Can Jiffy Latch-Lok Assemblies be used for die casting or transfer molding applications?
The Latch-Lok is not recommended for die cast or transfer molding applications due to the higher temperatures encountered in these processes. The custom internal spring that applies pressure to the rocker may begin to anneal.
How should timing of the Jiffy Latch-Lok Assemblies be handled?
Timing of the Latch-Lok Assemblies should be within +/-.005 of each other for release bars and latch bars. This will prevent one bar from latching or releasing ahead of another assembly and causing deflection of the plate or the creation of an overload condition on the latch bar. Shock loads can adversely affect the ultimate strength of the latch bar. Therefore, mold open speeds may need to be reduced.
What are the design guidelines and major considerations for use Jiffy Latch-Lok Assemblies?
A minimum of two Jiffy Latch-Lok Assemblies per mold are required. However, four units are preferred. Larger molds may require six, eight or more assemblies. The Latch-Lok should not be used to overcome springs. Springs can cause the plate to deflect and bind as soon as one latch bar is released, even if only the slightest timing difference is present. Latch bars and release bars must be properly aligned with the body. The bars should enter the body freely. The latch bar should be fully released prior to the stripper bolts starting to pull the plate. Check the stripper bolt length. There should be no preload on the latch bars in the locked position. Latch-Loks should only be used in a horizontal press; they are not recommended for use in a vertical press; Otherwise, the weight of the entire plate must be lifted.
When only two units are used, the bodies should be mounted on the centerline of the mold for balanced operation. If using more than two assemblies, symmetric positioning of the Jiffy Latch Lok assemblies about the mold centerline is recommended. Balance is critical in so the mold design should be symmetrical. If not, be aware of any binding that may take place.
What size Jiffy Latch-Lok should be used?
The following is based on usage of four Jiffy Latch-Lok assemblies in the mold.
- a) Mold Base Width of 7-7/8 and under use LL-050 assembly
- b) Mold Base Width of 9-7/8 to 14-7/8 use LL-101 assembly
- c) Mold Base Width of 15-7/8 and larger use LL-201 assembly.
Please note that the desired speed for the mold open sequence can affect the recommended size of Jiffy Latch-Lok assembly used. Also, the above mold base sizes consider standard offering for each size. If you are intending to use a special over-sized mold base, and/or if you are intending to use in a high-speed injection machine, it is recommended that either larger or more assemblies (more than four assemblies) be used.
What type of maintenance is recommended for Jiffy Latch-Lok Assemblies?
Lubricate the rockers periodically with a light lubricant such as lithium or oil containing P.T.F.E.
Jiffy Tite FAQs
Can Jiffy-Tite connectors be interchanged with Jiffy Matic connectors?
Yes. Jiffy-Tite connectors should not be interchanged with other brand connectors including other brands sold by DME.
What are the temperature limits and pressure limits for Jiffy-Tite Plugs?
Maximum pressure permitted is 200PSI. The thread sealant supplied with the fittings can withstand temperatures up to 400°F (204°C), however, if running water coolant in your mold, the water coolant temperature should not exceed the regional boiling point of water (typically 100°C or 212°F, but may be lower at higher elevation). If running oil coolant in your mold, it is not recommended to take Jiffy-Tite fittings to a temperature that exceeds 300°F (149°C).
What type of thread in the mold base plate is recommended to be used with the Jiffy-Tite connectors and plugs? How does this thread compare to DME Brass Pressure Plugs (inch type)?
The threads used on the Jiffy-Tite Plugs offered by DME are NPT (National Pipe Thread). The requirements for NPT are defined in ANSI B1.20.1
The threads used on the DME Brass Pressure Plugs (inch type) are NPTF (National Pipe Thread Fuel). The requirements for NPTF are defined in ANSI B1.20.3
It is important to differentiate between the two thread types because they are not the same. In layman terms, the NPTF spec is used with much tighter tolerances, so using an NPTF pressure plug with an NPT thread can reduce the amount of seal. Some customers make up for this using pipe tape and when using pipe tape for any application it is important to use pipe tape that is rated for the intended mold temperatures or environment. However, it is always recommended to use a female thread in the mold plate that is appropriately matched to the intended male thread. If you have further questions regarding the above ANSI specifications, we recommend that you purchase a copy of the specification at an authorized online distributor of ANSI standards. Please note that between the time of posting this information and you obtaining a licensed copy of the standard, the standard may be updated. DME makes no assurance that the standards listed above are current and it is recommended that you check with your authorized distributor of ANSI standards for the latest version of the standards listed above.
What type of thread is used on a Jiffy-Tite Extension Plug (JPB type)?
The threads are NPSM (Straight) threads, and are to be used with new or existing NPT tapered pipe-tapped hole in a mold or die. The straight thread on the extension plug allows for length adjustment.
Leader Pins FAQs
Are the heads of DME Leader Pins welded?
No, the heads of DME Leader Pins are machined.
I notice that you supply metric Leader Pins (or Guide Pins) with collars. What is the collar used for?
The collar is used to align the top clamp plate to the A plate of the mold. This is a common option for metric mold bases in Europe.
When installing my DME Leader Pin, should I use lubricant? Are there any recommendations for installing my DME Leader pin into my mold?
Yes, it is recommended to use a light lubricant such as oil containing P.T.F.E. Some mold makers or service technicians prefer to use grease however it is important to make sure both the grease and the utensil used to apply the grease (i.e., brush) is clean of any metal chips, flakes, or other debris as this form of debris can bind up between the leader pin and the mold during installation, and could cause galling. During installation is also recommended to install your DME leader pin as straight as possible into the leader pin hole, with pressure applied to the top of the leader pin. Striking the leader pin head on an angle can apply additional side loads that could cause galling during installation.
Locating Rings FAQs
Are there installation/machining instructions available for DME Locating Rings?
Not at this time. DME Mold Bases supplied with locating rings are already supplied with locating ring installation bore already machined, unless otherwise requested by the customer. The same applies if you order just a top clamp plate for a specific size of DME Mold base.
When ordering a DME locating ring alone, no installation or machining instructions are provided packaged with the locating ring.
Do you offer metric locating rings?
Yes, in the DME Mold Components catalog. We also offer a “blank” metric locating, through which you can machine the desired machine nozzle clearance hole (Inch-type “blank” locating rings are not available at this time).
How do I modify my mainframe to work on single-phase 240V?
The back panel has a full schematic of where each wire should be attached in the mainframe. The brass terminals have “fast-on” connectors attached to the end of each wire that you need to move according to the schematic on the back panel. You can also consult your user manual the DME catalog.
How often should I calibrate my mainframe?
Your mainframe does not require calibration.
What is the anti-arc clip used for in the mainframe
The clip is used to inhibit the triac from outputting any power until the module is fully inserted into the mainframe. This will assist in preventing arcing of the gold fingers when the controllers are accidentally inserted or removed while the power is turned on. The clip is installed in the 3rd position of each of the white edge connectors in the mainframe. Newer anti-arc equipped modules will not output any power until this anti-arc clip is installed in the mainframe. All mainframes built after January 1999 have this clip already installed in them.
What is the part number for the anti-arc clip used in the mainframe?
DME replacement part number RPM0046 (sold in packs of 20).
What is the replacement part number for the card guides used in my mainframe?
The mainframe uses DME replacement part number RPM0044 for the card guides.
What is the replacement part number for the inserts used in the connectors on the side of my mainframe?
The mainframe uses male inserts for the thermocouple connectors, DME replacement part number RPM0072, and it uses female inserts for the power connectors, DME replacement part number RPM0073.
What is the replacement part numbers for the pins used in the connectors on the side of my mainframe?
