CAEDSMouldDesign

Ejectorpinsandsleeves
SchoolofTechnologyandManagement,PolytechnicInstituteofLeiria

Introduction

The mould base comprises the majority of the bulk of an injection mould. Standard

offtheshelf mould bases are available for most moulding needs. Typical moulds

bases are outfitted with a locating ring and provisions for a sprue bushing in the

stationaryhalf(cavity)[Link]
halves come with clamp slots to affix the mould in the press. The moving half has
holes to accommodate bars that connect the press ejection mechanism to the ejector
[Link](guidepins)projectingfromcornersofthestationary
[Link]
from the mould face when the ejection mechanism is in the forward (eject) position.
Asthemouldcloses,thereturnpinsretracttheejectorplate(ifnotretractedalready)
inpreparationforthenextcycle.

At the most basic level, moulds consist of two main parts: the cavity and core. The
[Link]
[Link],thecoreandcavityseparateasthemouldopens,sothatthepart
can be removed. This mould separation occurs along the interface known as the
[Link]
feature such as the part top, bottom or centerline, or it can be stepped or angled to
accommodate irregular part features. Choose the partingline location to minimize
[Link]
avoided via reasonable adjustments in the parting line require mechanisms (Slide
Mechanisms)inthemouldtodisengagetheundercutpriortoejection.

When plastics products and their respective moulds are designed, the location of
ejectors is important to ensure proper stripping from the core. By selecting suitable
ejector components the visual appearance of the products can be considerably influ
enced, but it is even more important that the mould performance becomes more
[Link]
CADStandardElementsSoftware(CADLibrary).Thoseitemsalreadysuitablecanbe
selectedeasilyduringtheproductdesignstage.
This document is focused on the design, material, assembling and operation of ejec
tionsystems.

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Typically, moulds have ejector systems built into the moving half (see following Ejectionsystems
figure).Ejectortravelmustbesufficienttoclearthemouldingfromfixedmembersin
the mould. Undercuts or pickup ribs may be machined into mould members to

[Link]
[Link]
[Link]
ejectorbarmustcontainpushbacksorsafetyreturnpinstorepositiontheejectorpins
priortothestartoftheinjectionormouldfillingcycle.

Figure1 Componentsofastandardtwoplatemouldbaseejectionsystemsmountedonstatic
halfofthemould
The ejection unit of the moulding press activates these systems. Rods linking the
pressejectormechanismtoanejectorplateinthemouldenablethepresscontrollerto
controlthetiming,speed,[Link]
ejectpartsfromthestationarysideofthemouldviaindependentejectionmechanisms
[Link]
[Link]
injection moulds adds to the mould cost. Specialized ejection components, such as
knockout (KO) pins, KO sleeves, or stripper plates, project from the mould ejector
platetothepartsurfacewheretheypushthepartoutofthemould.
Manyfactorsdeterminetheamountofejectorareaneeded,includingthepartgeome
try,mouldfinish,materialreleasecharacteristics,andparttemperatureatthetimeof
[Link],thinwalledpartsgenerallyrequirelarger
ejectorsandgreaterejectorareathancomparablepartswiththickerwalls.
Draw polishing the mould steel in the direction of ejection generally helps ejection.
Thermoplastic polyurethanes, exceptions to this rule, usually eject more easily from
mouldswithfrostedfinishesthatlimitplastictometalcontacttopeaksinthemould
texture.
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CAEDSMouldDesign
Careful consideration is essential to decisions concerning the number and area of Ejectorpins
ejectors to be used and the type of system to be employed for the various types of
materials. It must be understood that, in most cases, the part being ejected may, to

somedegree,[Link],
mouldingpartsareejectedwhentheyarejustsufficientlyhardtopreventdistortion
andinmanycases,themoulditselfisheatedtoachievemaximumfeasibletempera
ture at ejection. The following figure illustrates desirable knockout pin locations for
softmaterialssuchaspolyethylene.

