Layout and Design: Hot Runner Guide

H O T R U N N E R T E C H N O L O G Y
Hot Runner Guide

Layout and Design
Stabilize your Process

CAT-14-0001_EN-Rev07 EN 05/2018
Hot Runner Guide
Layout and Design
The purpose of this Hot Runner Guide The Hot Runner Guide - Layout and Design is intended to help everyone who designs feed systems
for injection molds or simply wants to find out about designing feed systems in the following way:
à Overview of the Synventive hot runner product range

à Insight into the layout of feed systems with hot runner technology
à Help to select suitable hot runner components
Important note All the information contained in these pages is based upon our current knowledge and experience
gained from both theory and practise. However because of many factors outside our control they do
not guarantee the suitability of our products for any particular application. Always consult Synventive
for your specific application.
Table of Contents Introduction
Page 3 .................................................. The Custom Hot Runner Solution from Modular Components
Hot Runner Components
Nozzles
Page 4 .................................................. Overview of Nozzles Series
Page 5 .................................................. Key Nozzle Data
Manifolds
Page 6 .................................................. Basic manifold Dimensions
Flow Control
Page 7 .................................................. Actuators
Material Suitability
Page 8 .................................................. Nozzle Tip Description VTP Series

Page 9 .................................................. Nozzle Tip Description VSP Series
Page 10 .................................................. Nozzle Tip Description VSW, VTW Series
Page 11 .................................................. Nozzle Tip Description TTP, TTW Series
Page 12 .................................................. Nozzle Tip Description TFP Series
Tip Modifications
Page 13 ................................................. Tip Modifications VSP, VSW Series

Page 14.................................................. Tip Modifications VTP, VTW Series
Page 15.................................................. Tip Modifications TTP, TTW, TFP Series
Hot Runner Design
Page 16 .................................................. Shot Weight per Nozzle

Page 17 .................................................. Thermal Expansion Guidelines
Master Language is English CAT-14-0001_EN-REV07 For a specific application, please consult Synventive
© 2018 Synventive Molding Solutions. 2 / 18 All rights reserved. Errors and omissions excepted.
Hot Runner Guide
The Custom Hot Runner Solution from Modular Components
Hot Runner Components a)

1
b)
c)
Product Range Structure
d)
Hot runner systems may comprise of many
subsets, each customized for a specific
application.
a) Nozzles
Wide range of nozzles to suit most applica-

tions.
b) Hot Runner Systems
Available in standard shapes - I, H, X, Y - and e)

in any realisable custom shape, the ranges of
manifolds cover all possible injection configu-
rations and mold concepts.
3
c) Melt Flow Control Technology
Utilizing valve gate technologies, Synventive

provides solutions from traditional SVG to
activeGate® technology to meet the needs of
the most challenging applications.
d) Connections
To customer specification or Synventive

standard, Synventive hot runner systems
are available pre-wired, pre-plumbed and
pre-tested.
e) Hot Halves
Hot runner systems are supplied completely

mounted in mold plates, pre-wired, pre-piped
if required and fully adjusted.
Hot Runner Guide
Overview of Nozzle Series
Nozzle style
Nozzle size
Sprue bushings Single axis valve gate nozzles Threaded nozzles

(thermal gate) (pneumatic / hydraulic) (thermal gate / valve gate)
J=Ø6
06
06 S 06 E
J=Ø9
09
09SVP
09 S pneumatic 09 E01
J=Ø12
12
12SVP
pneumatic
12 S 12 E
12SVH
hydraulic
J=Ø16
16
16SVP
pneumatic
16 S 16 E
16SVH
hydraulic
12 16
12 EX 16
J=Ø22
22
22 S 22 E
16 22
16 EX 22
Hot Runner Guide
Key Nozzle Data
Key nozzle data Max. shot weight per nozzle (g) Major Dimensions
Nozzle style Thermal gate Valve Gate *Thermal Gate
mediumb)
mediumb)
Nozzle series
higha)
higha)
lowc)
lowc)
J L D Xn Xc
S 06 S ………………… 30 70 120 - - - Ø6 60…200 Ø20 - -

