Do's and Don'ts for Overmolding Liquid Silicone onto Thermoplastics - teflon inj/Do's and Don'ts for Overmolding Liquid Silicone onto Thermoplastics

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Do's and Don'ts for Overmolding Liquid Silicone onto Thermoplastics - teflon inj

Author：gly Date: 2024-09-30

A difference of opinion regarding a particular mold-design preference came up again recently. The conundrum was whether to intentionally leave a space or gap between the end of a hot sprue and the parting line of a cold-runner, two-plate mold. I’m not talking about the space required to compensate for linear thermal expansion. I’m referring to an additional space to mold a thin disk of plastic, about 0.005 to 0.050 in. thick, between the two surfaces.

Arburg has utilized the ISO TS 1467:2018 standard, which determines the greenhouse gas emissions of a product, to help its customers calculate the product carbon footprint (PCF) of its injection molding machines.

The worst reason I’ve heard for not molding a disk is, “We always had the sprue tip sit flush with the parting line.” That’s not a reason; that’s old-school resistance to change. As an old-school guy myself, I can confirm that is the way it was always done, and it was never questioned. Back then, if you molded a disk people would ask what happened.

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

Despite price increase nominations going into second quarter, it appeared there was potential for generally flat pricing with the exception of a major downward correction for PP.

Not molding a disk increases the rate of heat being sucked out of the hot-sprue tip and should reduce the risk of stringing. Conversely, you may want to mold a disk if the cycle time is fairly slow, the gate orifice is relatively small, or the material is the type that sets up fast, like crystalline nylon. Not molding a disk could suck out too much heat and can cause a cold slug to form behind the gate. Cold slugs require a tremendous amount of pressure to dislodge at the start of injection. I’m sure you’ve all heard a loud popping sound or felt the injection carriage shake when that happens. To make matters worse, this cold slug needs to get trapped by a cold well or runner overflow before it makes its way to the cavity. Molding a disk will reduce the rate of heat being sucked out of the hot sprue tip. This should reduce the risk of forming a cold slug.

Formnext Chicago is an industrial additive manufacturing expo taking place April 8-10, 2025 at McCormick Place in Chicago, Illinois. Formnext Chicago is the second in a series of Formnext events in the U.S. being produced by Mesago Messe Frankfurt, AMT – The Association For Manufacturing Technology, and Gardner Business Media (our publisher).

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The orifice diameter and molding material were the predominant factors in determining which type of metal to use for the hot-sprue tip, and how much land length was needed to obtain the ideal solidification rate to achieve the fastest possible cycle.

Going forward, Arburg’s goal is to calculate “a scientifically sound, holistic lifecycle assessment for injection molding machines.” Arburg says such an effort is underway at the Institute of Plastics and Circular Economy (IKK) at

Leibniz University in Hanover. There, Professor Hans-Josef Endres is working on in collaboration with Arburg, among others.

In this collection, which is part one of a series representing some of John’s finest work, we present you with five articles that we think you will refer to time and again as you look to solve problems, cut cycle times and improve the quality of the parts you mold.

ABOUT THE AUTHOR: Jim Fattori is a third-generation injection molder with more than 40 years of molding experience. He is the founder of Injection Mold Consulting LLC, and is also a project engineer for a large, multi-plant molder in New Jersey. Contact jim@injectionmoldconsulting.com; injectionmoldconsulting.com.

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While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

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When you drill down to the level of an individual screw, the complete parts list of an injection molding machine could consist of 11,000 indivdual items. To help it better manage that figure, Arburg categorizes all its raw materials into eight distinct materials groups. On this basis, an Allrounder consists of more than 55% plastic-coated cast iron, and another 35% of steel and sheet metal, whether they’re hot-treated, painted, plastic-coated or untreated. Plastic components, drives and electronic components account for only about 7% of the total weight.

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Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Because of this investigation into whether to mold a thin disk, I have reversed my old-school opinion. In all but the most extreme cases, the amount of heat loss from a hot-sprue tip to the moving half of the mold is probably not much of a controlling factor. Therefore, I now suggest intentionally molding a disk with a thickness of roughly 25% of the wall thickness of the part. But don’t forget to maximize the land or bearing length of the hot-sprue tip and pay particular attention to the cooling channels near or around the tip. This way, you prevent damage to the parting line of the mold caused by a variety of potential issues, and you maintain the ability to adjust the gate solidification rate by varying the tip’s land length and cooling temperature to prevent cold slugs or strings.

This month’s resin pricing report includes PT’s quarterly check-in on select engineering resins, including nylon 6 and 66.