The mainframe uses male pins for the thermocouple connections, DME replacement part number PIN0120, and it uses female pins for the power connections, DME replacement part number PIN0214.
Mold Bases and Plates FAQs
For metric mold bases, how are the mold bases shipped?
All metric mold bases are shipped DISSASSEMBLED. This is normal practice in Europe. If you order a complete metric mold base from DME, you or your mold maker are expected to assemble the complete mold base when you receive the shipment.
I cannot find CAD files for the DME X-Series, AX-Series, T-Series, nor for any of the Shuttle Mold Bases offered by DME. Is such CAD data available for download?
At this time, no CAD data is available for download for the X-Series, AX-Series, T-Series, or Shuttle Mold bases offered by DME.
What is the difference between a “US Standard” Mold Base, MoldBasics, and Edge Base?
US Standard mold bases by DME refers to the primary DME mold base offering in the USA and Canada. This standard was developed by DME in the late 1940s and has been an industry standard for over 60 years. Today, this includes A-Series, B-Series, X-Series, AX-Series, and T-Series which may vary in the number of plates used but for the most part, component positions in the X- and Y-axis directions are positioned in the same locations. For this reason, only the A-series plan views are detailed in the DME Mold Bases and Plates catalog.
MoldBasics, and Edge Base are modeled after the US Standard A-Series mold base, with some variations. MoldBasics was offered by DME as an economical form of the A-Series with some reduced or simplified features (although the MoldBasics mold base would be produced with the same exacting standards and quality as a US Standard A-Series mold base). For example, a MoldBasics mold base would not be shipped with finished ground parting line surfaces, and the mold maker would be expected to finish-grind the parting line surfaces.The Edge Mold Base is a unique standard offering, modeled after the US Standard A-series. However some of the features are in different positions versus DME A-Series. Please refer to the appropriate pages in the DME Mold Bases and Plates catalog for details specific to the Edge Mold Base.
Where can I find information on metric mold bases and plates?
All information regarding metric mold bases and plates can be found on the DME Europe website, located at http://www.dmeeu.com. Metric plates are not offered as standard in North America, however can be ordered special for you if you require metric mold bases or plates. There may be a premium charge in the special order. Contact DME Customer Service for more information regarding metric mold bases or metric plates.
Mold Date Inserts FAQs
Are the symbol rings in the dual-ring mold date insert replaceable separately, or must I order a complete assembly?
The dual-ring mold date insert components are not available separately.
Can I use DME mold date inserts in die-casting operations?
The DME dual-ring type (MD-XXXX), the DME Indexable, and DME Front Removable Mold Date Inserts are not to be used in die-casting operations.
Can I use DME mold date inserts with glass-filled applications?
The hardness of the steel is 50-55 HRc which means that glass fibers will wear down the lettering on the inserts at over time, and the amount of wear down will depend on part size, speed of injection, and overall cycle time.
I have a dual ring insert, but the size or length does not match the catalog. Where would I find the proper details?
If you have a mold date insert that has dimensions that do not match what is in the DME Mold Components catalog, then we regret to say that you do not have a genuine DME part. DME also does not offer special mold date inserts. Please check with the company that supplied the part or mold to you.
I have gone online to download CAD files for my mold date inserts, but I do not see the date symbol information on the CAD files. Are there CAD files available with the proper date information?
Not at this time.
What is the maximum operating temperature recommended for a DME Mold Date Insert (Indexable and Dual Ring types)?
The maximum operating temperature for a DME Mold Date Insert (both indexable and dual-ring) is 302°F (150°C).
Mold Springs FAQs
Are there any calculations or recommendations available to assist me with selecting a Mold Spring?
Some customers call in for assistance in selecting mold and die springs offered by DME. We present the following method. If you require additional assistance, please do not hesitate to contact us.
Please note: the terms compression vs. deflection, and force vs. load are used interchangeably in this text.
The general formula for compression springs is
F = L * K where:
F = force or load [lb]L = deflection or compression [in]K = spring constant [lb/in]
Our catalog always lists the force at 1/10” compression, and we will call it DC (DME Constant). This force is actually 10% of standard K spring constant defined in engineering calculations. The Engineering K is the theoretical load at 1” deflection and the DC is the load at 0.1” deflection, so K = 10 * DC
The DME catalog also lists the force at maximum allowable compression. The maximum compression is given as the percentage of the Free Length, although the length and percentage are seemingly inconsistent units.
The force at 0.1” compression is also marked with DC in the attached chart. The 50% Maximum Recommended Deflection means that the spring can be compressed by maximum 50% of the Free Length (we marked as FL in the chart), 30% deflection is when the spring is compressed by 30% of its Free Length. Since the force is proportional to the compression, the Force-Length graph is a straight line.
To better explain the numbers provided in the DME catalog, for example, let’s consider the SMD2030 spring as shown on page 343 in the DME Mold Components catalog:
- Catalog number: SMD2030
From the Catalog:
FL (Free Length) = 7.50 [in]DC = 1.2 [lb] (load at 0.1” deflection) => K = 10 * DC = 12 [lb/in]F50 = 45.0 [lb] (load at 50% deflection)
Let’s double-check the F50 force given in the catalog by calculation:
L50 = 0.5 * FL = 0.5 * 7.5 = 3.75 [in] (50% deflection)This is 3.75 / 0.1 = 37.5 times more than the 0.1 [in] deflection, so the F50 force is 37.5 times larger than the force at 0.1” deflection:
F50 = (0.5 * FL) * K = 3.75 * 12 = 45.0 [lb]
If we want to know the force at a certain (different) deflection, we need to multiply this number with the K spring constant.
For example: What would the load (force) be at 2.65 [in] deflection?
F = 2.65 * K = 2.65 * 12 = 31.8 [lb]
Usually we need a certain Pre-Load in the fully extended position in order to have a minimum force. The basic force calculation is the same as above. If we know the Travel (working compression) plus the Pre-Load, their sum is the Total Compression. The Total Compression should always be less than or equal to the maximum recommended deflection. The Total Compression (which is the Travel plus Pre-Load) divided by the percentage in the catalog gives you the minimum necessary Free Length. If this Free Length is available in the catalog, this is the spring you need to pick. If this calculated minimum Free Length is not available, you need pick the next longer standard Free Length.
Please note that if the calculated forces are acceptable, always try to use longer Free Length springs, so the Total Compression is less than the maximum allowable compression. This increases the useful life of the spring.
Another example (the same spring):
Pre load: 0.125”
Travel (working compression): 3.4”
Spring can be compressed to: max 50% (from the catalog) = 0.5
Total Compression = Pre Load + Travel = 0.125 + 3.40 = 3.525 [in]
3.525 / 0.5 = 7.050 [in] required minimum Free Length => this is not listed in the catalog => pick the next longer standard Free Length spring => 7.5 [in] => Recalculate the actual forces as described above with the K spring constant given in the catalog for the 7.5 [in] Free Length spring.
Performance Core Pins (Beryllium-Free Copper Alloy Core Pins)
Can beryllium-free copper alloy be machined utilizing conventional EDM?
Specific settings must be adhered to when utilizing EDM and beryllium-free copper alloy. Conventional EDM settings that are used for steel will result in high electrode wear and slow cutting. Call DME for specific details.
Can beryllium-free copper alloy be welded?
TIG welding with Argon being the shielding gas works best when welding beryllium-free copper alloy. Brazing, gas welding and silver soldering are not recommended
Can DME Performance Core Pins be used with DME Ejector Sleeves?
DME Ejector Sleeves are designed to be used with DME Ejector Pins only, and are not designed to be used with any DME Core Pin. The OD tolerance of a DME Performance Core Pin is +.0010/-.0000, while the ID tolerance of the sleeve is only +.0005/-.0000. Please use a DME Ejector Pin or Blade in conjunction with a sleeve since the ODs have a negative tolerance.
