Eliminate Waste and Drive Higher Yields

Hot runner injection molding methods
for consumer electronics

Eliminate Waste and Drive Higher Yields

Hot runner injection molding methods
for consumer electronics

Overview

Improved lean manufacturing and reduced cost

One of the most significant processing advancements in thermoplastic injection molding is the development of “hot runner” or “runnerless” melt delivery systems which eliminate the cold runner and sprue by never allowing these flow paths to cool. Hot runners are often utilised in production programmes where volumes exceed 200,000 units per year, reducing scrap by as much as 80%, for a very large savings in material costs. 

Tests in hot runner systems confirm that these time and money saving techniques can be used with Victrex materials with no degradation to the polymer.

80%
80%

Reduce scrap by as much as 80% and potentially save millions of dollars in material costs

400ºC
400ºC

No significant polymer degradation after extended residence time in barrel at recommended processing temperatures

Eliminate labor-intensive steps to trim and finish runner and sprue with highly efficient valve gates

Meeting the requirements

Meeting the requirements of consumer electronics market


 

Husky Hot Runner. © Courtesy: Husky 2015

High performance materials for efficient hot runner production: Thermal stability is key

While hot runners seem like an obvious choice, many polymers are limited by their sensitivity to thermal degradation when exposed to heat for long periods of time. Thermal degradation dramatically affects both mechanical properties and cosmetic properties of the molded part, so engineers must give serious consideration to the thermal stability of a material when selecting hot runner processing. 

Unlike many other engineering plastics, VICTREX™ PEEK polymers offer a solution to both the properties and processing challenges of many consumer electronics parts with their high temperature performance, broad chemical resistance, and excellent thermal stability. 

A range of VICTREX™ PEEK polymer grades were successfully processed using a Husky hot runner system with a Husky VX valve gate. A drop in molecular weight could lead to embrittlement or other loss of mechanical properties. Testing by Gel Permeation Chromatography (GPC) shows essentially no change in the polymer’s molecular weight after processing in the Husky system, even with processing temperatures of up to 400°C and extended residence time.

Eliminate waste and drive higher yields in consumer electronics

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