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Injection Molding Best Practices

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Injection Molding Best Practices2023-09-08T19:29:46+00:00

Common Hot Runner Cable Connection Problems

Common Hot Runner Cable Connection Problems Simple fixes can result in significant differences in your manufacturing process. You do not have to give in and just accept some common aggravating problems on the manufacturing floor. You may not think it’s worth changing some of the issues mentioned here. But what if these would make a difference to your bottom line? The problems that occur with hot runner cables can have a ripple effect on your whole manufacturing process and, of course, your finances. If the problem areas can be identified, often there are simple options to help. After all, streamlining manufacturing processes and lowering maintenance costs are definitely things we should strive for on a daily basis, right? Hot Runner Cable Problems: Pushed-Back/Bent Pins/Breakage Pushed-Back Inserts High

Hot Runner Performance

Preparing for Production Hot Runner performance is critical to maintaining production schedules and eliminating costly downtime. Following a pre-production checklist to ensure all tools are in place and ready to go gives your team the ability to work efficiently and effectively, saving both time and money. Having the tools to ensure your hot runner performance is peak is where Spark Industries comes in. Necessity is the mother of invention Manny Diaz developed the MoldXChecker as a result of feedback from customers who stated they would like to be able to test the hot half and the associated elements more quickly. Also, for obvious reasons, they would like less experienced employees to be able to manage the task without extensive training. Save time; save cash! This wish list also included

Minimizing Costs and Simplifying Hot Runner Repair

How will you minimize downtime and costly hot runner repair in your shop? The answer isn’t as complicated as you might think…here’s how Fast Heat by Spark Industries will help! You already know preventive maintenance is critical to the success of your shop. There will always be some amount of hot runner system repair, but if you keep on top of the preventive maintenance, your costs for hot runner repairs will be minimized…as will costly unplanned downtime. And the bonus results include more consistent high-quality part production and less material waste which translates directly into cost savings! You can avoid miswires, open circuits, and shorts by making a routine check of these a part of your PM Plan. Have your techs check cables, pins, and the individual elements

Hot Runner Temperature Controllers Boost Productivity and Quality

Want to know how to reduce scrap and increase productivity in your shop…Fast Heat by Spark Industries' temperature controllers are a must! Realistically, there are hundreds of ways to eliminate or reduce scrap on your  production floor that will increase those productivity numbers…from reintroducing scrap back into your processes to continuing to educate your technicians. Sure, but what options are practical, reliable and reasonable? Really the best approach is to attack from as many potential problem points as you can…diversify; man, material and machine…this way you can make sure your bases are covered, so to speak. So, yes, train your techs, choose the best process parameters and maintain your equipment as best you can. You can also go one step beyond for stability in material temps…and Fast

CableXChecker™: Diagnose Hot Runner Cable Issues

Effectively Getting to the Root of the Problem Diagnostic device helps molders check hot runner cables quickly and efficiently Spaghetti bowl?! That’s right…spaghetti! That’s what all the wires and cables inside a press might remind you of…and have you looked closely at all the pins and cables making up a hot runner system? Plastic injection molding is not for the faint of heart…it is both an art and a science. Hot runner injection molding involves lots of cables, wires and moving parts; these things are sometimes confusing and temperamental. Understanding and repairing this essential equipment is a big deal! So, how do you make the best of trouble shooting this often complicated equipment? First, we want to point out the obvious…that preventing issues is the best way

Low-Investment Molding Solution

Hot Runner Temperature Control: A Low-Investment Molding Solution Processing challenges and mold design considerations amplify the importance of the use of hot runner controls. Before we get started on the subject of using hot runner controls as a wide-reaching molding solution, we thought it worth mentioning where we are economically. The state of the economy absolutely causes lower-cost manufacturing solutions to be even more critical. We already know that tight budgets and supply chain concerns are definitely part of the challenges facing molders and manufacturers today. So, is the US in a recession? Forbes states, “According to the general definition—two consecutive quarters of negative gross domestic product (GDP)—the U.S. entered a recession in the summer of 2022.” How will you ensure that your plastic injection molding business

Reliable Hot Runner Temperature Control

Pulse technology demonstrates enhanced ergonomic features for accurate and reliable hot runner temperature control. Catchy intro… Well, we don’t really have one. But to be straightforward…Fast Heat Inc. by Spark Industries is simply the apex of the industry when it comes to hot runner controllers. Gear like the (showcased at Amerimold 2021 exhibit) Pulse hot runner temperature controllers which protect heaters and thermocouples also prevent operator error and enable users to specify production cycles; it’s hard to beat Fast Heat when it comes to considering the customer and how injection molding machinery will be utilized by the operator. Plus, Pulse controllers can be complemented with Fast Heat’s proprietary Mold and Cable Checker tools for diagnosing hot-half and cable issues. That’s a lot of indispensable assistance in

Hot Runner Cable Connector Anatomy

Hot runner cable connectors come in a wide range of specifications with some being much better than others. Our recent article in MoldMaking Technology magazine calls attention to the top 5 problems we typically see in the field. These include: Pushed-Back or Bent Pins Pushed-Back Inserts High Amp Deterioration Loose or Broken Latches Missing or Loose Ground Wire Connections The anatomy of connectors is shown in the featured image. Hoods come in low and high profiles with top or side cable entry and one or two locking levers.  Male contacts should be machined but the smaller 25-pin variety can be found in a rolled and crimped design, which is not recommended. Male pins (contacts) and female inserts are press-fit into their related insert bases. Housings are specified

Hot Runner Control Input and Output Communication

Hot Runner Control Input-Output Signals Hot runner control input-output signals are a terrific way to integrate hot runner temperature controls with injection molding machines, robots, conveyors, or other peripheral equipment. The Fast Heat Pulse Controller has four INPUT and OUTPUT channels. The channels are configurable per order, but the INPUT is typically a N/O (normally open) dry contact or a 10-32 DC voltage signal, and the OUTPUT standard is a N/O (normally open) dry contact. Each OUTPUT channel can have one or more ALARM STATUS or an AT TEMPERATURE notification assigned to activate it. Each INPUT channel is typically assigned to either RUN, STOP, BOOST, or IDLE.  Example use cases include but are not limited to:  % POWER ALARM – used to turn off a potentially leaking

Hot Runner Control Impact on Moldflow Analysis

Consistent Hot Runner Temperature Control is Key We've known for many years that Fast Heat clients value precise hot runner temperature control, especially for engineered resins, glass-filled applications and wide-spec regrinds. These materials require consistent temperature control to achieve "part-to-print" specifications. According to CAE, a leader in Moldflow analysis, altering material characteristics due to inconsistent temperature control is a common cause of warpage. Another aspect of achieving "part-to-print" specifications, as CAE calls it, are process settings. Again, the key to temperature control is not to introduce variation into the process due to fluctuating temperatures. Simply put, the manifold system is merely a passageway for the melt that is already supposed to be plasticized correctly by the injection molding machine. While gate location, gate type/size and sequential


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