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System Selection Guide
Your Complete Hot Runner
Configuration Guide
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System Selection Guide
2
3
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
Contents
Contents
Standard Hot Runner Configuration
Hot Runner System Overview
Selection Overview
Nozzle Range and Series Options
Nozzle Range Selection
Nozzle Series Selection
Typical Flow Length Ratios
Nozzle Flow Rates
Tip Grade Selection
Tip Style Selection
Tip Styles
Nut Grade Selection
Nut Type Selection
Nut Options
Nozzle Assembly Order Code for MJ and X-Range Series
Tip and Nut Options
Plastic Material and Tip and Nut Suitability
Gate Geometry Selection
Gating Options – MX / BX / SX / FlowLoc
™
Gating Options - YCN/Multi-Gates
YCN Nut
Multi-Gates
MX Nozzle
BX Nozzle
SX Nozzle
FlowLoc
™
Range
MJ Nozzle
Gating Options - MJ
VeriShot
™
Single Valve Gate System
MVG25 Headed Pin Valve Gate System
MVG40 Headed Pin Valve Gate System
MVG40 Threaded Pin Valve Gate System
MVG55 Headed Pin Valve Gate System
MVCH Valve Gate System
Manifold Components
Selecting a Manifold Configuration
Nexus
™
Systems
Hot Half System
Additional Considerations
System Selection Example
Meticom TC5100 / TC5200 Temperature Control System
Meticom TC5H Temperature Control System
G-Series GTV8 Integrated Sequential Controller
pg
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System Selection Guide
4
Hot Runner System Overview
Standard Hot Runner Configuration
KEY KEY
Valve Gate Assembly Back Plate
Manifold Assembly Manifold Plate
Nozzle Assembly Cavity Plate*
*Supplied by Customer
Cooling Channels
Valve Pin Actuator
Manifold
Nozzle
Back Plate
Manifold
Plate
Cavity
Plate *
Locating Ring
5
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
A Hot Runner System maintains a molten flow of plastic from the moulding machine nozzle to the gate of a plastic
injection mould.
Mastip Hot Runner System Benefits
• Efficient cycle times
• Improves part consistency and quality
• Minimised gate vestige
• Reduced injection pressure
• Valve gates allow for sequential filling and allow family part moulds
• Eliminates the cold runner that would be scrap or require re-grind
• Increased process control for fine tuning of mould and part
Hot Runner System Critical Areas of Performance
Manifold design considerations:
• Precise temperature control of the molten plastic
• Balanced flow to all cavities for even part filling
• Nozzle sizing for maintaining sufficient molten material flow
• Gate detail required to correctly fill the part and shut the gate
• No material traps or areas of flow hesitation to ensure quick colour change and prevent material degradation
• Minimum pressure drop across the Hot Runner System
• Reasonable melt residence time
• Maximum cooling of gate areas to ensure effective shut off to gates
Hot Runner System Overview
Single Nozzle Gating Directly onto Part
Single Nozzle Gating into a Cold Runner
Hot Runner System Overview
Fully Hot Versus Semi Hot Configuration
Fully Hot advantages:
• No material wastage
• Low cycle times
• Low part stress
Semi Hot advantages:
• Reduces cold runner weight
• Reduces cost of mould
• Suitable for difficult gate locations
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System Selection Guide
6
Selection Overview
Selection Overview
Fill in part and material details for later reference
ONE
Part Specification Value Unit
Part Description
Part Weight g
Cold runner weight (if applicable) g
Overall size of part L x W x H mm
Nominal Wall Thickness mm
Minimum Wall Thickness mm
Gate Requirements Value
Cosmetic? Y / N
Flat or recessed gate for label / printing? Y / N
Material Specifications Value
Material Type
Filler or Glass Fibre %
Manufacturer and grade OR
MFI - Value, Temperature & load
Mould Specifications Value
Number of Cavities?
Hot Half Construction? Y / N
Using the flow chart “Nozzle Range Selection” on page 10
select the required Nozzle Range.
TWO
Nozzle Range MX / BX / SX / TX / MJ
THREE
Using the flow chart “Nozzle Series Selection” on page 11 and the
associated tables on page 12 select the appropriate nozzle series.
Nozzle Series 09 / 13 / 16 / 19 / 27
FOUR
Using the flow chart “Tip Grade Selection” on page 13
and the associated table select the appropriate tip grade.
Tip Grade G1 / G2 / G5
SIX
Using the flow chart “Nut Grade Selection” on page 16
and the associated table select the appropriate nut grade.
Nut Grade H1 / H5
Using the flow chart “Nut Type Selection” on page 17 and the
associated tables on page 18 select the appropriate nut style.
SEVEN
Thermal Gate
Nut Style ONT
/ BN / BE / SN / SX / SL / RN / RSN / YCN
Valve Gate
Nut Style ONT
/ VBE / VSN
Using the flow chart “Gate Geometry Selection” on page 22
select the appropriate gate geometry.
EIGHT
units
Gate Diameter (mm) mm
Gate Land (0.2mm max) mm
NINE
Based on the number of cavities and/or the injection points
required per part specify your manifold by attaching a drawing
showing the required positions or using the L & R references as
per the manifold section of the Technical Guide.
Number of nozzles on manifold
The easiest way to select the correct hot runner system is to follow the nine steps below.
FIVE
Using the flow chart “Tip Style Selection” on page 14 and the
associated table on page 15 select the appropriate tip style.
For “Multi-Gate Selection” refer to page 28.
Thermal Gate
Tip Style
TT / IT / OT
Tip Extension (if applicable) +5 / +10
Multi-Gate
Tip Style 2A/3A/4A/1S/2S/3S/4S
Valve Gate
Tip Style TV / OV
7
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System Selection Guide
Notes
Notes
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System Selection Guide
8
Nozzle Range
Nozzle Series
Valve
Gate
Front
Loading
Single
Nozzle
09 13 16 19 27
MJ
Front loading heater for Hot Half use
Confined gate area
Close cavity pitching
Ï Ï Ï Ï Ï
Ï
MX Front loading heater for Hot Half use
Close cavity pitching
Ï
Ï
Ï
BX Cost effective solution
Special length nozzles available
Robust heater design
Limited single nozzle use
Ï
Ï
¤
SX Dedicated single nozzle solution
Two heaters for optimum control
Ï
Ï Ï
Nozzle Range and Series Options
Key Suitability
Available / Suitable
¤
Application dependant
Ï
Not available / Not suitable
Nozzle Range & Series Options
9
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System Selection Guide
Nozzle Range & Series Options
Nozzle Range
Nozzle Series
Valve
Gate
Front
Loading
Single
Nozzle
09 13 16 19 27
FlowLoc™ Heat conducting sleeves
with embedded heaters
Threaded base for leak-proof operation
Ï Ï
Ï Ï Ï
BM Multi-Gates manifold range
Close cavity pitching
Economical and robust coil heater
Ï Ï Ï Ï
Ï Ï Ï
SM Multi-Gates single nozzle range
Two heaters for maximum temperature
control
Wide moulding window
Ï Ï Ï Ï
Ï Ï
Nozzle Range and Series Options
Key Suitability
Available / Suitable
¤
Application dependant
Ï
Not available / Not suitable
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System Selection Guide
10
Nozzle Range Selection
Nozzle Range Selection
Yes
No
No
Yes
No
No
No
No
Yes
Easy fill
application?
Yes
Select SX
Select BX
*Shot weight
exceeds polymer in nozzle
or is an engineering
polymer
Easy fill applications
1
PP - L/t < 125 MFI = > 15
PE - L/t < 125 MFI = > 15
PS - L/t < 75 MFI = > 15
Front loading
required?
Close cavity
pitching?
Sensitive
material?
