Plastic Injection Design Guidance that is guiding the injection mold designer and injection molding mold manufacturer to do the design and manufacturing; You will know Some key points of the plastic injection mold design or manufacturing.

• How to do the plastic injection molded part design and injection mold design?
• What guidance will be followed during the plastic injecting part and mold design?
• Why do part design and mold design must follow these guidelines?

Upmold is a turkey plastic injection mold custom manufacturer, we offer part design, engineering support, material selection and testing services; our professional design service including the plastic injection part design assistant, complete part and mold design, Mold flow analyzing and reverse design.

• Parting Line
• Draft
• Undercuts
• Wall Thickness & Uniformity
• Bosses
• Gussets and Ribs
• Radii and Corners
• Material Shrinkage
• Gating
• Ventings
• Knit/Weld Lines

The draft angle is the amount of taper for molded or cast parts perpendicular to the parting line. It can be measured in degrees or mm/mm (in/in).

• Reduces the chance of damage to the part due to friction during release
• Reduces wear and tear and chances of damage to the mold
• Ensures a uniform, smooth, unscratched finish when required
• Ensures the integrity and uniformity of other surface finishes and textures
• Reduces overall cooling time by lessening or eliminating the need for unconventional ejection setups
• Most, if not all, of these benefits offer either direct or indirect overall production cost reductions

• Draft angles are generally a requirement of injection molding design (though there are a select few soft materials, like nylon, that can get away with draft angles of zero).
• Draft should be a part of design for manufacture, and all stakeholders and contributors should be aware of its need at the outset of the design process. This includes product designers, design engineers, and of course, the customer. This allows considerations for design requirements to be taken into account.
• Any draft is always better than no draft.

1) A draft angle of 1½ to 2 degrees is required for most parts

This rule of thumb applies to parts with mold depths of up to 2 inches. At this size, draft as low as 1½ degrees will allow for an easy, non-damaging release from the mold when the expected shrinkage of the thermoplastic material occurs.

2) Draft should average about an additional degree for each inch of depth

For deeper or larger parts, more draft is required to account for the additional surface area (and potential for friction upon mold release).

3) Draft should occur toward the “top” of the mold

In other words, the draft angle should follow the direction of the mold moving up or away as it separates. If you imagine a hollow box with drafted walls, the open top would be slightly wider than the bottom when draft is applied correctly.

4) Textured parts require more draft — sometimes much more

For parts where intricate textures or other raised or recessed surface features are designed,

draft should be added to the initial optimal 1½ to 2 degrees at the rate of another 1½ degrees per thousandth-inch (0.001”) of surface depth.

5) All components of a piece should be drafted

For complex geometries or parts with several tension-easing features like ribs, gussets or louvers (all integral components of good part design), ideally, all of these features — essentially, any area of contact with the mold — should incorporate a draft angle.

6) For metal-on-metal molding functions, more draft is required

This does not refer to injection molding metal, but rather to mold designs where one metal mold component makes direct contact with another.

Typically, 3 degrees of draft will be required to ensure that the mold can separate properly.

7) Draft may have to be incorporated on two sides of a part.

If the parting line for a molded part is in the middle (as with, for instance, a solid cylindrical part), draft should be incorporated on both ends of the part. This is because there are essentially not one but two mold release actions, both of which require draft.

8) At a bare minimum, half a degree of draft should be incorporated into vertical surfaces

This standard should not be adhered to in typical cases, but is more of a guideline when design requirements dictate a nearly uniform angle from top to bottom of a part wall or vertical surface. Half a degree of draft can provide a reasonable compromise between designs requiring straight walls, and the requirements of the injection molding process. In general,

however, performance and part throughput will not be as favorable as going with 1½ to 2 degrees of draft.

9) Again: Any draft is better than no draft

This point is important to remember (and repeat), especially if designers are highly resistant to incorporating draft. If a product design discussion does reach this extreme point, it is still beneficial for the engineer to advocate for some degree of draft, no matter how small. It is unlikely in most design cases that a perfectly straight, zero-degree draft angle is required.

10) Draft is a requirement — not a suggestion — for successful part production

Another point that benefits from mentioning twice: Draft is not a “nice-to-have” feature of design to manufacturing. It’s an important component of a well-designed part and an efficient, high-quality production process. A lack of draft angles can (and likely will) lead to an unacceptable number of rejected parts, and can damage expensive molds. Longer cooling times and complex part ejection requirements can slow production down to an unmanageable and unprofitable speed. In short, just about any other solution is preferable to forgoing draft angles in your injection molded parts.

