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Using Injection Molding Side Action for Design Optimization

August 23, 2024 · About 3 minutes
injection molding side action design
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In today’s fast-paced global market, mold design must adapt to current industrial needs and realities. With products having shorter lifespans, mold makers need innovative solutions to stay ahead. That’s where injection molding side action comes in. It is the game changer for handling complex geometries and tricky undercuts.

Designers and engineers must understand when and how to use the side actions to unlock its full potential. This article will explore side action, how it works, and the various types for your applications. We’ll break down the complexities and provide actionable tips to boost your precision molding capabilities. Our goal is to equip mold makers, designers, and manufacturers with the know-how to make informed decisions and stay competitive. Let’s get started!

What Is Injection Molding Side Action?

injection molding side action design

Side actions are specialized inserts that enable the creation of complex undercut geometries. These features are perpendicular to main parting line, making them impossible to produce with a standard straight-pull mold. With the incorporation of side actions into the mold design, the material can flow around them to form the undercut feature.

Side actions expand design possibilities by enabling complex part geometries. Their design allows them to address the undercut geometry, which poses a challenge in traditional straight-pull injection molding. In this process, the mold’s straight pull action is insufficient to release parts with undercuts. Injection molding side action overcomes this limitation by employing a cam-driven mechanism that withdraws the mold surfaces, allowing safe part ejection. 

However, the use of side actions requires careful consideration. After molding the part, the side actions must be manually or automatically removed to facilitate part ejection. It’s crucial to assess whether they are necessary or if alternative design approaches, such as slot features, can achieve the desired outcome. 

How Side Action Works?

Side actions enable the creation of complex geometries with undercuts that cannot be achieved with a standard two-part mold. These undercuts are characterized by inward-facing angles or projections. As a result, they can make part removal challenging without causing damage.

To address this, manufacturers use lateral movements, where sideways slide, or cam action engage with the mold cavity during closure. This facilitates the creation of undercut areas on the part. Precise guidance is ensured through angle pins, which interlock with side actions and accurately position them to form undercuts. During mold closure, these pins drive the side actions into their designated positions.

Controlled retraction of side actions after molding enables smooth part ejection without interference. Hydraulic or mechanical actuators manage this process, ensuring seamless operations. Retracting side actions before part ejection prevents damage to molded elements with undercuts. Doing this will result in the efficient production of high-quality parts with intricate details.

Types of Side Actions

how side actions work

When there is a need for side actions in the injection molding process, selecting the right type is vital to minimize tooling costs. Your manufacturer can recommend the most appropriate one for your injection molded part, as each type has unique cost considerations. Here are the different side action types you can consider.

Cams

Cams are clever mechanisms that enable mold opening by withdrawing undercut mold surfaces from the part. A common cam design uses an angled pin to control the action’s movement, mirroring the mold’s opening and closing speed. This allows for increased geometric complexity in part design without requiring external adjustments or operator interventions.

They enable the creation of parts with intricate details that standard molding techniques cannot achieve, and provide increased accuracy and precision in part design. They also reduce the need for secondary operations like drilling or machining and are compatible with other side actions like lifters or sliders.

Nevertheless, the cam pin requires ongoing monitoring throughout the production cycle. Due to steel’s compressible nature, excessive load can cause pin deformation, affecting part quality. Regular cam pin maintenance and inspection are crucial to ensure consistent performance and part accuracy.

Lifters

Lifters are necessary when designing parts with internal undercuts or features that need to be released without a draft. These include internal threads or bosses that require a specific orientation. Their mechanisms eliminate the need for an angled pin and reduce the risk of pin deformation.

However, internal features like draft, bosses, and ribs may require modification to accommodate lifter motion. Moreover, an injection mold lifter design can be complex, requiring careful planning and testing. Furthermore, ejector plate design and timing will help ensure proper lifter activation and retraction.

Sliders

In contrast to lifters, this type of side action creates and releases external undercut features. They offer versatile actuation options, including cam-driven, solenoid-driven, or hydraulic systems, enabling the creation of parts with complex external geometries.  Injection molding slides are essential when designing parts with external undercuts or features that need to be released without affecting the main core and cavity. This may include external threads or features that require a specific orientation. By doing this, they reduce the need for secondary operations like drilling or machining.

However, it’s important to consider that slider design can be complex. It requires careful planning and testing. Timing and synchronization with other mold actions are needed to ensure proper slider engagement and disengagement.

Unscrewing

Unscrewing actions, either automated or manual, facilitate the creation of screw or threaded features by precisely controlling the screwing process. This ensures thread quality and prevents damage between cycles. These actions are essential for consistent thread production, although hand-loaded cores may be a more cost-effective option for small production runs.

