auxiliary technologies advanced molding applications technical services overview Accu-Valve for optimum part quality

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1 overview Recognized as the hot runner technology leader for over 4 decades, Mold-Masters has developed the widest range of system solutions that go beyond the usual day to day requirements. Our MasterSOLUTION program draws from the experience gained through 145,000 installations developed worldwide. So, when your hot runner requirements go beyond the usual, there s no better partner than Mold-Masters. Our MasterSOLUTION program encompasses the following: advanced molding applications high-cavitation molding 32, 64,128 cavities and beyond stack molding melt transfer options sequential molding improved technology for large part molding co-injection molding co-injection applications Multi for multi-component molding multi-material and multi-color applications family molding produce different parts within the same tool insert/strip molding anti-drool for proper melt shut-off technical molding for the most challenging technical issues low voltage hot runner systems for fast thermal response medical molding horizontal hot tip designs packaging molding high-cavitation, tight pitches auxiliary technologies specialty gating broad selection for any application Accu-Valve for optimum part quality core ring valve gate ideal for difficult to mold radial parts horizontal hot tip hot tip performance for edge gate applications specialty manifolds custom manifold configurations Pivot-Link for angled surface molding Melt-Link manifold linking technology water-cooled gate inserts optimize fast molding cycles filter nozzles to avoid gate blockage technical services 2D/3D mold flow analysis early identification of any mold flow challenges engineering design proposals complete analysis of your molding application tight pitch applications Tip and Sprue gating tight pitch applications Valve gating automotive lens molding solutions for lens molding applications January 1, 2005 pg

2 high-cavitation An industry proven hot runner solution for molding of applications with 32, 64, 128 cavities and beyond. Industry leading solutions for high-cavity and ultra high-cavity molds in personal care, packaging and technical applications Master-Series manifolds and nozzles to provide optimal thermal profile from machine nozzle to gate for precise gate control Visco-Seal interface to cavity insert to ensure a robust and leak-proof shut-off - especially critical in high-cavity molds Mold-Masters hot-half packages offer the simplest and most cost-effective means of integrating your hot runner system into your mold TempMaster-Series hot runner controllers support up to 240 control zones Faster cycle times, faster color change, faster time to market guaranteed January 1, 2005 pg

3 stack molding Expertise in stack molding, from advanced melt transfer options to high-cavitation fast cycles and from tip gating to back-to-back valve gating, from a proven global supplier. Mold-Masters has designed and manufactured hundreds of stack mold systems Unique melt transfer options for any application or molding environment: - Single and multiple valve-to-valve - Conventional sprue bar (with optional anti-drool) Proven technology and expertise in: - High-cavitation, fast cycling tip gating on small parts - Multi-material solutions designed to minimize center section stack heights using our patented manifold technology - In-line, back-to-back valve gating January 1, 2005 pg

4 sequential molding Expertise in large part molding, including sequential valve gating, sequential control and mold flow analysis, from a proven global supplier. Industry leading solutions for long flow-length parts requiring sequential valve gating Runner design customized for optimal part filling Optional sequential valve gate controller available with the TempMaster-Series allows for precise filling control Technical services including sequential mold flow analysis January 1, 2005 pg

5 co-injection molding An industry proven hot runner molding solution for co-injection applications. The solution for producing parts that require one material for the outer surface and a second for the inner core Unique dual functioning Valve gate that allows for injection of alternating materials from the same nozzle Valve bushing technology guarantees precise valve pin alignment to gate Melt-Link technology reduces stack height January 1, 2005 pg

6 multi-material molding Hot runner solutions for molding multi-material and multi-color applications. Multi - the comprehensive program from Mold-Masters proven to meet the challenges of multi-component applications Ideal for personal care, packaging and technical applications Multi-color - patented brazed two-piece manifolds deliver true natural balance with significant savings in stack height Multi-Material - patented manifold technology and compact system design provides for endless design flexibility in 2, 3, 4 or more color/material applications using separate manifold systems Precise valve gate control allows for overmolding with a TPE resin to produce soft-touch grips for a variety of applications Innovative anti-drool mechanisms for multiple injection units No other company has produced more unique systems for multi-component parts than Mold-Masters January 1, 2005 pg