It’s also important to remember that draft angles are just one component of an effectively designed injection molded piece. Design for manufacture is one of the easiest ways to improve the quality and efficiency of your injection molding process, and it never hurts to stay up to speed on all injection molding best practices. As injection molding specialists here at RevPart, we’re happy to share our expertise with you as we incorporate those best practices into our service.

Wall thickness, material selection, ejection, shrink rates, finish/texture, wall depth, and manufacturing capabilities will influence the draft angle selection, When designing a part or before mold design, apply as much draft angle as possible at wall side—a general rule of thumb is 1 degree of draft per 1 inch of cavity depth, but that can change with the aforementioned factors. Try following these general guidelines:

• 0.5 degrees on all vertical faces is strongly advised.
• 1 to 2 degrees works very well in most situations.
• 3 degrees is minimum for a shutoff (metal sliding on metal).
• 1~3 degrees is required for light texture.
• 3~5 or more degrees is required for heavy texture.

Please check Texture Mini Drafting Chart for Mold Tech Texture Minimum Drafting Angle For Releasing

Section 8: Hydraulic and Pneumatic Standards and Design

Contents:
A) Hydraulic Standards
B) Pneumatic Standards

a) Hydraulic Standards:

1) Parker series 2-H hydraulic cylinders will be used. Viewmold typically uses a style “JJ” mount. NOTE: DO NOT USE PARKER MOUNTING STYLE “J” or “JB” DUE TO THE DECREASE IN PRESSURE RATING.
2) Hydraulic hoses are Heavy duty 3/8” or ½” inside diameter, purchased through NAPA. All hose to fitting connections will be crimped.
3) Viewmold Standard Hydraulic fittings and connectors. **** NOTE: DESIGN FOR “NPT” THREADS ONLY! – NO STRAIGHT (BSPP) THREADS! ****

K) PART # L) DESCRIPTION DECATUR PART #
FLUID POWER PRODUCTS
H2-62 ¼ BALL LOCK QUICK CONNECT FEMALE HYD080
H3-62 3/8 BALL LOCK QUICK CONNECT FEMALE HYD090
H4-62 ½ BALL LOCK QUICK CONNECT FEMALE HYD100
H2-63 ¼ QUICK CONNECT MALE HYD110
H3-63 3/8 QUICK CONNECT MALE HYD120
H4-63 ½ QUICK CONNECT FEMALE HYD130
3/8 DD-S 90^ ELBOW 3/8 PIPE THREAD FEMALE HYD140
3/8 CR-S 90^ ELBOW 3/8 PIPE THREAD MALE HYD150
8ETX-S 90^ TUBE ELBOW ¾-16 THREAD FEMALE HYD160
2107-12-8 90^ SWIVEL ELBOW ½ FEMALE ¾ MALE HYD170
1/2CD45-S 45^ ELBOW ½ PIPE THREAD MALE TO FEMALE HYD180
3/8CD-S 90^ ELBOW 3/8 PIPE THREAD MALE TO FEMALE HYD190
1/4MMS-S TEE MALE BRANCH ¼ PIPE THREAD HYD200
1/2MMS-S TEE MALE BRANCH ½ PIPE THREAD HYD210
1/4GG-S ¼ COUPLERS FEMALE HYD220
3/8GG-S 3/8 COUPLERS FEMALE HYD230
1/2GG-S ½ COUPLERS FEMALE HYD240
?X 3/8 GG-S ?TO 3/8 COUPLERS FEMALE HYD250
0107-2-2 STRAIGHT ADAPTOR 1/8 MALE HYD260
0207-2-2 STRAIGHT ADAPTOR ¼ FEMALE HYD270
0207-4-4 STRAIGHT ADAPTOR ¼ MALE HYD280
0107-4-4 STRAIGHT ADAPTOR ¼ FEMALE HYD290
0107-8-8 SRRAIGHT ADAPTOR ½ MALE HYD300
0107-12-12 STRAIGHT ADAPTOR ¾ MALE HYD310
1/4FF-S ¼ COUPLERS MALE HYD320
3/8FF-S 3/8 COUPLERS MALE HYD330
1/2FF-S ½ COUPLERS MALE HYD340
?X 3/8 FF-S COUPLERS 3/8 MALE TO ?MALE HYD350
3/8 X ¼ PTR-S HEX REDUCERES 3/8 TO ¼ HYD360
?X ?PTR-S HEX REDUCERS ?TO 3/8 HYD370
W68PL-6-6 STRAIGHT TUBE COUPLERS 3/8 MALE HYD380
1/2MMO-S TEE ½ FEMALE HYD390
1/2CR-S 90^ ELBOW ½ MALE HYD400
2017-6-6 3/8 SWIVEL ELBOW MALE TO FEMALE HYD410
1/2CD-S ½ MALE TO FEMALE ELBOW HYD420
1/2DD-S ½ FEMALE ELBOW HYD430
2107-8-8 ½ SWIVEL ELBOW MALE TO FEMALE HYD440
2107-12-6 3/8 TO ¾ SWIVEL ELBOW HYD450
3/8MMS-S 3/8 TEE MALE BRANCH HYD460