Select MX
Sensitive materials
POM
EVA
PVC Soft
2
Notes
1. These examples are for typical applications only
2. Rigid PVC is not recommended for X Range
* To calculate average mass of polymer in nozzle:
Nozzle flow bore diameter x nozzle length x density
Yes
Yes
Yes
No
Does confined
gate area require
MJ?
No
Single Nozzle?
Nozzle Range
Selection
Nexus
™
System
Yes
Select FlowLoc™
Range
Warning: Check nozzle is
suitable for application
Select MJ
Series
Range
MJ MX BX
09 20
13 24 31
16
26 34
19
36 36
27
45
All measurements in mm
11
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System Selection Guide
Nozzle Series Selection
Yes
Yes
Yes
Yes
No
No
No
No
Select Nozzle Series
List part features
Determine maximum
flow length (L/t)
Determine material
characteristics
Estimate number and
size of injection points
Perform fill and
pressure analysis
Is
pressure and fill
time OK?
Use flow rate data
to select nozzle
Is flow
rate above 75% of
nozzle capacity?
Is Valve Gate
required?
Go to Tip Grade
Selection
Select Actuator
Thin wall part or
filled material?
Increase number
and/or size of
injection points
Consider Valve Gate
Flow Rate =
Shot Weight
(Fill Time * No Nozzles)
The following may require
larger flow channels:
1. Shear sensitive material
2. Thin wall construction
3. Long flow lengths
4. Filled materials
Select one series
larger nozzle
Large flow rate
Sequential filling
Smooth gate
Part weight
Overall size
Wall section
Special features
L/t ratio is the maximum length the material
has to flow divided by the wall section
Refer to table on page 12 - Typical Flow Length Ratios
This is a good measure of how difficult it
will be to fill the part
Material type, grade
and typical L/t ratio
Use shot weight and typical
L/t ratios for starting point
Flow analysis software and material
grade is required to complete this stage
Refer to tables on page 12 - Typical Flow Length Ratios
+ Nozzle Flow Rates to select appropriate nozzle series
Nozzle Series Selection
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System Selection Guide
12
Nozzle Flow Rates
Use the table below to select the correct nozzle series based on the flow rate required and the material category.
If the material is a blend material (for example Medium-Difficult or Easy-Medium) always select the higher category to
ensure the part can be filled.
Material
Wall Section
2.0 1.5 1.0 0.8 0.7 0.6 0.5 0.4
ABS 170 96 43 27 21 15 11 7
CA 150 84 38 24 18 14 9 6
EVA 175 98 44 28 21 16 11 7
SAN 120 68 30 19 15 11 8 5
PA 150 84 38 24 18 14 9 6
PC 100 56 25 16 12 9 6 4
HDPE 225 127 56 36 28 20 14 9
LDPE 275 155 69 44 34 25 17 11
PMMA 130 73 33 21 16 12 8 5
POM 150 84 38 24 18 14 9 6
PP 250 141 63 40 31 23 16 10
UPVC 100 56 25 16 12 9 6 4
Typical Flow Length Ratios (L/t)
All flow lengths greater than this must be considered thin wall and the nozzle series selected accordingly.
1
Additives, flow length and thin wall sections all reduce the effective flow rate and shot weight.
To counter the reduced flow rate and shot weight select one nozzle series larger.
2
Refer to table on page 21 - Plastic Material and Tip and Nut Suitability.
For Multi-Gate Flow Rates refer to page 28.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Nozzle
Series
Material Specifications
Material Category
Easy Medium Difficult
09
Thermal Gate Flow Rate g/s 15 7
Shot Weight g 0.5 - 15 0.5 - 10
13
Thermal Gate Flow Rate
g/s 30 15 5
Valve Gate Flow Rate g/s 25 12
Shot Weight g 0.5 -45 0.5 - 30 0.5 - 15
16
Thermal Gate Flow Rate
g/s 125 65 25
Valve Gate Flow Rate g/s 95 50 20
Shot Weight g 1 -200 1 - 125 1 - 60
19
Thermal Gate Flow Rate
g/s 300 150 60
Valve Gate Flow Rate g/s 225 110 45
Shot Weight g 2 -625 2 - 300 2 - 150
27
Thermal Gate Flow Rate
g/s 600 300 125
Valve Gate Flow Rate g/s 420 210 90
Shot Weight g 10 -2000 10 - 1200 10 - 800
2
Nozzle Series Selection
13
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
Tip Grade Selection
Easy material?
Yes
Minimum gate
vestige or long
life required?
Yes
No
Difficult
material or
long life?
No
No
No
No
Filled material?
Processing
temperature
> 300ºC
Use G1
Use G5
Go toTip Style
Selection
G2 tip
Yes
Yes
Yes
For best gate:
Use minimal gate land (q)
and gate diameter (G)
Tip Grade Selection
Tip Grade Selection
Tip Grades
Tips are manufactured in various grades designed for different applications and wear resistance.
Tip Grade Recommended use Manufactured Material Tip Style Options
G1 Default grade suitable for easy materials Beryllium Copper with Nickel coating TT, IT, OT, TV, OV
G2 Long life tip suitable for easy unfilled materials
Beryllium Copper tipped with Steel,
Nickel coating
TT, IT
G5
Long life tip suitable for difficult and abrasive
materials
Carbide TT, IT
D2 Hard liner OT, OV
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
14
Tip Style Selection
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
No
No
Yes
Tip Style Selection
Valve Gate?
Yes
Gating direct
onto part?
Cosmetic gate
required?
Is material
sensitive to
separation
Long fibre filled
material?
Use TT
Is Valve Gate
an option?
No
Valve Gate?
Crystalline material?
(i.e. narrow moulding
window?)
Use TV
No
Use OT
Use OV
Use OV
Use TT or IT
Use IT
Use OT
Crystalline material?
(i.e. narrow moulding
window?)
If gating onto a cold runner and it is suitable to follow the guidelines of
“Plastic Material and Tip and Nut Suitability” on page 21, then OT is the preferred choice.
Tip Style Selection
15
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System Selection Guide
Tip Styles
Tip Styles
Thermal Gate Tip Styles
Extended
Torpedo Tip (TT+10)
Extended
Torpedo Tip (TT+5)
Multi Hole
Torpedo Tip (TT)
Single Hole
Torpedo Tip(IT)
Extended Single Hole
Torpedo Tip (IT +5)
Open Tip (OT)
Multi-Gate
Axial Tip (A)
Multi-Gate
Side Tip (S)
Extended Single Hole
Torpedo Tip (IT +10)
Torpedo Tip (TV) Open Tip (OV)
Valve Gate Tip Styles
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System Selection Guide
16
Nut Grade Selection
Nut Grade Selection
Filled material?
No
Go to Nut
Type Selection
Use H1
Yes
Use H5
Nut Grade Selection
Nuts are manufactured in various grades designed for different applications and wear resistance.
Nut Grade Recommended use Manufactured Material Nut Style Options
H1
Default grade suitable for unfilled
or lightly filled materials
Medium hardness
Tool steel
ONT, BN, BE, SN, SL,
SX, VBE, VSN
H5
Long life nut suitable for filled
or unfilled materials
High hardness
Vanadium tool steel
BN, SN, VBE
17
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System Selection Guide
Nut Type Selection
Is witness
ring on part
acceptable?
Is gate
cooling critical
to cycle
time?
Is a sprue
required?
Is part shaped
at gate area?
Crystaline
material?
Go to Gate Geometry
Selection
The BE bush nut has a larger contact
area that can be tuned to provide a
correct cooling rate for the application
Select Sprue Nut
SN, SX, SL
Select Open Nut
(ONT)
Select YCN Nut,
Sprue Nut SN, SX or SL
Yes
Yes
Select Bush Nut
BN
Yes
Yes
No
No
Yes
Gating
direct onto
part?
