Overview

Polyshot Manifold Systems
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The Polyshot Manifold System is a complete pre-engineered runnerless molding package. It is shipped fully assembled, tested, and ready to bolt onto the mold. It is also available as a “manifold only” unit (pictured) for moldmakers who prefer to construct their own hot half plates.

The Polyshot manifold is heated with replaceable flexible tubular heaters that are formed to the manifold grooves without the aid of special tools or fixtures. They can be replaced in the field by the customer if so required. Each nozzle is heated and controlled by its own heater and thermocouple. The thermocouple is positioned very close to the end of the nozzle, maximizing gate temperature control and shot to shot consistency.

Manifold flow balancing is achieved through the use of layered manifold construction (8 drops or greater) and in-house vacuum brazing technology. This proprietary technology allows flow channels to be created with large sweeping arcs with gradually changing diameters. This process also allows the use of hardened tool steel for the manifold which ensures long life with filled resins.

Section View Plate Fused Manifold

Description

Manifold diagram
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Nozzle Alignment: Polyshot Runnerless Molding Systems are designed to accommodate stress free thermal expansion. The center of the manifold is fixed in the mold by the nozzle interface engaged to the top clamp plate, and a dowel pin which fits into the manifold support plate. The nozzles are staged firmly into the manifold support plate at two points. The first point is the nozzle head, which fits into the manifold support plate. The second is the end diameter, which fits into the back of the cavity block. As the manifold heats up and expands, it is allowed to slide across the top of the nozzle seats. As it expands, a secondary dowel pin engaging both the manifold and the manifold support plates controls the final manifold position. When fully heated, the feed holes in the manifold are correctly aligned with the feed holes in the nozzles.

Flow Channels: Polyshot’s proprietary plate fusion technology allows for smooth material flow paths with no hold up areas or sharp corners. All manifolds are designed to be fully balanced. Polyshot’s plate fusion technology is especially beneficial in family molds, or typically unbalanced systems (for example, 12 cavity molds). Flow channel sizes can be changed in the manifold without jeopardizing quality or balance. This is not able to be achieved with a standard turn plug design.


Details

thermal expansion diagram

Thermal Expansion: The drawing above shows the process of thermal expansion as the hot runner system heats up. All of the expansion calculations are taken into consideration by Polyshot’s engineers during the design of the system, thereby relieving the customer of that concern.

Nozzle Sealing: Sealing of the nozzles to the manifold is accomplished through both mechanical and thermal means. The mechanical seal is accomplished by bolting each nozzle to the manifold using two socket head cap screws. The thermal seal takes place as the system heats up. The thermal expansion across the nozzle and manifold thickness allows a predetermined amount of preload to occur on the nozzle seat. The combination of these two mechanisms creates a reliable, trouble free seal.

Electrical Requirements: All Polyshot systems operate at 208 to 240 VAC. All nozzles draw a maximum of 2 amps, and the maximum draw of any single zone is 15 amps. The total amp draw is determined by the number of nozzles required and the size of the manifold.

Direct Gate Nozzles

Valve Gate Nozzles

General Purpose Nozzles

Material Compatibility

10M Pinpoint Nozzle

Description

10M Pinpoint Nozzle styles afford the absolute minimum gate vestige possible. They are used when it is necessary to gate directly into the part being molded. The pinpoint nozzle features a field replaceable tip that can be easily changed by the customer if necessary. It performs well when processing unfilled resins. Hardened tip inserts are available as an option when it is necessary to mold filled resins.

When using the pinpoint nozzle, all necessary tip clearances are machined into the mold cavity by the customer. This method allows only a small pinpoint mark to be left on the part after molding.

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Nozzle Body Section

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Part Number Length "L" (mm) Length "L" (in)
P-10M-NZ-P3 22.2 0.8748
P-10M-NZ-P4 34.9 1.3748
P-10M-NZ-P5 47.6 1.8748
P-10M-NZ-P6 60.3 2.3748
P-10M-NZ-P7 73.0 2.8748
P-10M-NZ-P8 85.7 3.3748
P-10M-NZ-P9 98.4 3.8748
P-10M-NZ-P10 111.1 4.3748

Gate Well Detail

Gate Ø Gage Dimension
0.0250 0.2188
0.0260 0.2183
0.0270 0.2178
0.0280 0.2173
0.0290 0.2168
0.0300 0.2163
0.0310 0.2158
0.0320 0.2153
0.0330 0.2148
0.0340 0.2143
0.0350 0.2138
0.0360 0.2133
0.0370 0.2128
0.0380 0.2123
0.0390 0.2118
0.0400 0.2113
0.0410 0.2108
0.0420 0.2103
0.0430 0.2098
0.0440 0.2093
0.0450 0.2088
0.0460 0.2083
0.0470 0.2078
Gate Ø Gage Dimension
0.0480 0.2073
0.0490 0.2068
0.0500 0.2063
0.0510 0.2058
0.0520 0.2053
0.0530 0.2048
0.0540 0.2043
0.0550 0.2038
0.0560 0.2033
0.0570 0.2028
0.0580 0.2023
0.0590 0.2018
0.0600 0.2013
0.0610 0.2008
0.0620 0.2003
0.0630 0.1998
0.0640 0.1993
0.0650 0.1988
0.0660 0.1983
0.0670 0.1978
0.0680 0.1973
0.0690 0.1968
0.0670 0.1963