Can I plate beryllium-free copper alloy?
Yes, many moldmakers will electroless nickel or hard dense chrome plate the pin. Even low temperature applications of titanium nitride coatings as well as Armoloy coatings have been utilized.
Can Performance Core Pins be used with standard steel ejector sleeves?
Many moldmakers use DME standard steel (H-13) Ejector Sleeves (nitrided & not nitrided) in conjunction with our Performance Core Pins which are a beryllium-free copper alloy.
Can PVC be molded against a beryllium-free copper alloy product?
PVC does not attack beryllium-free copper alloy. The material may tarnish under certain conditions. Copper cleaners such as Braso will remove the tarnish. Do not use abrasives to clean the copper alloy.
What are the thermal expansion differences and tolerance issues with Performance Core Pins vs. standard steel core pins?
Performance Core Pins move heat much more rapidly than steel pins. This heat removal is done by conduction. Many times the core pin rests on a chill plate or is in contact with 70-80 degree Fahrenheit water.
The most common problem is interference fit. For example, a .2
0 inch diameter Performance Core Pin has a tolerance applied of +.001/-.000. The corresponding Ejector Sleeve internal diameter (I.D.) has a tolerance of +0005/-.0000. Thus, the sleeve I.D. could be .0005 larger than the pin O.D. (outside diameter) or the pin could be .001 larger than the sleeve I.D.! This is a situation where galling will occur. Thus, the internal diameter of the ejector sleeve must be honed to accept the Performance Core Pin.
At operating temperature the desired sliding fit between the two dissimilar materials should be .001/.0015. Beryllium-free copper alloy has a coefficient of thermal expansion of .0000097in./in./degree Fahrenheit. H-13 steel has a coefficient of thermal expansion of .0000058in./in./ degree Fahrenheit. This thermal expansion difference of the materials means the copper alloy will expand at a greater rate than the steel. The coefficient of thermal expansion must be considered when designing molds with materials that expand at different rates. Consideration to the cavity and core material expansion rates must also be considered.
The plastic material shrinkage rate is another consideration when the copper alloy core pin is used in the mold. Shrink rates are typically reduced when copper alloy pins are used. One must ensure that the bearing length between the core pin and the ejector sleeve is not excessive. A general rule of thumb is that the bearing length should be 2 to 2-1/2 times the diameter of the core pin.
NOTE: When the bearing length approaches one inch, problems may result from excessive bearing length.
In conclusion, pay special attention to the working diameter tolerance of the copper alloy pin and the internal diameter tolerance of the ejector sleeve when grinding your pins to size. Remember a copper alloy pin conducts heat out of the steel and the copper alloy pin expands. Please note that the copper alloy pin will expand at even a greater rate when utilized in an environment of the 400º - 700º Fahrenheit range. You can always warm up your copper pin to the desired temperature and measure its thermal expansion. This can be done with or without being installed in an ejector sleeve.
I am interested in a D-MaxHot Sprue Bushing, but I want to process glass-filled thermoplastic. Can I do this?
It may be possible depending on the thermoplastic and application. If you require a recommendation, please contact your DME Customer Service Representative, who will put you in contact with a DME Technical Service Representative who will review your application requirements.
I can order CIH heaters for the DME Hot One nozzle assembly, but not for the D-Max Hot Sprue Bushing assemblies. Why can’t I order a CIH heater for my D-Max Hot Sprue Bushing assembly?
CIH heaters are not available at this time for the D-Max Hot Sprue Bushing product family.
I would like some information on servicing or installing my D-Max Hot Sprue Bushing assembly. Where can I find that information?
The necessary information is located in the “Resources” section of the DME Website, under “Packing Slips”, and can be found here. If you have a question that is not covered by the product packing slip/installation instruction, please contact your DME Customer Service Representative for assistance.
I would like to build my own hot runner system using D-Max nozzles, but I only see a hot sprue bushing option. Are D-Max nozzles available for placing under a manifold?
At this time, D-Max is available as hot sprue bushings only. You would order DME Hot One nozzle assemblies to place under a hot runner manifold. DME Hot One nozzle assemblies (for placing under a manifold) can be found at the following link here.
I would like to download CAD files from the DME website for the D-Max Hot Sprue Bushings, but when I go to the CAD Library section of the DME Website (PARTSolutions), I do not see the CAD download data. Where can I find the data that I need?
The CAD download data is currently directly linked to the part number information shown in the DME Hot Runner online digital catalog. The D-Max catalog pages can be found here.
I would like to relieve or reduce the amount of land contact between the seal off diameter of the nozzle tip and the surrounding mold steel. Where can I find instructions for this?
Please contact your DME Customer Service Representative, who will put you in contact with a DME Technical Service Representative to review your application with you. Because the amount that may be relieved from the seal-off diameter of a D-Max ring gate retainer, extended ring gate retainer or sprue gate tip depends on the intended application, no standard instructions are posted at this time. Do not modify or relieve the seal-off diameter of a D-Max point gate retainer.
On the main body of the bushing, there is both an external thermocouple as well as a thermocouple that is integral to the heater. Which thermocouple am I supposed to use?
For the head zone, use the thermocouple that is integral to the heater. For the main body heater, it is recommended to use the external thermocouple, and only use the thermocouple which is integral to the main body heater, as a back-up should the external thermocouple fail.
Sometimes I see a grey wire and purple wire with a D-Max nozzle heater. What wires are those?
The wires with purple or grey color wire insulator are power wires. Typically, a D-Max heater that has a specific thermocouple color code set, will be delivered with power leads that have a different color, or have an identifying strip, mark or heat shrink to help identify the power leads. Please note that if the power leads were identified by a strip, mark, or heat shrink and the leads are cut, the identifying strip, mark, or heat shrink will be removed. In such cases it is recommended to add marker tape to each power lead for ease of future maintenance.
What is the processing temperature upper limit that I can use with my D-Max Hot Sprue Bushing?
It depends on the application, as well as both the bushing assembly and the tip or tip assembly used. The D-Max unheated head hot sprue bushing assemblies are not recommended to be used with applications requiring greater than 480°F (249°C) melt processing temperature. If you have an application that exceeds 480°F (249°C) melt processing temperature, it is recommended to use a D-Max hot sprue bushing assembly with heated head.
The D-Max ring-gate and point-gate tip assemblies are available with standard needles as well as wear-resistant needles. Standard D-Max needles are not recommended to be used with any filled thermoplastic, and are not recommended to be used in applications that require greater than 480°F (249°C) melt processing temperature. Wear-resistant D-Max needles can be used with filled thermoplastics (not recommended for thermoplastics that have greater than 30% filler including glass, mineral, talc, other), and are not recommended to be used in applications requiring greater than 635°F (335°C) melt processing temperature.
D-Max sprue tips can be used with filled thermoplastics (not recommended for thermoplastics that have greater than 30% filler including glass, mineral, talc, other) and are not recommended to be used in applications requiring greater than 635°F (335°C) melt processing temperature.
If you have an application that requires greater than 635°F (335°C) melt processing temperature, if the intended thermoplastic has greater than 30% filler, or if you would like a recommendation as to the parts best suited for your intended application, please contact your DME Customer Service Representative and you will be put in contact with a DME Technical Service Representative to review your application requirements.
What is the upper limit injection pressure that I can use with my D-Max Hot Sprue Bushing assembly?
