STEPS IN MOULD DESIGN 2019 04 08

In designing a mould for manufacture and production, many aspects of the component, material
(both plastic and steel), construction of the mould, the moulding machine, machining facilities. . .
need to be considered. Suffice it to say that the design of the mould should be optimum.

Study of the component drawing

Features, dimensions, tolerances, functional and assembly requirements, material, . . . .

Material – manufacturer, trade name and grade, availability, shrinkage, processing

parameters, . . .

Gate, Parting Line, and any other mould-related information.

Surface Finish, texture requirements.

Mould-related decisions
Number of cavities

2-plate, 3-plate or any other type of construction.

Parting Line – flat, inclined, stepped (metal-matching draft of minimum 3⁰), profiled, 3D, . . .

Ejector type and position – Pin, Blade, Sleeve, Stripper, . . .

Gate type and position – Sprue, Edge, Tunnel, Curved Tunnel, Pin-point, Diaphragm, Ring, . . .

Calculation – Component weight, Shot weight, Plasticising capacity, Runner cross-section,

Gate dimensions, . . . . .

Core / Cavity construction – integral, split, . . . Consider easiness of machining, easiness of

replacement, maintenance. . . . .

Mould Base decisions

Choose a size from DME, Misumi, Muesberger, or any other good manufacturer.

In case of integral Core-holder / Cavity-holder, thickness below pocket should be according

to the catalogue. In case these plates have many holes, increase the thickness below pocket
by, say 10 mm.

To ensure that the Core and Cavity butt together (Parting Surfaces butting together}, create
a gap between their holder plates.

On each plate, provide two pairs of tapped holes on two opposite outside sides for lifting the
plates.

Mill Pry-bar slots on each plate at the 4 corners (or in the middle of each edge).

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 Increase the Ejector Stroke by 8 to 10 mm, more than the minimum required by the
component.

Unsupported span in Ejector Grid to be minimum: make changes from the sizes given in the
catalogue.

Provide Support Pillars (ø28 or ø38) where possible.

Provide Ejector Guides, when there are Ejector Pins less than ø6. Ejector Guide Pillars of
ø16. Provide 2 Ejector Guides when Ejector Plate size is less than 300 x 300 mm and 4
Ejector Guides when it is bigger size.

When Ejector Plate width is narrow, check whether 2 Return Pins are enough.

Provide Water Connectors at bottom of the mould or opposite to the operator.

Provide Eye Bolts with Carrier Bar on the top of the mould.

Provide Mould Feet (at bottom of the mould) towards the 4 corners of the mould.

Prefer direct clamping of the mould to the machine. Otherwise, Strap Clamps may be
used. Refer Machine Platen diagram.

Guide Pillars should engage in the Guide Bush before Cavity approaches the Core. Hence,
Guide Pillar lengths should consider this aspect.

Core / Cavity construction

Core / Cavity construction – integral, split, . . . Consider easiness of machining, easiness of
replacement, maintenance. . . . .

For round Core Pins, procure the next larger sized diameter Ejector Pin from the catalogue.
Cut it to the length required and modify the tip.

Water lines should have a minimum gap of 5 mm with Ejector Pin hole / Core Pin hole /
Insert opening / tapped holes.

Change positions of Water line, Ejector Pins and tapped hole, as necessary.

Other details

Boss

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 Ejector Adaptor

Runner

Tunnel Gate

Recommended design for a modified Tunnel Gate

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Gate Insert for Pin-point Gate

Sprue Length and Dia

The Sixty-to-Six thumb rule

Maximun thickness anywhere in the shot

decides the cooling time and therefore,
cycle time.

When the length of Sprue approaches 60

mm, the large diameter of Sprue also
approaches to about 6 mm. Then this 6
mm would be the thickest portion in the
shot and hence dictates the cycle time.

Do not exceed Sixty or Six !

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Machine selection

This should be based on :

Locking Force required

Shot Weight
Plasticising Capacity
Mould Base size

Mould Elements, bought-out

Apart from Mould Bases and Ejector Pins, Latches, Springs, many other elements
and mechanisms are also available in the market. Providing these elements will
allow shorter mould manufacturing time and the mouldmaker can focus on the
manufacture of Core, Cavity and other important items.

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