Standard Gate Well

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Gate Well for PP & PE Only

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Minimum Spacing Requirements

M10 Pinpoint
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NOTE: Nozzle centerlines must be located at least 33mm [1.30″] radially away from the centerline of the nozzle interface.

M11 Pinpoint Nozzle

Description

M11 Pinpoint Nozzle tip style uses a pinpoint gate design to allow the absolute minimum gate vestige possible. The gate well area is machined directly into the mold cavity by the mold maker. This nozzle can be used for most resins with part sizes of 30 grams or less. Can run glass or mineral filled resins with an optional tip.

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Nozzle Body Section

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Part Number Length "L" (mm) Length "L" (in)
M11-NZ-P3-R2 24.2 0.951
M11-NZ-P4-R2 36.9 1.451
M11-NZ-P5-R2 49.6 1.951
M11-NZ-P6-R2 62.3 2.451
M11-NZ-P7-R2 75.0 2.951
M11-NZ-P8-R2 87.7 3.451
M11-NZ-P9-R2 100.4 3.951
M11-NZ2-P10 113.1 4.451
M11-NZ2-P11 125.8 4.951
M11-NZ2-P12 138.5 5.451
M11-NZ2-P13 151.2 5.951
M11-NZ2-P14 163.9 6.451
M11-NZ2-P15 176.6 6.951

Gate Well Detail

Gate Ø Gage Dimension
0.0250 0.2188
0.0260 0.2183
0.0270 0.2178
0.0280 0.2173
0.0290 0.2168
0.0300 0.2163
0.0310 0.2158
0.0320 0.2153
0.0330 0.2148
0.0340 0.2143
0.0350 0.2138
0.0360 0.2133
0.0370 0.2128
0.0380 0.2123
0.0390 0.2118
0.0400 0.2113
0.0410 0.2108
0.0420 0.2103
0.0430 0.2098
0.0440 0.2093
0.0450 0.2088
0.0460 0.2083
0.0470 0.2078
Gate Ø Gage Dimension
0.0480 0.2073
0.0490 0.2068
0.0500 0.2063
0.0510 0.2058
0.0520 0.2053
0.0530 0.2048
0.0540 0.2043
0.0550 0.2038
0.0560 0.2033
0.0570 0.2028
0.0580 0.2023
0.0590 0.2018
0.0600 0.2013
0.0610 0.2008
0.0620 0.2003
0.0630 0.1998
0.0640 0.1993
0.0650 0.1988
0.0660 0.1983
0.0670 0.1978
0.0680 0.1973
0.0690 0.1968
0.0700 0.1963
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Minimum Spacing Requirements

NOTE: Nozzle centerlines must be located at least 33mm [1.30″] radially away from the centerline of the nozzle interface.

M15 Pinpoint Nozzle

Description

M15 Pinpoint Nozzle styles afford the absolute minimum gate vestige possible. They are used when it is necessary to gate directly into the part being molded. The pinpoint nozzle features a field replaceable tip that can be easily changed by the customer if necessary. It performs well when processing unfilled resins. Hardened tip inserts are available as an option when it is necessary to mold filled resins.

When using the pinpoint nozzle, all necessary tip clearances are machined into the mold cavity by the customer. This method allows only a small pinpoint mark to be left on the part after molding.

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Nozzle Body Section

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Part Number Length "L" (mm) Length "L" (in)
M15-NZ-P4-R2 31.5 1.240
M15-NZ-P5-R2 44.2 1.740
M15-NZ-P6-R2 56.9 2.240
M15-NZ-P7-R2 69.6 2.740
M15-NZ-P8-R2 82.3 3.240
M15-NZ-P9-R2 95.0 3.740
M15-NZ-P10-R2 107.7 4.240
M15-NZ-P11-R2 120.4 4.740
M15-NZ-P12-R2 133.1 5.240
M15-NZ-P13-R2 145.8 5.740
M15-NZ-P14-R2 158.5 6.240
M15-NZ-P15-R2 171.2 6.740

