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Home / Servo-driven injection molding machine for easier connector demolding: 20% increase in ejector thrust

Servo-driven injection molding machine for easier connector demolding: 20% increase in ejector thrust

2025/12/08 By le zhan

Injection molding of connectors and plug-in products 1-2

A consumer electronics miniature connector manufacturer found that their existing hydraulic injection molding machine couldn’t generate enough stable ejection force to eject high-precision USB-C connectors smoothly. 12% of their monthly production was scrap—parts stuck in the mold, pins bent, shells cracked—due to either a malfunctioning ejection mechanism or excessive ejection force. Clearly, this was due to insufficient ejection thrust from their injection molding machine. After selecting a Topstar servo-driven injection molding machine, the ejection thrust increased by 20% compared to the standard model, allowing the connector to be cleanly and precisely ejected while avoiding damage. Therefore, we will tell you how Topstar’s servo-driven injection molding machine solved the biggest demolding problem.

The Problem of Connector Demolding in Injection Molding

Connectors and plug-in products are among the most demanding in injection molding applications—they are small, complex, and require extremely tight tolerances. The design of these products makes demolding a significant challenge: thin walls easily adhere to the mold surface, locking mechanisms require overlocking, and there are fragile parts such as pins or terminals. However, most manufacturers, when purchasing a injection molding machine, often focus only on injection speed or clamping force, neglecting the performance of the ejector, the final and most critical step in the production process.

Our market research found that 52% of manufacturers cited demolding issues as their most significant pain point in production, ranking above machine downtime and material waste. Traditional machines account for 78% of demolding failures, with hydraulic ejectors providing inconsistent thrust, either peaking prematurely or rapidly diminishing mid-stroke. The problem isn’t just about thrust, but also about control. Connectors require “just the right” ejector performance: sufficient thrust to remove parts from the mold, yet with a smooth, adjustable speed to avoid impact damage.

The Problem of Connector Demolding in Injection Molding

Topstar’s Servo-Driven Injection Molding Machine: 20% Increased Ejection Thrust

Topstar’s TMⅡ servo-driven injection molding machines come standard with a 20% upgrade in ejection thrust. This isn’t just about increased power, but more importantly, about controllable power.

First, we upgraded the existing motor to a high-torque servo motor and a precision helical gear transmission, reducing energy loss by 12%. The direct result is a jump in ejection thrust from 5000 Newtons to 6000 Newtons on our 300-ton machine—enough to handle glass fiber reinforced nylon connectors.

However, without stability, mere thrust is meaningless. Therefore, our TMⅡ servo-driven injection molding machine employs closed-loop feedback, with over 10 sensors monitoring the ejector’s position, speed, and thrust 1000 times per second, adjusting the servo motor in real time. This means that each cycle delivers precisely the thrust you set—no more deviations. This 20% upgrade also shortens cycle time. Because the servo motor can accelerate and decelerate smoothly, eliminating the “jerkiness” typical in hydraulic systems, the ejector stroke is faster.

Servo-Driven Injection Molding Machine 2-2

Features Designed Specifically for Connector Injection Molding

We not only increased the ejection thrust by 20%, but also incorporated three features designed and optimized for specific connector challenges.

  1. Adjustable Ejection Speed

Connectors come in a wide variety—from miniature 2mm board-to-board connectors to rugged industrial plugs. Topstar’s servo-driven injection molding machines allow you to adjust the ejection speed from 0.1 mm/s to 150 mm/s.

  1. Multi-Stage Ejection Profiles

Many connectors have undercuts, requiring a two-step ejection process: first, a gentle pull to release the undercut, then a complete ejection to pop the part out. This servo-driven injection molding machine stores over 100 custom ejection profiles—you can program the first stage to release the undercut and then the second stage to complete it.

  1. Mold Protection Sensor

Even with perfect thrust, a contaminated mold or a deformed part can cause jamming. Our servo-driven injection molding machine has a built-in mold protection function: if the ejector encounters resistance 10% higher than expected, it immediately reverses and stops the cycle, alerting the operator via the human-machine interface (HMI) screen.

Case Studies of Connector Production Using a Servo-Driven Injection Molding Machine

While data is essential, real-world customer case studies better demonstrate how a 20% increase in ejection force can fundamentally transform production operations. Below are three case studies from Topstar customers, covering the consumer electronics, automotive, and medical connector sectors.

Case Study 1: Consumer Electronics

Challenge: Due to unstable ejection force, the scrap rate for USB-C connectors reached 12%; mold disassembly was required 2-3 times per week. Solution: Topstar TMⅡ300T servo-driven injection molding machine. Results: Scrap rate reduced to 3%; no mold disassembly required; cycle time reduced by 0.6 seconds.

Case Study 2: Automotive Industry

Challenge: Glass fiber-reinforced nylon automotive pin headers got stuck in the mold, resulting in an 8% scrap rate and 1-hour delays per jam. Solution: Topstar TMⅡ300T servo-driven injection molding machine. Results: Scrap rate reduced to 0.5%; output increased by 22%.

Case Study 3: Medical Industry

Challenge: A 2mm-precision medical connector broke during ejection; inconsistent manufacturing processes raised concerns about FDA approval. Solution: Topstar TMⅡ200 servo-driven injection molding machine with a multi-stage ejection mechanism. Results: Scrap rate reduced to 0.8%; consistent process data met FDA standards.

Injection molding of consumer electronics connectors and plug-in products

The key to connector injection molding lies in precise ejection thrust

Smaller parts, tighter tolerances, faster production speeds, and lower costs. Traditional injection molding machines cannot meet these demands, trapped in a vicious cycle of scrap, delays, and mold damage. Topstar’s servo-driven injection molding machine, with 20% more ejection thrust, effectively solves this problem. It allows the injection molding machine to focus more on the most critical step: cleanly, quickly, and reliably removing parts from the mold.

 

 

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