

• A product geometry and orientation in

the mold determines the number and
location of the mold’s parting surfaces.
• If the mold has no undercuts or special
requirements, then only parting surface
may be necessary.
• However, if the mold has internal or
external undercuts, then the additional
parting surfaces may be necessary
along with the associated ejection
components to actuate the sliding cavity
and /or core inserts to release the trapped
area of the moldings so that they maybe RTV Silicone Rubber Molding Process Description
ejected.

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Estimate ejection force
• The ejection force required to remove a
Mold Ejection Force Formula
molding from a core is a function of normal
force between the surface of the molding and
the surface of the mold, together with the
associated draft angle and the coefficient of
static friction between the molded part and the
core insert.
• To estimate the ejection force, the friction force
is first computed as:

• The ejection force is then calculated as the

component of friction force that is normal to
parting surface:

Feject = cos 0. Ffriction

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Estimate ejection force

• The relationship between these forces are

represented in Figure 11.5.
• Approximate values for the coefficient of
friction vary from 0.5 for highly polished
surface (with low surface roughness) to
more than 1.0 for rough and/or
textured surfaces.
• As the draft angle decreases from zero,
the ejection forces decrease with the
cosine of the draft angle.
• The normal force acting between the
molded part and the core is driven by the
internal tensile stresses in the plastic,
which will cause the plastic molding to
hug the core like an elastic band.

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Estimate ejection force

• The normal forces is estimated as the integral of the residual tensile stresses in the molded part taken
across the effective area of the molded part:

• Fnorma

• Unfortunately the estimation of the residual tensile stresses is a complex function of the processing
conditions, mold geometry and material properties. A detail treatment is well beyond the scope of this
course. For this reason, conservative simplifying assumptions are applied to provide an estimate of the
ejection force.
• The analysis assumes that the tensile stresses in the molding are the result of the thermal contraction
of the mold.
• This assumption will cause the analysis to over predict the ejection forces since in the practice of the
polymer:
• Maybe in a compressive state before the application of thermal shrinkage
• May tend to relax

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Estimate ejection force

• Since the polymer melt cannot support tensile stress in a fluid state the thermal strain is estimated for
the solidified plastic as the coefficient of thermal expansion of the plastic material (CTE), multiplied by the
difference between the solidification temperature, and the ejection temperature:

E=CTE,,,,

• While there will be stress relaxation as the polymer melt becomes rigid, a conservative assumption is that
the strain develops with the material at its room temperature modulus. The resulting tensile stress internal
to the part can then be computed as a constant throughout the entire molding is:

P-Ee…

• To estimate the normal and ejection forces, the cross section area upon which the stress effectively act must
be calculated. This effective area is not the projected are of the molding, but rather the cross sectional area
of the molding in different directions

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Estimate ejection force

• Figure 11.6 demonstrates the governing concept by

sectioning the molding into two halves.
• As previously suggested, the molding is similar to
an elastic band wrapped around the mold core.
• When the molding is sectioned, the normal forces
between the two halves are relieved. As such the
normal force can be well estimated as the tensile
stress multiplied by the cross sectional area:

• Fno

• Combining all the previous terms provides the

following estimate of the ejection force

• Feject

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Estimate ejection force
Ejection force estimation example

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Ejector push area and parameter

• Once the ejection forces on the molding have been

estimated, the next step is to determine the total push
area of the ejectors onto the molded part.
• Specifically, there is a minimum push area that is
required to avoid excessive compressive stress on the
ejection system components as well as excessive shear
stress on the plastic moldings.
• These two phenomena are illustrated in Figure 11.8 for a
single pin ejecting a portion of the laptop bezel.

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Ejector push area and parameter

• When the pin is actuated with the ejection system, a reaction force
will develop between the pin and the molded part before the part is Compressive stress on the pin
ejected
• The magnitude of this force is related to the total ejection force
required to eject the part as well as the number, location and
geometry of the ejectors.
• The compressive stress on the pin is the force on the pin divided by
the area of the pin.
• To avoid fatigue and/or buckling of the ejection system
components, compressive stress levels must be maintained below a
Total push area of all ejectors
critical; threshold. This critical stress is dependent upon the
material; and treatment of the ejectors. Most ejector pins and
sleeve are made of hardened materials. With fatigue limit stresses
on the order of 800 MPa.
• A conservative mold design, however may assume a lower fatigue
limit stress of 450 MPa for P20. In either case, the total push area
of all ejectors to void excessive stresses must meet the requirement.
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Ejector push area and parameter
Calculation example for push area of all ejectors

Total push area of all ejectors

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Ejector push area and parameter

Calculate:
1. Shear stress exerted on the
molded part.
2. Total parameter of the ejector
system.