7 family molding Innovative solutions for producing different parts within the same tool. Technical services including family mold flow analysis Advanced manifold design that can incorporate the necessary artificial balancing or asymmetrical configurations A broad selection of standard and specialty gating methods for even the most demanding part application Runner design customized for optimal part filling Optional sequential valve controller available with the TempMaster-Series allows for precise filling control January 1, 2005 pg

8 insert/strip molding Innovative hot runner solutions that facilitate complex insert or strip molding. Positive anti-drool shut-off for insert molding applications Valve shut-off or spring-loaded anti-drool shut-off Side melt entry systems for vertical inject molding machines Innovative melt inlet shut-off technologies for applications where the melt channel nozzle must disengage from the hot runner system Manifold designs with close pitch inline configurations to match custom punch press dies for continuous strip molding applications Small systems for small parts capable of molding engineering grade materials January 1, 2005 pg

9 technical molding An innovative company that can work with me to solve my most challenging technical issues such as additives, extremely large or small parts, engineering-grade resin and maintaining original polymer properties. Master-Series nozzles offer an uncompromising heat profile to maintain the polymer s ideal processing window, resulting in consistent part quality from shot-to-shot and cavity-to-cavity A full range of high performance nozzles and accessories offer equal performance from subgram parts to parts weighing several kilograms Constructed from SS420, the Master-Series nozzle body delivers a new level of durability System components proven in both high temperature and high pressure applications Endura Technology on the tip gate components produces exceptional wear and corrosion resistance, allowing your system to handle the most aggressive resins, additives and fillers We offer technical services including 2D-3D mold flow analysis and engineering design proposals January 1, 2005 pg

10 low voltage hot runner systems You spoke Industry proven durable, low voltage hot runner solutions for extremely fast thermal response We delivered The Sub-Compact Master Shot (Sub-CMS) line of hot runners uses 24V reliability and patented heater fusion technology for the fastest thermal response in the industry Available for use with a variety of gating methods including multi angled and hot tip gating, perfect for tight pitch applications Profiled heater element is fused into the tip creating both a reliable and robust design for accurate and quick gate area control Compact manifolds with tight cavity spacing and metallurgically fused 230V heaters. Integral heated machine nozzle pad for simplicity and isothermal conditions Patented pressure disks for minimum heat loss and zero cold clearance Replaceable thermocouple ensures accurate and responsive control used with industry proven TempMaster-Series temperature controllers Over 10 years of successful sub-cms applications January 1, 2005 pg

11 tight pitch applications - Tip and Sprue gating Industry proven hot runner solutions for high-cavity molds with pitches as tight as 14mm. An expanded line of small nozzles including the new Master-Series Femto-Lite, a no-compromise solution in a miniature package featuring: - Minimum pitch = 19mm - Mold cut out = 12mm The Femto nozzle offers a slightly larger and more robust system featuring: - Minimum pitch = 22mm - Mold cut out = 16mm Femto-Lite The Femto product line also offers the optional compact flange with a minimum pitch of 14mm. Instead of the standard circular shape, the compact flange features a more elliptical shape. This allows the nozzles to be placed closer together for a tighter pitch. Femto with compact flange nozzle range minimum pitch runner diameter mm inch mm inch Femto with compact flange Femto-Lite Femto January 1, 2005 pg

12 tight pitch applications - valve gating Industry proven hot runner solutions for high-cavity, valve gated molds with pitches as tight as 28mm. The Femto nozzle when using the HY550X hydraulic actuator offers: - Minimum pitch = 28mm In some applications, the pitch can be reduced further with Mold-Masters Synchro Plate Technology, which eliminates the need for an individual actuator for each nozzle Syncro Plate Technology January 1, 2005 pg