Injection molded parts with threaded features, like screws and fasteners, can be difficult to remove. While external threads perpendicular to the line of the draw can be easily incorporated into the mold design, internal threads, and non-perpendicular external threads necessitate an external unscrewing mechanism. This mechanism is inserted into the mold before injection and then carefully unscrewed from the part after the material has hardened.

Collapsible Core

Collapsible cores facilitate the release of circular undercut features, operating similarly to lifters. By collapsing inward, they provide clearance for part ejection. During molding, parts are formed directly around the action, which collapses once the material solidifies. This allows for easy removal of both the action and the part from the mold. Thus, they are ideal for features with circular undercuts or large internal threads. Collapsible core actions can also be used to create threaded features, further expanding their versatility.

Side ActionsProsConsApplications
CamsPrecise control, complex movements possible, high durabilityHigh cost, complex design, requires skilled laborComplex geometries, multi-cavity molds, high-volume production
LiftersSimple design, low cost, easy to maintainLimited movement, not suitable for complex geometries Undercuts, holes, recesses, simple geometries
SlidersSmooth movement, low friction, easy to design Limited movement, not suitable for complex geometries Slots, grooves, ribs, simple geometries
UnscrewingPrecise control, high durability, suitable for complex threadsHigh cost, complex design, requires skilled laborThreaded features, screws, bolts, nuts 
Collapsible CoreAllows for negative draft, precise control, high durabilityHigh cost, complex design, requires skilled labor Holes, pockets, recesses, complex geometries with negative draft 

Design Guidelines for Side Action Molds

injection-2K-mold

Designing and implementing effective side actions requires careful consideration of several key factors. Let’s examine each of them.

Understand the Need for Side Actions

Identifying the need for side actions is the first step in designing an effective side action mold. This involves recognizing features in the part design that require side actions, such as undercuts, holes, or recesses parallel to the mold opening direction. For example, a part with a threaded hole perpendicular to the mold opening direction would require a side action to create the thread.

Designers must consider the molding process and potential challenges during production. This way, you can determine the type and complexity of side actions needed. Additionally, you should consider factors such as parting line placement, material flow, and cooling to ensure optimal side action performance.

Basic Principles for Designing Side Action Molds

Designing side action molds requires a deep understanding of the basic principles that govern their operation. Design for manufacturability is important, ensuring the injection molding design accommodates side actions without compromising the molding process. 

  • Select the appropriate side-action mechanism (hydraulic cylinders, mechanical cams, or pneumatic systems) based on specific requirements.
  • Ensure precision alignment and tight tolerances between side actions and main mold components to minimize wear and tear and maintain dimensional accuracy.
  • Implement robust retraction and locking mechanisms to ensure side actions fully retract when not used and lock during injection processes, reducing part breakage and enhancing safety.
  • Use high-quality materials for side actions to withstand mechanical stresses and ensure consistent production.
  • Incorporate efficient cooling channels and thermal management systems to prevent heat expansion issues and maintain continuous function.
  • Design side actions for easy maintenance to allow for quick access, disassembly, and reassembly to minimize downtime and production losses.

Material selection is also vital, as the chosen materials must withstand the stresses and wear associated with injection molding side action movements. You must also consider factors like strength, hardness, and lubricity to ensure the longevity and durability of the mold. Furthermore, designers should consider the thermal properties of materials, as well as their resistance to corrosion and wear. For instance, a mold designed for a high-temperature material like polycarbonate would require careful consideration of thermal expansion to ensure precise side action movement.

Integrating Side Actions into Mold Design

A well-designed mold should accommodate side actions seamlessly. It must ensure sufficient space for components that operate laterally without interfering with other mold elements. This provision enables the efficient integration of side actions to facilitate smooth operation and minimize potential conflicts within the mold.

Cam and slide mechanisms are common options to achieve smooth, controlled movements. Optimizing cam profiles will help make the operation even more efficient. As such, incorporating them is also important. Lifters and core pulls are ideal for complex geometries, requiring precise control and synchronization with other mold movements. Additionally, designers should consider the use of sensors and monitoring systems to ensure optimal side action performance.

Managing Side Actions and Parting Line Relationship

Interference between side actions and the parting line can lead to production issues. Optimizing parting line placement can optimize their operation, reducing the risk of interference. Effective side action management involves carefully timing the engagement and disengagement of these mechanisms during the molding cycle. 

By switching them on or off at defined points, manufacturers can avoid part damage, achieve precise molding, and exercise tight control over dimensional accuracy. This will result in parts that meet exacting standards. Furthermore, designers should consider the use of parting line inserts and other features to enhance mold durability and longevity.

Ensuring Mold Durability and Longevity

Designers should prioritize accessibility when locating side actions and additional mechanisms, enabling easy maintenance and swift replacement when needed. This consideration streamlines servicing, reduces downtime, and prolongs the tool’s operational life. It ultimately enhances production uptime and overall manufacturing productivity.