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Ejector push area and parameter

• The analysis and examples

indicate that for most molding
applications, the design of the
ejector system is driven more by
the yield stresses exerted on the
plastic molding rather than by the
compressive stresses on the pin.
• However, compressive stress can
cause buckling in long, slender
members such as ejector pins/
• For this reason, further analysis on
the compressive stresses is
important, and will be
subsequently used to avoid pin
buckling.

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Type, number and size of ejector

• Once the required push area and perimeter of the ejectors is known, different ejector systems designs can
be developed.
• The mold designer should consider different designs with a varying number and sizes of ejectors.
• There are advantages and disadvantages to have a large quantity of small ejector pins compared to have
fewer but larger ejector pins.
• With respect to tooling and operation costs, a smaller number of large ejector requires a lower number of
mold components and features to be machined. For this reason, the mold is less expensive to manufacture
and maintain.
• Meanwhile the larger size of ejectors will tend to have very low compressive stresses and thus be less
susceptible to buckle.
• With respect to design flexibility and mold operation, however a larger number of small ejector pins
are preferred.
• There are several reason:
a) Greater number of ejector pins allows more frequent placement of the ejector across the cavity
b) This higher density of ejectors will tend to provide more uniform venting and ejection
c) At the same time smaller sized ejectors allow greater design flexibility with respect to the
placement of the ejectors.
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Type, number and size of ejector

• Molds contain many tightly spaced and complex features, so small Typical ejector
ejector sizes allows pins to be effectively placed between cooling lines,
down narrow cores, on side walls or ribs, etc. components
• The mold designer should remember that the previous analysis only
ejector pins
provides a lower limit for number and size of ejectors.
blades
• The mold designer can always add ejectors or increase the ejector size
sleeves
to improve the uniformity of ejection or reduce stress in the molded part.
stripper plate
• The mold designer must also determine the type of ejector to be used at
slides
various locations.
lifter
• Typical ejector components include ejector pins, blades, sleeves, stripper
angle pins
plate, slides, lifter, angle pins, core pulls, collapsible cores, expandable
core pulls
cavities, split cavity molds, and others.
collapsible cores
• The selection of the most appropriate component is heavily dependent on
expandable cavities
the requirements and geometry of the application.
split cavity molds

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Type, number and size of ejector

10 or 40 ejector
pins? Which
one is better?

• 10 or 40 ejector • 10 ejector pins • 40 ejector pins

pins? • Minimum pin diameter • Minimum pin diameter
• Same diameter each is 4.5 mm is 1.125 mm
• Same total perimeter • Forces are uniformly • Forces are uniformly
• Same shear stress on distributed, each distributed, each
the moulded part. compressive stresses is compressive stresses is
30 MPa. 100 MPa.

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Type, number and size of ejector

• The design for 10 evenly spaced, 4.5 mm ejector pins is shown in Figure
11.9.
• Since the gates are located on the left and right side walls, the ejector pins
located at the center of the top and bottom walls would provide needed
venting at the end of flow.
• This design, however, may be unsuitable for two reason :
a) The may not be enough ejectors at locations near where the
molding will stick in the mold. In particular the ribs and bosses
will tend to shrink onto the core and so require nearby ejector pins.
b) The ejector pin diameter is slightly large give the close proximity
of the nearby ribs.
• In this design, only 1 mm of steel separates the ejector hole from the
surface of the mold cavity.
• With the melts pressures, stresses will develop in the steel, deforming
the ejector holes to be non- round, causing the ejector pins to bind.
• Eventually, cracks will propagate between the ejector hole and the mold
cavity. For these reasons, the ejector pins should be made smaller and
more strategically located.