13 automotive lens molding Industry-leading solutions for multi-colored automotive lens applications. Angled, multi-colored manifold systems - proven expertise in building a wide array of custom, no compromise angled solutions Pivot-Link - innovative technology for angled surface molding offering superior performance and ease of tool design and integration Extensive manifold swing flexibility facilitates installation Rotates through 3 axes Main pivot point ranges from -30 to +90 angled manifold Pivot-Link January 1, 2005 pg

14 medical molding A broad range of gating solutions, high-cavitation and uncompromising part quality, to meet the challenging demands of the medical industry. Expertise in high-cavitation molding for complex medical applications Accu-Valve, the new cylindrical valve gate solution that offers superior gate cosmetics combined with excellent gate area - durability guaranteed Horizontal Hot Tip gating for side gating using a pinpoint gate on syringe barrels, pipettes and other components requiring gating on the base of the part to prevent core shift a proven solution An expanded line of small nozzles, including the new Femto-Lite, a no-compromise solution in a miniature package January 1, 2005 pg

15 packaging molding Faster color changes, better cycle times, superior uptimes all from a hot runner line that offers endless design possibilities. Melt-Link technology to minimize stack height for multi-cavity systems Visco-Seal interface to cavity insert to ensure a robust and leak-proof shut-off. Combined with our new Master-Seal, it provides a guaranteed leak proof solution Master-Series manifolds and nozzles offer superior thermal profile from machine nozzle to gate, critical to optimizing cycle times Endura Technology applied to our tip gate system delivers exceptional wear resistance and gate control - increasing mold uptime and gate quality An expanded line of small nozzles including the new Femto-Lite, a no-compromise solution in a miniature package January 1, 2005 pg

16 auxiliary technologies specialty gating A broad selection of standard and specialty gating methods for even the most demanding part application. Tit Edge* For parts that require inside side gating into the wall of the part Multiple gates per nozzle Hot Edge Perfect for side gating on vertical part walls or ribs Use the polymer in the nozzle well to act as thermal insulation without any direct gate area contact with the mold steel Suited for amorphous and thermally stable polymers Angled Tip Similar to the hot tip in performance but is designed to gate onto an angle or curved part surface Multi Tip* For parts that require multiple gates in close proximity (e.g. gears) Extended Hot Tip For parts that require inside gating in difficult to reach locations, leaving no gate marks on the outer surface Multi Angled Tip For parts that require gating into an angled surface Multi Valve For parts that require multiple valve gates in close proximity to each other Liner Valve Capable of processing reinforced engineering grade materials The transfer seal forms the actual gate, offering an economical gate replacement method Reduced diameter witness mark on the added part. Where a replaceable gate insert is desirable but space is limited on the part or a larger witness is objectionable *These gating methods are represented in the catalog section of the Master-Series Resource Guide Spiral Hot Tip Utilizes a spiral-finned torpedo placed in the melt stream to remove heat from the gate area during part solidification January 1, 2005 pg

17 auxiliary technologies Accu-Valve for optimum part quality A cylindrical valve gate system capable of running commodity resins - as well as more sensitive materials - that offers exceptional gate area durability guaranteed. Accurate new alignment technique that provides progressive guidance of the pin into the gate Pin guidance is independent of manifolds heat expansion, which is particularly critical in large systems Optimal gate appearance through: - Precise gate area finish - Precise gate area heat control Accu-Valve accommodates high heat applications and the most critical processing windows Tested in production conditions using materials such as PET, Valox, PA-6/6, TPE & ABS Designed to create an uninterrupted flow path from manifold to gate January 1, 2005 pg

18 auxiliary technologies core ring valve gate An effective solution for molding circular parts with high dimensional tolerances and center holes. The core ring valve gate - Allows for radially injected material into parts (ie.gears) with center holes to achieve dimensional stability and no melt lines - Pin sits on the inside and disperses plastic 360 degrees around. January 1, 2005 pg

19 auxiliary technologies horizontal hot tip An industry proven solution with hot tip performance for edge gate applications The horizontal hot tip enables the processing of thinned walled cylindrical parts to be directly edge gated without the need for sub runners A design that utilizes torpedo tips that are oriented 90 degrees to the cavity wall. Perfect for parts such as pipettes, syringe barrels and needle lids to be direct gated without compromising cavity strength, cooling or interfering with cavity side mold components such as pins or unscrewing mechanisms. Horizontal hot tip advantages: - Ideal for slender cylindrical parts that require a cosmetic side gate - Uniform part cooling is now possible - Eliminates potential for cold slug January 1, 2005 pg