Optimizing parting line placement can reduce wear and stress on side action components. At the same time, adequate lubrication and cooling are essential to minimize wear and maintain efficient operation. Designers must consider the long-term implications of their design decisions, ensuring that the mold is designed to withstand the rigors of production. Additionally, consider using maintenance-friendly features to enhance mold durability and longevity. These include easy-access components and modular designs. 

Manufacturing of Side Action Molds

The manufacturing process for side action molds involves several critical stages, from design to assembly. Each stage requires careful attention to detail to ensure the final product meets the required specifications and performs optimally.

Design Phase

This stage requires close collaboration between designers, engineers, and manufacturers to ensure the design is feasible and meets the required specifications. Computer-aided design (CAD) software helps create detailed designs and simulations, taking into account factors such as material selection, thermal expansion, and stress analysis. The design phase also involves careful consideration of the side action mechanism, as we discussed above. These include the cam and slide movements to ensure precise control and synchronization.

Choose Mold and Component Materials

Selecting the right materials for the mold and side action components helps ensure optimal performance. The chosen materials must possess the necessary strength, durability, and thermal properties to withstand the rigors of the injection molding process. Steel, aluminum, and copper alloys are commonly used materials for side action molds, each offering unique benefits and drawbacks. For instance, steel molds provide high strength and durability but may require additional cooling measures. On the other hand, aluminum offers excellent thermal conductivity but may be prone to wear. The material selection process involves considering corrosion resistance, lubricity, and cost factors.

Machining and Fabrication

This involves creating the individual components of the mold, including the side action mechanisms. This stage requires precision machining and fabrication techniques to ensure accurate dimensions and tolerances. CNC machines and other specialized equipment help achieve the required precision level. You must consider surface finish and texture to ensure optimal performance. For example, you may need a smooth surface finish for components that come into contact with the molten material. So, you must incorporate this in your design.

Heat Treatment

This is another crucial stage that requires careful temperature and timing control to achieve the desired material properties. Manufacturers use heat treatment techniques like annealing, quenching, and tempering to enhance the materials’ strength, hardness, and thermal conductivity. Annealing may help to reduce the hardness of a material, making it more suitable for machining. On the other hand, quenching may help increase the hardness of a material, making it more resistant to wear.

Assembly

The final stage involves assembling the individual components of the mold. Careful alignment and positioning of components here will help ensure precise movement and operation. Specialized tools and equipment are essential for accurate assembly, and the final product is tested and validated to ensure optimal performance. At this stage, clearance and tolerances are essential to ensure smooth operation. Excessive clearance between components may lead to reduced precision and accuracy. 

Choosing the Right Mold Maker

When selecting a plastic injection mold maker, you must choose a partner with extensive industry experience, advanced technology, and a skilled design team. Such a partner can deliver high-quality molds that meet your specific requirements and deadlines. A reliable mold maker should offer flexible customization options to accommodate unique part designs. They must also ensure efficient production cycles to minimize lead times and timely delivery to meet your production schedules. 

They should also provide transparent pricing to avoid hidden costs, robust after-sales support for maintenance and repairs, and clear communication channels. To ensure a successful partnership, evaluate potential mold makers’ track records, certifications, and customer testimonials. Look for providers that prioritize quality, innovation, and customer satisfaction and have a proven history of delivering high-performance molds that meet or exceed expectations.

For expert injection mold tooling services, consider partnering with a trusted provider like RapidDirect. By carefully evaluating potential mold makers and selecting a qualified partner, you can streamline your production process, reduce downtime, and achieve high-quality results that drive business success.

Try RapidDirect Now!

Conclusion

Incorporating undercuts into part designs allows engineers to achieve geometric complexity but poses challenges for mold removal. Manufacturers overcome this by integrating specialized side actions into production tooling, facilitating effortless release of undercut features. Injection molding side actions represent a crucial innovation for creating complex geometries and addressing undercut challenges in modern mold design.

The integration of side actions into mold designs, along with attention to material selection and maintenance, ensures the production of high-quality parts with intricate details. Partnering with a trusted digital manufacturing expert like RapidDirect simplifies the entire product lifecycle, from prototyping to mass production. Our dedicated team ensures high-quality materials, timely delivery, and efficient processes to drive optimal results. Contact us today to get started.

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    Written By
    Lucas Bennett is a mechanical engineer with expertise in manufacturing, 3D printers, automobiles, EVs, renewable energy, and HVAC. He has worked on projects from trainee engineer to senior engineer and deputy project manager and specializes in writing manufacturing content. In his spare time, he’s an avid reader and loves tinkering with DIY tech projects.

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