The D-Max Hot Sprue Bushing assembly is not to be used in applications that exceed 20000 PSI injection pressure. However please note that if you are approaching 20000 PSI injection pressure, the injection processing window for a typical injection molding machine will most likely become significantly reduced, which may affect your ability to mold good parts. In such cases it is recommended to refer to your injection molding machine specifications or to speak to a technical representative for the manufacture of your injection molding machine.
What types of nozzle heaters are available for order as replacement items for a D-Max Hot Sprue Bushing assembly?
The “RBP”-type heaters used on the nozzle bodies.
All suggested replacement items for any D-Max Hot Sprue Bushing assembly are shown in the associated packing slip/installation instruction. The D-Max packing slips are located in the “Resources” section of the DME Website, under “Packing Slips”, and can be found here.
D-Max HSB, Polivalve FAQs
I see a wire that is green with yellow tracer. Is that the ground wire?
Yes. If a ground wire is present, the ground wire lead color may be either be solid green, or green with a tracer.
I see a wire that is green with yellow tracer. Is that the ground wire?
Yes. If a ground wire is present, the ground wire lead color may be either be solid green, or green with a tracer.
I am interested in a DME Valve Gate Hot Runner System from DME, but I want to process glass-filled thermoplastic. Can I do this?
It may be possible depending on the thermoplastic and application. Please contact your DME Customer Service Representative, who will put you in contact with a DME Technical Service Representative who will review your application requirements.
I would like some information on servicing or installing my DME Valve Gate hot runner system. Where can I find that information?
At this time there are no packing slips or installation instructions available for download from the “Resources” section of the DME Website. Please contact your DME Customer Service Representative for assistance, who will put you in touch with a DME Technical Service Representative.
I would like to build my own hot runner system using DME valve gate nozzles and cylinder assemblies. Can I do this?
In general, Polivalve hot runner nozzle, components, and cylinder components are not available for building your own valve gate hot runner system. We do offer a Unitized “drop-in” system.
I would like to order a single drop valve gate system. Is this available?
DME can offer pneumatic valve gate hot runner systems for single cavity molds. Please contact your DME Customer Service Representative who will put you in contact with a DME Technical Service Representative to review your application.
I would like to relieve or reduce the amount of land contact between the seal off diameter of the nozzle tip and the surrounding mold steel. Where can I find instructions for this?
Please contact your DME Customer Service Representative, who will put you in contact with a DME Technical Service Representative to review your application with you. Because the amount that may be relieved from the seal-off diameter for a full-body or extended full-body tip depends on the intended application, no standard instructions are posted at this time. Do not modify or relieve the seal-offdiameter of a DME bodiless or high-performance bodiless tip.
Sometimes I see a grey wire and purple wire with a Polivalve nozzle heater. What wires are those?
The wires with purple or grey color wire insulator are power wires. Typically a Polivalve heater that has a specific thermocouple color code set, will be delivered with power leads that have a different color, or have an identifying strip, mark, or heat shrink to help identify the power leads. Please note that if the power leads were identified by a strip, mark ,or heat shrink and the leads are cut, the identifying strip, mark, or heat shrink will be removed. In such case s it is recommended to add marker tape to each power lead for ease of future maintenance.
What is the benefit or advantage to using a tapered valve pin shut off versus a cylindrical or “straight” valve pin shut off in a DME hot runner system? I notice that DME offers both styles.
DME offers both styles of valve pin shut-off, as different customers have different preferences. DME recommends cylindrical valve pin shut-off if possible.
What is the processing temperature upper limit that I can use with my DME Valve Gate Hot Runner System?
It typically depends on the application, as well as the tip or tip assembly used. All potential DME Valve Gate applications are reviewed by the DME Technical Service team for feasibility.
When using a high performance bodiless tip with standard conductive capsule, do not use with filled thermoplastics or with applications requiring more than 480°F (249°C) melt processing temperature.
When using a high performance bodiless tip with wear-resistant conductive capsule, filled thermoplastic applications are possible depending on the application (not recommended for filled thermoplastics that have more than 30% filler including glass, talc, mineral, other). Not recommended for applications that require greater than 635°F (335°C) melt processing temperature.
When using a regular bodiless tip, filled thermoplastic applications are possible depending on the application (not recommended for filled thermoplastics that have more than 30% filler including glass, talc, mineral, other). Not recommended for applications that require greater than 635°F (335°C) melt processing temperature.
When using a full body tip or extended full body tip, filled thermoplastic applications are possible depending on the application (not recommended for filled thermoplastics that have more than 30% filler including glass, talc, mineral, other). Not recommended for applications that require greater than 635°F (335°C) melt processing temperature.
In all cases, if you have an application requiring a valve gate that exceeds the recommended upper processing temperature or if you have an application requiring a valve gate that exceeds 30% filler, please contact your DME Customer Service Representative, and you will be put in contact with a DME Technical Service Representative to review your application requirements.
What is the upper limit injection pressure that I can use with my DME Valve Gate Hot Runner system?
The DME Valve Gate Hot Runner System is not to be used in applications that exceed 20000 PSI injection pressure. However please note that if you are approaching 20000 PSI injection pressure, the injection processing window for a typical injection molding machine will most likely become significantly reduced, which may affect your ability to mold good parts. In such cases it is recommended to refer to your injection molding machine specifications or to speak to a technical representative for the manufacture of your injection molding machine.
What types of nozzle heaters are available for order as replacement items for a DME Valve Gate hot runner system?
The embedded heaters are used on the nozzle bodies. All suggested replacement items for any DME Valve Gate hot runner system will be listed on the system drawings delivered with the hot runner system.
Recycling Inserts FAQs
I have downloaded CAD geometry for a DME Recycling insert, but the CAD file does not show the desired symbol. Where can I find DME Recycling Insert CAD geometry that have the symbols that I wish to see in my mold design?
Unfortunately the CAD files for the DME US Offering do not have the symbols included at this time and we are working to add these features. The CAD files are correct for the size of the insert.
Returning Items FAQs
What is DME’s return policy?
All returned items require a Return Merchandise Authorization (RMA) number from DME. Returns are subject to a quality inspection to validate whether it can be returned to inventory.
- Mold bases, plates and special components are non-returnable items
- Items returned to DME without prior authorization (RMA) may be returned to sender
- Items returned for stated defect or non-conforming reason require detailed explanation
- No products are returnable beyond 30 days after receipt
- Contact DME for more information:
DME U.S. – 800-626-6653 DME Canada – 800-387-6600 Worldwide – 248-398-6000 Email – [email protected]
Runner Shut Offs FAQs
Can I disassemble my Runner Shut-Off for repair?
Can I use a regular (Steel) screw driver to turn my DME Runner Shut Off?
We recommend that a brass rod be used with one end of the brass rod modified to be similar to the tip end of a flat screw driver. This will reduce opportunities to damage or scratch the runner flow channel in the DME Runner Shut Off.
How critical is the press-fit for the hole installation into a mold?
The press-fit tolerances shown both in the DME Mold Components Catalog as well as in the documentation supplied with the packaged product is very important because too loose of a press fit could allow the insert to move out of position, while too tight of a press fit might prevent the center core from rotating when required.
What is the maximum mold temperature recommended to be used when there are DME Runner Shut Off?
The maximum recommended mold temperature is about 250°F (120°C).
Where can I find installation specifications?
There are installation sizes and tolerances shown in the DME Mold Components Catalog, as well as instructions are provided with the packaged product. If you would like an electronic copy of the instructions, please contact us.
When my quote says my request has a 5-day delivery, does that mean it will take 5 days to get here?
No, the specified delivery is the number of days it will take to complete the work on your request and be ready to ship.
Stack Molds and Other DME Multi-Parting Line Systems FAQs
What does DME offer regarding systems that increase productivity by reducing labor, capital investment, floor space, and time?