M) PART # N) DESCRIPTION DECATUR PART #
NAPA PRODUCTS
NAPA 06U-I06 3/8 X 3/8 MALE NPT PIPE RIGID STRAIGHT HYD010
NAPA 06U-J06 3/8 X 3/8 MALE NPT PIPE SWIVEL STRAIGHT HYD020
NAPA 08U-I08 ½ X ½ MALE NPT PIPE RIGID STRAIGHT HYD030
NAPA 08U-J08 ½ X ½ MALE NPT PIPE SWIVEL STRIAGHT HYD040
NAPA 08U-I04 ½ HOSE X ¼ PIPE MALE NPT STRAIGHT HYD041
NAPA 08U-I06 ½ HOSE X 3/8 PIPE STRAIGHT HYD042
NAPA 08U-P08 ½ HOSE X ½ TUBE STRAIGHT HYD043
NAPA 06U-I08 3/8 X ½ MALE NPT PIPE RIGID STRAIGHT HYD050
NAPA 06U-J08 3/8 X ½ MALE NPT PIPE SWIVEL STRAIGHT HYD060
NAPA 06U-I04 3/8 X ¼ MALE NPT PIPE STRAIGHT HYD070

b) Pneumatic Standards:

1) Air poppet valves will be purchased through National or PCS. All manufacturer specifications for installation will be followed.
2) Pneumatic cylinders will only be used when specified by the customer.

Section 7: Standard Mold Components

Defines standard component types and suppliers

1) All mold components will be purchased through DME, Progressive, PCS, Parker, Balluff, and National only as listed by type below. Standard components will NOT BE ALTERED as supplied from the Vendor without special instructions for and documentation to the Customer.

2) Standard mold component types are as follows:

-Leader pins——————————–DME “GL” type (hardened and precision ground) or Class “S” Thomson Shafting
-Bushings———————————–DME “LBB” type (bronze plated and precision ground)
-Guided ejection leader pins————-DME “PF” or “GL” type or Class “S” Thomson Shafting

-Guided ejection bushings————— DME “GEB” type (bronze plated and precision ground)
-Locating rings—————————–DME “6521” OR “6522” (VARIABLE DEPENDING ON MOLD DESIGN)
-Sprue bushings—————————-DME “B” or “U” series
-Three plate bushings———————-DME “TEB” type
-Wear Plates——————————–DME “WPB” type (bronze plated)
-Angle pins——————————— DME “APD” type, MDE “EX” ejector pins, or Class “S” Thomson Shafting, or DME “GL” type leader pins
-Mold and Die springs——————– DME / Raymond type (blue, red, gold)
-Parting line locks————————- Progressive Top Lock “TL” type
-Bar locks———————————–DME tapered interlocks (rectangular)
-PKO extensions—————————-Progressive Hex series or puck style
-Recycling and mold dating inserts——DME, PCS, or Progressive
-Ejector pins——————————–DME “EX” type
-Ejector sleeves—————————–DME “S” type
-Ejector Blades——————————National “Shank and Blade” type
-Air poppet valves————————–National or PCS
-Accelerated ejectors———————–PCS / Cumsa (patented, round) type
-Stop buttons———————————PCS “SP” type
-Hydraulic Cylinders———————–Parker series 2H
-Limit switches (ejector plates)———–DME “Thinswitch”
-Limit Switches (cylinder)—————–Parker “EPS” style (mounted directly to cylinder)
-Limit Switches (other)——————–Balluff Series F 60 Mechanical

3) Off-set (“zero”) Corners on all mold plates will have a .50” x 45-degree chamfer along the entire edge.

