INTELLIMOLD FAQ

Q - Does Intellimold work on a family tool with dissimilar cavities?

A - Absolutely. Our experience has been that we treat a multi-cavity tool just as we would a single cavity tool, with one transducer at the last place to fill. Because Intellimold fills with even pressure, all cavities will realize that equal melt pressure.

Q - What effect does Intellimold have on grain?

A - On this type of application, or on optical quality reflective surfaces, Intellimold packs the melt against the surface as it is filling. Any shrinkage of the material is compensated by the IMP calculation every millisecond. This keeps material pushed into the grain or tool surface before it forms a semi-solid skin. In conventional molding, this skin can form during the transition time from fill to pack and hold and the semi-solid skin is trying to be pushed back into the grain of the tool.

Q - How much help can I expect from Intellimold I fixing a parting line flash problem?

A - Intellimold may be able to correct parting line flash if it is related to the part processing. If the parting line flash is a result of poor tool maintenance or inadequate tonnage, Intellimold will not offer any benefit.

Q - Can Intellimold improve the flow lines on the A-Surface?

A - The Intellimold process measures and controls the mold filling. Because we have the ability to measure and control continuously during the cavity filling process, Intellimold can match the non-linear filling characteristics of the mold with a non-linear fill pattern. Intellimold typically improves flow lines.

Q - Can Intellimold eliminate tiger stripes?

A - Tiger stripes are a result of velocity changes during the normal filling process and the material sliding across the mold surface. The internal melt pressure Intellimold applies to the molten material forces the material against the tool surface as it fills the cavity. This allows the material to begin the cooling process (skinning), as the cavity fills, while still allowing the molten material in the middle of the flow to push into the cavity. This in turn reduces if not eliminates the sliding of the material on the mold surface, which causes tiger striping.

Q - Do I need to modify my current machine for Intellimold?

A - The only modifications are to the tool and the nozzle. A transducer is placed in the tool at last place of fill. Then another is placed in the nozzle body. The Intellimold system is then wired to your machine without hydraulic or mechanical modifications. It works in conjunction with your existing machine control system.

Q - If I want to run a tool on a limited production run that does not

A - Yes. The Intellimold feature can be switched on or off for any type of molding process required.

Q - This process seems similar to other monitoring systems with transducers placed in the tool. Is it?

A - No, not at all! Other systems only monitor the pressure in the mold cavity. Intellimold is the ONLY method to MONITOR AND CONTROL measurement of pressure transitions in the nozzle and the mold cavity in Real Time. That means during the shot.

Q - With Intellimold, will I have to make frequent process changes like I do with my existing system?

A - No. Intellimold controls the processing variables and adjusts the screw velocity to match the non-linear behavior of the material automatically during every shot in milliseconds as the part is being molded. Therefore, process changes as you are accustomed to are a thing of the past.

Q - This seems like a much more sophisticated system than conventional process control. Is set up a difficult procedure?

A - Actually, even though Intellimold controls molding better and much more precise, it is much simpler to set up and operate than conventional process control. Set up procedures require input of recommended pressure, temperatures and processing factor information right from the Material Spec Sheet provided by your material supplier. Once set, Intellimold operates like cruise control maintaining constant processing automatically, from shot to shot with out violating that preset information.

Q - If Intellimold transducer would fail, will Intellimold still work?

A - Intellimold Process Control has the ability to execute injection profiles (up to five segments) based on the feed back from the nozzle transducer only. There is only one shortfall, and it would be the loss of the non linear transfer between the fill and pack.