- Stack Molds
- Helical Gear (pre-engineered design assemblies and standard off-the-shelf components)
- Injection molding presses specifically designed for MPL systems (in collaboration with Milacron)
- Design Services – design assistance or complete system design
- View animations of the DME Stack Mold Helical Gear Systems.
Are the Edge Mold plates milled together?
The cavity plates are milled together. All other plates are added to the assembly as needed.
Can DME test steel for defects?
Yes, DME can ultrasonically test for voids, cracks and other defects. The size of your plate will determine your cost. Please contact Customer Service for a quote.
Can I have my #7 Stainless Steel plate heat treated?
No, we do not recommend having your #7 Stainless Steel heat treated to a higher RC. It should be left at standard 32-37RC.
How does DME square up a mold base?
Square Milling, it is more accurate and faster than square grinding.
Will DME produce a special Mold base or Unit die with special features?
Yes. Please provide a drawing that details the desired features and we will review. If feasible and economical, DME will provide a quote. Please be aware that in some cases, DME may ask a customer sign a waiver as we will not be able to guarantee longevity of product depending on the special feature requested.
I am attempting to assemble a Stellar nozzle body and the parts appear to be different than what is shown in the Stellar MNA design guides. Where can I find information regarding the components that I currently have?
The Stellar hot runner system has undergone continuous improvement over time to better meet the needs of our customers. Please contact your DME Customer Service Representative for assistance.
I am building my own hot runner manifold using Stellar nozzle assemblies that are threaded into an MNA manifold. Do I need a wire channel, or can I just lay the nozzle heater and thermocouple wires in the manifold pocket or even over the manifold?
Stellar nozzle heaters and nozzle thermocouples are designed to be “Front load”, meaning that provided the mold is designed to accommodate front load heaters and thermocouples, you do not have to remove the mold from the injection press in order to replace a Stellar nozzle heater or nozzle thermocouple. For this reason we recommend that a wire channel on the parting line side of the nozzle retainer plate be used to capture and route all the nozzle heater wire leads and nozzle thermocouple wire leads over to the electrical connectors or electrical box for the mold. This will increase the longevity of the nozzle heater and nozzle thermocouples.
It is recommended to keep the nozzle heater lead wires and nozzle thermocouple lead wires as far away from the manifold as possible. It is not recommended to capture and route the Stellar nozzle heater lead wires or the Stellar nozzle thermocouple lead wires inside a wire channel that is located in the manifold pocket in the nozzle retainer plate. Do not drape the Stellar nozzle heater lead wires or the Stellar nozzle thermocouple lead wires over the manifold. Do not lay the lead wires at the bottom of the manifold pocketin the nozzle retainer plate.
I notice that some Stellar nozzles use a retaining ring to retain the nozzle heater, while other heaters do not. Why is that?
When using the Stellar sprue tip, a retaining ring is used to retain the nozzle heater. This would apply regardless if using a standard or high-performance heater. Other Stellar tip styles currently offered by DME do not use a retaining ring to retain the nozzle heater. For more detail, please refer to the MNA (round or rectangular) design manuals here, or contact your DME Customer Service Representative for assistance.
I would like a nozzle assembly that will fit into a space that is smaller than the gate detail or heater clearance hole size that is shown in the Stellar MNA design guide books. Does DME offer anything that will fit my requirement?
We do have options to fit into smaller spaces. Please contact your DME Customer Service Representative, and you will be put in contact with a technical representative that review your application requirements with you.
I would like some information on servicing or installing my Stellar hot runner system. Where can I find that information?
The necessary information is located in the “Resources” section of the DME Website, under “Packing Slips”, and can be found here. Also, design manuals for the Stellar pre-engineered manifold assemblies (“MNA”) in both rectangular and round styles, are available for download from the DME Website and can be found here. If you have a question that is not covered by the product packing slip/installation instruction or by the design manuals, please contact your DME Customer Service Representative for assistance.
I would like to build my own hot runner system but would like to use compression-style Stellar nozzle bodies. Can I do this?
The Stellar compression-style hot runner system is available as a package system designed by DME Applications Engineering. Only the threaded-head configurations of the nozzle assemblies are available for ordering off the shelf to build your own hot runner system. For more information, please refer to the MNA (round or rectangular) design manuals here, or contact your DME Customer Service Representative for assistance.
I would like to perform frequent color changes. Do I require a gate shell insulator for each Stellar nozzle assembly?
Gate shell insulators are not used with the Stellar hot runner nozzle product line.
I would like to relieve or reduce the amount of land contact between the seal off diameter of the nozzle tip and the surrounding mold steel. Where can I find instructions for this?
It is not recommended to modify the seal-off diameter any Stellar nozzle tip or tip retainer. It is possible to modify the leading face of a Stellar Sprue tip, however if you are not familiar with what to do, it is recommended that you contact your DME Customer Service Representative first, who will put you in contact with a DME Technical Service Representative to review your application with you. No standard instructions are posted at this time.
What does “MEN” mean?
An “MEN” is an abbreviation for “Manifold Extension Nozzle”, which mates the injection machine barreltip to the DME hot runner manifold. “MEN” is common nomenclature for all DME hot runner systems, including Stellar hot runner systems. Another common name is “nozzle seat” which is another term for an “unheated” MEN. Nozzle seats or “unheated” MENs are not used with the Stellar “MNA” hot runner system product line (all MENs used with Stellar MNA hot runner systems, are “heated”).
Please note, some hot runner manufacturers will refer to an MEN as a “Sprue bushing”. At DME, Sprue Bushings are different products and are not heated (do not have a separate heat source). DME Sprue Bushings are shown in the DME Mold Components Catalog.
What does “MNA” mean?
The Stellar Hot Runner system product line includes optional standard manifolds designed to be used specifically with the threaded-style Stellar nozzle assemblies (nozzle assemblies are “threaded” into the manifold). One of these manifolds would be referred to as an “MNA” (plural = “MNAs”). An MNA is an abbreviation for “Manifold Nozzle Assembly”. When you order a Stellar MNA system, you are ordering the manifold, manifold components, manifold extension nozzle (“MEN”), nozzle assemblies and tip assemblies. It is not uncommon for a customer to refer to the Stellar standard manifold itself as an “MNA” but in reality that is a misnomer. For more information on Stellar MNAs, please refer to the MNA (round or rectangular) design manuals here, or contact your DME Customer Service Representative for assistance.
What is the processing temperature upper limit that I can use with my Stellar Hot Runner system? Can I process filled thermoplastic with a Stellar Hot Runner system?
It depends on the application, as well as both the tip type and heater used.
When attempting to process thermoplastics that require greater than 525°F (274°C) processing temperature, the “High-Performance” Stellar heater is recommended. Some customers have success using standard Stellar heaters in applications that require greater than 525°F (274°C) processing temperature.
The Stellar standard point tip is not to be used with any filled thermoplastic, and is not recommended to be used in applications that require greater than 480°F (249°C) melt processing temperature. Stellar standard point tips are used with a threaded retainer, which retains the tip to the nozzle body assembly. The Stellar wear-resistant point or through-hole tips can be used with filled or unfilled thermoplastic (not recommended for applications exceeding 30% filler including glass, talc, mineral, other), and are not recommended to be used in applications that require greater than 635°F (335°C) melt processing temperature. Stellar wear-resistant npoint or through-hole tips are used with a threaded retainer, which retains the tip to the nozzle body assembly.
The Stellar sprue tip can be used with filled or unfilled thermoplastics (not recommended for applications exceeding 30% filler including glass, talc, mineral, other) and is not recommended to be used in applications that require greater than 635°F (335°C) melt processing temperature. Stellar sprue tips are threaded and are not used with an additional threaded retainer, when assembling to the nozzle assembly. For more information, please refer to the MNA (round or rectangular) design manuals here, or, contact your DME Customer Service Representative for assistance.