4) One leader pin and one return on off-set corner are to be off-set a minimum of 0.125” to 0.25” to prevent rotation of mold plates during assembly/disassembly.

Section 6: injection mold ejector System Standards and Design

Contents:
A) injection mold ejector pin design standards
B) injection mold Guided ejection design standards
C) injection mold Spring return standards
D) injection mold Hydraulic ejector standards
E) injection mold Press Knock-out (PKO) design standards

A) injection mold ejector pin design standards

1) No ejector pins smaller than .093” (3/32”) diameter are to be used. 3/32” DIA. EJECTOR PINS MUST BE THE 2” SHOULDER TYPE.
2) Use the largest size ejector pin possible.
3) Ejector pins should be cleared to within ¾” of molding surface.
4) Ejector pins should be designed to “PUSH” the part, NOT “PULL” the part.
5) Ejector pin “bosses” can be used only with Customer approval of size and locations. Normally these “bosses” will cause part sink or distortion, therefore use with caution.
6) Ejector pins and Pin Plate must be like- numbered for ease of assembly.
7) All contoured ejector pins must be keyed to prevent rotation by a pocket in the pin plate (refer to drawing S6-1). NO DOWELS WILL BE USED FOR KEYS.
8) All ejector pins must be DME “EX” type or equivalent.
9) There can be no ejection under a slide or lifter detail without written Customer approval. If the customer accepts ejection under a slide or lifter detail, limit switches must register both forward and back movement of the ejector system. DME standard “Thin Switch” limit switches are acceptable.
10) National standard Ejector Blades and Ejector Blade shanks (two piece design) or equivalent are to be used. Other standard single piece Ejector Blade types can be used if necessary.
11) Rectangular ejectors and push bars can be used. In cases where the rectangular ejectors and push bars contact the parting line, the return pins must be pre-loaded with a spring behind the head with a minimum of .100” preload (refer to drawing S6-2).

B) injection mold Guided ejection design standards
1) Ejector plates must be guided with two ejector guide pins and ejector guide bushings minimum. Four Guide Pins and Bushings are considered standard, and “normal practice”. The amount and size will be determined based on the mold size and number of ejector plate activated actions.
2) Guide pins will be DME Standard Guided Ejection Leader Pins (DME “PF” or “GL” type).
3) Guide Bushings will be DME Standard Bronze Plated Guided Ejection Bushings (DME “GEB” type).

C) injection mold Spring return standards

1) Spring return will only be designed when specified by the Customer.

2) Use DME standard medium duty (blue) mold and die springs or equivalent. Total spring compression should never exceed 35% of the free length. Spring pre-load should be designed to provide twice the weight of the ejector bar/pin plate assembly if possible.
3) If external springs are used, provide spring cages securely installed on the pin plate with S.H.C.S. (refer to drawing S6-3).
4) In cases where the rectangular ejectors and push bars contact the parting line, the return pins must be pre-loaded with a spring behind the head with a minimum of .100” preload (refer to drawing S6-2).

D) injection mold Hydraulic ejector standards
1) Parker Series 2-H Hydraulic Cylinders will be used. The selection of cylinder bore size and cylinder mount style will be determined by mold size and the amount of ejector plate activated actions. UPmold normally uses a style “JJ” mount. DO NOT USE PARKER MOUNTING STYLE “J” or “JB” DUE TO THE DECREASE IN PRESSURE RATING.
2) “T” style couplings will be used to secure the cylinder rod end to the Back Clamping Plate. (Refer to drawing S6-4)
3) Use Parker “EPS” style solid-state proximity switches mounted directly to the cylinder, or DME Standard “Thin Switch” limit switches mounted to the mold plates to register forward and back ejector plate travel.
4) Hydraulic cylinders used to activate the ejector system will be plumbed into a common port for “push” and “pull” sequence. The mold rails or sub-plates can be used as a hydraulic manifold.

E) Press Knock-out (PKO) design standards

1) The PKO pattern will be designed press specific for UPmold (refer to SECTION 9: Molding Machine Standards).
2) 3.50” “diamond” and 4” x 16” patterns have 1.25” diameter clearance through the Back Clamping Plate. 6” x 28” pattern and above have 2.25” diameter clearances through the Back Clamping Plate. UPmold PKO tap size for all patterns is 5/8”-11 or ½”-13.
3) When PKO extensions are specified, Progressive standard “Hex Series” extensions or “puck” style extensions are to be used.