Yes
No
No
No
Select Bush Nut
BE
No
If gating onto a cold runner a Sprue Nut is recommended.
Nut Type Selection
Nut Type Selection
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System Selection Guide
18
Witness
Modify
Witness
Modify
Nut Options
Witness
Modify
Witness
Ï
Modify
Ï
Witness
Ï
Modify
Witness
Modify
Witness
Modify
Witness
Modify
Witness
Modify
Witness
Modify
Witness
Modify
Witness
Modify
Ï
Key Value
Yes
Ï
No
Witness Nut will leave a circular witness mark on part
Modify Nut must be modified to suit application
Ød4
Series Standard Nut Ød4 Retro Nut Ød4
13 10 13.1
16 12 16.1
19 15 19.1
27 23 27.1
Bush Nut (BN)
Bush Nut
Full Contact (BE)
Sprue Nut +5 (SN) Sprue Nut + 20 (SX) Sprue Nut + 35 (SL) Retro Sprue Nut (SN-R) YCN Nut (YCN)
Valve Gate Nut Types
Thermal Gate Nut Types
Retro Nut (ONT-R)Open Nut (ONT)
Valve Bush Nut
Full Contact (VBE)
Valve Sprue Nut (VSN)
Thermal Gate and Valve Gate Nut Types
For a Dome Nut supply
R1 and K dimensions
at time of order.
K
1R
Dome Nut (BD)
Nut Options
19
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System Selection Guide
Nozzle Assembly Order Code for MJ & X-Range Series
Nozzle Assembly Order Code for MJ and X-Range Series
NOZZLE
RANGE
NOZZLE
NUT
NOZZLE
SERIES
NOZZLE
LENGTH
TIP
EXTENSION
(OPTIONAL)
TIP
GRADE
EXAMPLE OF A
FINAL ORDER CODE
G1 H1*
G2 H1*
G5 H1*
G5 H5
+5
+10
INCH
(BX25 ONLY)
137
187
237
287
337
METRIC
045
055
065
075
095
115
130
145
175
225
275
09
13
16
19
25
27
T
BN
BE
SN
SX
SL
SNR
V
VBE
VSN
RN
YCN**
T
I
O
MJ
MX
BX
SX
TX
(open)
* Larger gate diameters are available as standard
** Refer to page 26 for order code diagram for YCN Nut
INDICATE NUT GATE
DIAMETER SEPARATELY
NUT
GRADE
MX TT 13 075 +10 G2 H1
NOZZLE
TIP
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
20
Tip and Nut Options
Key Tip Suitability
Available
éééé
Highest rating
Ï
Not Available
Tip and Nut Options
1
Not available in X13
3
Not available in SX series
2
Not available in X27
4
Not available in H5
TIPS
Grades Nut Style Features Plastic (Refer to page 21)
G1 G2 G5 ONT
BN
BE
SN
SX
4
/SL4
Gate
Quality
Flow
Rate
Flow
Marks
Easy Medium Difficult
Thermal Gate
TT
Multi Hole
Torpedo Tip
ééé éé éé éééé éééé ééé
TT+5
Extended
Torpedo Tip
Ï Ï Ï ééé éé éé éééé éé Ï
TT+10
Extended
Torpedo Tip
Ï Ï Ï ééé é éé éééé é Ï
IT
Single Hole
Torpedo Tip
ééé éé ééé éééé éééé ééé
IT+5
Extended
Torpedo Tip
Ï Ï Ï ééé éé ééé éééé éé Ï
IT+10
Extended
Torpedo Tip
Ï Ï Ï ééé é ééé éééé é Ï
OT
Open Tip
Ï éé ééé éééé éééé ééé é
Multi-Gate
(A)
Axial Tip
Ï Ï Ï Ï ééé éé éé éééé Ï Ï
Multi-Gate
(S)
Side Tip
Ï Ï Ï Ï éé éé éé éééé Ï Ï
Valve Gate
TV
Torpedo Tip
Ï Ï éééé éééé éé éééé ééé é
OV
Open Tip
Ï éééé éééé ééé éééé ééé é
1
3
3
2
4
1
1
1 1
21
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System Selection Guide
Plastic Material and Tip and Nut Suitability
Plastic Material and Tip and Nut Suitability
Material
Category
Nozzle Series and Tip
09 13 16 19 27
TT
1 2
TT
IT
OT
OV
TT
IT
TV
1
OT
OV
TT
IT
TV
1
OT
OV
TT
IT
TV
1
OT
OV
A
S
Easy
PP
PE
PS
Ï
SB
Ï
EVA
Ï
Medium
ABS
¤ Ï
AS
¤ Ï
POM
¤ Ï
SAN
¤ Ï
PA6
¤ ¤ ¤ ¤ ¤ Ï
PMMA
¤ ¤ Ï
ASA
¤ ¤ Ï
TPE
¤ ¤ Ï
Difficult
PA66
¤ ¤ ¤ ¤ ¤ Ï
PBT
Ï ¤ ¤ ¤ ¤ Ï
PC
Ï ¤ ¤ ¤ ¤ Ï
PPS
Ï ¤ ¤ ¤ ¤ Ï
PPE
Ï ¤ ¤ ¤ ¤ Ï
PPU
Ï ¤ ¤ ¤ ¤ Ï
PET
Ï ¤ ¤ ¤ ¤ Ï
PES
Ï ¤ ¤ ¤ ¤ Ï
PPO
Ï ¤ ¤ ¤ ¤ Ï
LCP
Ï ¤ ¤ ¤ ¤ Ï
PEI
Ï ¤ ¤ ¤ ¤ Ï
PP + FILL
Ï
G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5
Ï
PA + FILL
Ï
G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5
Ï
SAN + FILL
Ï
G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5
Ï
PA66 + FILL
Ï
G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5
Ï
PBT + FILL
Ï
G5/H5
¤
G5/H5
¤
G5/H5
¤
G5/H5
¤ Ï
PC + FILL
Ï
G5/H5
¤
G5/H5
¤
G5/H5
¤
G5/H5
¤ Ï
PPS + FILL
Ï
G5/H5
¤
G5/H5
¤
G5/H5
¤
G5/H5
¤ Ï
PPE + FILL
Ï
G5/H5
¤
G5/H5
¤
G5/H5
¤
G5/H5
¤ Ï
PPU + FILL
Ï
G5/H5
¤
G5/H5
¤
G5/H5
¤
G5/H5
¤ Ï
PET + FILL
Ï
G5/H5
¤
G5/H5
¤
G5/H5
¤
G5/H5
¤ Ï
Key Tip Suitability
Suitable
G5 Very suitable with Grade 5 tips and H5 nuts only
¤
Application dependant
G5 Application dependant and Grade 5 tip and H5 nuts only
Ï
Not suitable
Not available in G5
Only available in G2
1
2
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System Selection Guide
22
Gate Geometry Selection
Gate Geometry
Selection
Minimal gate
vestige required?
Use standard land (q)
and gate diameter (G)
Finished
Use minimal land (q)
and gate diameter (G)
For easy materials
use G2 TT/IT tip
For Valve Gate the gate
diameter and land does
not affect gate quality
Yes
No
Gate land
(‘q’) Size
Cosmetic Gate Gate Life Other Factors
>0.20mm
Not Recommended Increased injection pressure, premature gate freeze off
0.20mm * **** Recommended for materials with high % filler
0.15mm ** *** Recommended for materials with medium % filler
0.10mm *** ** Good balance between gate cosmetics and life
0.05mm **** * Strong cavity steel required. Cooled inserts required near to gate
<0.05mm
Not Recommended Sharp edge breaks on first few shots, poor wear resistance
Limited cooling at gate can result in stringing
Thermal Gate Land Length (q)
Recommended Thermal Gate Diameter (ØG)
Material Tip Grade
Nozzle Series
09 13 16 19 27
Unfilled
G1/H1 - 0.8 - 1.3 0.9 - 1.4 1.1 - 1.6 1.8 - 2.5
G2/H1 0.7 – 0.8 0.7 – 1.3 0.8 - 1.4 1.0 - 1.6 1.6 - 2.5
G5/H1 - 0.9 – 1.3 1.0 - 1.4 1.2 - 1.6 2.0 - 2.5
Filled
G5/H1 - 1.0 – 1.4 1.2 – 1.5 1.5 - 1.8 2.4 - 2.8
G5/H5 - 1.4 –1.6 1.5 – 1.7 1.7 – 2.0 2.6 – 2.8
It is always recommended to start with a small gate and adjust as required.
