How do you minimize gate marks and flash with gate location?

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Mold flow analysis is a powerful tool for optimizing the design and performance of injection molding processes. It can help you reduce defects, improve quality, and save costs by simulating how the molten plastic will fill and cool in the mold cavity. One of the key factors that affects the mold flow is the gate location, which is the point where the plastic enters the mold. In this article, we will explain how to use mold flow analysis to determine the best gate location for your injection molding project.

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1 Why gate location matters

The gate location has a major impact on the flow pattern, pressure, temperature, and orientation of the plastic as it enters the mold cavity. It also affects the final part's appearance and strength, specifically at the gate area where plastic solidifies last. If the wrong gate location is chosen, it can result in issues such as gate marks - visible blemishes or depressions on the part surface caused by the gate freezing off before the cavity is fully filled - flash, which is excess plastic that escapes from the mold and creates thin edges or protrusions on the part, weld lines - weak spots or seams on the part where two or more flow fronts meet and fuse together - and short shots - incomplete filling of the mold cavity due to insufficient pressure or material.

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Kim Winterfeldt

Controls Engineer at iMFLUX (retired)
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if you're struggling with gate location in todays 'world of Plastics' you may want to investigate a new tool builder! most tools today are designed for tool making profit. using the correct tonnage machine helps also to a well designed tool.

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Geoff Crumblin

Injection Moulding SME at Breville Group
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Of course the former statement is correct. If the gates freezes before the cavity is full, it results in a short. The gate must remain alive until the plastic has reached maximum weight. It's all in the text books. Search scientific/decoupled injection moulding

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Geoff Crumblin

Injection Moulding SME at Breville Group
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Good answer. And the minimum hold time is whan the part weight stops increasing. That pack time relates to the current process temperature settings, if they change, then the study must be repeated.

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Jordon May

Process Engineering Lead | Dad of 1
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Contradicting statements made relating to the gate freezing off. “…specifically at the gate area where plastic solidifies last.” And “…caused by the gate freezing off before the cavity is fully filled.” I don’t feel either of these are true, especially the first statement. The gate is designed to cure first when filling, which is a scientific test called “gate freeze”. You want the gate to freeze at a controlled point before the part is cooled to control equal volume of plastic entering the part(s) each cycle. Also, if the gate froze last, what would be the point of cooling time in the cycle?

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2 How to use mold flow analysis for gate location

Mold flow analysis software can help you evaluate different gate locations and compare their effects on the mold filling and cooling behavior. By using this software, you can visualize the flow pattern, pressure, temperature, and orientation of the plastic in the mold cavity for each gate location option. It can also be used to identify potential defects such as gate marks, flash, weld lines, and short shots for each gate location option. Furthermore, you can optimize the gate location to minimize defects, balance the flow, and reduce the cycle time and clamping force.

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3 Tips for choosing the best gate location

When selecting the best gate location for an injection molding project, there is no universal solution as it depends on a variety of factors such as part geometry, material properties, mold design, and processing conditions. However, some general tips can help guide your decision. It is recommended to place the gate close to the thickest section of the part, to avoid placing it near or on cosmetic or functional features, and to align it with the direction of the main flow. Additionally, multiple gates should be used for large or complex parts and mold flow analysis should be used to test and verify the gate location prior to making the mold. This will help to ensure a successful outcome and reduce time and money spent on trial and error or rework.

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4 How to minimize gate marks and flash with gate design

Besides selecting the most suitable gate location, you can also reduce gate marks and flash by optimizing the gate design. This includes the shape, size, and type of the gate that connects the runner system to the mold cavity. To optimize your gate design for minimal gate marks and flash, select a gate shape that matches the cross-sectional shape of the part to reduce flow resistance and shear stress. Additionally, choose a gate size that is large enough to fill the cavity quickly and completely, but not too large to cause excessive pressure and flash. Lastly, pick a gate type that allows for easy and clean separation of the part from the gate, either through manual or automatic trimming. Doing so can help you ensure a successful manufacturing process.

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Andres Estrada

NetSuite Specialist | Leading Continuous Improvement Initiatives | WMS Implementation Expert
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Employing multiple gates in injection molding can significantly reduce gate sizes, thereby minimizing gate marks and flash. This strategy involves optimizing gate design to match the part's cross-sectional shape, reducing flow resistance and shear stress. Selecting the right gate size is crucial: it should be large enough for efficient cavity filling but small enough to avoid excessive pressure that causes flash. Additionally, choosing a gate type that ensures easy part separation can streamline the manufacturing process, enhancing overall quality and efficiency. This approach requires a balanced consideration of gate shape, size, and type.

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5 How to improve your injection molding skills with mold flow analysis

Mold flow analysis is a powerful tool for anyone looking to improve their injection molding skills. It can help you understand how different variables affect the mold flow behavior and final part quality, as well as experiment with different scenarios and options without risking damage to the mold or wasting material. Mold flow analysis can also be used to troubleshoot existing problems or prevent potential ones, and optimize the injection molding process for greater efficiency, lower costs, and better results. If you’re interested in learning more about mold flow analysis and how to use it for your injection molding projects, our online courses and tutorials are a great place to start.

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How do you minimize gate marks and flash with gate location?

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1 Why gate location matters

2 How to use mold flow analysis for gate location

3 Tips for choosing the best gate location

4 How to minimize gate marks and flash with gate design

5 How to improve your injection molding skills with mold flow analysis

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