Plastic Injection Mold Core

Name: Injection Mold Core Inserts for Quality Tooling – Frigate
Price: 249.00 USD
Availability: InStock

Plastic Injection Mold Core performance directly impacts dimensional consistency across multi-cavity tools. For applications requiring sub-10-micron tolerances, Frigate ensures core concentricity and perpendicularity through fine-tuned EDM profiling and ultra-precision grinding. Tool steel cores undergo stress-relief cycles to prevent deviation during thermal expansion, maintaining uniformity in high-cavitation environments such as medical disposables and microfluidic components.

Material Specification

P20, H13, S7, Stainless Steel (420/440C), NAK80, or customer-approved alloy

Hardness (HRC)

48-52 HRC (H13), 28-32 HRC (P20), 37-43 HRC (NAK80)

Surface Finish (Ra/RMS)

Core/Cavity – 0.05–0.2 µm (Mirror), Ejector Pins – 0.4–0.8 µm, Non-critical – 1.6–3.2 µm

Dimensional Tolerances

±0.02 mm (Critical), ±0.05 mm (Standard), ±0.1 mm (Non-critical)

Core & Cavity Geometry

As per approved 3D CAD model (STEP/IGES) with draft angles (1°–3° typical)

Product Description

Plastic Injection Mold Core degradation from cyclic thermal loading is mitigated by material selection based on thermal conductivity and expansion coefficients. Tool steels like H13 and maraging variants are vacuum heat-treated and tempered for cyclic stability, while copper alloys with nickel-chromium diffusion barriers are used where heat extraction rates are critical. These configurations reduce crack propagation and surface fatigue during high-frequency mold opening and closing.

Cooling Channel Design

Diameter – 6–12 mm, Pitch – 3–5× channel diameter, ±0.1 mm alignment tolerance

Ejection System Features

Ejector pins (Ø2–10 mm), Sleeves, Lifters; Hardness – 50+ HRC; Fit tolerance – H7/g6

Gate Type & Location

Submarine, Edge, or Hot Runner (per design); Gate land – 0.5–1 mm; Position tolerance – ±0.05 mm

Texture/Polish Requirements

SPI-A1 (Mirror) to SPI-D3 (Textured), VDI 3400

Certification Standard

ISO 9001, IATF 16949 (Automotive), AS9100 (Aerospace), or material certs (e.g., DIN 1.2316)

Technical Advantages

Plastic Injection Mold Core cooling architecture governs part solidification speed. Frigate incorporates conformal cooling channels via additive manufacturing and cross-drilled inserts where AM is infeasible. Material thermal diffusivity is modeled against resin shrinkage behavior to optimize core-to-cavity thermal gradients. This approach reduces cycle time variability in high-throughput molding environments while ensuring core temperature stability.

Plastic Injection Mold Core surfaces are exposed to continuous abrasive and adhesive wear from glass-filled resins and complex ejection geometries. Coatings such as PVD-applied CrN and DLC are applied based on tribological load profiles. Surface roughness is maintained below Ra 0.2 µm to facilitate demolding of high-clarity optical parts and minimize buildup. Coating-substrate bonding is validated with scratch adhesion testing for critical applications.

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Industry Applications

Automotive Connectors

Plastic Injection Mold Core forms tight-tolerance terminal housings ensuring pin alignment and dimensional stability under thermal cycling and vibration.

Medical Syringes

Used to create high-cavitation syringe barrels with precise concentricity and flash-free ejection for sterile, disposable medical-grade applications.

Consumer Electronics Casings

Shapes micro-featured housings with controlled wall thickness and ejector clearance for snap-fit assembly and consistent EMI shielding coverage.

Optical Lenses

Enables molding of clear polycarbonate lenses with sub-micron surface finish and tight curvature tolerances for precision light path control.

Telecom Components

Used in high-density fiber optics parts requiring low warpage, accurate core pin alignment, and minimized insertion loss across ports.

Industrial Gears

Forms fine-tooth gear profiles in engineering polymers, maintaining dimensional fidelity and eliminating post-machining in closed-loop servo applications.

Structural Rigidity Under High Injection Pressure

Plastic Injection Mold Core deflection affects cavity fill symmetry and part wall thickness. Cores are analyzed using FEA under dynamic pressure loads up to 180 MPa. Cross-sectional geometry, support land depth, and interface rigidity are engineered to limit core tip displacement under peak fill rates. Material selection favors modulus-to-density optimization for weight-sensitive tooling without compromising stiffness.

Plastic Injection Mold Core features such as collapsible sections, threads, and lifter paths require precise integration with mold actuation systems. High-aspect-ratio core pins are fabricated with controlled runout, and guided shutoffs are used to eliminate flash at undercuts. Geometric constraints are validated against moldflow outputs to prevent premature wear or ejection interference.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure long-term dimensional stability of Plastic Injection Mold Core during high-volume production?

Frigate uses vacuum heat-treated tool steels with low retained austenite to minimize distortion during thermal cycling. All Plastic Injection Mold Cores are stress-relieved and finish-machined after heat treatment. This prevents dimensional drift over extended production runs. Cores are validated with CMM across multiple critical features before shipment.

What steps does Frigate take to prevent corrosion in Plastic Injection Mold Core used for hygroscopic or aggressive polymers?

Frigate selects stainless tool steels like 1.2083 or applies nitriding treatment for corrosive environments. For resins like PA66 or PC, moisture-resistant core materials are used. Cores are also passivated or coated based on pH and chemical interaction. This ensures long core life even in high-humidity or chemically reactive conditions.

Can Frigate provide Plastic Injection Mold Core with integrated sensors or monitoring features?

Yes, Frigate offers cores with embedded thermocouples or pressure sensors for process monitoring. Sensor channels are precisely machined to avoid affecting mechanical strength or thermal uniformity. The integration allows real-time mold temperature and pressure feedback during injection. This data helps optimize molding parameters and prevent defects.

How does Frigate handle ultra-thin wall molding in terms of Plastic Injection Mold Core deflection?

Frigate uses high-stiffness core materials like tungsten or maraging steel for thin-wall applications. FEA is used to analyze deflection under injection pressure. Cores are designed with support land reinforcement and optimal core/cavity interface geometry. This ensures accurate wall thickness and prevents part deformation during filling.

What material testing does Frigate perform on core materials before manufacturing Plastic Injection Mold Core?

Frigate performs hardness testing, grain size evaluation, and ultrasonic flaw detection on incoming tool steel. This verifies material homogeneity and internal soundness. Test data is recorded and matched with each core’s batch number. This quality traceability ensures consistent mechanical and thermal performance during molding.

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