iMARC™ Single-Axis systems are primarily designed to provide dynamic mold balance control, along with single-axis intra-cavity control.
The dynamic control of mold balance offered by the Single-Axis iMARC™ systems allow a user to optimize the mold balance for any material, any mold and any molding machine without ever taking the mold out of the press.
As an example of the control offered by the iMARC systems, refer to Figures 1A-1C. Figure 1A shows the traditional filling imbalance in an 8-cavity mold (inside cavities fill first). One half of the mold was then retrofit with a Single-Axis iMARC system. As you can see in Figure 1B, the right side of the mold now shows an over-rotation indicated by the outside cavities filling before the inside cavities. Note the intra-cavity imbalance indicated by the slanted flow front, particularly on the inside right cavities.
The mold was opened and a slight adjustment was made to the first and second iMARC systems to provide a balanced filling between the cavities, as well as a balanced filling within the cavities on the right (Figure 1C). This balance was easily achieved through simple adjustments made at the parting line of the mold. This process was completed without having to take the mold out of the press and without having to restrict gates or perform other types of ineffective artificial pressure balancing.
Figure 1A: Conventional Runner
Figure 1B: Over-rotation
Figure 1C: Cavity-to-cavity + Intra-cavity balance
Dynamic Control of Filling Patterns
In regard to the intra-cavity control, the Single-Axis iMARC systems can alter the location of the high sheared material around the perimeter of a part. For example, Figures 2A through 2C show a two cavity mold with varying degrees of iMARC control. Figure 3A is the “zero position," which allows the mold to perform as if it were a traditional runner design. In this configuration, the high sheared material will create a biased filling toward the inside of the parts as shown. By utilzing the iMARC system, a processor can achieve various filling patterns to aid in part quality optimization as shown in Figures 2B and 2C.
Figure 2A: Standard Filling Pattern
Figure 2B: Balanced Filling Pattern
Figure 2C: Reversed Filling Pattern
For many applications, Figure 2B is the desired result; however, the most desirable filling pattern should always be based on the quality requirements of the molded part. By controlling the flow of high sheared material within the cavity, a processor can also alter the molded-in stresses; and therefore, the resulting shrinkage and warpage of a molded part. This can be very beneficial for many types of parts, particularly when molding lenses where the performance of the part is directly related to the molded-in stresses.
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