Section 5: injection mold Venting Standards and Design

1) Vent land will be .06”. The vent clearance can be .12” – .50” wide x .02” deep (refer to drawing S5-1) and are always routed to atmosphere. Vents are normally ground. Milled vents must be polished.
2) Perimeter vent land should be .125” minimum to .250” maximum.
3) Always vent directly opposite the gate and at all runner ends/cold well slugs.
4) Ejector pin vents are sometimes necessary. Refer to drawing S5-2 for ejector pin vent design guidelines.
5) Common vent depths (INCHES):

ABS————————————– .001 – .0015
ACETAL——————————– .0005 – .001
ACRYLIC——————————-.0015 – .002
CELLULOSE ACET, CAB———–.001 – .0015
ETHYLENE VINYL ACET.———.001 – .0015
IONOMER——————————.0005 – .001
LCP—————————————.0005 – .0007
NYLON———————————-.0003 – .0005
PPO/PPS (NORYL)——————–.001 – .002
POLYCARBONATE——————.0015 – .0025
PET, PBT, POLYESTERS————.0005 – .0007
POLYSULFONE———————–.001 – .002
POLYETHYLENE———————.0005 – .0012
POLYPROPYLENE——————-.0005 – .0012
POLYSTYRENE———————–.0007 – .0012
HIGH IMPACT POLYSTYRENE—.0008 – .0012
PVC (RIGID)—————————-.0006 – .001
PVC (FLEXIBLE)———————-.0005-.0007
POLYURETHANE———————.0004 – .0008
SAN—————————————.001 – .0015
T/P ELASTOMER———————-.0005 – .0007

Section 4:injection mold Cooling Standards and Design

Defines methods to provide optimum mold temperature control

1) All molds must be recessed for DME 300 Series Jiffy Quick Disconnects or equivalent Counter bores will be 1.125” diameter to allow for socket. (Refer to drawing S4-1)
2) All mold actions requiring cooling must have ½” I.D. reinforced flexible hoses routed to outside without interference. Jiffy-Tite extension plugs are preferred when possible.
3) In cases where water manifolds are required, CITO type manifolds are preferred.
4) Use DME standard 300 Series male Jiffy-Tite plugs and 300 Series Jiffy-Tite Extension Plugs or equivalent.
5) All baffles are to be DME standard brass plug baffles or equivalent. NO PRESS-FIT BLADES ARE TO BE USED.
6) All pipe plugs are to be brass. Do not use expandable plugs with “o”-rings.
7) All water lines are to be clear of all obstructions. All circuits are to be air checked with 100 lbs. air pressure per square inch.
8) No waterlines are to be less than ¼” from ejector pins or tapped holes. Avoid designing water directly under tapped holes. Water should be spaced no less than 5/8” from molding surfaces where possible.
9) The amount of water and spacing of water circuits is determined on a custom basis. All considerations will be given to provide the maximum water coverage possible, balancing optimum cooling and optimum ejection. Any areas that are difficult to cool should be considered for sub-inserting with MOLDMAX. All MOLDMAX inserts must be cooled to provide efficient transfer of heat.
10) Water connections must not interfere with mold clamping ledges.
11) Stamp water circuits In and Out. (Example: “IN 1” “OUT 1”)
12) Standard water line drill and NPT taps:
.25” (1/4”) diameter with 1/16”-NPT
.34” (11/32”) diameter with 1/8”-NPT
.43” (7/16”) diameter with ¼”-NPT
.56” (9/16”) diameter with 3/8”-NPT
.68” (11/16”) diameter with ½”-NPT
.93” (15/16”) diameter with ¾”-NPT
1.15” (1-5/32”) diameter with 1”-NPT
1.50” (1-1/2”) diameter with 1-1/4-NPT
13) “O”-rings must be designed with a grooved pocket to completely retain the “O”-ring
(Refer to drawing S4-2). Industrial Standard groove diameters and depths will be used such as supplied through PARCO, Standard Die, etc. (usually available through “O”-ring supplier)

Section 3: Runner System Standards and Design

Contents:
A) Surface Runner and gate Design Standards
B) Hot Runner Design Guidelines
C) Three plate runner and Pin-Point gate design Standards

