Precision Injection Mold Nozzles, Tips, and Tooling for Automotive Part Manufacturers
Polyshot Corporation specializes in the development of innovative injection molding nozzles, tips, and tooling engineered to eliminate waste while simultaneously improving quality and efficiency.
Beyond building precision tooling solutions, our company is in the business of problem solving. We help customers achieve superior results while addressing their specific manufacturing challenges and requirements. The following customer success story is a case in point, in which we developed a unique injection molding tip specifically for LCP (liquid crystal polymer) material. The client was an automotive part manufacturer requiring precision results with higher product consistency, and Polyshot delivered.
Meeting the Challenges of LCP (Liquid Crystal Polymer) Injection Molding
The client was a major manufacturer of automotive plastic connectors. Like many in the industry, they were struggling with consistently molding LCP connectors, trying many different tooling solutions in an attempt to produce a good quality part with little to no vestige.
They contacted Polyshot for assistance in developing a truly optimized solution for their needs. Polyshot developed a custom nozzle tip specifically designed for LCP material. We carefully considered their production requirements and ensured their requirements would be met reliably. As a result, the customer overcame their production challenges and was able to deliver their parts more consistently and cost-effectively.
A Look at Polyshot’s Engineered Injection Molding Solutions
This technology is used for many applications, from hot sprue bushings to multi cavity hot runner systems. The “Conan” style tip is typically used for small parts (single or multi-cavity) which are being processed with high engineering resins. That makes it ideal for this and many other automotive injection molding applications which demand an exceptionally high degree of accuracy and consistency.
- Hot Sprue Bushings – We offer a selection of precision hot sprue bushings, including micro bushings and pinpoint gate designs.
The Leading Manufacturer of Runnerless Molding Systems
Multi-Tip System – The Polyshot Multitip System is designed to allow precision injection molders additional flexibility in the design, manufacture, and operation of their molds. The Multitip module can be used as a stand alone unit or it can be mated to a Polyshot Hot Runner Manifold to create 8, 16, 32, etc. cavity molds.
The multi-tip module is a fully self-contained hot runner system consisting of a nozzle or manifold interface, externally heated flow passages, and two styles of field replaceable tips. The use of a fully hardened distribution body allows 2, 3, 4, 6 or 8 tips to be integrated into the system. It is heated by internal cartridge heaters surrounding the entire distribution body. The Multitip operates on one zone of control and is monitored by an independent thermocouple located as close to the gate orifice as possible.
Single-Nozzle Valve Gate System – Designed with precision, the Polyshot Single Valve Gate Nozzle System is amongst the most compact and mechanically reliable units on the market. We’ve crafted this unit, keeping the customer’s requirements at the forefront.
The Challenges of LCP Injection Molding
Polyshot works closely with customers to solve their unique production challenges and meet their specific manufacturing requirements. In this case, we had to innovate around the challenges of LCP injection molding while maintaining the customer’s requirements for a clean finish and accuracy in geometrically complex parts.
- High Melt Flow and Thin-Wall Molding – LCP has an extremely low viscosity in the molten state, which allows it to fill very thin walls and intricate geometries. However, that means a higher risk of flashing and makes precise mold design critical.
- Rapid Solidification – LCP cools and solidifies very quickly, limiting the time available for material flow. It therefore requires carefully controlled mold temperatures (typically 120–160°C) throughout the process.
- Flow Orientation and Part Warpage – Due to its high anisotropy, LCP molecules align along the flow direction, leading to uneven shrinkage and warpage. To accommodate, injection speed must be carefully controlled, and gate placement must likewise be properly designed.
Innovative Injection Molding Equipment Solutions Since 1989
Committed to innovation in injection molding, Polyshot doesn’t simply follow the trends to produce standard or currently popular equipment. We apply decades of experience within the industry to develop novel equipment solutions and value-adding technologies which truly help our customers achieve better quality, efficiency, and speed of delivery.