Instead of pulling your hair out trying to calculate the perfect amount of linear thermal expansion, the easiest way to deal with the problem is to heat the sprue, and if necessary, the mold base, up to the processing temperatures. Measure the distance between the face of the sprue and the parting line and adjust accordingly. That will get you very close to being “spot on” without all the mathematical hassle.

Unless the calculation for linear thermal expansion is off, a hot sprue shouldn't extend beyond the parting line. Calculating that thermal-expansion value is a lot easier said than done. In fact, the chances of being “spot on” are pretty slim. In order to get precisely where you need to be, adjustments typically need to be made when assembling the mold, as well as after the initial try-out.

Sustainability continues to dominate new additives technology, but upping performance is also evident. Most of the new additives have been targeted to commodity resins and particularly polyolefins.

We also varied the amount of outside contact of each of those tips. The goal was to get the fastest gatefreeze time to minimize the cycle, but not too fast, which would create cold slugs or cause the mold to be difficult to start up. If the gate-freeze time was too long, it would extend the cycle, or cause stringing. The diameter of the gate orifice was a fixed dimension—just large enough to keep the injection pressures at a reasonable value for the given wall thickness and flow length.

One argument against molding a disk is the increased chance of the injection pressure causing the hot sprue to “blow back.” Most hot sprues have a standard 1-in. diam. If the peak injection pressure was, for the sake of argument, 14,000 psi of plastic pressure, there will be 11,000 psi trying to push the hot sprue toward the fixed platen. If the molding machine is small and has an associated small amount of nozzle-touch force, there’s a chance the hot sprue will in fact blow back. If the hot sprue is retained by a 1/4-20

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There’s a lot of conjecture about just how much heat is or isn’t transferred from the face of the hot sprue to the moving half of the mold when you don’t mold a disk. If the heat transfer is really that important, and sometimes it really is, then the focus should be more on the outside contact or land area of the hot sprue tip—not the face of the tip. If you don’t mold a disk, the face of the tip is only contacting steel for a portion of the molding cycle while the mold is closed. But the land area of the tip is always in contact with the adjoining steel.

Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

Join this webinar to explore the transformative benefits of retrofitting your existing injection molding machines (IMMs). Engel will guide you through upgrading your equipment to enhance monitoring, control and adaptability — all while integrating digital technologies. You'll learn about the latest trends in IMM retrofitting (including Euromap interfaces and plasticizing retrofits) and discover how to future-proof your machines for a competitive edge. With insights from industry experts, it'll walk you through the decision-making process, ensuring you make informed choices that drive your business forward. Agenda: Maximize the value of your current IMMs through strategic retrofitting Learn how to integrate digital technologies to enhance monitoring and control Explore the benefits of Euromap interfaces and plasticizing retrofits Understand how retrofitting can help meet new product demands and improve adaptability Discover how Engel can support your retrofitting needs, from free consultations to execution

Gifted with extraordinary technical know how and an authoritative yet plain English writing style, in this collection of articles Fattori offers his insights on a variety of molding-related topics that are bound to make your days on the production floor go a little bit better.

Join Engel in exploring the future of battery molding technology. Discover advancements in thermoplastic composites for battery housings, innovative automation solutions and the latest in large-tonnage equipment designed for e-mobility — all with a focus on cost-efficient solutions. Agenda: Learn about cutting-edge thermoplastic composites for durable, sustainable and cost-efficient battery housings Explore advanced automation concepts for efficient and scalable production See the latest large-tonnage equipment and technology innovations for e-mobility solutions

After successfully introducing a combined conference for moldmakers and injection molders in 2022, Plastics Technology and MoldMaking Technology are once again joining forces for a tooling/molding two-for-one.

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While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

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Using the internationally recognized Greenhouse Gas Protocol, which organizes emissions into three areas—Scope 1, Scope 2 and Scope 3—Arburg says its machines are considered Scope 3 assets. These assets include indirect emissions from upstream and downstream business processes.

All molding materials have an acceptable melt-temperature range, as specified by the manufacturer. That range can be as much as 50° F or more. It’s not uncommon for a processor to exceed these upper and lower specified temperature limits in order to fill out the cavities or improve the aesthetics or dimensions of a part. It’s called “processing around” a part- or mold-design issue. Table 3 shows that unless you have a fairly long hot sprue and a fairly high temperature deviation, the hot sprue really doesn’t expand as much as you might think.

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Although these different material groups differ significantly in terms of the CO2 emissions generated during their production, Arburg says a weighted mean value can be determined along the lines of the distribution. This so-called emissions factor is around 1.83 [kg CO2 equivalent per kg product] for an Allrounder. The CO2 equivalent for the complete injection molding machine thus corresponds to the emissions factor multiplied by the press’ weight.