23
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System Selection Guide
Notes
Notes
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
24
Gating Options – MX/BX/SX/FlowLoc
™
13 16 19 27
13 16 19 27
Ï
13 16 19 27
13 16 19 27
Ï
13 16 19 27
13 16 19 27
13 16 19 27
Ï
13 16 19 27
L (nozzle)L (nozzle)L (nozzle) 5.0
20.0
35.0
Ød4
Ød4
Ød4
Ød4
Ød4
Ød4
Ød4
Ød4
0
Ød4
5.0
10.0
Gating Options - MX/BX/SX/FlowLoc
™
Standard Sealing Diameter
Series 13 16 19 27
Ød4 10 12 15 23
13 16 19 27
Ï
ONT ONT +5 ONT +10
SN +5 SX +20 SL +35
BN / BE VBE VSN
25
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
13 16 19 27
Ï Ï Ï
13 16 19 27
Ï Ï Ï
Axial Gate* Side Gate*
Gating Options – YCN/Multi-Gates
13 16 19 27
Ï Ï Ï
20.0
35.0
Ød4
Ød4
Ød4
Ød4
5.0
10.0
YCN +20 YCN +35
Gating Options - YCN
Gating Options - Multi Gates
Standard Sealing Diameter
Series 13 16 19 27
Ød4 10 12 15 23
13 16 19 27
Ï
* Pocket dimensions to be supplied by Mastip
L (nozzle)
L (nozzle)
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
26
YCN Nut
YCN Nut is designed for X-range nozzles, providing open flow moulding. An ideal moulding solution
for indirect-feed via a cold runner. Ideal for Thermal Gate applications.
P7 P4 N3
P7
Easy material/
Low temperature
Gate is located 7mm forward
of the heat source
E.g. PP, PE, ABS,
ASA, SAN
P4
Mid-Range
Gate is located 4mm forward
of the heat source
E.g. PC, POM, PMMA
N3
Difficult material/
High temperature
Gate is located 3mm behind
the heat source
E.g. PA, PBT, PET, PPS
PEI, PPO
X13 X16 X19 X27
20mm 20mm 20mm 35mm
Features
• Internal nut profiles to suit different materials
and temperature requirements
• No high-conductivity tip insert required
• Tipless nut provides open flow moulding
• Minimises melt shear
• Lowers the overall pressure drop through the gate
• Provides a broad repeatable moulding window
Applications
• Moulding applications that suit open flow injection
• Cosmetic gate is not required on moulded part
• Ideal for indirect-feed via a cold runner
• Moulding applications where a moulded
sprue is acceptable
• Thermal Gate applications
Unfilled X Range – YCN Nut Style
Series P7 P4 N3
13 Ø1.2 Ø1.3 Ø1.3
16 Ø1.4 Ø1.5 Ø1.5
19 Ø1.8 Ø2.0 Ø2.0
27 Ø2.2 Ø2.5 Ø2.5
Filled X Range – YCN Nut Style
Series P7 P4 N3
13 Ø1.6 Ø1.8 Ø1.8
16 Ø1.8 Ø2.0 Ø2.0
19 Ø2.2 Ø2.5 Ø2.5
27 Ø2.7 Ø3.0 Ø3.0
Gate Diameter
X-Range YCN Nuts are stocked with standard gate diameters
according to the nozzle series,
nut style and filled or unfilled material.
7 4
3
Custom gate and taper available on request.
YCN Nut Extension
YCN Nuts are stocked with a standard extension length
Standard sprue taper is 6º
YCN Open Tipless Nut
Gating OptionsYCN Nut
27
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
YCN Nut
YCN Nut Selection
Nozzle Order Code for X-Range YCN Nut Series
NOZZLE
RANGE
MX
BX
SX
YCN
NUT
NOZZLE
SERIES
NOZZLE
LENGTH
GATE
PROFILE
POLYMER
CLASSSIFICATION
YCN
13
16
19
27
045
055
065
075
095
115
130
145
175
225
275
P7
P4
N3
U (Unfilled)
F (Filled)
EXAMPLE OF A
FINAL ORDER CODE
BXBX YCN 27 175 P4 F
Yes
Yes
Moulded
Sprue
Acceptable
In-Direct
Feed via
Cold Runner
Valve Gate
and/or Sequential
Filling
No
No
Cosmetic
Gate
Yes
Yes
Yes
No
No
Moulded sprue
on part requires
repeatable forms
No
YCN Nut
Selector
YCN Nut
Select Alternative
Option
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
28
Multi-Gates
Gate StylesMulti-Gates
Gate Nozzle Series L (Nozzle)
Axial
Gate
BM 27 75 95 115 145 175 225 275
SM 27 75 95 115 145 175 225 275
Side
Gate
BM 27 69 89 109 139 169 219 269
SM 27 69 89 109 139 169 219 269
Nozzle Series Material Specifications Material (Polyolefin)
M27
Flow Rate g/s/gate 15
Shot Weight g 0.5 - 15
Gate Size – Axial mm 0.7 - 1.0
Gate Size – Side mm
0.5 - 1.0
(max 70% part well thickness)
BM / SM Standard Gate Lengths
Multi-Gate Flow Rates
Multi-Gates
Mastip’s Multi-Gate solutions are engineered specifically for challenging applications requiring close
pitch gates in restricted areas where conventional gating methods aren’t possible.
3 Gates
3A
4 Gates
4A
2 Gates
2A
1 Gate
1S
2 Gates
2S
3 Gates
3S
4 Gates
4S
PCD PCD PCD
Axial Gate
Side Gate
Gate Well
Diameter
Gate Well
Diameter
Gate Well
Diameter
Gate Well
Diameter
Features
• Axial multi-gates allow close cavity pitching with
a pitch circle diameter (PCD) from 10.00 to 22.00
with the ability to offer 2 to 4 gates per tip
• Side multi-gate allowing close cavity pitching
with a gate well diameter from 22.30mm to
26.80mm with the ability to offer 1 to 4 gates
per tip
• Highly conductive tip allowing for precise
thermal control
• Tip flow channels designed to optimise
and balance the thermal profile
• The M-Range nozzles are designed specifically
for multi-gate solutions incorporating BX/SX
proven technology
Applications
• Multiple part direct injection gating with one
nozzle either in an Axial or Side gate tip style
• Side multi-gates allow internal side gating on
single complex round parts that need a highly
balanced fill
• Axial multi-gates allow for direct gating on single
complex round parts that need a highly balanced fill
• Only polymers that are easy to process such as
polyolefins with long residence times to be
processed through the multi-gates
L
L
Axial Side
L
L
29
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
Multi-Gates
Multi-Gates Selection
* Number of gates required not included in flow chart, contact Mastip.
Multi-Gate
Selection
Thermal Gate
Side Gate
Multi-Gate – 1S, 2S, 3S, 4S
Alternate Solution
Axial Gate
1-4 Gates
per Side tip*
Polyolefin
No
Yes
Yes
Yes
Multi-Gate – 2A, 3A, 4A
Yes
Yes
2-4 Gates
per Axial tip*
NoNo
No
Yes
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
30
MX Nozzle
MX Nozzle Overview
MX nozzle, specifically designed for multi cavity manifold systems and hot halves.