If you are interested in using a Stellar hot runner system to processing thermoplastic that has a melt temperature that exceeds 635°F (335°C), or that has filler that exceeds 30%, or if you have questions as to what is appropriate for your intended application, it is recommended that you contact your DME Customer Service Representative, who will put you in contact with a DME Technical Service Representative to review your applications requirements.
What is the upper limit injection pressure that I can use with my Stellar Hot Runner system?
The Stellar Hot Runner system is not to be used in applications that exceed 20000 PSI injection pressure. However please note that if you are approaching 20000 PSI injection pressure, the injection processing window for a typical injection molding machine will most likely become significantly reduced, which may affect your ability to mold good parts. In such cases it is recommended to refer to your injection molding machine specifications or to speak to a technical representative for the manufacture of your injection molding machine.
What types of nozzle heaters are available with a Stellar hot runner system?
Currently there are two types of nozzle heaters currently available for the Stellar hot runner system product line: Standard and High-Performance. Standard heaters are commonly used to process commodity-grade thermoplastic applications, while High-Performance heaters are commonly used to process “engineered-grade” thermoplastics that typically have more demanding process requirements. Depending on your application, it may be possible to use standard Stellar heaters to process certain engineered-grade thermoplastics. For guidance on what is recommended for your application, please contact your DME Customer Service Representative, who will put you in contact with a DME Technical Service Representative to review your application requirements.
Sintered Vents FAQs
Can DME Sintered Vents be used with Die Casting?
We do not recommend using DME Sintered Vents in die casting operations, because once clogged with metal, the vents cannot be cleaned. For Die Casting, we recommend that DME Chill Vents be used instead.
I cannot fit a DME Sintered Vent in my desired vent location. Can you recommend alternatives to the DME Sintered Vent in such situations?
The alternative to the DME Sintered Vent is a custom vent installed by the mold maker. Mold makers can create a vent by grinding a flat on an ejector pin, or use a hand grinder to create a groove or slit vent along the parting line of the mold. The disadvantages of these methods are: Non-uniformity of the vents and the vents cannot be easily replaced if they are damaged, the vents must be instead remachined. The use of standard vents is a much more cost-effective method of venting a mold.
I have downloaded CAD files from the DME Website for a DME Sintered Vent, but I do not see the pores on the CAD part. Can I obtain a CAD file that shows the full geometry?
Not at this time.
I would like to mold Urethane, and I would like to use a DME Sintered Vent in the mold. What DME Sintered Vent should I use?
Urethane tends to be very sticky and could potentially clog sintered vent pores very quickly. Some customers have had success using sintered vents with molding Urethane, and some other customers have not had success molding Urethane using sintered vents. Furthermore, not all Urethanes are made equal and some grades could clog a sintered vent faster than other grades. As a general rule we do not recommend using sintered vents with molding Urethane due to the gases and residues emitted. Instead we recommend that you machine a custom vent in the mold at the end of the flow front.
What are possible symptoms of insufficient venting in my mold?
Symptoms of insufficient venting in a plastic injection mold may include burning of a plastic part or a short shot. Symptoms in die casting typically present themselves as defective parts due to trapped air or gas.
Where can I find details regarding recommended pore size versus resin?
Please refer to the DME Mold Components catalog as we give application recommendations there. Please be aware that these are general suggested guidelines, and actual performance can vary with the specific grade and viscosity of the resin intended to be processed. If you need more specific information, or need to know at what pore size will a particular resin type or grade will pass through, please contact your resin supplier for information. Be prepared to specify the desired pore size that you are considering, as well as provide estimated processing parameters including estimated peak injection pressure.
Where can I find information regarding recommended cleaning agents for cleaning my DME Sintered Vents?
Cleaning agents will depend on the type of plastic being molded. We ask that you contact your resin manufacturer or supplier and ask for recommended cleaning agent that is appropriate for removing the type of plastic that you are molding from the sintered vent pore size. When cleaning, it is recommended to use the appropriate cleaning agent with an ultrasonic bath.
Where can I find recommended installation specifications for my DME Sintered Vent?
Recommended installation and tolerances are given in the DME Mold Components Catalog. The vent is tapped into the installation hole with a plastic or wooden hammer. Use of a metal hammer or other hard tool is not recommended due to chipping or clogging that might occur in the vent.
Where is the best place to place a DME Sintered Vent in my mold?
Sintered Vents are usually installed in the mold location that is last to fill. This is typically the point at which the plastic can burn due to trapped gas associated with high temperature and pressures.
Sprue Bushings FAQs
I would like to modify my DME Sprue Bushing. What is permitted and how hard is the sprue bushing material?
DME offers a few types of Sprue Bushings: “A” series, “B” series, “U” series, “UV” Series, “LN” Series, “AR” series, “UR” series, “L” series and Performance Sprue Bushings. All but the Performance Sprue Bushings are made from steel with a base hardness of 43-45 HRc, and the “LN” series has an additional surface treatment that brings the surface hardness up to about 60-62 HRc.
The Performance Sprue Bushings are made from a copper alloy and have an additional hardened 420 Stainless steel insert. The “PSB” type Performance Sprue Bushings are directly replaceable with the existing DME “B” Series Sprue Bushings. The “PSU” type Performance Sprue Bushings are directly replaceable with the existing DME “U” Series Sprue Bushings.
Note: If you order a sprue bushing separate from your mold base, it is important to check the fit of the sprue bushing OD to your mold base OD. In some cases mold makers will need to open up the sprue bushing hole in the mold base and fit to suit. A tight tolerance of no more than 0.0004 inches clearance across the two mating diameters is recommended, as some resins will flash past 0.0005 inches clearance.
When ordering a complete mold base from DME, customers must specify if the sprue bushing is to be installed (normally the sprue bushing is shipped with the mold base but not installed). If requesting to ship the mold base with the sprue bushing installed, DME will ensure a proper fit between the sprue bushing and the mold base plates.
If it is not requested by a customer to have the sprue bushing installed into the mold base, the sprue bushing will be shipped in the crate not installed, and the mold maker will need to check the fit between the sprue bushing and mold base plates and may have to modify as described above.
Most modifications are made to the front face of the sprue bushing as mold makers add a runner channel.
Note: That the distance from the underside of the sprue bushing head to the front of the sprue bushing (at the molding surface) is slightly oversized relative to standard plate thicknesses provided by DME. If the it is requested (when ordering a complete DME Mold Base) to have the sprue bushing installed, the front of the sprue bushing will be ground to ensure proper fit. However, when ordering a sprue bushing separate, mold makers are expected to perform this secondary operation.
Straight Shots FAQs
Does DME sell band heaters for the DME Straight Shot or High Performance Straight Shot?
DME does not sell any band heaters for the Straight Shot or High Performance Straight Shot.
I am retrofitting a mold with a Straight Shot bushing assembly, and I need a different body length than what is offered as standard. Can I have a special bushing length made by DME?
It is recommended against using bushing lengths that differ from standard offering as the nozzle and/or bushing heaters have been developed over many years, and special orders could increase both product price and delivery time required. It is recommended to use the next longer length (if available) and use a spacer plate behind the A-plate to make up the required difference. Please note that if a special nozzle length is required, it may not be possible to order a special nozzle length depending on the requirement. In such cases, please contact your DME Customer Service Representative for assistance.
I plan to use a T-Series Straight Shot Hot Sprue bushing. Is it possible to have the bushing flush with the back of the mold such that it does not stick out of the back of the mold?
