+86 17727725162 jqj014950@topstarltd.com

Home / Relationship between mold material thickness and mold temperature controller settings

Relationship between mold material thickness and mold temperature controller settings

2025/05/07 By Topstar

When injection molding, mold temperature controllers ensure consistent part quality and cycle times. A critical but often overlooked factor is the thickness of the mold material itself. Mold material thickness directly affects the heat transfer rate, with thicker mold sections storing more heat and dissipating it more slowly, while thinner mold sections heat and cool faster. Therefore, we must adjust the mold temperature controller settings based on mold material thickness to optimize temperature uniformity and prevent warping.

This how-to guide will share the specific adjustments required for different mold thicknesses – temperature setpoints, coolant flow, heating power, and PID adjustments. These settings are adjusted to achieve tight temperature control of the mold surface during injection molding.

Mold Temperature Controller: Adjusting Temperature Setpoints Based on Mold Thickness Variations

The first parameter to consider when setting up a mold temperature controller for different mold thicknesses is the temperature setpoint. Thicker mold parts have a larger thermal mass and therefore require higher set temperatures or longer preheat times to achieve thermal equilibrium. For a mold component that is 80 mm thick, the operator may need to increase the set point by 5-10°C above the recommended nominal temperature for thinner parts. Conversely, thinner molds, such as 20-30 mm, heat up quickly; setting the temperature too high may result in overheating, localized thermal gradients, and potential thermal damage to the mold steel.

We recommend performing multiple in-depth thermal analyses when setting up the mould temperature controller. Sensor data can indicate whether the operator needs to adjust the set point in stages—first by increasing the temperature to preheat the core, then by decreasing it to maintain a steady state. This enables differentiated control of different thicknesses throughout the mold.

thickness of mold materials in injection molding

Optimizing Coolant Flow for Thick Molds

In addition to set point adjustments, thick mold sections require increased coolant flow from the mold temperature controller to remove excess heat during the cooling phase effectively. Coolant channels in thick mold plates must handle higher volumetric flow rates, typically 20-30% higher than those in thin molds. Inadequate flow rates result in extended cooling times and uneven temperature distribution, exacerbating cycle inefficiencies and part warpage.

Consider tubing size and pump capacity when setting up a mold temperature controller. For molds thicker than 60 mm, upgrade to larger diameter hoses (e.g., 3/4-inch to 1-inch) and high-flow pumps to deliver up to 10 L/min per cooling circuit. Some mold temperature controllers feature automatic flow control that adjusts pump speed based on temperature differential feedback, ensuring optimal coolant delivery without manual intervention.

Increase heating power for faster temperature ramps.

Thick molds require increased heating power from the mold temperature controller to reach the setpoint temperature within a practical preheat window. For example, a 15-kW heater may be sufficient for a thin mold, but a 30-kW system may be required for a 100-mm steel block. The mold may never reach optimal operating temperature without adequate power, resulting in poor melt flow and incomplete cavity filling.

Calculate the required power density to configure a mold temperature controller for thick molds. Ensure you appropriately size and evenly distribute cartridge or oil-jacketed heaters to avoid hot spots. Topstar’s mold temperature controllers offer programmable ramp rates for a fast full-power preheat phase and a reduced-power hold to maintain thermal equilibrium. This strategy minimizes preheat time while maintaining system life and energy efficiency.

PID Tuning of Mold Temperature Controllers for Thermal Response

The effectiveness of any mold temperature controller depends on accurate PID tuning. Thick molds respond more slowly to control inputs due to their greater thermal inertia. Standard PID settings optimized for thin molds often result in overshoots or longer-lasting temperature swings when applied to thick-walled sections. To accommodate slow thermal dynamics, operators should adjust PID gains: reduce proportional gain to avoid overcorrection; extend integral time to prevent saturation; and set derivative term to a moderate value to dampen oscillations.

mould-temperature-controller-15-12

Topstar’s intelligent mold temperature controllers include an auto-tuning algorithm that identifies the best PID parameters based on the mold’s response curve. When dealing with thick molds, the controller’s auto-tuning feature can be enabled during a test cycle to measure thermal hysteresis and iteratively optimize the control loop. Proper PID tuning ensures that the mold temperature controller maintains the setpoint within ±0.5°C, providing consistent part quality and reducing scrap rates caused by temperature-induced process fluctuations.

Mastering Temperature Control

The relationship between mold material thickness and mold temperature controller settings is multifaceted: temperature setpoints must be aligned with thermal mass, coolant flow must be adjusted to dissipate heat effectively, heating power must be calibrated for fast warm-up, and PID loops must be tuned for slow response dynamics. By following these principles, manufacturers can ensure uniform mold temperatures, reduce cycle times, and deliver consistent part quality.

Prev: How to solve the problem of inaccurate positioning of linear robots?

Next: How does an all electric injection molding machine address Short-Shot Defects in Medical bottle Caps？

TRENDING POSTS

HOT TOPIC

Get A Quick Quote