Machine Selection Guide

Insert Molding Identify the insert material, dimensions, orientation, quantity per cycle, positioning points, and loading method. Metal terminals, pins, bushings, connectors, wires, and pre-assembled components require specific fixture and access arrangements.
Overmolding Review the substrate geometry, material, insert position, required plastic coverage, mold access, and removal method. The loading sequence must support repeatable positioning before mold closing.
Special Applications Two-color molding, silicone molding, cable overmolding, and precision components require specific injection performance, mold structures, table layouts, or automation interfaces to ensure stability.

Resin Requirements Identify the resin family, specific grade, processing temperature range, melt viscosity, and required drying conditions to prevent material degradation.
Reinforced Materials Glass-fiber and mineral-filled materials directly affect screw geometry selection, plasticizing capacity, required injection pressure, and barrel wear considerations.
Injection Capacity Material density and shot volume affect injection-unit sizing. The required shot must be evaluated from the complete part and runner system, together with the intended operating range of the injection unit.

Projected Area Calculate the projected surface area of all cavities and relevant runner sections in the mold closing direction.
Cavity Pressure Clamping force depends on projected area, cavity pressure, material behavior, cavity count, and processing conditions. A practical calculation is required clamping force equaling projected area multiplied by cavity pressure and a safety factor.
Verification The final selection should be confirmed against the actual part, resin, cavity layout, mold design, and molding conditions. Clamping force must be reviewed alongside mold dimensions and injection requirements.

Mold Envelope Check mold length, width, height, weight, platen dimensions, mounting position, opening stroke, daylight, and ejector stroke against machine limits.
Table Clearance For slide and rotary configurations, verify the usable table area during complete movement. Mold components must clear the machine structure throughout loading, molding, and unloading.
Fixture Space Insert fixtures often extend beyond the mold base. Review fixture height, locating points, loading direction, operator access, and space required for future handling equipment.

Fixed Table Suitable when inserts can be loaded and parts removed within the fixed mold position without table movement.
Slide Table Useful when the mold needs to move toward the operator for insert placement, inspection, or part removal, improving safety and ergonomics.
Rotary Table Suitable when loading and molding can be arranged at separate stations. The workflow allows one station to be loaded while another is in the molding cycle.
Tie-Barless Useful when open access around the mold is important for large inserts, complex fixtures, or specific multi-directional loading arrangements.

Shot Size Calculate the required material volume from the complete part and runner system. The selected injection unit should provide a stable operating range.
Screw Diameter Screw diameter must match the resin type, shot requirement, plasticizing rate, and process conditions. Reinforced materials require specialized screw and barrel metallurgy.
Injection Pressure and Speed Required pressure and speed depend on material viscosity, wall thickness, flow length, gate arrangement, and part geometry. Thin sections and long flow paths require precise injection control.

Standard Hydraulic Suitable where traditional hydraulic operation provides the required clamping force, injection stability, motion, and cycle performance for the application.
Servo Hybrid Considered when the process requires hydraulic molding functions combined with servo-controlled machine movements and optimized energy management.
All-Electric Considered where precise motion control, high repeatability, clean operation, and lower energy consumption are primary selection factors.

Output and Cycle Define required output, target cycle time, production shifts, and expected machine utilization. Cycle planning must include loading, molding, cooling, ejection, and part removal.
Insert Handling Measure the actual time required to place and position inserts. For multi-cavity applications, fixture design and operator access directly affect production rhythm.
Automation Planning Review automatic insert loading, part removal, auxiliary equipment, robot interfaces, and future automation during initial machine selection to build a unified production cell.