Circularpart

Square part

Rectangular part

Figure2 [Link]
arepreferableejectorpinlocationsforsoftflexibleplastics.
Ejectionmarksmaybestyledintothepartwhendesirablebyaddingdesignconfigu
ration in these areas. This is accomplished by decorating or adding a series of
concentricringsontheejectorpinsurface.
A summary of standardised ejector pins and sleeves is shown in the table on next
page. They are available in two steel grades: (1) tool steel, throughhardened with a
hardness of ~60HRc, and (2) hot work steel, with a core strength of ~45HRc and a
nitridedsurfaceof~[Link]
ontheshaft,andonlytheforgedheadisdark,[Link]
ingonthenitridingtreatment,[Link]
thatundergothebathnitridingprocess(Tenifertreatment)showthetypicaldullgray
[Link],e.g.,indiecastingmolds,thistypeofsurfaceismost
suitable,[Link]
[Link]
these pins are subsequently treated by a special sulfating process to obtain a visual
[Link]
bright surface, but the same mechanical properties apply as for Tenifertreated ejec
tors. Because a certain amount of wear on ejectors can never be avoided, for a new
[Link],
[Link]
dards offer oversize ejectors. Remachining of nitrided pins and sleeves in the radial
directionisnotrecommended,becausethiswouldremovethe~0.1mmthicknitrided
[Link].

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CAEDSMouldDesign
Ejector sleeves are of excellent help in ejecting complex areas of mouldings without
[Link]
same steel grades as ejector pins. For special applications, stepped sleeves are also
available as standards. For long ejectors, extension rods (Figure) can be applied to
provide stability to thin pins and sleeves. They fit standard ejector components and
eliminatetheneedforexpensivecustommadeoversizeitems.

Figure3 Extensionforinjectorpinsandsleeves:1)screwcap;2)extension;3)lookingtab;4)
groove;5)ejectorsleeve
Onthebasisofresistancetobuckling,acertainmaximumdiametertolengthratiohas
been established for all ejectors; therefore, suitable ejector pins with small diameters
[Link],andwhenejectors
are worn, only the standard ejector, which is mounted to the sturdy rod (2) with a
screw cap (1), needs to be replaced. A locking tab (3) pressed into the groove (4)
preventslooseningofthescrewcap(1).Forusewithejectorsleeves(5),theextension
[Link],theboreinthe
screwcapmustbemachinedtosuittheshaftdiameterdofthepinorsleeve.
Forspecialejectionapplicationsunderthinribsorextremelynarrowcontours,blade
ejectorsareavailable.

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CAEDSMouldDesign

Table1. Summaryofstandardejectorpinsandsleeves
Drawing

Designation
Standard

2D

3D

Ejectorpin
with
cylindrical
head
DIN1530A
ISO6751

HotWorkSteel
1.2343

Nitrided950
HV0.3
Corestrength
1400n/mm2

Toolsteel
1.2516

Through
hardened
602HRc

Shouldered
ejectorpin
with
cylindrical
head
DIN1530C
ISO8694

HotWorkSteel
1.2343

Nitrided950
HV0.3
Corestrength
1400n/mm2

Toolsteel
1.2516

Through
hardened
602HRc

Ejectorpin
withconical
head
DIN1530D

HotWorkSteel
1.2343

Nitrided950
HV0.3
Corestrength
1400n/mm2

Toolsteel
1.2516

Through
hardened
602HRc

HotWorkSteel
1.2343

Nitrided950
HV0.3
Corestrength
1400n/mm2

Toolsteel
1.2516

Through
hardened
602HRc

HotWorkSteel
1.2343

Nitrided950
HV0.3
Corestrength
1400n/mm2

Toolsteel
1.2516

Through
hardened
602HRc

Bladeejector
DIN1530F
ISO8693

Hardness

Material

Ejectorpinsdesign
andmaterial

Ejectorsleeve
DIN16756
ISO8405

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CAEDSMouldDesign

Figure4 Specialbladeejectorexample:1)ejectorblade;2)guidebushing;3)guideshellhalves;

4)splitguide

The very thin ejector blade (1) is solidly held by the guide bushing (2) and is sup

ported along its entire length by the guide shell halves (3). This design prevents

[Link],asplitguidebushingis

available,[Link]

thebladeslotthroughthecavityblockcanthusbeeliminated.