09 S ………………… 70 120 250 - - - Ø9 60…400 Ø27 - -
12 S ………………… 500 800 1500 - - - Ø12 60…650 Ø35 - -
16 S ………………… 1000 1500 2000 - - - Ø16 96…627 Ø50 - -
22 S ………………… 1500 2500 5000 - - - Ø22 96…627 Ø60 - -
09 SVP pneumatic ………………… - - - 10 50 80 Ø9 50…400 Ø27 - -
12 SVP pneumatic ………………… - - - 80 150 300 Ø12 50…400 Ø35 - -
12 SVH hydraulic ………………… - - - 80 150 300 Ø12 50…400 Ø35 - -
16 SVP pneumatic ………………… - - - 250 600 1500 Ø16 100…395 Ø50 - -
16 SVH hydraulic ………………… - - - 250 600 1500 Ø16 100…395 Ø50 - -
E 06 E-02 ………………… 30 70 120 10 45 80 Ø6 60…200 Ø20 20 22,5

09 E ………………… 70 120 250 40 80 120 Ø9 60…400 Ø27 27 28,5
12 E-04 ………………… 500 800 1500 100 250 500 Ø12 96…627 Ø35 35 35,5
12 E-05 ………………… 500 800 1500 100 250 500 Ø12 96…627 Ø40 42 39
16 E-04 ………………… 1000 1500 2500 500 800 1500 Ø16 96…627 Ø50 50 48
12 EX 16-01 ………………… 700 1000 2000 250 450 1000 Ø12 - Ø16 196…647 Ø50 50 48
12 EX 16-02 ………………… 700 1000 2000 250 450 1000 Ø12 - Ø16 196…647 Ø50 52 49
22 E-04 ………………… 1500 2500 5000 800 1200 2000 Ø22 96…627 Ø60 60 53
16 EX 22-01 ………………… 1200 2000 3500 650 1000 1700 Ø16 - Ø22 196…647 Ø60 60 53
16 EX 22-02 ………………… 1200 2000 3500 650 1000 1700 Ø16 - Ø22 196…647 Ø60 60 53
S
*Thermal Gate nozzle related minimal distance (theoretical)
Xn minimal distance between nozzles
Xc minimal distance between nozzle and center support
S
Viscosity of melt L
(at medium melt tempera- B M A
ture and at a shear rate of
1000 1/s)
> 150 Pa s a) high J
Shot weight based on gating type and PC, PMMA PEEK, PES,
L
viscosity of melt PSU, PEI, POM
B M A
= 60...150 Pa s b) medium E
Major dimensions and heater zones ABS, SAN, ASA, PBT, PET, Xc
POM (Copo), PA, PPE, PPO,
J
PPS, PC/ABS, PC/PBT D
Xn
< 60 Pa s c) low
PP, PE, PS, LCP, TPE
E L
Xc
D
Xn
Hot Runner Guide
Basic Manifold Dimensions
Available manifold series V-37 V-42 V-45 V-50 V-55 V-65

M= M1= M= M1= M= M1= M= M1= M= M1= M= M1=
Nozzle size 37 36 42 50 45 50 50 60 55 70 65 80
Nozzle series J2 max. J2 max. J2 max. J2 max. J2 max. J2 max.
NT V A B NT V A B NT V A B NT V A B NT V A B NT V A B
06 06 E …… 10 10 10 15
09 09 E …… 10 10 15 12 12 10 15
12 12 E …… 14 12 15 15
16 16 E …… 18 12 20 20
12 EX 16 18 12 20 20
22 22 E …… 22 22 20 20
16 EX 22 22 22 20 20
NT: Open nozzles V: Valve gate nozzles
B
A
Major dimensions J2
M1
Hot Runner Guide
Actuators
a hydraulic pneumatic electric
HYC4520M
PNC3008B
PNC4508B
PNC6018B
ELA4308P
ELA5708P
ELA8708P
ELA8716P
Actuators
VP4008P
VP8016P
HYZ3908
QCVG16
HB2508
HB4016
PB4008
PB6016
PB8016
Nozzle Nozzle Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc Xc
size series
06 06 E - 38 - - 42 - - ## 55 - 45 60 - -
09 09 E - 38 61 53 - - 61 - 61 77 97 55 - - - 90 90
12 12 E 96 61 - 100 - - 76 77 97 - 97 - - - -
16 16 E 140 61 - 100 - - 76 97 - 97 - - - -
12 EX 16 140 61 - 100 - - 76 97 - 97 - - - -
22 22 E 140 61 - 100 - - - 97 - 97 - - - -
16 EX 22 140 61 - 100 - - - 97 - 97 - - - -
Actuator bolted to the manifold Actuator in mold plate