1.
MX FEATURES
Mould design
• Efficiently designed profile to allow closer cavity pitching
• Shares the same gate profiles as BX and SX
• Available in both thermal and valve gate options
• Consistent nozzle lengths across the range
• Ability to mould large parts with smaller nozzles
due to optimum flow characteristics
Operation
• Wide moulding window
• Excellent temperature profile and thermal stability
• Operates at low moulding pressure and temperature
• Optimum cycle times due to superior thermal insulation
• Uses an advanced micro coil heater with integrated
heat deflection tube
Installation and maintenance
• Front loading capability for easier servicing of tips,
heaters and thermocouples
• Simple machining and installation requirements
• Improved reliability due to the use of advanced materials
• Common tip and nut options provide ready availability of
spare parts
Heater Cap
7
Dowel Pin
1
Body
2
Heater Sleeved
Tip
4
Thermocouple
5
Thermocouple Clip
6
Snap Ring
8
Nut
9
3
31
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
Ø10.0
Ø22.9
Ø12.0
Ø24.9
Ø15.0
Ø31.5
L (nozzle) 12.0
A/F = 24
A/F = 26
A/F = 36
12.0
L (nozzle)
15.0
L (nozzle)
Ø6.0
Ø28.0
Ø7.0
Ø30.0
Ø8.0
Ø40.0
MX13 MX16 MX19
MX Nozzle
MX Nozzle Series
MX Standard Lengths
Series L (nozzle)*
13 Series 45 55 65 75 95 115 130 145 175
16 Series 45 55 65 75 95 115 130 145 175
19 Series
55 65 75 95 115 130 145 175
* Custom lengths available on request, BX recommended
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
32
BX Nozzle
BX Nozzle Overview
BX nozzle is designed to provide cost sensitive solutions for low to medium cavitation
applications, not requiring hot half construction.
1.
BX FEATURES
Mould Design
• Ability to easily order special length nozzles
• Shares the same gate profiles as MX and SX
• Available in both thermal and valve gate options
• Consistent nozzle lengths across the range
• Ability to mould large parts with smaller nozzles
due to optimum flow characteristics
Operation
• Wide moulding window
• Excellent temperature profile and thermal stability
• Operates at low moulding pressure and temperature
• Optimum cycle times due to superior thermal insulation
• Uses an economical and robust coil heater
Installation and Maintenance
• Simple machining and installation requirements
• Improved reliability due to the use of advanced materials
• Common tip and nut options provide ready availability of
spare parts
Dowel Pin
Body
Heater
Heater Cover
Tip
Thermocouple
Thermocouple Clip
Heater Cap
Snap Ring
Nut
10
9
8
7
6
5
4
3
2
1
33
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
A/F = 31
A/F = 34
A/F = 36
12.0
15.0L (nozzle)
L (nozzle)
Ø6.0
Ø34.0
Ø7.0
Ø38.0
Ø8.0
Ø40.0
12.0L (nozzle)
Ø10.0
Ø27.0
Ø12.0
Ø30.0
Ø15.0
Ø33.0
A/F = 4520L (nozzle)
Ø23.0
Ø43.0
Ø12.0
Ø50.0
BX13 BX16 BX19
BX27
BX Nozzle Series
BX Nozzle
BX Standard Lengths
Series L (nozzle)*
13 Series 45 55 65 75 95 115
145 175
16 Series 45 55 65 75 95 115 130 145 175
19 Series 55 65 75 95 115 130 145 175
27 Series 75 95 115 145 175 225 275
* Custom lengths available on request
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
34
SX Nozzle Overview
With two heaters the SX nozzle is perfectly suited for all single nozzle applications.
1.
SX FEATURES
Mould Design
• Ability to easily order special length nozzles
• Shares the same gate profiles as MX and BX
• Consistent nozzle lengths across the range
• Ability to mould large parts with smaller nozzles
due to optimum flow characteristics
Operation
• Separate heater for the nozzle head for
maximum temperature control
• Wide moulding window
• Excellent temperature profile and thermal stability
• Operates at low moulding pressure and temperature
• Optimum cycle times due to superior thermal insulation
• Uses economical and robust coil heaters
Installation and Maintenance
• Simple machining and installation requirements
• Improved reliability due to the use of advanced materials
• Common tip and nut options provide ready availability of
spare parts
SX Nozzle
Thermocouple Clip
Sprue Heater Cover
Sprue Heater
Body
Heater Cover
Snap Ring
Thermocouple
Heater Cap
Nut
Tip
Circlip
Sprue Thermocouple
Dowel Pin
Heater
1
2
3
5
6
7
8
9
10
11
12
13
14
4
35
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
Ø23
Ø43
Ø12
Ø30
Ø10
Ø27
Ø15
Ø33
Ø3*
7
5
26
18
L (nozzle)
L (nozzle)
Ø32
A/F = 36
Ø40
Ø24
Ø6
A/F = 46
Ø50
Ø38
Ø30
Ø4*
Ø8
L (nozzle)
20 26
7
5
A/F = 46
Ø5*
Ø38
Ø50
Ø30
Ø12
L (nozzle) 25 25
7
5
Ø7
Ø4*
Ø32
7
26
A/F=36
Ø40
18
5
Ø24
SX Nozzle
SX16 SX19
SX27
SX Nozzle Series
SX Standard Lengths
Series L (nozzle)**
13 Series 45 55 65 75 95 115 145 175
16 Series 45 55 65 75 95 115 145 175
19 Series 55 65 75 95 115 145 175
27 Series 75 95 115 145 175 225 275
* Open to suit machine nozzle size ** Custom lengths available on request
SX13
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
36
FlowLoc™ Range
FlowLoc
™
Range Overview
1.
FLOWLOC™ FEATURES
Design
• Available in 16, 19 and 27 Series nozzle in a variety of
lengths with the ability to order special length nozzles
• Features a threaded base to attach securely
to the manifold
• Available in thermal gate
• Suitable for low to high cavity applications
• Shares the same gate profiles as existing X-Range nozzles
Operation
• Incorporates advanced heating technology with
embedded heaters for exceptional thermal performance
• Threaded nozzle screws directly into the manifold
providing a secure, leak-proof solution
• Capable of processing a wide range of polymers
including abrasive fillers
• Excellent thermal profile along the entire length
of the nozzle ensures a wide moulding window
• Suitable for high pressure applications
Installation and Maintenance
• Simple installation via threaded base
• Utilises Mastip’s proven X-Range tips and nuts
• Individual components are readily available on
express order from our service team
FlowLoc™ Technology Range are designed to provide a secure, leak-proof solution for multi-cavity manifold systems.
Thermocouple Clip
Tip
Thermocouple
Heater Cap
Nut
Stainles Steel
Body
Heater
1
2
3
4
5
7
8
Circlip
6
37
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
TX16
TX19
TX27075 – TX27175
FlowLoc
™
Range
FlowLoc™ Range
FlowLoc™ Standard Lengths
Series L (nozzle)*
16 Series 75 95 115 130 145 175
19 Series 75 95 115 130 145 175
27 Series 75 95 115 130 145 175 225 275
* Lengths can be customised to suit your requirements on request
TX27225 – TX27275
L (nozzle)
A/F = 36
20.00
Ø12.0
L (nozzle)
A/F = 36
20.00
Ø12.0
L (nozzle)
20.00
Ø8.0
A/F = 30
L (nozzle)
20.00
Ø7.0
A/F = 27
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
38
MJ Nozzle Overview
MJ nozzle, specifically designed for close cavity pitching.
1.