Ejectionmovement

Figure5 Assemblyexampleofejectorpins.

Undercuts, part features that prevent straight ejection at the parting line, tend to Mouldingand
increase mould complexity and lead to higher mould construction and maintenance ejectingpartswith
[Link],redesigntheparttoavoidundercuts.
undercutsslide
Minor part design changes can often eliminate problematic undercuts in the mould. mechanisms
For example, adding throughholes can give access to the underside of features that
would otherwise be undercuts. Undercut features that cannot be avoided through
redesign require mechanisms in the mould to facilitate ejection. These types of
mechanisms include sideaction slides, lifter rails, jiggler pins, collapsible cores and
[Link].
Sideaction slides use cam pins or hydraulic (or pneumatic) cylinders to retract por
[Link]
(see following figure). As the mould closes, the cam pins return the slides to their
[Link]
cylinderscanactivateatanytimeduringthemouldingcycle,anadvantageinapplica
tionsrequiringtheslidestoactuatepriortomouldopeningorclosing.

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CAEDSMouldDesign

Slidemechanisms

a)

b)

c)

d)

e)

f)

g)

Figure6 Slidemechani[Link]
noncirculargeometriesd)e)motionactivatedbyspringsf)interiorslidemechanismg)motion

activatedbyhydraulicorpneumaticsystems.

Shallowundercutscanoftenbeformedbyspringloadedliftersorlifterrailsattached
to the ejector system. These lifters move with the part on an angle during mould
opening (see following figure a) or ejection until the lifter clears the undercut in the
part. A variation on this idea, the jiggler pin (see following figure b), has angled
surfacestoguidethepinawayfromtheundercutduringejection,thenreturnittothe
mouldingpositionastheejectorsystemretracts.

Lifterrails

Afterejection

Beforeejection
Beforeejection

Afterejection

a)

b)

Figure7 Lifterrailsattachedtotheejectorsystem:a)angledlifters;b)lifterrailwithangled
surfaces.
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CAEDSMouldDesign
Lifterrails
Example

a)
b)

Figure8 Realexampleoflifterrailsattachedtotheejectorsystem:a)angledlifters;b)lifterrail

withangledsurfaces.(CourtesyofaPortuguesemouldmakingcompany)

Featuressuchasinternalthreads,dimples,slots,orgroovesontheinsideofholesor Collapsiblecores
capsmayrequirecollapsiblecores.

Figure9 Plasticfeaturesthatmayrequirecollapsiblecores.
These complex cores are made in segments that collapse toward the centre as they
retract during mould opening (see following figure). As soon as the inner core is
retracted, the segments move inward, thereby releasing the product. Setting up of
moulds is easy, because adjusting the collapsible cores is done during mould con
[Link]
hardenedandreadytouse,exceptforthegrindingoftherequiredthreadsorunder
cuts.

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CAEDSMouldDesign

Beforeejection
Cavity

Coreplatealignment
Ejectionplate

Afterejection

a)
b)

Beforeejection

Figure10

Afterejection

Collapsiblecoresforexternalmouldingofpartsurfaces.

a)

Expanded

Collapsed

b)

Figure11
Collapsiblecoresforinteriormouldingofpartsurfaces:a)schemeofassem
blingandoperationofananteriorcollapsiblecore;b)collapsiblecore.

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CAEDSMouldDesign
Smallsizecoresaresuppliedwithsegmentsseparatedfromeachotherbyfixedribs.
Consequently,undercutsonthemoulding,e.g.,threads,alsoshowaninterruptionon
[Link]
thecore,anditissuggestedthatanairblowoffbeused;inaddition,infraredsafety
[Link]
able in a variety of standard sizes from various mouldcomponent suppliers, these
specialty cores are typically modified to produce the desired undercut shape. The
number and complexity of individual core components limit the minimum size of
collapsible cores. Collapsible cores are rarely used for inside diameters less than 16
mm.