HB Series HYZ Series
PB Series QCVG Series
Xc
VP Series
Actuator with backing plate Electric actuator in mold plate

PNC####B Series ELA Series
Xc Xc
Hot Runner Guide
Nozzle Tip Description - VTP
Nozzle Tip Selection
From the nozzle tip descriptions, individual configurations can be selection to suit a specific application.
VTP
Valve Gate - Tapered Pin - Plunged Through
F=0, F=30, F= 0-30 MOD

Universal tip
For direct gating or cold runner applications
Recommended for all common polyolefin and amorphous resins
Talc filled resins
GF not recommended
Inner part made of heat conductive material
Melt is covered and controlled until gate
Tip face must always be against plastic to avoid heat loss and mechanical loads when closing mold
Wall thickness in gating area >= Gate-diameter
Industrial standard for head and rear lamp applications
Gate quality lower than straight needle, risk of flash
Unsuitable for cosmetic gating and amorphous plastics when direct gating on part
Non-homogeneous cavity surface temperature
Significant effect with slow needle opening, strongly recommended for activeGate®
VTP-SC
Most effective solution for color change applications
Slightly hotter tip surface than VTP
Flame retardant resins
Hot Runner Guide
Nozzle Tip Description - VSP
VSP
Valve Gate - Straight Pin - Plunged Through
F=0, F=30, F= 0-30 MOD

Universal tip
For direct gating or cold runner applications.
For all common resins
Talc filled resins
GF< 30% crystalline; PA6.6 GF<20%
Wall thickness in gating area >= Gate-diameter
Gate quality better than tapered needle
Processing with polyolefins and amorphous plastics the front tends to stick if the mold cooling is not
optimal ( VSP WA , W-Tip )
No significant effect with slow needle opening (activeGate)
VSP-SC
For color change applications
Slightly hotter tip surface than VSP
VSP-WA Wear A
Internal and external component - best possible wear resistance (abrasion and corrosion) with a
standard heat transfer rate
Barium sulfate *
Work around for bad mold cooling and sticking
VSP-WC Wear C
External component – best possible wear resistance (abrasion and corrosion) with a standard heat
transfer rate
Internal component – high heat transfer rate
GF>30% crystalline; PA6.6 GF>20%; LGF
* For a specific application, please consult Synventive
Hot Runner Guide
Nozzle Tip Description - VSW, VTW
VSW
Valve Gate - Straight Pin - Blind

For direct gating and cold runner applications
Recommended for most common resins
Wear and/or Cooling insert strongly recommended
Talc filled resins
GF < 20%(crystalline materials) GF<30% (amorphous and polyolefin materials)
Wall thickness in gating area min 0,7 – 1,0 x Gate-diameter recommended
Gate quality better than tapered needle
Unsuitable for crystalline resins with narrow process windows (PA 4.6, …)
If not using separate wear inserts, hardened gate area to greater than 54 HRC
VSW-SC
For use on color change applications, when a straight and blind tip is requested
Slightly hotter cavity surface than VSW
VTW
Valve Gate - Tapered Pin - Blind

For most common amorphous resins recommended
Wear and/or Cooling insert strongly recommended
Talc filled resins
Wall thickness in gating area min 0,7 – 1,0 x Gate-diameter recommended
Industrial standard for head and rear lamp applications
If not using separate wear inserts, hardened gate area to greater than 54 HRC
Unsuitable for glass fiber resins
VTW-SC
For use on color change applications, when a blind tip is requested
Slightly hotter cavity surface than VSW
Hot Runner Guide
Nozzle Tip Description - TTP, TTW
TTP
Thermal Gate - Torpedo – Plunged Through
All Tips F=0, F=30, F= 0-30 MOD

For most common resins recommended
Sprue as short as possible
Talc filled resins
GF < 20% (crystalline materials) GF<30% (amorphous and polyolefin materials)
Processing with polyolefins and amorphous plastics the front tends to stick if the mold cooling is not
optimal ( W-Tip )
Unsuitable for highly filled resins (>30%) full flow or valve gate recommended
TTP-SC
For color change applications, if thermal gate is requested
Slightly hotter tip surface than TTP
TTW
Thermal Gate - Torpedo - Blind
Inner component made of heat conductive material

