Project Background
InjectFast is proud to share this successful collaboration with a renowned professional-grade building materials tools brand. The company specializes in the research, development, and manufacturing of high-precision tools and accessories for tile and stone installation. Precision is at the core of their brand promise.
One of their critical components — the Connector (axis part) used in premium packaging — presented significant injection molding challenges due to its highly uneven wall thickness, with the thinnest section measuring only 1.4mm. The client required uncompromising dimensional accuracy and consistency across large-volume production.
Project Challenges
- Extreme Thin-Wall & Uneven Thickness: Minimum wall thickness of 1.4mm demanded exceptional melt flow control, high-speed filling, and precise pressure management.
- Material Behavior: Polypropylene (PP) is prone to flow issues and degradation in thin-wall applications if temperature and pressure are not tightly controlled.
- Multi-Cavity Balance: A 32-cavity mold required outstanding flow balance across all cavities to ensure part-to-part consistency.
- High-Volume Stability: The solution needed to deliver high yield rates and long-term production reliability.
InjectFast Solution
After a thorough technical assessment, InjectFast’s engineering team recommended and implemented the StellarONE 10 Open Gate Hot Runner System.
System Configuration:
- 8-point gating solution using 8 × StellarONE 10 hot nozzles
- Each nozzle feeds 4 cavities (1-to-4 configuration)
- Optimized layout for a 4×8 cavity arrangement
Why StellarONE 10? The StellarONE 10 series excels in thin-wall and multi-cavity applications thanks to its superior temperature uniformity, stable pressure control, and reliable open-gate design. This configuration enabled excellent flow balance while maintaining the gentle handling required for thin-wall PP parts.
Product Specifications
- Part Name: Connector – HR010076PCN
- Material: Polypropylene (PP)
- Molding Temperature: 180–230°C
- Part Weight: 9g
- Dimensions: Ø70 × 37mm
- Wall Thickness: Max 2.5mm | Average 2.9mm | Min 1.4mm
- Cavities: 32 cavities (4×8 layout)
Core Requirement: Achieve stable filling and excellent weight balance across all 32 cavities at 1.4mm minimum wall thickness.
Project Results
- Perfect Filling: Successfully overcame filling challenges in the 1.4mm ultra-thin areas. No short shots or flow marks.
- Outstanding Balance: Part weight variation controlled within ±5% across 32 cavities — significantly better than typical industry standards for multi-cavity thin-wall molds.
- High Precision & Consistency: All dimensional tolerances and surface quality requirements were fully met.
- Client Feedback: The customer was highly satisfied with the final product quality, production stability, and overall performance of the hot runner system.
This project once again demonstrates InjectFast’s deep expertise in solving complex thin-wall, high-cavity hot runner applications for demanding industries.
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Contact InjectFast today for professional hot runner solutions tailored to your specific needs.