20 auxiliary technologies specialty manifolds A wide array of custom no-compromise solutions to address any molding challenge. Here are a few examples of the hundreds of specialty manifolds we build for advanced molding applications: Multi-Material - patented manifold technology and compact system design provides for endless design flexibility in 2, 3, 4 or more color/material applications using separate manifold systems Family Molds - different parts produced in the same mold at the same time Stack-Molds - high-cavitations can double part production Spin Stack - to produce multi-material/multi-color parts with different designs Asymmetrical configurations - could be both number of drops or actual manifold design Combination valve gate with Sprue gate on same manifold Angled designs - typically used in automotive lens molding Multi Level - 2-piece brazed manifold that facilitates up to 3 levels of melt channels January 1, 2005 pg

21 auxiliary technologies Pivot-Link Innovative technology for angled surface molding offering superior performance and ease of tool design and integration. Extensive manifold swing flexibility facilitates installation Pivot-Link rotates through 3 axes Integral hydraulic unit is easy to install (clearance machining only) Pin height adjustable All standard components Main pivot point ranges from -30 to +90 Replaceable manifold heater element Pivot-Link is ideal for multi-colored automotive lens applications January 1, 2005 pg

22 auxiliary technologies Melt-Link Technology that allows manifolds to be linked together without the additional stack height associated with a bridge, or main manifold. Reduces stack height of hot runner system Allows equal stack height on both sides of a stack mold (avoids having to use longer nozzles to clear the bridge on one side) Provides accurate management of thermal expansion of the hot runner system by allowing the design to be broken into simple independent segments Provides a unique assembly method that makes Mold-Masters back-to-back valve gate stack mold possible Allows close pitch valve manifolds to be linked together. (Where the close pitch of the valve pins would interfere with positioning of conventional bridge solution) January 1, 2005 pg

23 auxiliary technologies water-cooled gate inserts Assist the mold designer and mold maker to provide effective cooling to quickly extract heat from the gate area. Provides highly effective cooling to the gate area to help ensure that gate cooling does not limit the overall cycle Allows productivity from high volume to be optimized Achieves efficient gate cooling for those applications where the gates are difficult to access with conventional cooling techniques January 1, 2005 pg

24 auxiliary technologies filter nozzles An effective solution to eliminate harmful contaminants from entering the melt and blocking the main flow The Mold-Masters filter nozzle removes contaminants from the molten plastic by utilizing a three part system consisting of a body, inner filter torpedo and nozzle tip. Foreign particles that are larger that the filter gap do not enter the melt and remain outside the main flow - resulting in clog-free injection molding, minimal pressure drop and faster molding cycles. The filter nozzle is easily accessible for maintenance, thus reducing down time and creating more efficient processes. Spiral flow action of the melt within the nozzle causes increased mixing of the melt Heated and unheated filter nozzles are available January 1, 2005 pg

25 technical services 2D/3D mold flow analysis The ability to identify and analyze mold flow challenges at the early, conceptual stages to ensure that the final designs will meet or exceed the quality and cycle time specifications. Using the latest simulation software, Mold-Masters offers: Filling, cooling and packing stage simulation Optimized gate positioning Sequential control parameter simulation Pre-determined weld line positioning Gate sizes selection Melt channel sizing to give required performance Residence time and color change capability evaluation Evaluation of pressure requirements January 1, 2005 pg

26 technical services engineering design proposals The hot runner system is pivotal for so many decisions relating to my molding application. Can you show me what my hot runner system will look like? For those demanding projects, a Mold-Masters engineering design proposal will allow you to: Evaluate the total mold design by overlaying the hot runner or hot half drawings into your mold prints Modify and finalize the hot runner layout during the planning phase of your project Finalize the required mold steel sizes Optimize your molding machine selection January 1, 2005 pg