A) Surface Runner and gate Design Standards

1) Upmold will NOT specify runner or gate size/configuration without a MOLD FLOW ANALYSIS performed by a reputable source and close documented communication with the Customer. Unless clearly documented on the mold quotation and agreed to by UPmold, the Customer will specify the runner and gate size/configuration and be responsible for part production cycle times.
2) Trapezoidal runners are preferred due to ease of machining and design. Full round runners are acceptable and common, and are necessary with some material types. All runner intersections will have radii added in the direction of flow and have cold slugs at each intersection. Refer to drawing S3-1 for cold runner design guidelines.
3) Edge gate designs are to be the “double chisel” type that can easily be detached from the part. Refer to drawing S3-2 for edge gate design guidelines.
4) Fan gates are commonly used to assist in reducing part warp or to maintain flatness. Refer to drawing S3-3 for fan gate design guidelines.
5) Sub-gate designs vary, and should be addressed on an individual basis. Refer to drawing S3-4 for sub-gate design guidelines.
6) Tunnel (“Cashew”) gates can only be used with specific material types. Refer to drawing S3-5 for “Cashew” gate design guidelines.
7) Runner shut-off inserts will be the DME “MRS” Type. When the DME “MRS” Type is not useable, refer to drawing S5-6 for an alternative custom design.

B) Hot Runner Design Guidelines
1) The Customer will specify the Hot Runner Supplier. Husky, Incoe, Mold Masters, DME, and Synventive are the preferred Hot Runner suppliers at UPmold. Any Hot Runner suppliers not listed must be approved by the Engineering Manager and specified by the Customer. UPmold will NOT specify flow channel, nozzle type, or gate size/configuration without a MOLD FLOW ANALYSIS performed by the hot runner supplier or by a reputable source and close documented communication with the Customer. Unless clearly documented on the mold quotation and agreed to by UPmold, the Customer and hot runner supplier will specify the flow channel, nozzle type, and gate size/configuration and be responsible for part production cycle times.
2) All manifold pocket and nozzle-well machining tolerances as specified by the Hot Runner supplier will be adhered to by UPmold.
3) Temperature control of at the nozzle well/gate detail is critical. Water is to be designed as close as possible to the nozzle well/gate without compromising the surrounding steel. Consider water jackets in all designs as the mold quotation allows (refer to drawing S3-7). Provide a cooling baffle opposite the gate, preferably on a separate cooling circuit.
4) In cases where nozzle cleaning is necessary in the molding press, the system will be designed with parting line accessible S.H.C.S. to disassemble the hot runner system plate assembly as shown in drawing S3-7. Guide pins must be longer than the Nozzle tips to protect the nozzle tips during assembly/disassembly of the “hot half”.

C) Three Plate Runner and Pin-Point Gate Design Standards
1) DME Three plate extension bushings will be used.
2) Trapezoidal runner configurations are preferred. UPmold will NOT specify runner or pin-point gate size/configuration without a MOLD FLOW ANALYSIS performed by a reputable source and close documented communication with the Customer. Unless clearly documented on the mold quotation and agreed to by UPmold, the Customer will specify the runner and pin-point gate size/configuration and be responsible for part production cycle times.
3) Pin Point gates need to be designed so that the gate will break off at the desired location. A gate indent (spherical radius detail) is needed to allow for the vestige “carrot” left at the part surface. Refer to drawing S3-8 for details.
4) Sucker Pin design and location is critical, and the design is very dependent on the plastic material specifications. Refer to drawing S3-9 for details.

Section 2: Slides/Lifters Standards and Design

Contents:
A) Mechanical injecion mold Slide Design Standards
B) Hydraulic injecion mold Slide Design Standards
B) Injection Mold Lifter Standard

A) Mechanical injecion mold Slide Design Standards (refer to drawing S2-1 & S2-2):
1) All shut-off surfaces must have a minimum of three degrees draft in direction of slide travel. Any shut-off angle less than three degrees must have written customer approval.
2) Two angle pins will be required on any slide design that exceeds seven inches in length. Consider a center Slide Guide for all long slides.
3) There must be a minimum of three degrees difference between the angle pin and back wedge.
4) The back wedge surface of the slide must have a lamina bronze (preferred) or 0-1 steel wear plate to allow for adjustment and for maintenance of wear surfaces.
5) The back wedge must be designed to resist injection pressure by backing up the entire molding surface. A double-wedge design must be considered for all large molding surfaces.
6) There must be a minimum of 0.20” ( 0.37” preferred ) clearance between slide detail and the molded part when slide is in the back position.
7) There can be no ejection under the slide detail without written Customer approval. If the customer accepts ejection under the slide detail, limit switches must register both forward and back movement of the ejector system.
8) Slides that mold large areas of part shape must have sufficient cooling. Consider Mold Max sub-inserts for difficult to cool details.
9) All deep rib details must be sub-inserted for venting.
10) Consider spring-loaded slide face ejection for all long wall or deep rib details.
11) Superior slide locks of sufficient weight retention can be used for slide retention in the back position.
12) Slides with flat faces that engage the cavity in direction of slide travel must be designed with face-loaded or external springs to prevent gaulding. In designs with slides on the “TOP” of mold, slide-face-mounted or external spring designs are to be used instead of Superior slide locks.
13) There must be a minimum of 6-points hardness (RcC) between the Gib material and the slide material.
14) The length of the slide foot must be 50% of the overall height of the slide.
B) Hydraulic injecion mold Slide Design Standards
1) All mechanical slide design standards relative to shut-off, molding surfaces, and cooling will apply to the Hydraulic Slide designs.