MJ FEATURES
Mould design
• Nozzle pocket profile for improved cooling
performance and gate strength
• Optimal flow characteristics for ease of moulding
• Close cavity pitching
Operation
• Wide moulding window
• Excellent temperature profile and thermal stability
• Operates at low moulding pressure and temperature
• Short cycle times
Installation and maintenance
• Simple installation
• Front loading for ease of servicing
• Improved reliability
MJ Nozzle
Dowel Pin
Body
Tip
Heater
Thermocouple
Snap Ring
1
2
3
4
5
6
39
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
A/F = 20
Ø4.0
Ø24.0
12.0L (nozzle)
Ø7.0
Ø14.0
MJ Nozzle Series
MJ Standard Lengths
L (nozzle)*
09 Series 75 95 115 130 145 175
* Custom lengths available on request
MJ Nozzle
MJ Gating Options
ONT ONT +5 ONT +10
L (nozzle)
5.0
10.0
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
40
1.
VeriShot™ Single Valve Gate System
VeriShot
™
Single Valve Gate System
VERISHOT™ FEATURES
Design
• Available to suit TX16, TX19 &
TX27 series threaded nozzles
• Compact annular design
• Reduced mould height
• Multiple gate profiles to suit
a broad range of applications
• VeriShot™ functions as a locating
ring for mould alignment
• Locating ring supplied in metric and
imperial sizes
Operation
• Advanced heating technology
• Exceptional thermal performance
• Capable of processing a wide range
of polymers
• Adjustable valve pin
• Incorporates superior FlowLoc
™
Technology providing a secure,
leak-proof solution
Installation and Maintenance
• Simple Installation
• Utilises proven X-Range tips and nuts
Mastip’s VeriShot™ is an extremely compact, adjustable single valve gate system. The VeriShot™ incorporates
advanced heating technology for exceptional thermal performance in applications requiring high cosmetic finish,
high flow rates and dimensional accuracy.
Cap Screw M6
(metric option)
or ¼ UNC
(inch option)
Locating Ring
Cap Screw M8 x 90
Striker Plate
Dowel Pin Ø5 x 28
Upper Manifold
Pin Locking Screw
Valve Pin
Wear Strip Top
O-Ring ID 79 x 3
Piston
O-Ring ID 100 x 3
Wear Strip
Bottom
O-Ring ID 79 x 3
O-Ring ID 115 x 3
O-Ring ID 5 x 1.5
Cylinder
Cap Screw M5 x 40
O-Ring ID 6 x 1.5
VeriShot
™
Heater
Dowel Pin Ø5 x 28
Valve Pin Seal
Dowel Pin Ø3 x 12
FlowLoc
™
Nozzle
1
2
4
Dowel Pin Ø6 x 20
3
5
6
7
8
10
11
12
13
14
15
16
18
19
20
21
22
24
25
Lower Manifold
27
26
28
Thermocouple
29
30
Button Cap Screw
M4 x 8
23
Dowel Pin
Ø6 x 20
17
Valve Pin
Adjustment
Packers
9a
9b
9c
9d
41
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
VeriShot™ Single Valve Gate System
VeriShot™ Nozzle Compatibility
Description FlowLoc
™
Nozzle Tip Supplied Pin Size L (nozzle)
VeriShot
™
16 TX16
OV / TV
Ø2.5 x 300 75 - 175
VeriShot
™
19 TX19 Ø3.0 x 400 75 - 175
VeriShot
™
27 TX27 Ø5.0 x 600 75 - 275
FlowLoc™ (nozzle)
ØD
Ø170.00
Ø140.00
L (nozzle)
76.00 Min
146.0
54.00
17.00
92.0
Metric Inch
ØD 100-160mm 4”- 6”
VeriShot™ Single Valve Gate System
Note
1. Lengths can be customised to suit your requirements on request
2. Multiple diameter locator ring sizes now come as standard to suit your requirements.
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
42
MVG25 Headed Pin Valve Gate System
1.
MVG25 FEATURES
Mould Design
• Available to suit MX and BX Nozzles
• Standard minimal pitching is
55mm – can be modified to fit 43mm
• Backplates 50mm minimum
• Conical or Cylindrical shut off
• Easy machining of the pockets
• Pneumatic circuit integrated with
the backplate
Moulding Benefits
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results
in better part quality
• Reduced gate cooling requirements
Installation and Maintenance
• Easy machining and installation
• Easy seal replacement
• Valve pin height is adjustable
• Comes with Headed Pin design,
with incremental adjustment
MVG25 Headed Pin Valve Gate System
Blanking Plate Screw
Blanking Plate Seal
3
Pin Locking Screw
4
Pin Head Seal
5
Valve Pin Adjustment Packer6a
6d
6c
6b
7
Valve Pin
Valve Pin Adjustment Packers
Piston
9
Piston Main Seal
8
Piston Rod Seal
10
Circlip
11
Cylinder
12
Cylinder End Seal
13
Locating Spacer
14
15
Valve Pin Seal
Blanking Plate
2a
2b
1
43
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
MVG25 Headed Pin Valve Gate System
MVG25 Headed Pin Valve Gate System
MVG25 Nozzle Compatibility
Description Nozzle Tip Nozzle Length Supplied Pin Size
MVG25-P1 Headed Pin MX13 / BX13 OV 45 – 175 Ø2.0
MVG25-P1 Headed Pin MX16 / BX16 OV / TV 45 - 175 Ø2.5
MVG25 Blanking Plate
Ø
54.0
50.0 Min10.0
MVG25 Spacer
MVG25 Valve Pin
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
44
MVG40 Headed Pin Valve Gate System
MVG40 Headed Pin Valve Gate System
1.
MVG40 FEATURES
Mould Design
• Available to suit MX and BX Nozzles
• Standard minimal pitching is 75mm
- can be modified to fit 58mm pitching
• Backplates 55mm minimum
• Conical or Cylindrical shut off
• Easy machining of the pockets
• Pneumatic circuit integrated with the backplate
Moulding Benefits
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results
in better part quality
• Reduced gate cooling requirements
Installation and Maintenance
• Easy machining and installation
• Easy seal replacement
• Valve pin height is adjustable
• Comes with Headed Pin design,
with incremental adjustment
Blanking Plate Screw
1
Blanking Plate Seal
3
Pin Locking Screw
4
Valve Pin
6
Valve Pin Adjustment Packer
5a
Piston Main Seal
7
Piston
8
Piston Rod Seal
9
Valve Pin Adjustment Packers
5b
5b
5b
Circlip
10
Cylinder
11
Cylinder End Seal
12
Locating Spacer
13
Valve Pin Seal
14
Blanking Plate
2a 2b
45
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
MVG40 Nozzle Compatibility
Description Nozzle Tip Nozzle Length Supplied Pin Size
MVG40-P1 Headed Pin MX13 / BX13 OV 45 - 145 Ø2.0
MVG40-P1 Headed Pin MX16 / BX16 OV / TV 45 - 145 Ø2.5
MVG40-P1 Headed Pin MX19 / BX19 OV / TV 55 - 175 Ø3.0
MVG40-P1 Headed Pin BX27 OV / TV 75 - 275 Ø5.0
MVG40 Headed Pin Valve Gate System
MVG40 Headed Pin Valve Gate System
MVG40 Blanking Plate
Ø
75.0
55.0 Min10.0
MVG40 Cylinder Assembly
MVG40 Spacer
MVG40 Valve Pin
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
46
MVG40 Threaded Pin Valve Gate System
MVG40 Threaded Pin Valve Gate System
1.
