1. Core Logic of Hot Runner Precision Injection Molds for Complex Part Molding

Core Pain Points in Complex Part Molding

Complex parts typically have irregular cavities, coexisting deep cavities and thin walls, flawless surface quality (Ra≤0.03μm), and micro-features (minimum size ≤0.5mm). Traditional cold runner molds suffer from insufficient filling, large pressure loss, obvious weld lines, and 15%-25% runner waste, failing to meet efficient mass production and cost control needs, especially in multi-cavity molding.

Core Advantages of Hot Runner Technology

Hot runner systems maintain melt in a molten state via constant temperature control of runners and gates, addressing cold runner defects. Key advantages: material utilization rate exceeds 98% without runner waste; filling pressure loss is reduced by 30%-40% for deep/irregular cavities; temperature control accuracy reaches ±0.5℃, ensuring stable melt fluidity and part quality.

Matching Principles of Core Parameters

Parameter matching follows "part characteristics - mold parameters - process parameters" logic: nozzle temperature is 15-30℃ higher than plastic melting point; manifold temperature difference ≤1℃ for uniform multi-cavity filling; gate size is 0.8-1.2 times the part’s minimum wall thickness; injection pressure is 10%-15% higher than cold runner molds to compensate for flow resistance.

2. Key Role of Spline Test Molds in Complex Part Molding

Core Design Points

Spline test molds replicate mass production mold features with parameter adjustment flexibility, adopting "standard spline (ISO 527-2 Type 1A) + simulated cavity" design. The simulated cavity mirrors complex parts’ key structures and wall thickness gradients. Cavities use S136 pre-hardened steel (HRC 48-52) for wear resistance; hot runner systems are equipped with needle valve gates for independent temperature control and switch timing adjustment.

Core Test Items and Data Application

Dimensional accuracy: Coordinate measuring machine ensures spline tolerance ≤±0.01mm; adjust hot runner temperature or injection pressure if simulated cavity deviation exceeds 0.005mm;

Mechanical performance: Tensile strength (≥50MPa for 3C parts) and elongation at break are tested to avoid performance degradation;

Surface quality: Ra value detection and visual inspection for no defects; optimize gate position and runner layout;

Stability: 500 consecutive splines with dimensional fluctuation ≤±0.003mm to confirm stable process windows.

Linkage Optimization with Mass Production Molds

Optimal process parameters from spline tests are directly transplanted to mass production molds. For insufficient filling in tests, adjust gate size or runner layout, and verify via re-testing to avoid mass production delays from mold modifications.

3. Hot Runner System Optimization for Complex Part Molding

Customized Structure Design

Multi-cavity molding: Balanced manifold with runner length deviation ≤5mm and filling time difference ≤0.2s for ≥16 cavities;

Deep/irregular parts: Extended needle valve nozzles (5-10℃ higher than main runner) with optimized head shape to avoid cavity interference;

Micro parts: Micro hot runner systems (nozzle diameter ≥1.2mm, gate size ≥0.3mm) with high-precision temperature sensors (response time ≤0.1s).

Intelligent Temperature Control Upgrade

PID adaptive algorithm improves temperature control accuracy to ±0.3℃;

Partitioned independent temperature control for main runner, manifold, and nozzles;

Abnormal temperature warning (≥±1℃ deviation) to prevent part scrapping or mold damage.

Collaborative Runner Balance and Filling Simulation

CAE simulation optimizes manifold runner size to ensure cavity pressure difference ≤5MPa; determines optimal gate quantity (weld lines ≤2) and corrects simulation parameters with spline test data to reduce mold modification costs.

4. Technical Trends and Production Implementation

Technical Trends

Focus on precision (hot runner part machining accuracy ±0.002mm), intelligence (sensor-integrated remote monitoring), and environmental protection (20%-30% energy-saving heating elements and degradable plastic adaptation).

Production Key Points

Material adaptation: Adjust parameters based on plastic properties (380-400℃ for PEEK);

Mold maintenance: Regular runner cleaning and inspection of heating elements/sensors every ≤1000 mold cycles;

Process stability: Parameter fluctuation ≤±5% with emergency plans for key dimension deviations.

Spline Test Mold Optimization

Develop multi-material compatibility, integrate online detection modules, and adapt to CAE simulation parameter reverse iteration to shorten mold development cycles.

This article presents a full-process solution covering "design - test - mass production" via hot runner technology and spline test collaboration, effectively addressing precision, stability, and efficiency challenges in complex part molding, aligning with industry precision manufacturing demands.