2) Parker series 2-H hydraulic cylinders will be used. The selection of cylinder bore size and cylinder mount style will be determined by slide size, amount of molding surface (injection pressure), and sequence of hydraulic pull and set. DO NOT USE PARKER MOUNTING STYLE “J” or “JB” DUE TO THE DECREASE IN PRESSURE RATING.

3) In cases where the slide rod is screwed directly into the slide body, make sure wrench flats can be easily accessed for assembly, or use a double-rod-end cylinder.
4) “T” style couplings can be used to secure the cylinder rod end to the slide. (Refer to drawing S2-3)
5) Unless otherwise specified by the Customer, use Parker “EPS” style solid-state proximity switches.

C) injecion mold lifter Design Standards (refer to drawing S2-4):

1) Whenever possible use the Progressive Standard Unilifter Round Core Blade Undercut Release System with a standard Progressive head detail or a custom manufactured head detail retained to the rod portion of the assembly with a rolled dowel. All Progressive Application Guidelines must be adhered to.
2) The head design of the lifter must have a minimum of 3-degrees shut-off.
3) Maximum angle acceptable for lifter travel is 11 degrees without special design considerations.
4) Provide a .003” to .005” pad on top of the lifter to prevent part “drag”.
5) Most parts will have a tendency to “ride” with the lifters (remaining on the detail formed by the lifters), which will not let the parts fall free. In situations where there are no details/side walls to retain the parts, consider extending ejector pins into the wall section and/or add “gripper” details to the face of the ejectors (REQUIRES THAT EJECTOR PINS BE KEYED). Molded guide posts can also be considered, but must be approved by the Customer.

Section 1: Injection Mold Design

The following information defines the minimum requirements for Upmold injection molds produced by Upmold Engineering. Alternatives that will contribute to improved tool life, minimum wear, ease of molding, and ease of Manufacturing will be considered within the confines of the original quotation and Customer supplied mold design and build standards. The Engineering Manager must approve any deviations from the Upmold standards, and any deviations must be documented and approved by the Customer.

Contents:
a) Upmold injection Mold Standard Description
b) Mold Series Description
c) Common mold steels and applications for Upmold molds
d) Drawing format and standards
e) Solid Model Geometry format, construction, and standards

A)Upmold injection Mold Standard Description

*Upmold:
Cycles: 50’000 to 250’000 Save
*Built for medium production. Upmold molds are not recommended for abrasive or corrosive materials without written customer approval, and appropriate plating of all part related items.
*All mold plates must be a minimum of SAE 1030 steel. AISI 4130 steel is commonly used due to price and availability of SAE 1030 steel.
*Core and Cavity blocks (In-solid designs), Core and cavity inserts, sub-inserts, and other non-moveable items are to be constructed with a minimum of P-20 steel.
*Slides, lifters, bar ejectors, and similar actions can be constructed of P-20 steel also, but must have a minimum of 3-degrees shut-off on all seal surfaces. Nitriding is required otherwise, as in the case of straight wall lifter designs. Hardened S-7 steel should be considered for all lifter designs.
*Slides must have lamina bronze wear plates with grease grooves.
*Ejector plates must be guided with two guide pins and ejector guide bushings minimum. The amount will be determined based on the mold size and number of ejector plate activated actions.
*Integral parting line locks must have lamina bronze wear plates if the interlock angle is less than 10-degrees. Standard inserted hardened interlocks are acceptable as the part design permits. All interlock designs must protect internal shut-offs.
*Cooling is required in all part-related features insofar as possible, and in mold plates as required for specific temperature control, such as in plates encompassing hot runners, valve gate actuators, etc.