MVG40 FEATURES
Blanking Plate Screw
Blanking Plate
Blanking Plate Seal
Pin Locking Screw
Valve Pin
Piston Main Seal
Piston
Piston Rod Seal
Circlip
Cylinder
Cylinder End Seal
Locating Spacer
Valve Pin Seal
1
2a
3
4
6
5
7
8
9
10
11
12
13
2b
Mould Design
• Available to suit MX and BX Nozzles
• Standard minimal pitching is 75mm
- can be modified to fit 58mm pitching
• Backplates 55mm minimum
• Conical or Cylindrical shut off
• Easy machining of the pockets
• Pneumatic circuit integrated with the backplate
Moulding Benefits
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results
in better part quality
• Reduced gate cooling requirements
Installation and Maintenance
• Easy machining and installation
• Easy pin adjustment and seal replacement
while the mould remains assembled
• Comes with Threaded Pin design fully adjustable
47
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
MVG40 Nozzle Compatibility
Description Nozzle Tip Nozzle Length Supplied Pin Size
MVG40-P2 Threaded Pin MX13 / BX13 OV 45 - 145 Ø2.0
MVG40-P2 Threaded Pin MX16 / BX16 OV / TV 45 - 145 Ø2.5
MVG40-P2 Threaded Pin MX19 / BX19 OV / TV 55 - 175 Ø3.0
MVG40-P2 Threaded Pin BX27 OV / TV 75 - 275 Ø5.0
MVG40 Threaded Pin Valve Gate System
MVG40 Blanking Plate
Ø
75.0
10.0 55.0 Min
MVG40 Cylinder Assembly
MVG40 Spacer
MVG40 Valve Pin
MVG40 Threaded Pin Valve Gate System
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
48
MVG55 Headed Pin Valve Gate System
1.
MVG55 FEATURES
Mould Design
• Available to suit BX Nozzle in 27 Series
• Standard minimal pitching is 95mm –
can be modified to fit 74mm
• Backplates 55mm minimum
• Easy machining of the pockets
• Pneumatic circuit integrated with
the backplate
Moulding Benefits
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results
in better part quality
• Reduced gate cooling requirements
Installation and Maintenance
• Easy machining and installation
• Easy seal replacement
• Valve pin height is adjustable
• Comes with Headed Pin, with
incremental adjustment
Blanking Plate Screw
1
Blanking Plate
2a 2b
Blanking Plate Seal
3
Pin Locking Screw
4
Valve Pin Adjustment Packer
5a
Valve Pin Adjustment Packers
5c
5b
5d
Valve Pin
6
Piston Main Seal
7
Piston
8
Piston Rod Seal
9
Circlip
10
Cylinder
11
Cylinder End Seal
12
Locating Spacer
13
Valve Pin Seal
14
MVG55 Headed Pin Valve Gate System
49
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System Selection Guide
MVG55 Headed Pin Valve Gate System
MVG55 Headed Pin Valve Gate System
55.0 Min10.0
Ø95.0
MVG55 Blanking Plate
MVG55 Cylinder Assembly
MVG55 Spacer
MVG55 Valve Pin
MVG55 Nozzle Compatibility
Description Nozzle Tip Nozzle Length Supplied Pin Size
MVG55-P1 Headed Pin BX27 OV / TV 75 – 275 Ø5.0
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System Selection Guide
50
MVCH Valve Gate System
Back Plate Screw
1
Back Plate
2
Cylinder
3
Cylinder Screw
4
Lock Nut
5
Pin Holder
6
Pin
7
Pin Holder Cap
8
Steel Spacer
9
Insulation Spacer
10
Seal
11
1.
MVCH FEATURES
Mould Design
• Available to suit MX 16, 19 and BX 16, 19 and 27 series
• Standard minimal pitching is 58mm
• Backplates 86mm minimum
• Easy machining of pockets
• Hydraulic actuation
Moulding Benefits
• Improved part quality
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results in better part quality
• Reduced gate cooling requirements
Installation and Maintenance
• Adjustable pin length
MVCH Valve Gate System
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System Selection Guide
MVCH Valve Gate System
MVCH Nozzle Compatibility
Description Stroke Tip Supplied Pin Size Nozzle L (nozzle)
MVCH2505-2.5 5 TV
Ø2.5
MX16 / BX16 45 - 115
MVCH2510-2.5 10 OV
MVCH2505-3 5 TV
Ø3.0
MX19 / BX19 55 - 115
MVCH2510-3 10 OV
MVCH2505-5 5 TV
Ø5.0
BX27 75 - 225
MVCH2510-5 10 OV
80x58
86 MVCH2505
96 MVCH2510
15.0
L (nozzle)
54x54
MVCH Valve Gate System
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
52
Manifold Components
Exploded view of a Standard 2 Drop Hot Runner System
Sprue Bush & Heater
2
Manifold Heater
& Ceramic Connector
4
Manifold
5
Nozzle
9
Locator
7
Spacer Assembly
1
Thermocouple
3
End Plug Assembly 6
Orientation Dowel Pin
8
Manifold Configuration
53
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System Selection Guide
Selecting a Manifold Configuration
Selecting a Manifold Configuration
When deciding on a manifold layout it is important to consider the following:
• The number of injection points required per cavity
• The number of cavities in the mould
• Minimum distance between nozzles
• Balancing of the manifold
• Spacing of cavities to provide adequate room for cooling
• Gate and cavity
• Strength of the mould
• Sufficient steel between cavities
• Mould size versus machine platen size
• Total shot weight
For multi-cavity moulds balancing is critical to achieve consistent dimensions, cosmetic appearance and processing
conditions across cavities. It is therefore strongly recommended that for multi-cavity moulds a manifold layout providing
natural balancing is used.
Natural Balancing: In order to achieve natural balance, the material must flow through identical geometry from the
machine nozzle to each of the gates.
This means identical:
• Flow distance
• Runner diameters
• Number and angle of bends
This ensures that every gate receives material in exactly the same condition. With natural balance, the balance is
inherent in the design, and is not based on a specific material or processing temperature.
Rheological balancing: Is a method of balancing by using different runner sizes to artificially provide identical pressure
drop at each gate. To accurately predict this, the flow properties of the material must be known, along with the flow rate
and anticipated processing temperature. Any variation from the processing conditions used during design will result in
an unbalanced system.
Some drop configurations can not be naturally balanced unless the drops are on a PCD and must therefore be
rheologically balanced. E.g. 3, 5, 7, 9, 10, 11, 13, 14, 15, 17-23 etc
All standard Mastip manifolds (except 3 Drop 3x1) are naturally balanced.
L
L
L
L
R2
R1
L1
L2
Best Configuration
Poor Configuration
Equal and symmetrical drop positions
Unbalanced drop positions
Refer to the Manifold Guidelines Section for standard drop configurations.
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
54
1.
Nexus™ Systems
Nexus
™
Systems
NEXUS™ SYSTEMS
• Fully customised to suit
your application requirements
• Able to process commodity and
engineering grade polymers
• Fast, simple installation out of the box
• Advanced heating technology with
embedded heaters
• FlowLoc™ nozzles connect securely
to manifold via threaded base
• Stainless steel nozzles
• Proven performance of X-Range
nozzle technology
• Customised trunking for wiring
• Advanced heating technology for
superior thermal performance
• Leak-proof solution via screwed
in nozzles
• Accidental cold starting will not
result in polymer leakage
• User-friendly maintenance
• Excellent thermal profile
ensures a wide moulding window
• Unit removes easily from mould
facilitating quick, easy service and
maintenance
Mastip’s Nexus™ Pre-Assembled and Pre-Wired hot runner systems are designed for fast, simple installation out of the box without
requiring any further technical assembly. Nexus
™
Systems incorporates superior FlowLoc™ technology providing a secure, leak-
proof solution. The FlowLoc
™
range ensures an excellent thermal performance using the latest heating technology.
55
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System Selection Guide
Hot Half System
1.