For most common resins recommended
Talc filled resins
GF < 20% (crystalline materials) GF<30% (amorphous and polyolefin materials)
If not using separate wear inserts, harden gate area to greater than 54 HRC
Unsuitable for highly filled resins (>30%) full flow or valve gate recommended
TTW-SC
Most effective solution for color change applications, if thermal gate and blind tip is requested
Slightly hotter cavity surface than TTW
Hot Runner Guide
Nozzle Tip Description - TFP
TFP
Thermal Gate – Full Flow – Plunged Through
All Tips F=0, F=30, F= 0-30 MOD

For shear sensitive resins, with do not tend to string
For cold runner applications
Suitable for highly filled resins
Talc filled resins
Limited for direct gating because of possible gate vestige
Sprue as short as possible
Unsuitable for cosmetic gating
Gate tends to string
Gate vestige not defined
TFP-SC
Best solution for color change applications, if valve gate is not necessary and gating at cold runner
Slightly hotter tip surface than TFP
Hot Runner Guide
Tip Modifications 12E, 16E, 22E Series
Illustrations simplified, schematically drawn and not to scale.
VSP
Standard Alternate Cutout
Space Restrictions, Contoured

or Angled Parting Line
Angled Gating Angled Gating Angled Gating Angled Gating
Option 1 Option 2 Option 3 Needle modification

Angle max 10° (recom.) Angle max 25° (recom.) Angle >25° NOT applicable
Extended land tip orifice Consult Synventive
with Valve Pin to accommodate
VSW
Angled Gating Angled Gating Angled Gating Angled Gating
Angle to part Option 1 Option 2 Option 3

Angle max 10° (recom.) Angle max 10° (recom.) Angle >10°
Valve pin +1,5 mm Consult Synventive
Consult Synventive
Preferred Available Not Available
Hot Runner Guide
VTP
Standard Alternate Cutout
Space Restrictions, Contoured

or Angled Parting Line
Angled Gating Angled Gating
Option 1 Option 2
Angle max 10° (recom.) Angle max 25° (recom.)
Extended land tip orifice with
reduced orifice and Valve Pin
to accommodate.
Tappered pin extended =
special part
VTW
Angled Gating Angled Gating Angled Gating
Angle to part Option 1 Option 2

Angle max 10° (recom.) Angle max 10° (recom.)
Tappered pin extended =
special part
Hot Runner Guide
TTP
Standard Alternate Cutout Dimple
Space Restrictions, Contoured According to customer

or Angled Parting Line specification depth max. 1 mm
Angle to part Option 1

Angle max 10° (recom.)
TTW
Angle to part Option 1

Angle max 10° (recom)
TFP
Standard Alternate Cutout Dimple Angled Gating Angled Gating
Space Restrictions, Contoured According to customer Angle to part Option 1

or Angled Parting Line specification depth max. 1 mm Angle max 10° (recom.)
Hot Runner Guide
Shot Weight per Nozzle
The term “maximum shot size per nozzle” denotes

the performance capacity of a hot runner nozzle, 1
that is, the maximum quantity of plastic melt that
can pass through the nozzle during operation
without damaging the nozzle or plastic material.
The reason performance capacity is specified in
terms of weight rather than volume flow is that it is
more readily understandable to the user, who has
usually received information on the weight of the W W = + +
molded parts to be produced.
How to find the shot weight per nozzle (W) is
shown on the right for three different applications.
Several parts per nozzle

 Multi cavity mold with sprue bushing
 Gating on cold sub runner
 Shot weight per nozzle = Parts + runner
2
One part per nozzle
 Multi cavity mold with manifold system
 Direct gating on to the part W1
 Shot weight per nozzle = part
W1 = W2 =
Several nozzles per part
 Single cavity mold with manifold system
 Direct gating on to the part W2
 Shot weight per nozzle = Section of the
cavity which is filled by one nozzle
The maximum shot size that can be
achieved depends on several factors:
à Injection time
à Type of plastic: viscosity, additives, etc. 3
à Runner length/diameter
à Maximum permitted pressure loss
à Residence time
When the above factors are taken into
consideration, conflicting requirements may W1
arise in some cases.
W1 =
Flow channel as big as possible:

W2 W2 =
à Iow pressure loss
à low shear rate
Flow channel as small as possible: W3 =
à Iow residence time W3
à good melt exchange