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Ejectors layout

Mould base ejector cooling slider lifter electrode The ejector assembly. The hole layouts made from the steel

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Ejectors layout

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Ejectors layout

Effectiveness of ejectors

size location.

the locations where pushing on rigid

the ejection forces areas of the
are generated molded part

• The previous example implied that the effectiveness of an ejector is not simply a function of its size but also its location.
• In general, ejectors will be more effective when placed near the locations where the ejection forces are generated.
• Furthermore, the ejectors will be more effective when pushing on rigid areas of the molded part.
• A common but ineffective layout arise when ejector pins are uniformly distributed across the mold cavity.
• Such an approach can give rise to the layout design shown in Figure 11.10 with an ejector pin located relatively far from
the ribs and side walls of the molding.

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Ejectors layout
• Since the molding has shrunk onto the core, the
ejection force is being generated by the friction
between the molding and the mold core at the rib
and side wall.
• By placing the ejector pins far from these two
sticking points, a significant moment and
deflection will be applied before the molding is
stripped off the core.
• The design can be improved by adding ejector
pins closer to the rib and side wall as shown in
Figure 11.11.
• In this case, three additional pins are added to
provide ejection force close to the molding. • However, this ejector pun layout may lead to a potential
• To avoid excessive stress in the core insert due to cooling issue since there may not be enough clearance to
the provision of the ejector hole, an allowance provide a cooling line in the core insert between the rib and
of at least one ejector pin diameter should be the side wall.
specified between the surface of the mold cavity • As such, the diameter of the ejector pins may be reduce
and the surface of the ejector hole. slightly to allow the addition of cooling line if desired.

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Ejectors layout

• Another alternative layout is to provide an

ejector pun underneath the rib or side wall as
shown in Figure 11.12.
• This design has the direct benefit that the
friction force and the ejection force are in-
line, such that very little deformation of the
molding will occur.
• One common problem arises due to the
thinner of ribs and side wall compared to the
large ejector pin diameter.
• To avoid very small ejectors that may buckle
during operation, a solid boss or ejector pad
may be provided on the rib.
• When the ejector pin is actuated forward, the
force is transmitted from this pad down the • Since the ejector pin pushes directly on the ejector pad, no
length of the rib and to the surrounding areas draft angle is required so the ejector pad diameter can be
of the part. maximized.

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Ejectors layout
• One issue with the use of the ejector pad,
however is the high volumetric shrinkage
that can lead to sink on the aesthetic surface
of the part.
• For this reason, a cored out boss ejected
with an ejector sleeve can provide for higher
quality ejection albeit with a higher mold
manufacturing cost.
• The need for ejector pads can be eliminated
through the use of contoured ejector pins
as shown in Figure 11.13.
• In this case, the ejector pin is aligned with
one side of the rib or wall, and then
contoured to push on the top surface of the
feature.
• The pin is then contoured and extended • Compared to the previous designs, this layout allows for effective
down along the side of the feature so as to transmission of the ejection forces and compact ejector pin
also push on the parting plane of the spacing without any changes to the molded part design.
molding.
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Ejectors layout
• This last approach requires careful ejector pin design as
well as careful alignment of the ejector pin to the part
features.
• Furthermore, there is a possible problem that can arise
with the use of contoured ejectors extending outside the
parting line of the mold cavity as indicated in Figure 11.13.
• Specifically if the ejector pin is too short, then a gap will
form between the top of the ejector pin and the opposite
surface of the cavity insert.
• If this gap is larger than the thickness of a vent, then
flash is likely to occur.
• Meanwhile, if the ejector pin is too long, then the pin • Alternatively, the mold designer may choose to place
will be compressed on mold closure. the ejector pin within the mold cavity and contour
• With repeated ejection cycles, the pin can fatigue and the pin as for the rib in Figure 11.13.
buckle. • In these cases, slight errors in the contour of the pin
• Given that the required length of ejector pin is difficult will be non-aesthetic surfaces and so be less
to precisely determine due to the stack up in tolerances significant with respect to the quality of the molding.
across the mold assembly, the mold designer may wish to
use a steel safe approach with multiple length
adjustments.
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 Ejector Design ( Part 2)
Ejector system analyses and designs
• Ejector pin
• Ejector blade
• Ejector sleeve
• Ejector plate

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Ejector system analyses and designs

