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Interactive Online Training

MOLD DESIGN

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Paulson’s online Mold Design course offers a focused approach in understanding many aspects of tooling and molding processes. This intensive course is authored by industry expert Kruse Training.

Goals of this Course:

  • Learn the basics of mold design and how various design elements impact a molded part
  • Gain an understanding of various gate styles and how they influence the molding process
  • Learn how to optimize different runner systems to achieve high quality molded parts

Description of this Course:

Gate design and placement are key factors in mold design. Gate type, placement, and size significantly affect the outcome of molded part so should be understood for maximum benefit. Gate placement options are often limited by design restrictions and other part-related constraints, understanding and utilizing industry best practices are useful in achieving optimal results.

Cold runner systems are another important aspect of mold design. By optimizing cold runner shapes and sizes, important molding processes such as pressure drops, polymer shearing, packing and cooling behavior, gate sealing time, and overall cycle time can be made more efficient as well.

Future Mold Design Lessons will focus on mold cavity and waterline layouts, waterline sizing, mold cavity steel selection, and mold cavity venting. The lessons contain simulations and real parts to reinforce the learning outcome and the students’ overall understanding of interactions within a real-life molding environment.

Recommended For: Entry Level Personnel, All Personnel

Length: 18 Lessons (lessons are approximately 15-20 minutes long each)

Language: English


Gates Lessons Include:

Lesson 1 – Cold Sprue

This lesson covers the purpose of gates and what types of gates are available, when and why direct cold sprue gates are used, and how sprue sizes influence injection pressures, clamp tonnages, packing pressure, and overall cycle time.

Lesson 2 – Pin-Point Gates

This lesson covers when and why pin-point gates are used in mold design, the advantages and disadvantages of using pin-point gates, and the impact of gate sizes on injection pressures and pack pressure distribution.

Lesson 3, Part 1 – Round and Oval Dual Sub-Gates

The first part of this lesson covers when and why sub-gates are used in mold design, how different gate designs and sizes impact injection pressures, and how to evaluate shear rates using different gate styles.

Lesson 3, Part 2 – Round and Oval Six Gate Sub-Gates

The second part of this lesson covers round and oval sub-gates and how they impact injection pressures, how to evaluate shear rates using different gate styles, and a comparison of injection pressures between dual gate and six gate set-ups.

Lesson 3, Part 3 – Ejector Pin Sub-Gates

The third part of this lesson covers when and why ejector pin sub-gates are used in mold design, different ejector pin styles and the advantages/disadvantages of each, and how different gate and pin sizes relate to injection pressures and clamp tonnages.

Lesson 4 – Edge Lapped Chisel Gates

This lesson covers different types of edge gate systems, including standard, lapped and chisel edge gates. The advantage and disadvantage of each system are discussed as well as how they impact injection pressures, shear rates, pack pressures, and clamp tonnages.

Lesson 5 – Fan Gates

This lesson covers when and why to use fan gates in mold design, the advantages and disadvantage to using fan gates, and how different gate sizes impact overall filling behaviors, injection pressures, and packing distribution.

Lesson 6 – Film Gates

This lesson covers when and why to use film gates in mold designs, how to evaluate filling behavior using film gates of different sizes, and how film gates of various shapes and sizes impact injection pressures, packing and cooling behaviors, and clamp tonnages.

Lesson 7 – Disk Gates

This lesson covers when and why to use disk gates in mold designs, and how hot and cold sprues impact injection pressures, clamp tonnages, and shear rates.

Lesson 6 – Ring Gates

This lesson covers when and why to use ring gates in mold designs, and how ring gate styles impact filling patterns and injection pressure requirements.


Cold Runner Lessons Include:

Lesson 1 – Types and Design

The first lesson in the Cold Runners section includes how cold runner shapes affect material flow, the impact of cold runner shapes and sizes on injection pressures, filling velocity, shear rates, and temperatures.

Lesson 2, Part 1 – Runner Patterns

The first part of this lesson covers the filling behavior for two runner systems with different types of gates and how the differences in gates sizes impact pressure spikes, pressures at fill, shear rates, and shear stress at fill.

Lesson 2, Part 2 – Runner Patterns

The second part of this lesson covers cavity spacing and runner layout. Topics covered include fill patterns and injection pressures for different mold runner layouts, how pressure curves shift based on flow length, how injection pressure is related to runner volumes, and the impact of runner layout on cycle times, cooling behavior, and clamp tonnages.

Lesson 3, Part 1 – Optimizing Cold Runner Sizes

Topics covered in the first part of this lesson include: factors to consider in cold runner designs, how to optimize cycle time using different gate runner designs, how different gate designs and sizes influence injection pressures, cooling behavior, and clamp tonnages, and how reducing runner volume can save money.

Lesson 3, Part 2 – Optimizing Cold Runner Sizes

The second part of this lesson covers optimizing cold runner systems, how different systems influence injection pressures, cooling behavior, and clamp tonnages, and how runner and overall shot volume are related to material usage and cost.

Lesson 4 – Artificially Balancing a Cold Runner

This lesson covers why unbalanced runner systems have unbalanced filling behaviors and pressure spikes, the steps needed to artificially balance a runner system, how to achieve optimal filling patterns, injection pressures, and cooling behaviors, and why adding flow length may balance a fill pattern but create shear-related imbalances.

Lesson 5 – Balancing Multi-Gated Runner Parts

This lesson covers the factors to consider when implementing a multiple gating strategy, how different runner dimensions impact filling behaviors and injection pressures, how to analyze tracer result to see behind the flow-front of a part filling, and how to use a “runner design sensitivity test.”

Lesson 6 – Balancing Family Molds

The topics covered in this lesson include: advantages and disadvantages to using family molds, how to design a two-gate runner system for two sets of molds, how different runner systems impact fill patterns ad injection pressures, and whether four-cavity part and runner systems could be a solution for parts with different volumes.

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