The values for the maximum shot weight of
a Synventive nozzle have been derived from
practical experience as well as theoretical
studies. They are valid for non-filled materi-
als. For a specific application, please always
consult Synventive.
Hot Runner Guide
Thermal Expansion Guidelines
Ratio of Pitch Dimension to Nozzle length for threaded Nozzles

The thermal expansion of the manifold makes the nozzle move while the nozzle tip is fixed inside the mold cutout. In order to allow the nozzle to bend
without being damaged the nozzle must adhere to a minimum length. These graphs show the minimum length of threaded nozzles in relation to its pitch
dimension.
NOTICE
06E max length is 200 mm
09E max length is 400 mm
06E & 09E min. length 60 mm
Suitable pitch dimensions for

06E & 09E Nozzles

09E Nozzles only
NOTICE
12E04 min. length is 60 mm
16E & 22E min. length is 110 mm
12E04, 16E & 22E
max. length 650 mm

12E04, 16E & 22E Nozzles

12E04 Nozzles only
www.synventive.com
North America
Synventive Molding Solutions Inc.
10 Centennial Drive
Peabody, MA 01960, USA
Tel.: +1 978 750 8065
Fax: +1 978 646 3600
E-Mail: [email protected]
Europe
Synventive Molding Solutions GmbH
Heimrodstr. 10
64625 Bensheim, Germany
Tel.: +49 (0) 6251 / 9332-0
Fax: +49 (0) 6251 / 9332-90
Asia
Synventive Molding Solutions (Suzhou) Co.Ltd.
12B Gang Tian Industrial Square
Suzhou Industrial Park, China 215021
Tel.: +86 512 6283 8870
Fax: +86 512 6283 8890
CAT-14-0001_EN-REV07 2018-May-07
© 2018 Synventive Molding Solutions DTP: KA

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H O T R U N N E R T E C H N O L O G Y

Hot Runner Guide

Stabilize your Process

Layout and Design

à Overview of the Synventive hot runner product range

Table of Contents Introduction

Hot Runner Components

Page 8 .................................................. Nozzle Tip Description VTP Series

Page 13 ................................................. Tip Modifications VSP, VSW Series

Hot Runner Design

Page 16 .................................................. Shot Weight per Nozzle

The Custom Hot Runner Solution from Modular Components

Hot Runner Components a)

Wide range of nozzles to suit most applica-

b) Hot Runner Systems

Available in standard shapes - I, H, X, Y - and e)

Utilizing valve gate technologies, Synventive

To customer specification or Synventive

Hot runner systems are supplied completely

Overview of Nozzle Series

Sprue bushings Single axis valve gate nozzles Threaded nozzles

Key Nozzle Data

Nozzle style Thermal gate Valve Gate *Thermal Gate

S 06 S ………………… 30 70 120 - - - Ø6 60…200 Ø20 - -

E 06 E-02 ………………… 30 70 120 10 45 80 Ø6 60…200 Ø20 20 22,5

Basic Manifold Dimensions

Available manifold series V-37 V-42 V-45 V-50 V-55 V-65

NT: Open nozzles V: Valve gate nozzles

a hydraulic pneumatic electric

Actuator bolted to the manifold Actuator in mold plate

Actuator with backing plate Electric actuator in mold plate

Nozzle Tip Description - VTP

Nozzle Tip Selection

F=0, F=30, F= 0-30 MOD

Nozzle Tip Description - VSP

F=0, F=30, F= 0-30 MOD

* For a specific application, please consult Synventive

Nozzle Tip Description - VSW, VTW

Inner part made of heat conductive material

Inner part made of heat conductive material

Nozzle Tip Description - TTP, TTW

All Tips F=0, F=30, F= 0-30 MOD

Inner component made of heat conductive material

Nozzle Tip Description - TFP

All Tips F=0, F=30, F= 0-30 MOD

Tip Modifications 12E, 16E, 22E Series

Illustrations simplified, schematically drawn and not to scale.

Space Restrictions, Contoured

Angled Gating Angled Gating Angled Gating Angled Gating

Option 1 Option 2 Option 3 Needle modification

Angle to part Option 1 Option 2 Option 3

Preferred Available Not Available

Tip Modifications 12E, 16E, 22E Series

Illustrations simplified, schematically drawn and not to scale.

Space Restrictions, Contoured

Angled Gating Angled Gating

Angle to part Option 1 Option 2

Preferred Available Not Available

Tip Modifications 12E, 16E, 22E Series