Hot Half System
HOT HALF FEATURES
Applications
• Fully customised to suit
your application requirements
• Able to process commodity
and engineering grade polymers
Features
• Plates available in high quality
P20 steel or 420 stainless steel
• Proven performance of X-Range
nozzle technology
• Delivered fully assembled and
fully wired
Benefits
• Advanced heating technology for
superior thermal performance
• Easy servicing of nozzles, tips,
thermocouples and heaters
• Heaters are front loading
• Excellent thermal profile ensures
a wide moulding window
• 3-year leak proof guarantee
All Mastip’s Hot Half solutions, from low to high cavity thermal or valve gate systems,
are delivered as a complete solution to integrate seamlessly with your completed mould.
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
56
To select a Hot Runner System to match your part and material specifications consideration must
be given to the following:
• Gate type
• Gate size
• Nozzle range and series
• Nozzle tip style
• Nozzle nut type
Additional Considerations
Additional Considerations
Selecting Material
There are three broad categories of materials each relating to its moulding characteristics:
• Easy
• Medium
• Difficult
When selecting material consider the following:
• Materials with large percentages of filler (for example, >15%) or very low MFI, the material classification moves up a grade (for
example, easy to medium).
Selecting a Gate Type
When designing an injection mould, the type, size and location of the gate is one of the most important consideration
for correct moulding of the part. Incorrect gate position can result in uneven filling, over packing, and dimensional
instability.
Available gate types include:
• Direct gating
• Valve gating
Direct gating is the most common gate type as it offers simple construction and reliability.
Refer to the Nozzle Section for more information about Gate Types
The following factors must be considered when selecting a gate type:
• Shot size of part
• Material to be moulded
• Material
• Viscosity
• Additives
• Glass fibre
• Flame retardant
• Gate surface finish
• Thickness of part walls
• Longest flow length of part
• Required cycle time
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System Selection Guide
Additional Considerations
Gate Size
The correct gate size ensures a good thermal gate is achieved and minimises the pressure drop across the gate while
maintaining its structural integrity. Parts with very thin wall sections or very long flow lengths need a larger nozzle and
gate to achieve proper filling, this may require increasing the nozzle by one to two series.
The gate sizes effects the:
• Flow rate
• Pressure drop through the system
• Cycle time
• Thermal gate shut off after filling
• Cosmetic impact of the gate on the part
• Cooling in the gate area
The gate size is dependent on the:
• Material
• Material viscosity
• Part wall thickness
• Gate cooling*
* Gate cooling is a complex variable and consideration must also be given to cycle time, gate profile, and land length.
small gate
amorphous
material
crystalline
material
large gate
small gate
low MFI
material
high MFI
material
large gate
small gate
thin
part wall
thick
part wall
large gate
small gate
cold gate
cooling
hot gate
cooling
large gate
gate size vs material gate size vs MFI
gate size vs
part wall thickness
gate size vs gate cooling
Gate Size Variables
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
58
Nozzle Series Selection
19 Series Nozzle is best suited due to the required flow rate of 52.5 g/sec. and the ABS material fitting the
medium to difficult material category.
Working Example of a System Selection
Part Details
Description Fluorescent Light Base
Overall Size 700 x 150 x 40 mm
Wall thickness (t) 1.5mm
Part Volume (V) 220ml
Part Model - Fluorescent Light Base
Material
Type ABS
Grade Cycolac T-XS 30001
Flame retardant Yes
Specific Gravity (SG) 1.3
L/t for wall thickness 96
Material Category Medium - due to flame
retardant move up one
grade to difficult.
Hot Runner System Initial Estimates
Number of Nozzles (N) 4
L/t 87.5 with 4 Nozzles
To calculate the number and size of nozzles required to fill a part an initial estimate of the number of nozzles or injection
points must be made. A good starting point is to limit the flow length / part thickness (L/t) ratio to the
typical values for that type of material. Refer table on page 12 - Typical Flow Length Ratios.
1
2
3
Hot Runner System Analysis Results
Injection Pressure 93.65MPa
Injection Time (T) 1.36
Total Flow Rate (F) (V*SG)/T=(220*1.3)/1.36=210g/s
Flow Rate per Nozzle (F/N)=210/4=52.5g/s
4
System Selection - Example
59
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System Selection Guide
1.
METICOM TC5100 / TC5200 FEATURES
Features
• TC5100 accommodates 12 to 36 zones
• TC5200 has 26 to 72 zones and can
accommodate up to 120 zones in a
network
• The modularized design allows for easy
maintenance and configuration
Benefits
• Soft Start function to protect heaters
during startup
• Idle mode after power failure, to protect
hot runner system and mold
• Self test on startup
• CE certified
• Easy to use touch screen interface
• Mould and module diagnostics
• Quick multi-zone setup
• Power usage display
• Synchronous heating and cooling
• Automatic heater and thermocouple
detection and monitoring
Meticom TC5100 / TC5200 Temperature Control System
Temperature Control System
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
60
Temperature Control System
Meticom TC5H Temperature Control System
1.
METICOM TC5H FEATURES
• Blown Fuse
• Display function of current and output
ratio
• Smart SOFT START function
• Auto/Manual Selection function
• PID Automatic Temperature Control
• Output percentage limit setting
• LCD display module
• One-key start (stop)/standby (boost)
function
• Built-in alert alarm
• CE Certified
• Over-voltage protection
• Heater short-circuit protection
• Automatic detection of wire breakage of
heater
• TRIAC short-circuit protection
• Detection for reverse troubleshooting
sensor wiring temperatures
TC5H 2 Zones 4 Zones 6 Zones 8 Zones 12 Zones
Type T5B02 T5B04 T5B06 T5B08 T5B12
Power Switch Capacity (A) 32 32 63 63 63
Output Connector 16 pins x 1 16 pins x 1 16 pins x 2 16 pins x 2 24 pins x 2
Power Cable 5.5mm
2
x 5C x 3M 5.5mm2 x 5C x 3M 8mm2 x 5C x 3M 8mm2 x 5C x 3M 8mm2 x 5C x 3M
Easy Input Switching Yes Ye s Yes Ye s Ye s
Dimension W x H x D (mm) 179 x 204 x 329 281 x 204 x 329 383 x 204 x 329 485 x 204 x 329 587 x 204 x 329
61
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System Selection Guide
Sequential Control System
G-Series GTV8 Integrated Sequential Controller
1.
GTV8 FEATURES
• Regulation of the injection quantity from
each individual gate
• Quality of the moulded part can be
improved by removing or repositioning of
weld lines
• Injection is performed with minimum
clamping force due to the gates not all
opening simultaneously
• Optimum control over part fill
• Pneumatic only
• Standard GTV8 cabinet configurations
are 8 zones compact design
Technical Specifications
Mains input power Single phase AC 220V (50/60 Hz)
Injection signal input power supply 24VDC, 220VAC
Solenoid output power supply Signal voltage, 100mA/Zone
Operating temperature range -10 ºC to 50 ºC
Operating modes Two modes (Continuous Sequence and Intermittent
Sequence)
Timer Increment 0.1 seconds
Timer Range 0 - 999 seconds
Automatic input voltage Yes
Manual override Yes
© Copyright Mastip Technology Limited. Information subject to alteration. V3.20 www.mastip.com
System Selection Guide
62
Notes
Notes
© Copyright Mastip Technology Limited. Information subject to alteration. 40-000-070 V3.20
Mastip Head Office New Zealand
Physical Address
558 Rosebank Road, Avondale
Auckland 1026, New Zealand
Postal Address
PO Box 90651, Victoria St West
Auckland 1142, New Zealand
Phone: +64 9 970 2100
Email: mastip@mastip.com
Mastip Regional Office Europe
Phone: +33 0 809 400 076
Email: europe@mastip.com
Mastip Regional Office North America
Phone: +1 262 644 9400
Email: northamerica@mastip.com
Mastip Regional Office China
Email: china@mastip.com
For a full list of Distributors,
please visit www.mastip.com
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