B) Mold Series Description

1. Upmold  A Series Mold: Design allows for through pocketing of inserts (refer to drawing S1-1)
2. Upmold  B Series Mold: Design allows for blind pocketing of inserts and “in solid?core/cavity (refer to drawing S1-2)
3. Upmold  X Series Mold: Style “A?Design allows for through pocketing of inserts and stripper plate ejection (refer to drawing S1-3).
4. Style  B design allows for blind pocketing of inserts and stripper plate ejection (refer to drawing S1-4)
5. Upmold AX Series Mold: Design allows for cavity floating plate action (refer to drawing S1-5)
6. Upmold  T Series Mold: Design allows for three-plate runner with pin point gating requiring two floating plates to remain with the stationary side (refer to drawing S1-6)
7. Upmold  RG Series Mold: Design allows for injection and ejection to be on the stationary side (refer to drawing S1-7)

C) Common mold steels and applications for Upmold molds

Defines the common steel types and their applications.

Examples given are the most common types as used by Upmold. The Customer will specify the general steel types.

HRS – Hot rolled steel –SAE 1030: Ejector housing plates, clamping plates, back-up plates, support pillars, mold “feet” (NOTE: Due to the limited availability of HRS, all mold plates can be 4130/4140 (#2) steel.)

4130/4140 (#2 Steel) – Prehardened 30-36 RcC : General mold base plates

P-20 – Prehardened 30-36 RcC : High grade base plates, large cores and cavities, core and cavity inserts, slides, sub-inserts

420M (Prehardened 420 stainless steel) – Prehardened 30-35 RcC : large cores, cavities, inserts, slides

S-7 – Air hardening 54-56 RcC – Cavities, Cores, inserts, lifters, stripper rings, slides

420 SS – Stainless 50-52 RcC – Cavities, cores, slides, inserts

FP-100 Lamina Bronze – Wear plates – Must provide grease grooves.

O-1 – Oil hardening 58-62 RcC – Gibs, slide guides, wear plates

Ampco-18 – Gibs, slide guides, and wear plates

D) Drawing format and standards

Defines the Upmold 2-D drawing layout and standard drafting aids for the Block-out, Preliminary, and final design drawings.

Final drawing 2-D Mold Layout to include:

•  Over-all dimensions (length, width, mold stack height, stroke, plate thickness. Etc.).
•  “Top?of mold designated
•  Ups to clarify actions, water layout, and special features
•  “Exploded?Ups as required (Example: 3-Plate molds, Floating cores, etc.)
•  Enlarged Up of gate(s) with dimensions
•  Steel types and hardness
•  Watts, Volts, Amps per zone, Hot Runner information
•  Power and Thermocouple connectors/junction box
•  General Notes and tolerances, Texturing information, special sequencing notes, paint requirements, coating/plating requirements, etc.
•  Material List to include quantity required, detail number, over-all dimensions, catalog number, material type, and supplier (Standard Upmold format)
• Water and hydraulic connector information noted.
• Water and hydraulic thread sizes noted.
• Eyebolt sizes noted.
•  Completed title block with material and shrink, press size and model, etc.
•  Press tie bars shown in plan Ups
•  Layer list if applicable
•  Detail Ups and dimensions as required. NOTE: The 3-D solid model will be considered “dimensioned details?unless the Customer requires dimensioned detailed Ups. We will maintain the “data-driven?approach unless otherwise specified by the customer and compensated appropriately.
• Tooling Data Sheets

E) Solid Model Geometry format, construction, and standards

Defines the Unigraphics Solid Modeling requirements, Upmold data layering specifications, Upmold construction techniques, general mold functionality fit and function standards, and Upmold design for manufacturability requirements.

Final 3-D Mold Data to Include:

1. All components, actions, and blocks in Solid Model format. NOTE: The Upmold layer list must be followed. The data must represent the actual steel conditions insofar as possible
2. all vents, vent clearances, and parting line clearances
3. any sub-inserts required for in-process ECN’s and/or corrections (NOTE: Design data must reflect steel conditions insofar as possible)
4. Engraving information (2-D Geometry with depth and width noted is acceptable)
5. All Hot Runner/Nozzle components, including electrical connector pockets/junction boxes, etc.
6. All hydraulic cylinders. NOTE: Complex hydraulic plumbing should be modeled as needed
7. All lifting holes, brackets, lifting straps, safety straps, protecting pillars (i.e.: “feet?, etc.
8. Water manifolds if required
9. Press platen and tie bars