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Having a hot sprue shut off against the parting line versus intentionally molding a thin disk has been the subject of controversy for many years.

However, Arburg notes that two aspects of how and where it makes its machines change the calculation. Vertically integrated, Arburg manufactures around 60% of its Allrounder components itself, with this production occurring exclusively at its central location in Lossburg, Germany. That facility utilizes carbon-neutral renewable energies such as solar, wind and geothermal energy, as well as combined heat and power. Beyond that, since 2016, electricity purchased regionally has come entirely from sustainabile sources. This means that the emissions factor for Arburg’s electricity mix is actually only 0.17 instead of 0.366—53% lower than the German average.

When, how, what and why to automate — leading robotics suppliers and forward-thinking moldmakers will share their insights on automating manufacturing at collocated event.

Table 4 shows that the amount of possible contact area on the side of a hot-sprue tip can be considerably less or considerably more than that of the face of the tip. The amount of land length in the mold, as specified by hot-sprue manufacturers, varies tremendously. I like to hedge my bets and often increase the land length as much as possible.

Start by picking a target melt temperature, and double-check data sheets for the resin supplier’s recommendations. Now for the rest...

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Probably the best argument for leaving a gap and molding a thin disk is that it guarantees the hot sprue will never extend beyond the parting line of the fixed half of the mold. If it did, the face of the hot sprue would quickly hob the moving side. It was also reported that if the tip extends too far, the repetitive impact against the moving half of the mold can cause the tip to slowly unscrew—making the damage that much more severe and often cause the tip to crack near the notch-sensitive threads. That makes sense, considering the threads of a hot-sprue tip are coated with an anti-seize lubricant, as opposed to an anaerobic adhesive, such as Loctite. Those are both very good reasons for wanting to mold a disk.

Ultimately, the parts the machines are molding also have an impact on the press’s PCF. In general, Arburg notes that the specific energy requirements for the production of technical molded parts in smaller quantities is significantly greater than for the production of fast cycling packaging items.

Unlike the corporate carbon footprint (CCF), which is calculated for an entire company on an annual basis, PCFs include the quantities of greenhouse gases emitted and removed over the entire service life of a product.

Several people said they like the molded disk because it acts as a cold well to catch any solidified material residing in the gate of the hot sprue. I don’t agree. Plastic flows in the path of least resistance.

Using that figure, the electricity-related CO2 equivalent for the Allrounder 370 H is actually only 490 kg versus 1160 kg, while for the Allrounder 570 the emissions amount to 1240 instead of 2670 kg CO2.

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You may not want to mold a disk if the cycle time is fairly fast, the gate orifice is relatively large, or the material is a type that likes to string, such as ABS. The additional heat transfer helps reduce the damaging strings from forming by increasing the solidification rate. It’s the exact reason some molds are designed with water-cooled bushings around a hot-sprue tip.

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Thousands of people visit our Supplier Guide every day to source equipment and materials. Get in front of them with a free company profile.

Ultradent's entry of its Umbrella cheek retractor took home the awards for Technical Sophistication and Achievement in Economics and Efficiency at PTXPO.

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The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

Depending on the molding material, that can mean the difference between flashing or hobbing the mold. Using a “generic” expansion coefficient for every type of mold steel is a mistake. These coefficients not only vary from one type of steel to another, they also vary from one supplier to another.

technotrans says climate protection, energy efficiency and customization will be key discussion topics at PTXPO as it displays its protemp flow 6 ultrasonic eco and the teco cs 90t 9.1 TCUs.

For its purposes, Arburg records CO2 in four process steps it undertakes when building a press: painting or coating; mechanical machining and processing; electrical production; and assembly.

With some regularity, problems with a thermocouple or a controller can cause the temperature of the hot sprue to increase—sometimes through the roof. These are the most common reasons:

To illustrate this, Arburg explains that a hybrid Allrounder 570 H with a clamping force of 204 metric tons (m.t.) and a net weight of approximately 18,000 lb has raw material-related emissions of around 15,190 kg of CO2 during its manufacture. At the other end of the scale, a 61 m.t. Allrounder 370 weighing 7275 lb generates a CO2 equivalent of around 6040 kg.

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Arburg calculates that electricity related CO2 emissions during production generate an emissions factor of 0.366 [kg CO2 equivalent per kWh] for the standard German electricity mix in the year 2020. On that basis, the electricity requirement is 2900 kWh for the Allrounder 370 H, with a CO2 equivalent of around 1,160 kg, while for the Allrounder 570 H, the electricity requirement would be 7295 kWh with emissions around 2670 kg CO2.