Yes, it is possible, but you will need to modify the bushing. You would modify the parting-line side face of the larger outer diameter of the bushing, and machine back to ensure the back of the bushing body does not protrude past the locating ring. Please note that you cannot machine the front tip-end face of the bushing back, meaning that you will have a thicker stripper plate.
Optionally you can use an ER-Series (Short Style) Straight Shot Bushing, machine back the parting line face of the larger outer diameter of the bushing as described above, and you will need to add the taper to the front of the bushing body to match with the internal taper of the replacement stripper bushing.
Please note:1. Customers are required to machine the taper onto a T-series or TR-Series Straight Shot Hot Sprue Bushing body, in order to match with the internal taper of the replacement stripper bushing. The taper at the tip end of the T-Series Straight Shot Hot Sprue bushing is not delivered in a pre-machined format.
2. The S-Series, E-Series (long style), ER-Series (long style), T-Series and TR-Series Straight Shot Hot Sprue Bushings have a 0.31 inch diameter flow channel. The E-Series (short style) and the ER-Series (short style) Straight Shot Hot Sprue Bushings have a 0.25 inch diameter flow channel. Care must be taken when using a short-style E or ER-Series Straight Shot Hot Sprue bushing to replace a T or TR-Series Straight Shot Hot Sprue bushing, as the flow channel sizes are different.
I would like some information on servicing or installing my Straight Shot or High Performance Straight Shot Hot Sprue Bushing Assembly. Where can I find that information?
The necessary information is located in the “Resources” section of the DME Website, under “Packing Slips”, and can be found here.
I would like to gate into a dimple. Can this be done?
It may be possible depending on intended application. Please contact your DME Customer Service Representative for assistance. Examples of permissible modifications are given in the DME Catalog.
I would like to mold parts out of glass-filled PB T using a High Performance Straight Shot. Is this ok?
Some customers have had success processing both filled and/or engineered grade thermoplastics using the High Performance Straight Shot Hot Sprue Bushigs. The success is largely based on the application. When intending to process engineered or filled thermoplastics through a DME single-drop bushing, it is recommended to use a heated-head D-Max Hot Sprue Bushing. Please contact your DME Customer Service Representative, and you will be put in touch with a Technical Service Representative who can help you select an appropriate product for your application.
In the DME Hot Runner Catalog, I see a “typical application” drawing of a T-Series Straight Shot bushing, and there appears to be a key that holds the bushing in place. Is this key required, and where can I find details on it?
We do recommend that you “key” the bushing in place, however the size and shape of the key depends on your preferred mold design. The key slot would be added to the body core in the same manner as shown in the DME Catalog, and this key slot cannot be more than ¼ inches (6.35 mm) into the bushing body. It is recommended that the key be at least 1/8 of an inch thick, and be made from hardened tool steel.
What angle does the heater rigid cable exit the back of the High Performance Straight Shot Hot Sprue Bushing assemblies?
The High Performance Straight Shot Hot Sprue Bushing assembly heater has a rigid cable exit that is oriented 5 degrees off the centerline or center axis of the bushing assembly. The other Straight Shot Hot Sprue Bushing assemblies have an option of either 5 degrees as described, or 90 degrees off of the center axis. An example is shown in the DME Hot Runner Catalog for the regular Straight Shot Hot Sprue Bushing assemblies.
Please note: do not attempt to bend the rigid cable exit on either the Straight Shot or High Performance Straight Shot heaters.
What kind of Straight Shot Hot Sprue Bushing is recommended for processing engineered grade materials?
Standard Straight Shots are to be used for commodity resin applications only. Only the High Performance Straight Shot Hot Sprue Bushing may be used with select engineered resin applications. If you are uncertain, please call us and ask to speak to a DME Hot Runner Technical Service Representative for recommendations as to what DME Hot Runner product is most appropriate for your intended molding application.
What material type is used for the High Performance Straight Shot Hot Sprue Bushing tips?
A wear-resistant material is used because of the higher processing temperatures and filled materials that may be used with the High Performance Straight Shot Hot Sprue Bushing.>
Support Pillars FAQs
I am trying to determine how many DME Support Pillars that I require in my mold. How do I do this?
When building larger molds, including hot runner molds, some mold makers may choose to build using rails and pillars instead of cutting a manifold pocket out of a single plate. Regardless of what is chosen, enough force distribution is required to keep the two halves of a plastic injection mold closed during injection. The more you reduce in terms of number of pillars, size of pillars and even distribution of pillars, the more you can introduce load imbalance into your mold plates. If the plates are not thick enough, this can also lead to bowing of the plates and flashing of the parting line faces. Put simply, if you do not have mold design best practices at your disposal then it is recommended to consult an experienced mold shop or to use computer-aided simulation software to examine the estimated forces acting on your mold as well as the stresses within your mold. From there, you can determine if more support pillars are needed to better distribute, balance and transmit loads from the injection machine platen to the parting line face of the mold.
Threadless Pressure Plugs FAQs
Can the DME Threadless Pressure Plug be used with oil or glycol?
Yes, but do not exceed the maximum pressure and temperature limits.
What is the maximum temperature and pressure limit recommended for the DME Threadless Brass Pressure Plug (inch type)?
The maximum pressure permitted is 72 PSI. The maximum temperature permitted for the component 300°F (149°C), however if running water, it is not recommended to take the temperature of the water cooling over 90% of water boiling temperature specific to your geographical region (water boiling temperature varies with air pressure, and air pressure varies with geographic elevation).
WARNING: If you are running water cooling and manage to boil the cooling water, steam is generated which can cause scalds or burns.
Three Plate Extension Bushings FAQs
What is intended to interface with the back of the three-plate extension bushing assembly (in the spherical radius area)?
The injection machine nozzle tip. Be sure to choose a machine injection nozzle tip with an appropriately-sized spherical radius to match properly with the spherical radius that is located at the back of the 3-plate extension bushing assembly. Also, it is important to size the exit orifice of the injection machine nozzle tip to match the inlet diameter of the sprue in the 3-plate extension nozzle assembly.
Where can I find recommended installation instructions for the 3-plate extension bushings?
Machining and installation information is provided in the DME Mold Bases and Plates catalog. Additional installation instructions are provided packaged with the components. If you would like an electronic copy of the instructions, please contact us.
I notice that some thermocouples have a different color code scheme than others. What do the different color code sets mean?
Note: The following applies to thermocouples (or heaters with integral thermocouples) sold out of the DME USA Hot Runner Catalog. It does not apply to heaters or thermocouples sold out of the DME Molding Supply Catalog.
DME has taken steps to meet the growing needs of our customers around the world. One of these steps has been to progress to an “International” thermocouple color code per IEC 584-3 (Black = positive, White.
Up to the recent past, most DME thermocouples (or heaters that have integral thermocouples) have had a color code based on the ASTM E230 standard, in which the positive thermocouple wire lead (magnetic) has a white color insulation, and the negative thermocouple lead has a red color insulation. This is traditionally common in North America:
Please note that some products will continue to have the ASTM E230 standard color code (White=positive, Red = negative).
Both color codes shown above are correct. It will be important to ensure proper wire up of the thermocouple. If the thermocouple is wired up backwards (polarity of the thermocouple is reversed), the thermocouple will fail to give the temperature controller a correctly interpretable signal. For clarity, the following color code chart may be used:
-J type therm standards.jpg
Toggle-Lok Positive Early Ejector Return FAQs
Are the Bermer Early Return and the Toggle-Lok the same?
Yes. This device was obtained from Bermer Tool and Die.
Does DME manufacture specials of the Toggle-Lok?
