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Title:
Kwik-Mold Inc.
The Basics of an Injection Mold
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Moldmaking Guide
Rev.: A
Created by:
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Last Modified:
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1.Moldmaking Standard(AISI,DIN,JIS)
US (AISI)
Inch
EUROPE/(DIN)
Metric
LOCAL/Japan(JIS)
Metric
Projection
Third angle
First angle
Both
Unit
IN/LB
MM/KG
MM/KG
Moldbase
DME
HASCO
Futaba/LKM
1040
H13
Steel
0-1
420
P20
S-7
A2
D2
Standard
components
Knockout
Holes
1.2344
1.2343
1.2083
1.1730
1.2311
1.2510
1.2739
1.2767
P5,NAK55,NAK80
DME
HASCO
Dadio/minglee
7 ,4 x16, 6 x2 8
200,100 x 400
200,100 x 400
PipeThread
NPT
MM/BSP
MM/BSP
Locatingring
4.000INCH
100/110/125MM
100/110/125MM
Spruebushing
R1/2, R3/4
R10,R15,R40,90
R10,R15,R40,90
Screw
UNC
MM
MM
Ejection Pins
DME
HASCO
HASCO
Leader pins
Bushings
DME
HASCO
HASCO
spring
ASSOCIATE
DAIDO,HASCO
DAIDO,HASCO
HASCO,Synventive,
Mold-Master
HASCO,Synventive,
Mold-Master
Hotsprue
hotrunner
INCOE,DME,KONA,
MOLD-MASTER,YUDO
Oil cylinder
MILLER/PARKER
PARKER
PARKER
Gear/rack
DP
Module - MM
Module - MM
Reference
mold
GRT, NOVA
PHILIPS,GE-BELGIUM PHILIPS,GE-BELGIUM
Kwik-mold is dedicated to building tools that enable our customer mold high-quality part quickly and profitably
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Moldmaking Guide
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Rev.: A
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2.Standard components:
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Locatingring
Moldbase
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Rev.: A
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Lifter
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Kwik-Mold Inc.
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Moldmaking Guide
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Rev.: A
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Last Modified:
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3.The class of injection molds:

There are five categries in SPI-SPE standard:
1.Class101 :1,000,000 cycles or above high production precision mold
1.Detailed mold drawing required.
2.Hardness of moldbase steel:280BN.(DME #2 / 4140)
3.Molding surfaces must be hardened to a minimum of 48HRC,All other moving parts,such as
slides,heel blocks,guide rails,wear plates should harden to 50HRC.
4.Parts moving against one another should be different and have a minimum hardness
difference 4 HRC.
4.Guided ejection.
5.Wearplate needed for slides.
6.Temperature control provisions to be in cavity,core or slide.
7.Plates or inserts containing cooling channels be of a corrosive resistant material or treated to
prevent corrosion.
8.Parting line locks required.
2. Class 102 :less than,medium to high production
1. Detailed mold drawing required.
2. Hardness of moldbase steel:280BN.(DME #2 / 4140)
3.Molding surfaces must be hardened to a minimum of 48HRC,All other moving parts,such as
slides,heel blocks,guide rails,wear plates should harden to 50HRC.
4.Parting line locks required.
5.The following items is determined by customer:
A. guided ejection
B. wearplate
C. waterline treatment
D.cavity or core surface treatment
3. Class 103 :less than 500,000 cycle,medium production
1. Detailed mold drawing required.
2. Hardness of moldbase steel:165BHN. (DME #1/ 1040 )
3. cavity or core steel:P20(28~32HRC) or higher(36~38HRC).
4. Other items per customer.
4. Class 104:less than100,000 cycle,small production
1. Detailed mold drawing required
2. Hardness of moldbase steel:P20(28~32HRC) or 1040,AL7075.
3. cavity or core material :P20,1040 or AL 7075.
4. Other items per customer
5. Class 105:less than 500 ,prototype production or test
1. May be constructed from cast material or epoxy or other material offering enough strength.
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4.Types of Injection Mold:

4.1 Two Plate Mold:
It is also called single parting surface mold, one of the simplest injection mold .The mold maily
includes two half: the stationary half and movable half,which forming the shape of molded plastic
part.The sprue and main runner stay with a half,subrunner lies on the parting surface,molded part and
runner material kept with B half and then were ejected by ejection system on the B half.(figure 1.1).
All other type mold has the commen part with two plate mold.
4.2 Three Plate Mold( Pin-Point Gate Mold):

This kind of mold includes two parting surfaces which divide the mold into three half:A half,B half
and stripper plate. It is used when the part can not be gated at the out peripheral and has more
complicated structure:the parting sequence is controlled by stripper bolt or other devices:such as DME
latch-lock.(Figure1. 2).
2-PLATE MOLD
3-PLATE MOLD
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4.3. Hot Runner Mold(including hot sprue)

The melt can not freezed with the aide of heating device and there is no runner reground.It is also
called runnerless mold(Figure 3), Primary advantages of hot runner molding include:
1).Materials cost savings - no
runner to regrind or reprocess
9).No runners to remove or
2).Least expensive cost / piece
regrind
3).Reduction of energy costs
10).Reduces the possibility of
4).Shorter, faster cycle times - no
contamination
runners to cool
11).Lower injection pressures
5).Smaller machines - reduced
12).Lower clamping pressure
shot volume into runners
13).Consistent heat within the
6).Automated processing ?runners
cavity
do not need demolding
14).Shorter cooling time
7).Gates at the best position for
15).Shot size reduced
economical design
16).Cleaner molding process
8).Elimination of runners means
17).Eliminates nozzle freeze
Resin could be used for hotrunner molding: PE, PE, ABS, POM, PC, HIPS and PS.
The frenquently used in our workshop:
1) with hot manifold(Figure1. 3),
2)Insulate runner mold (Figure1.4)
Hotrunner mold
Insulate runner mold
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4.4 Throughly harden(44HRC or above)