Gate Well Detail

Gate Ø Gage Dimension
0.0250 0.2188
0.0260 0.2183
0.0270 0.2178
0.0280 0.2173
0.0290 0.2168
0.0300 0.2163
0.0310 0.2158
0.0320 0.2153
0.0330 0.2148
0.0340 0.2143
0.0350 0.2138
0.0360 0.2133
0.0370 0.2128
0.0380 0.2123
0.0390 0.2118
0.0400 0.2113
0.0410 0.2108
0.0420 0.2103
0.0430 0.2098
0.0440 0.2093
0.0450 0.2088
0.0460 0.2083
0.0470 0.2078
Gate Ø Gage Dimension
0.0480 0.2073
0.0490 0.2068
0.0500 0.2063
0.0510 0.2058
0.0520 0.2053
0.0530 0.2048
0.0540 0.2043
0.0550 0.2038
0.0560 0.2033
0.0570 0.2028
0.0580 0.2023
0.0590 0.2018
0.0600 0.2013
0.0610 0.2008
0.0620 0.2003
0.0630 0.1998
0.0640 0.1993
0.0650 0.1988
0.0660 0.1983
0.0670 0.1978
0.0680 0.1973
0.0690 0.1968
0.0700 0.1963
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Minimum Spacing Requirements

M15 Pinpoint Spacing
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NOTE: Nozzle centerlines must be located at least 33mm [1.30″] radially away from the centerline of the nozzle interface.

M10VG Valve Gate Nozzle

Description

M10VG Valve Gate Nozzle eliminates the gate vestige. They are used when it is necessary to gate directly into the part being molded without leaving a vestige. The valve gate nozzle features a field replaceable tip that can be easily changed by the customer if necessary. It performs well when processing unfilled, low temperature resins and is best for part sizes up to 5 grams. The valve pins can be actuated by pneumatics or hydraulics.

When using the valve gate nozzle, all necessary tip clearances are machined into the mold cavity by the customer. This method allows for the smallest witness mark to be left on the part after molding. The valve gate pin mark will resemble an ejector pin mark on the part.

M10VG Valve Gate Nozzle
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Nozzle Body Section

M10VG
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Part Number Length "L" (mm) Length "L" (in)
M10VG-HFNZ-P4-R1 29.0 1.143
M10VG-HFNZ-P5-R1 41.74 1.643
M10VG-HFNZ-P6-R1 54.4 2.143
M10VG-HFNZ-P7-R1 67.1 2.643
M10VG-HFNZ-P8-R1 79.8 3.143
M10VG-HFNZ-P9-R1 92.5 3.643
M10VG-HFNZ-P10-R1 105.2 4.143
M10VG-HFNZ-P11-R1 117.9 4.643

Gate Well Detail

Gate Ø Gage Dimension
0.025 0.1726
0.026 0.1725
0.027 0.1724
0.028 0.1723
0.029 0.1722
0.030 0.1721
0.031 0.1720
0.032 0.1719
0.033 0.1718
0.034 0.1717
0.035 0.1716
0.036 0.1715
0.037 0.1714
Gate Ø Gage Dimension
0.038 0.1713
0.039 0.1711
0.040 0.1710
0.041 0.1709
0.042 0.1707
0.043 0.1706
0.044 0.1704
0.045 0.1703
0.046 0.1701
0.047 0.1700
0.048 0.1698
0.049 0.1696
0.050 0.1695
M10VG Gate Well
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Minimum Spacing Requirements

M10vg Spacing
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NOTE: Nozzle centerlines must be located at least 30mm [1.18″] radially away from the centerline of the nozzle interface.

M11VG Valve Gate Nozzle

Description

M11VG Valve Gate Nozzle eliminates the gate vestige. They are used when it is necessary to gate directly into the part being molded without leaving a vestige. The valve gate nozzle features a field replaceable tip that can be easily changed by the customer if necessary. It performs well when processing filled or unfilled resins and is best for part sizes of 30 grams or less. The valve pins can be actuated by pneumatics or hydraulics.

When using the valve gate nozzle, all necessary tip clearances are machined into the mold cavity by the customer. This method allows for the smallest witness mark to be left on the part after molding. The valve gate pin mark will resemble an ejector pin mark on the part.

M11VG-NZ-PX-R2 Assembly
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Nozzle Body Section

M11VG
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Part Number Length "L" (mm) Length "L" (in)
M11VG-NZ-P4-R2 36.9 1.452
M11VG-NZ-P5-R2 49.6 1.952
M11VG-NZ-P6-R2 62.3 2.452
M11VG-NZ-P7-R2 75.0 2.952
M11VG-NZ-P8-R2 87.7 3.452
M11VG-NZ-P9-R2 100.4 3.952
M11VG-NZ2-P10 113.1 4.452
M11VG-NZ2-P11 125.8 4.952


Gate Well Detail

Gate Ø Gage Dimension
0.025 0.1566
0.030 0.1561
0.035 0.1556
0.040 0.1549
0.045 0.1541
0.050 0.1532
0.055 0.1522
0.060 0.1510
0.065 0.1497
0.070 0.1481
0.075 0.1464
0.080 0.1443
M11VG Gate Well
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Minimum Spacing Requirements

M11vg Spacing
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NOTE: Nozzle centerlines must be located at least 76mm [3.00″] radially away from the centerline of the nozzle interface.