Unfortunately, DME does not manufacture special sizes of the Toggle-Lok. However, the DME Mold Components Catalog has several pages devoted to component sizing so that customers may manufacture their own special sizes to suit specific needs.
Does the Toggle-Lok use springs?
No. The Toggle-Lok is an externally mounted device used to positively return the ejector assembly before the mold closes. It does not utilize springs. Instead, it uses a positive cam linkage and actuator lever rather than springs, hydraulics, or pneumatics.
Vector Form Lifter Systems FAQs
What does DME offer that will efficiently assist in the molding of parts with undercuts?
Among its line of products that are effective in the molding of parts with undercuts, DME offers the popular VectorForm Lifter System. This product can be used with angles ranging from 5º (minimum) to 30º and beyond. The VectorForm Lifter System maximizes design flexibility and provides off-the-shelf installation for most lifter applications. Learn more about the VectorForm Lifter System and view an animation at www.dme.net/vectorform.
Vortex Core Pins and Plugs FAQs
Can Porcerax II be heat treated to a higher hardness than provided?
Yes, Porcerax II can be heat treated to 50 52 HRC maximum.
Does DME offer cleaning of the Porcerax II?
Yes, we offer a 1-3 day turnaround for an ultrasonic cleaning process in a proprietary solution. Based on the resin to be cleaned out, different solutions may be used.
Does DME offer Vortex products in larger inserts as a special?
Yes. As a special item, DME can quote your requirement for Vortex cavity inserts. Contact DME at 1-800-626-6653.
How long does it take to clean Porcerax II?
It depends on what you are trying to clean out of the Porcerax II. For EDM oil or water, you can put the Porcerax II in an oven at least 250 degrees F and that will evaporate the water and make the oil more viscous. This will eventually cause the oil to leak out of the material.
For resins, it depends on type of resin and how contaminated the pores are. I advise you check with your resin supplier for the recommendation on the best solvent to use to break down the resin.
How often should I clean the Vortex Core Pins or Plugs?
As an approximate guideline, for Engineering resins you should clean the Porcerax II® every 15k-20k shots. For Commodity resins you should clean the Porcerax II® every 25k-30k shots.
Additionally, it is a good idea to view the surface pores under a digital microscope over the life of the Porcerax II® insert. Follow the cleaning instructions in the Application Guide for Vortex Core Pins & Plugs found on the DME website under Resources/Application Guides.
How thick should I go when designing my Porcerax II insert application?
Thickness of the Porcerax II insert is very important for a couple of reasons. First, you want a thick enough part that will withstand injection pressure. If you go too thin you run the risk of cracking the material. The material has a base hardness of 30‐40 HRC and can withstand most of the variables regarding injection molding. Second, by using a piece of Porcerax II that is large enough to put in a drilled and tapped hole for an NPT fitting, you allow the Porcerax II material to be cleaned much easier. After the solvent has cleaned most of the trapped materials in the pores, place your NPT fitting in the Porcerax II material, plug it into your shop air, and let it blow through the Porcerax II material.
Should I keep spare Porcerax II products on hand?
It is advisable to have spare sets of the Vortex Core Pins or Plugs so you can install them while you have your previous products cleaned.
What about materials with flame retardants like ABS?
Due to the fact flame retardants emit more gas than regular polymers, they require more frequent cleanings. A good way to provide for cleaning Porcerax II® is to have a blow back system in place in the mold, so that as the mold opens to eject the part, reverse the air flow and have a blast of air go through the Porcerax II® into the cavity. This accomplishes two things: First, it will help aid with the ejection of the part, and second, it will help purge any film that might build up on the Porcerax II® from the flame retardants.
What is the maximum temperature of Porcerax II? What is the recommended way to re‐open the pores of Vortex pins & plugs after machining?
Do not take Porcerax II over 800 Degree F.
What size pore should I use for my resin?
Depending on the emissions or gas residue given off during molding, the molder may have to evaluate whether to use a 7 or 20 micron pore size. Resins such as ABS, polypropylene, soft PVC, polyethylene, acrylic, polyurethane, and polystyrene work very well with a 7 micron (.0003") pore size. For low viscosity or talc filled resins, it may be necessary to have an automated system reverse the airflow after each shot to purge the impurities from the pores. NOTE: Rigid PVC resins will work with limited success until the corrosive gases close the pores. This can still be a feasible method if disposable Porcerax II® inserts are used. Please note the 20 micron pore size (.0008") will vent about 25% more gas than the 7 micron pore size.
Your literature states that polishing to an 800‐1000 grit finish opens the pores for a 7 micron insert. What can we do to achieve the airflow we require?
You can polish Porcerax II to an 800‐1000 grit finish for the 7 micron and 400‐600 grit finish for the 20 micron.
However, you need to blow air, 40 to 60 psi, back through the Porcerax II along with wearing a mask and eye protection, while you are polishing the Porcerax II to push out the grit and compound that is being forced down into the pores during polishing. You then need to clean the Porcerax II several times, using Acetone in an ultrasonic cleaner and blow Acetone back through the Porcerax II in the opposite direction of the venting air flow several times at 80 to 100 psi. (NOTE: It is important the Porcerax II be cooled to room temperature before ultrasonic cleaning.)
Use proper safety guidelines when doing this. Acetone only breaks down the lubricants that were used. Acetone will not affect the grit and compound. Using the blow back air during polishing will push the grit and compound out during the polishing. To try and open your pores you can try and do the cleaning of the Porcerax II as mentioned above. If this does not work, you will need to EDM the surface down to get below the clogged pores and then polish as discussed above. After polishing, clean again. If your location is not permitted to use Acetone, then find a solvent that will breakdown the lubricants that were used during machining.
Wear Plates FAQs
Can I use two DME Bronze-Plated Wear Plates in mold with the two plates rubbing against each other?
This is not recommended (having the two plates rub against each other). The material that wears against the bronze-plated wear plate should be different and have a higher hardness than the bronze plating. It is recommended to have at least 6-8 HRc hardness points difference (higher) in the material that is intended to rub against the bronze-plated wear plate, versus the surface hardness of the bronze-plated wear plate itself.
I run a clean-room facility. What kind of residue can I expect a DME wear plate to leave?
Material: Copper and tin. In such cases it is recommended to place the wear plate as far as possible from the cavity. Use grease or lubricant oil to reduce wear.
I want to drill holes in a self-lubricated wear plate. How can I find out the graphite insert locations?
Please contact DME Engineering for assistance. You will need to provide your specific part number.
Is there an upper temperature limit for the bronze-plated wear plates, ways, and gibs?
The bronze-plated wear plates, ways and gibs can be used into working temperatures of up to 400°F (204°C).
What are the bronze-plated wear plates, ways, and gibs made from, and do you have any recommendations for lubrication?
Bronze-plated wear plates, ways and gibs are made from low carbon, extra-fine grain steel electroplated with a bronze alloy. The hardness of the bronze is about 180 Bhn minimum (for hardness conversion charts, please refer to the DME Mold Bases and Plates catalog). The bronze plating has a natural lubricity and is ideal when used against hardened steel. We recommend any good grade of light machine oil suitable for machine way applications to extend the life of the wear surface.
What is the coefficient of friction for your bronze-plated wear plates, ways, and gibs?
Self-lubricating wear plates are made from an aluminum-bronze alloy and have oil-impregnated graphite plugs.
What is the difference between the bronze-plated wear plates and the self-lubricated wear-plates?
Self-lubricating wear plates are made from an aluminum-bronze alloy and have oil-impregnated graphite plugs.
What is the maximum pressure that can be applied to the DME bronze-plated wear plates?
2700 PSI (pounds per square inch).
When should bronze plated wear plates be replaced?
After 0.003 inches (about 0.076 mm) of maximum wear.