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Nippon Die Industry Co., Ltd. / Electroformed Flat Pin Gate Bushings
➀Purpose
With conventional round gates, the gate flash was significant, requiring a cutting process with nippers after molding.
Furthermore, attempts to improve the situation by reducing the gate diameter led to poor resin flow and longer molding cycles, resulting in productivity issues.
Therefore, we introduced electroformed flat-pin gate bushings with the following objectives:
・Eliminating post-processing steps by reducing gate flash
・Improving productivity by shortening the molding cycle
②Key Points for Implementation
・Flat design significantly reduces gate residue
By changing from a round gate to a flat design, gate marks are minimized and stabilized, eliminating the need for post-processing.
・High thermal conductivity and mirror finish shorten cycle times
Made of electroformed nickel alloy with high thermal conductivity, the mirror-finished inner surface ensures high cooling efficiency and allows for shallower draft angles.
As a result, molding cycle times are reduced.
・High durability and reduced maintenance
Made from electroformed nickel alloy with a hardness of HRC 55–60, it offers excellent wear and corrosion resistance, ensuring a long service life.
This also reduces the frequency of maintenance.
・Ease of implementation
It can be easily retrofitted or modified for existing molds, minimizing implementation costs and labor requirements.
③Examples
In conventional molding using round gates,
・The amount of residual material in the gate is inconsistent, resulting in stringing.
・Reducing the gate diameter to address this issue worsens resin flow and increases molding time.
To address these challenges, we introduced electroformed flat-pin gate bushings.
The flat shape allows the resin to flow stably across a wide surface area, improving the gate’s cutting performance.
④Results
・Consistent improvement in gate residue
Molded part quality has improved, and the appearance is now excellent.
・Elimination of post-processing steps
The need to cut gates with nippers has been eliminated, resulting in fewer process steps and reduced costs.
・Improved productivity through shorter molding cycles
Improved cooling efficiency has shortened the molding time per cycle, leading to increased production efficiency.