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Plastics Technology’s Tech Days is back! Every Tuesday in October, a series of five online presentations will be given by industry supplier around the following topics: Injection Molding — New Technologies, Efficiencies Film Extrusion — New Technologies, Efficiencies Upstream/Downstream Operations Injection Molding — Sustainability Extrusion — Compounding Coming out of NPE2024, PT identified a variety of topics, technologies and trends that are driving and shaping the evolution of plastic products manufacturing — from recycling/recyclability and energy optimization to AI-based process control and automation implementation. PT Tech Days is designed to provide a robust, curated, accessible platform through which plastics professionals can explore these trends, have direct access to subject-matter experts and develop strategies for applying solutions in their operations.

Lastly, kudos to those of you who realize that much of what I said here about hot sprues feeding a cold runner in a two-plate mold also applies to a hot sprue in a three-plate mold, and to molds with various other types of hot-feed systems.

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The Plastics Industry Association (PLASTICS) has released final figures for NPE2024: The Plastics Show (May 6-10; Orlando) that officially make it the largest ever NPE in several key metrics.

If all this isn’t confusing enough, it turns out that the coefficient of thermal expansion for tool steel really isn’t a fixed value. The value increases as the steel temperature increases. How do you account for that?

So far, I’ve given you several good reasons to mold a disk, and very few to have the hot sprue “kiss-off” against the B-plate. Now let’s discuss what happens to the process with and without a disk. Some people say that if you don’t mold a disk, the face of the hot sprue will contact the B-plate, which will suck the heat out and change the intended heat profile. To some extent, that’s true; but, depending on the mold, having the heat sucked out of the face of a hot sprue can either be a good thing or a bad thing.

ΔL is the increase in length of the hot sprue at the processing temperature. La is the unsupported length of the hot sprue at ambient temperature; Tp is the processing temperature of the molding material. Ta is the ambient temperature (typically 68 F); α is the coefficient of thermal expansion of the material—typically steel. Ta and La are for the most part, fixed values; α is also a fixed value, but are you using the right one? I checked the coefficients of thermal expansion for various types of steels used in injection molds (see Table 1). They ranged from 6.1 to 7.3 Å~ 10-6 in./in.-.F. The difference between the highest and lowest values is an extremely small number (0.0000012 in./in.-.F), but it’s an important one. If you have a 10-in.-long hot sprue running at 600 F, and your coefficient of thermal expansion is off by just 0.5 Å~ 10-6 in./in.-.F, that’s a difference of 0.003 in.

SHCS, there’s a chance the bolt will, over time, fracture from fatigue, and then the hot sprue will blow back. However, this blow-back argument is moot if the hot sprue is retained by a combination flanged and clamp-type locating ring, such as Progressive Components Part LR519. This type of locating ring not only retains the hot sprue, it is fully supported by the fixed platen.

However, a disk will function as a “flash trap.” That is a thin web of material, usually added down the sides of a runner to prevent flashing. The thin web solidifies prior to the melt-delivery system reaching significant pressure. Therefore, a thin molded disk will help prevent the surrounding area from getting damaged by flash. Another good reason for molding a disk.

Core Technology Molding turned to Mold-Masters E-Multi auxiliary injection unit to help it win a job and dramatically change its process.

The same formula used to calculate how much the hot sprue will increase in length should also be used for the mold base (Table 2). The amount of thermal expansion is negligible at mold temperatures below 80 F, but higher temperatures are definitely a factor to consider. For example, if you’re running PEEK with a mold temperature of 375 F and the hot sprue is 10 in. long, the mold plates over that distance will grow about 0.021 in. If you don’t take that into consideration, you’re going to mold a disk whether you want one or not.

If you performed the measurement procedure above, the only thing that can cause a problem is if the processing temperatures change out on the production floor. Unfortunately, the processing temperatures out on the floor almost always differ from what was recommended and designed for.

Discover how artifical intelligence is revolutionizing plastics processing. Hear from industry experts on the future impact of AI on your operations and envision a fully interconnected plant.

Unless the disk is very thick, or the material has a very low viscosity, the initial flow of material is going to go right into the wide-open runner—not into a thin disk. In fact, the disk is probably not going to even fill out until the material flow reaches the restrictive gates and the pressure starts to build. Therefore, it’s highly unlikely that a molded disk acts as an effective cold well.

Additive technology creates air pockets in film during orientation, cutting down on the amount of resin needed while boosting opacity, mechanical properties and recyclability.