M15VG Valve Gate Nozzle

Description

M15VG Valve Gate Nozzle style eliminates the gate vestige. They are used when it is necessary to gate directly into the part being molded without leaving a vestige. The valve gate nozzle features a field replaceable tip that can be easily changed by the customer if necessary. It performs well when processing filled or unfilled resins and is best for part sizes between 30 and 125 grams. The valve pins can be actuated by pneumatics or hydraulics.

When using the valve gate nozzle, all necessary tip clearances are machined into the mold cavity by the customer. This method allows for the smallest witness mark to be left on the part after molding. The valve gate pin mark will resemble an ejector pin mark on the part.

M15VG-NZ-PX-R2 Assembly
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Nozzle Body Section

M15VG
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Part Number Length "L" (mm) Length "L" (in)
M15VG-NZ-P4-R2 31.8 1.250
M15VG-NZ-P5-R2 44.4 1.750
M15VG-NZ-P6-R2 57.2 2.250
M15VG-NZ-P7-R2 69.9 2.750
M15VG-NZ-P8-R2 82.6 3.250
M15VG-NZ-P9-R2 95.3 3.750
M15VG-NZ-P10-R2 108.0 4.250
M15VG-NZ-P11-R2 120.7 4.750
M15VG-NZ-P12-R2 133.4 5.250
M15VG-NZ-P13-R2 146.0 5.750
M15VG-NZ-P14-R2 158.8 6.250


Gate Well Detail

Gate Ø Gage Dimension
0.030 0.2358
0.035 0.2353
0.040 0.2348
0.045 0.2343
0.050 0.2337
0.055 0.233
0.060 0.2323
0.065 0.2314
0.070 0.2305
0.075 0.2296
0.080 0.2285
0.085 0.2273
0.090 0.2261
0.095 0.2247
0.100 0.2231
0.105 0.2214
0.110 0.2196
0.115 0.2175
0.120 0.2152
0.125 0.2127
M15VG Gate Well
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Minimum Spacing Requirements

M15vg Spacing
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NOTE: Nozzle centerlines must be located at least 76mm [3.00″] radially away from the centerline of the nozzle interface.

G-050M General Purpose Nozzle

Description

G-050M General Purpose Nozzle styles are commonly used when the formation of a small sprue is acceptable. They are often used when processing filled materials. Because the entire flow path of the nozzle is constructed of hardened tool steel, it is highly resistant to wear. They are also used when it is necessary to gate into a cold runner system. The end of the nozzle is designed to accommodate the machining of a .188 radius through it.

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Nozzle Body Section

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Part Number Length "L" (mm) Length "L" (in)
G-050M-3-R2 22.225 0.875
G-050M-4-R2 34.925 1.375
G-050M-5-R2 47.625 1.875
G-050M-6-R2 60.325 2.375
G-050M-7-R2 73.025 2.875
G-050M-8-R2 85.725 3.375
G-050M-9-R2 98.425 3.875
G-050M-10-R2 111.125 4.375

Gate Well Detail

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Minimum Spacing Requirements

NOTE: Nozzle centerlines must be located at least 33mm [1.30″] radially away from the centerline of the nozzle interface.

G-050M Spacing
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MS75-G General Purpose Nozzle

Description

MS75-G General Purpose Nozzles are commonly used when the formation of a small sprue is acceptable. They are often used when processing filled materials. Because the entire flow path of the nozzle is constructed of hard­ened tool steel, it is highly resistant to wear. They are also used when it is necessary to gate into a cold runner system. The end of the nozzle is designed to accom­modate the machining of a .188 radius through it.

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Nozzle Body Section

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Part Number Length "L" (mm) Length "L" (in)
MS75-NZ-G3-R2 22.2 0.875
MS75-NZ-G4-R2 34.9 1.375
MS75-NZ-G5-R2 47.6 1.875
MS75-NZ-G6-R2 60.3 2.375
MS75-NZ-G7-R2 73.0 2.875
MS75-NZ-G8-R2 85.7 3.375
MS75-NZ-G9-R2 98.4 3.875
MS75-NZ-G10-R2 111.1 4.375
MS75-NZ-G11-R2 123.8 4.875
MS75-NZ-G12-R2 136.5 5.375
MS75-NZ-G13-R2 149.2 5.875
MS75-NZ-G14-R2 161.9 6.375

Gate Well Detail

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Minimum Spacing Requirements

NOTE: Nozzle centerlines must be located at least 33mm [1.30″] radially away from the centerline of the nozzle interface.

G-MS75 Spacing
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