Ejector Pins

Ejector Blades Ejector pin for

Ejector Ejector blade
mold and tool
system
designs
Ejector sleeve

Ejector plate
Ejector sleeve Ejector plate

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Ejector pin
• Ejector pins are typically hot forged and cylindrically Ejector pins
ground from hard steels.
• Subsequently, the pins are nitride and polished to provide Hot forged and Custom ordered
a vary hard and smooth surface for low wear and friction. cylindrically
• Ejector pins are available from several suppliers in ground • different materials
standard diameters ( 1mm- 25mm) and length (150 mm • surface treatments
to 500 mm). Nitride and • precise diameter or
• Typically mold makers cut and grind standard ejector pins polished length,
• threads for mating
to the finished length and contour specified in the mold
with ejector plate,
design. Standard
flats, grooves etc.
• However, ejector pins may be custom ordered with diameters
varying options including different materials or surface
treatments, precise diameter or length, threads for Cut and grind
mating with ejector plate, flats, grooves etc.

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Ejector pin
• While ejector pins are available in a range of diameters and
lengths, the long pins with small diameters should be
avoided.
• The reason is that such slender pins tend to buckle under
load as shown in Figure 11.16.
• In this figure, the loading of an ejector pin corresponds to a
column with the top end supported by the bore of the ejector
hole, and the bottom end pinned by the ejector retainer plate.
• If the compressive load become too large, then the pin
may bow or buckle in an unknown direction.

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Ejector pin

Standard Early Ejector Return

assembly, Double Ejection

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Ejector pin

• The result from this example indicated that the minimum diameter required to avoid buckling is on
the same order of magnitude as the minimum diameter required to avoid excessive compressive
stress in the pin or excessive shear stress in the molding.
• The results from the buckling analysis and example are strongly dependent upon the length of the
ejector pin, if the pin length was longer, then the buckling constraint would be dominant.
• The mold designer should perform analysis for their molding application to confirm the driving
constraint and ensure and adequate ejector design.

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Ejector pin
• A small ejector pin diameter might be desired in some
molding applications for aesthetic or pin positioning
requirement.
• If the minimum pin diameter required to avoid buckling is
greater than the desired pin diameter, then a stepped pin
with a larger diameter shoulder can be investigated.
• Step pins typically have a shoulder approximately 1mm
larger in diameter than the head of the ejector pin, and a
typical shoulder length of 50mm.
• When necessary, the mold designer can custom order
ejector pins with multiple steps and tapers for a given
application.
• If a stepped ejector pin is used, however, the mold designer
Superior mold base ejector step pins h-13
should ensure that a suitable hole and clearance is
tool steel
specified in the support plate and core insert.

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Ejector blade
• Ejector blades are typically large diameter ejector pins,
that are contoured to present a rectangular cross section
to the core insert.
• As shown in Figure 11.17, the ejector blade’s large width
and small thickness allow for the blade to be positioned
directly below ribs.
• This position is very effective since the blade applies the
ejection force at the location where the friction forces
between the molding and the mold core are generated.
• Furthermore, the ribs is stiff and so will effectively eject
nearby portions of the rib and part.

• Finally, the rib is not an aesthetic surface, and so should not be adversely affected by the witness mark left
by the ejector blade, through this is a potential area of stress concentration during the molding’s end-use.

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Ejector blade
• The detailing of the ejector blade,
shown in Figure 11.17, is very
similar to that previously discussed
for ejector pins.
• Clearance should be provided in the
support and core inserts to allow for
free actuation of the ejector blade,
with the mating being provided
between the rectangular section of
the ejector blade and the tightly
mating surfaces in the core insert.

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Ejector blade
• To provide the rectangular hole in the
core insert, wire or plunge EDM is
necessary.
• The amount of EDM can be minimized
by specifying the clearance hole close
to the surface of the mold cavity, with a
typical land equal to twice the width
of the ejector blade.
• The mold designer should also ensure
that the length of travel between the
ejector blade’s tapered shoulder and
the narrowed hole in the mold insert
exceed the maximum stroke of the
ejector system.
• Otherwise, the moldier may
inadvertently seize and damage the
ejector blades.
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Ejector blade

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Ejector blade

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Ejector sleeve
• The function of ejector sleeve is similar to
ejector blade, whereby both are typically
used to push on a vertical section of the
molded part.
• The design of the ejector sleeve varies
significantly, however since it is a hollow
cylinder that slides along a fixed core pin to
provide an ejection force at the bottom
surface of a molded boss.
• Ejector sleeves are very effective
components for part injection, since they
push on a stiff portion of the part at a
location where friction forces between the
molding and the core occur.

