Essence News - Generic Blog Listing

[Essence]-Synventive Synflow (No Index)

Dr. Ing. Simon Wurzbacher — Tue, 14 Jan 2025 10:50:51 GMT

November 2023
Dr. Ing. Simon Wurzbacher & Dr. Ing. Julian Schild

Targeted Control of the Pin Opening Speed:

"Bright Prospects"

Surface blemishes in the form of differences in gloss level are typical defects on flat, sequentially filled parts.
With Synflow technology, parts quality can be ensured easily and in a reproducible manner.

There are many causes for surface defects on injection-molded flat parts. In addition to the influence of the tool – particularly the cavity surface or the temperature control, it is often the selected injection molding parameters that can lead to surface defects. The severity of such defects depends considerably on the properties of the plastic, i.e., due to additives or basic polymer or their mixing ratio in the case of blends.

Hesitation lines are visible defect lines that can often appear as gloss changes or blush on the part surface. These hesitation lines that appear in the form of a gloss level difference on the part surface crosswise to the flow direction are caused by local pressure fluctuations during sequential filling through valve gate nozzles.

[Essence]-Synventive - Priamus Fill Control (No Index)

mmueller2@onebarnes.com (B. Eng. Max Müller) — Tue, 14 Jan 2025 10:50:47 GMT

Dr. Ing. Simon Wurzbacher & Dr. Ing. Julian Schild & B. Eng. Max Müller

Priamus Fill Control simplifies cascade injection molding in family molds

"A Family in Sync"

When injection molding specialists talk about balancing, they are referring to the synchronous reaching of the end of the melt flow in the cavities. It would consequently be better to refer to this as “synchronizing.” This synchronization of the end of the melt flow is influenced by several parameters: the molding compound, the injection molding machine, the tool, and the hot runner. With family molds, in particular, with multiple connections of the parts, synchronizing becomes an even greater challenge. We show an alternative to complex manual cascade settings in a realistic test set-up.

Manual cascade settings and adjustments to process interferences

Setting up a complex cascade application from scratch is time-consuming and requires a lot of experience. During process development, the setter encounters a conflict between even mold filling (preventing flow marks, flow lines, and air inclusions) and a homogeneous holding pressure effect (preventing local sink marks). At the same time, they must move the unavoidable flow lines into acceptable areas of the part. To achieve the quality of the required part, this conflict is influenced by adapting the cascade switching times of the valve gate nozzle depending on the screw position. These switching times, however, are in turn dependent on the injection speed and the division of the volumetric flow to the respective valve gate nozzles.

For family molds that produce an assembly ‒ for example, a door trim panel ‒ the cascade settings become even more complex due to the different part properties, especially the part volume and wall thickness. The described division of the volumetric injection flow between the open valve gate nozzles means that a change in the switching time on one part will influence the filling of the other part. In addition to controlling the quality of several parts, the setter is confronted with the challenge of synchronizing the end of the flow path of all parts to avoid overpacking.

[Essence]-Synventive Dynamic Feed (No Index)

Dr. Ing. Simon Wurzbacher — Tue, 14 Jan 2025 10:50:44 GMT

March 2023
Dr. Ing. Simon Wurzbacher & Dr. Ing. Julian Schild

Optimized Flow Control with Synventive Dynamic Feed for Family Molds:

"One Tool, One Shot, Three Parts"

Family molds offer great potential for reducing costs. They are able to produce several components with different sizes and wall thicknesses in one shot. The challenge lies in the design of the molds and the process control. Synventive solves this task with a cavity-independent pressure control.

The term “family mold” has been used in toolmaking for decades. In contrast to multi-cavity molds, where the focus is on the quantitative scalability of manufacturing identical parts, different parts are placed in one parting plane of a family mold and completed in the same injection molding cycle. One option is that a complete assembly can be removed from the family mold and assembled directly. The following distinction is made for the potential parts of family molds:

mirrored parts
parts that will be joined to form an assembly later

Examples of mirrored parts are the side mirrors or scuff plates on cars. One example of a combined assembly from an automotive application is the door trim panel assembly, consisting of the waist rail, map pocket, and trim panel. Other typical applications are parts with identical or similar functions, such as a housing or the front and rear bumpers.

In contrast to conventional manufacturing of injection molded parts in individual molds, only one injection molding machine is used, saving space and usually allowing for parallel production, reducing the cycle time, and generating lower running and setup costs.

[Essence]-Synventive Tech Center (No Index)

Susanne Schröder — Tue, 14 Jan 2025 10:49:49 GMT

April 2022
Susanne Schröder

The KUNSTSTOFFE editorial team visits the new MOLDING SOLUTIONS Tech Center at Foboha in Haslach/Germany:

"Leading-Edge Process Control in Family Molds"

Family molds belong to the state-of-the-art in injection molding – at least when wall thicknesses and volumes of individual components vary considerably. Using a trial mold soon ready for series production, Synventive demonstrates that – though demanding – optimal process control can be achieved using the right technology. The filling of each mold cavity is controlled individually and in real time. The Kunststoffe editorial team were among the first guests at the new Tech Center.