A less common reason for temperature override is the quality of the controller itself. I once started up six brand-new hot-runner molds with six brand-new controllers. When we turned the controller on for the first mold, all the zones shot right past their setpoints. The same thing happened to the second mold, and the third, and so on for all six molds. It turned out that a blown-film extruder in an adjoining room had a very large DC motor on the same power line. It was spewing out a massive amount of electrical noise, which affected all the controllers. It took an oscilloscope and a very savvy tech-service rep to solve that one.

Most impactful to the calculation is whether the machine utilizes an electric, hydraulic or hybrid drive. Going further, the calculation is also impacted by whether one or two-circuit pump technology or hydraulic accumulators are used, as well as other options like servo-electric dosing or ejection. Arburg notes that any features that enable simultaneous, dynamic and fast movements and shorten cycle times have a positive effect on the carbon footprint during use. The same applies to the screw diameter and installed power, so that the greater the shot weight and the smaller the power consumption, the better.

A lot simpler to understand and calculate than a carbon footprint, this ‘footprint’ measures your energy use per kg of plastic processed.

If the raw material and electricity-related emissions are added, the total CO2 equivalent for a “cradle to gate” analysis is 6530 kg for the Allrounder 370 H and 16,430 kg for the Allrounder 570 H. So what does that actually mean? By comparison, Arburg says each person in Germany generates an average carbon footprint of around 12,000 kg/yr, depending on personal consumption, mobility, housing and nutrition.

Previously we have discussed the effects of temperature and time on the long-term behavior of polymers. Now let's take a look at stress.

I decided it was time to see if I could get some closure on the matter—or at least present all the arguments for and against, so that mold designers can make an informed decision about which option suits their needs or application best. Not surprisingly, I couldn’t find a single word about this subject on the internet, nor in any of the plastics reference books, seminar handouts, or magazine articles I have collected over the years. So I reached out to several well-respected hot-sprue manufacturers, tool makers, processors and materials company technical representatives for their thoughts. I was amazed how their steadfast opinions on the preferred design, as well as their reasons, varied from one extreme to the other.

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Processors with sustainability goals or mandates have a number of ways to reach their goals. Biopolymers are among them.

In fact, for sprues with large orifices, I prefer a shorter nozzle body with an extended nozzle tip, specifically to increase the land length. It’s a steel-safe condition that can easily be reduced if there’s an issue. I once helped tweak the process of a high-volume mold running a very fast cycle. Every second meant tens of thousands of dollars per year. We tested tips out of H-13 steel, 420 stainless, and BeCu alloy.

August 29-30 in Minneapolis all things injection molding and moldmaking will be happening at the Hyatt Regency — check out who’s speaking on what topics today.

While prices moved up for three of the five commodity resins, there was potential for a flat trajectory for the rest of the third quarter.

Multiple speakers at Molding 2023 will address the ways simulation can impact material substitution decisions, process profitability and simplification of mold design.

While the major correction in PP prices was finally underway, generally stable pricing was anticipated for the other four commodity resins.

In the first step, Arburg looks at the “cradle to gate” carbon footprint of its machines—that is the amount of carbon emitted in the manufacture of the press. This extends through raw material extraction and the manufacturing phase. All told, this portion of the machine’s existence only accounts for 5% of its CO2 emissions. On a cradle-to-grave basis, which weighs a machine’s entire life, most of the PCF is generated during the use phase at the customer’s factory. The remaining remnant is associated with emissions made during the machine’s distribution and disposal.

“As a machine manufacturer, Arburg is actively and comprehensively involved in carbon accounting in order to provide reliable and comparable indicators and meet the ambitious climate targets,” the company stated in release, noting it earned an “above-average” B grade in the Carbon Disclosure Project (CDP).

Any features that enable simultaneous, dynamic and fast movements and shorten cycle times have a positive effect on the carbon footprint during use. Photo Credit: Arburg

This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

As the European Union’s Green Deal takes effect and companies strive toward climate neutral production by 2050, knowing the product carbon footpring (PCF) of the entire supply chain will become increasingly important for European businesses. Arburg notes that in Germany the laws go even further, enforcing a 65% reduction in CO2 emissions by 2030 with carbon neutrality by 2045.

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This Knowledge Center provides an overview of the considerations needed to understand the purchase, operation, and maintenance of a process cooling system.

Remembering that fully 95% of an injection molding machine’s PCF is attributed to its operation, Arburg says a key parameter to assess that is the specific energy requirement [kWh per kg], which is calculated from power consumption per material throughput. As a rule of thumb, the shorter the cycle time and higher the shot weight, the smaller the specific energy requirement and better the CO2 equivalent.