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Ejector sleeve

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Ejector sleeve
• A typical ejector sleeve assembly design is provided in
Figure 11.18. In this design, a highly conductive core
pin is seated in the rear clamp plate and secured with a
socket heat set screw.
• The core pin passes through the rear clamp plate,
ejector plate, ejector retainer plate, support plate
and core insert to hollow out the desired portion of the
mold cavity.
• The ejector sleeve is held by the ejector retainer plate
and passes through the support plate and core insert.
• In the design of Detail A, the end of the ejector sleeve is
coplanar with the top of the boss and adjacent rib.
• During the ejection cycle, the ejector plate is move
forward, causing the ejector sleeve to slide along the
core pin and push the boss off the core pin.

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Ejector sleeve
Ejector pins sleeves or rails to prevent distortion during ejection

Sleeve ejector system – how to work

• Just like the ejector pin and blades, the reverse actuation of the ejector retainer plate causes the ejector
sleeve to retract into the core insert for the next molding cycle.
• Given the geometry of the ejector sleeve, there are typically no issue related to the stress or buckling.
• However, the detailed design of the ejector sleeve is especially critical since it slides along between a
stationary core pin and the stationary core insert.
• The actual location of the ejector sleeve is governed by the concentric mating of the ejector sleeve with the
ejector hole in the core insert.
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Ejector sleeve
• Since the core pin is internal to the sleeve, the
wall thickness and concentricity of the molding
around the core pin is governed by the tolerance
stack up of the ejector hole, ejector sleeve and
core pin.
• To reduce dimensional variations in the molded
part, clearances for venting should be
minimized.
• Details B to F in Figure 11.18 provide examples
of clearance in the various mold plates.
• The mold designer should ensure that the core pin
has suitable clearance through the ejector plate
and ejector retainer plate, otherwise a slight lack
of concentricity between the ejector sleeve and
the core pin may cause sleeve to bind.

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Ejector plate
• The function of ejector or stripper plate is similar to that of an ejector sleeve, in both are typically used to
push a periphery of the molded part.
• The design of the plate varies significantly, however since it normally pushes on most or all of the entire
periphery of the molded part.
• For this reason, the plate has a significantly larger area than a single ejector sleeve and a completely
different construction.

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Ejector plate
• The design of a mold with the stripper plate is
shown in Figure 11.19.
• In this design, the stripper plate replaces the
B plate, and is made to float between the A
plate and the support plate.
• To locate the core insert, a locating dowel has
been placed to mate the center of the core
inserts with the support plate.
• Socket head cap screws are used to securely
fasten the core insert to the support plate.
• Portion of the stripper plate are designed to
extend beneath the bottom surface of the
molding, but not to interfere with the outer
surfaces of the core inserts.

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Ejector plate
• As shown in Figure 11.20, the moldings are
ejected by the opening of the mold when the
stripper bolt engages the stripper plate and
pulls the moldings off the cores.
• Since the stripper plate fully engages the
bottom of the part, the ejection forces are
uniformly distributed across the moldings
resulting in low imposed stress, little
deformation and reliable ejection.
• One interesting aspect of this plate design is
that the ejector retainer plate and leader pin
may be used as the rear clamp plate.
• More conventional design, however used the
forward actuation of the ejector plate to
engage the stripper plate to eject the molded
part.

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Ejector plate

Ejector
puller bolts
to push the
stripper
plate when
ejecting

• There are some important items to note with regard to the design details A and B, which are identified in
Figure 11.20, and magnified in Figure 11.21.
• One significant issue with respect to this specific molding application is the location of the parting line
along the top of the cup.
• From the viewpoint of the mold design, the center of the rounded top would be the best location to mate
the stripper plate with the core inset since it would provide a reliable sliding surface.
• However this mating location would result in an undesirable and possibly sharp witness line.
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Ejector plate
• As such, the mating location has been
moved towards the interior of the core
insert.
• While this provides an improved witness
line location and a significant push area for
the stripper plate to push on the molded cup,
it also results in a sharp edge at the
parting line of the stripper plate.
• This sharp edge can damage the vertical
surface of the core insert and will likely
quickly wear.
• For this reason, the mold designer may wish
to avoid the use of a stripper plate or
request the redesign of this section of the
cup to provide a flat push area to mate with
the stripper plate.

BDD 40903 Prepared by : Mohd Hilmi Othman 52