Cavity,core or other moving part must be harden to a minimum of 46HRC by heattreatment such as
Quenching,Carbonitriding, Nitriding.:.
Steel used for this kind of mold:H13,420,S7,A2,D2,O1.
4.5 Pre-hardened(below44HRC)
Steel used for Cavity,core or other moving parties is preharden and no other heattreatment needed.
Offtenly used steel: P20,1045, 420H ,NAK80,AL7075,BeCu.
It is a common practices that the harden mold must be inserted,that is the cavity and core has different
steel with the mold base;On the contrary,the cavity shape of preharden mold often directly machined
from the A plate.
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4.6.Terminology used in moldbuilding:

4.6.1 Undercut
Th part draft direction is different with mold opening direction,such as thru hole on the part side
wall,snap structure, and undercut releasing system needed to mold this kind of part.
Two kind of mechanism offten used for undercut releasing:
a)Slide:for external underut
b)lifter:for internal undercut
4.6.2. Floating cores

Floating core used for two condition:
A)Part is a thin long shape and has a small draft angle.
B)Part has a small undercut distance and slide or lifter could not be used.
It works as following:
1.The floating core and the part was ejected together,
2.the undercut was forced deformaed to release from core insert.
Special care must be taken :the stroke limit and return of floating core.
The floating core could be square or cylinder. One typical example:
The space for undercut deformation could be get after first ejection,then the part could be ejected by
ejection pins.
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Kwik-Mold Inc.
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Moldmaking Guide
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Rev.: A
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Last Modified:
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4.6.3.Floating A plate
It works as follow:
The spring loaded A plate opens first(PL1),the undercut releasing system retract at the same time,when
the stripper bolt reach its end stroke,mold opening at PL2 takes place.
It is often used when undercutreleasing system located on the cavity side.
First Mold Opening
Second Mold Opening
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4.7 General requirement of 2D mold drawing:

4.7.1 Dimmensioning
1.Tool overall size(LxWxH);
2.Cavity/core size;
3.E.J. stroke/slide travel/lifter travel;
4.The sprue offset;
5.Runner position,sizeand surface roughness;
6.Water plug mounting data;
7.The screw data;
8.Tolerance noted where the accurate fitting required;
9.Create the HATCH layer,the color setting per following:
Dimension lines:green
extension lines:red
text :cyan
4.7.2 Hatch line

1.The small insert must be hatched,using ANSI31or ANSI32,the hatchline color:yellow;
2. Hatch line for molded part and runner:
Line space:0.03;
Line color:medium faded magenta;
3.the hatch pattern,line space,scale and angle must be the same for one insert in different view;
4.7.3 Vent
1.vent must be machinined at the end of runner,the last filled and shutoff posioion;
2.Vent channel located on A or B side,depending on machinability;
3.one detailed view(4X) showing size of venting;
4.7.4 Stamp IN" & "OUT" on all waterlines

4.7.5 Cavity I.D.
4.7.6 Section view and detailed view
1.the detailed view needed for the small component or structure;
2.shutoff position and angle showed in detailed view;
4.7.7 lengthen the end of runner and radiu all the corner
4.7.8 chamfer or radius all the edge where necessary
4.7.9 Identified all the screws,standard part and selfmade part
4.7.10 the stroke limit of movable part(such as slide,lifter)
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4.7.11 Material list

1.The name conforms to the generalKwik-Mold convention:
Cavity Block
Core Block
Cavity Insert
Core Insert
Cavity Pin
Core Pin
Slide(Slide Body/Slide Retainer,Heel Block,Guide Rail,Wear Plate);
Lifter
Logo Insert
Date code
Recycling insert
Floating plate
Stripper plate
2.The enough order info must be provided for the standard part. The material supplier and hardness
required must be specified for selfmade part.
4.7.12 Example assembly drawing

The following item must be carefully checked when do the review:
1.document name;
2.waterline diagram;
3.detailed view of gate;
4.detailed view of venting;
5.date stamp;
6.mold temperature;
7.mold info;
8.material list;
9.the tie bar of molding machine;
10.locating ring Dia.;
11.sprue size;
12. Knock-out holes position and size;
13.pipe size;
14.moldbase overall dimension;
15.weight of tool;
16.safety strip;
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Rev.: A
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Last Modified:
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Page No.

The Basics of an Injection Mold

The Basics of an Injection Mold

The Basics of an Injection Mold

The Basics of an Injection Mold

3.The class of injection molds:

The Basics of an Injection Mold

4.Types of Injection Mold:

4.2 Three Plate Mold( Pin-Point Gate Mold):

The Basics of an Injection Mold

4.3. Hot Runner Mold(including hot sprue)

Insulate runner mold

The Basics of an Injection Mold

4.4 Throughly harden(44HRC or above)

The Basics of an Injection Mold

4.6.Terminology used in moldbuilding:

4.6.2. Floating cores

The Basics of an Injection Mold

First Mold Opening

Second Mold Opening

The Basics of an Injection Mold

4.7 General requirement of 2D mold drawing:

4.7.2 Hatch line

4.7.4 Stamp IN" & "OUT" on all waterlines

The Basics of an Injection Mold

4.7.11 Material list

4.7.12 Example assembly drawing

The Basics of an Injection Mold

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