Using the same operation principle of both, lifters and collapsible cores, with the Flexiblecores

flexiblecoreconceptsmallundercutscanbeeasilyreleased.

a)
b)

Figure12
Flexiblecores:a)operating;b)examplesofseveraldifferentgeometries

Forproductswithinternalthreads,specialconsiderationsarerequiredwhendesign
ing the unscrewing mechanism. A variety of devices can drive the rotation of the
threaded cores, including rackandpinion devices actuated by mould opening (fol
lowingfigurea),motors,orhydrauliccylinders(followingfiguresbandc);ormotor
drivengearandchainmechanisms.

Unscrewing
mechanisms

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CAEDSMouldDesign

Activatedbypiston

a)

b)

c)

Figure13
Applicationofunscrewingdrivecomponents:a)activationcomponents
usinghydraulicor,pneumaticactivatedpistons;b)activationofrotationusingthemould
movement;c)actuationofrotationusingthehydraulicmachineejector.
Themoulddesignshouldincludeprovisionstolubricatethevariousmovingpartsof
the unscrewing mechanism. Slides, cams, collapsible cores, and unscrewing mecha
nismsaddtothecostandcomplexityofthemould,aswellasthemouldmaintenance
cost. It would be of advantage to integrate the unscrewing drive into the mould,
wheretherotationisinitiatedbyaleadscrewdrivenbythemouldopeningmotion.
Whenthemouldisinstalled,onlyaspecifiedopeningstrokeneedstobeset;therefore,
suchunscrewingmouldsarealsoverysuitableforautomaticmouldchanging.
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CAEDSMouldDesign
In some injected parts the ejection must be done using, accelerated ejector pins. The Acceleratedejector
application of these systems turns possible, both the ejection of some undercut fea pins

turesandtheejectioninoneorientateddirection.

[Link]

nally the system has a rack and rotates the wheel that gives an advance to the

extractorpinassembled(followingfigurea).Theaccelerationofthecentralejectorpin

[Link]

cation of these kinds of systems can avoid the intervention of a human or robot to

removethepartfromthemould.

a)

b)

c)

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CAEDSMouldDesign

Standardejectionaccelerators(onleft)andexampleofapplicationand
Figure14

operation(onright)

The following figureshows a systemfor accelerating ejection developed bya Portu

guesemouldmakingcompany.

Figure15
Customisedsystemforacceleratingtheejection.

Thereleaseoflargeboxtypeshapesorsimilarproductsissubstantiallyassistedwith Airassisted
theuseofairpoppetvalvesorejectionpinspressurizedwithair..Ejectiondifficulties ejection
can arise if a vacuum forms between the part and mould during ejection. Typically,
thisdifficultydevelopsindeeplycored,[Link]
asairpoppetvalves(seefigure)[Link]
the vacuum and deliver pressurized air between the part and mould surface during
ejection. The air poppet valves are built into the cores of the injection moulds. The
springloadedconicalseatispushedforwardbytheapplicationofcompressedairat
the same time as ejection starts. In some cases it is even sufficient for the poppet to
open by itself during ejection to break the vacuum. Air poppet valves are mounted
[Link],auxiliarytoolssuchas
counter bores and reamers are available. Appropriate devices and fittings for air
supplyareofferedbythesuppliersofthesestandardcomponents.

d)

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CAEDSMouldDesign

a)

b)

c)

Airpressure

Figure16
Ejectionsystemsassistedbyairpressure:a)Airpuppetvalves(left)and
operation(right);b)Ejectionpinsassistedbyairpressure(left)andoperation(right);c)
exampleofamouldwithanairpuppetvalve.

Ejectorpinsandsleeves14

CAEDSMouldDesign
Designsrequiringthinwallsorareaswhichhaveundercutsontheinteriorrequireone
stage of ejection to remove the parts from the cams or the mould force forming the
inner feature design and the second stage to remove the part from the mould. This
double system permits the part to be freely ejected from the mould. This design
maybe used for all materials. It is illustrated by the following figures. The ejection
motion of the machine is automatically subdivided into two stepless adjustable
strokes. The return travel is performed with either the hydraulic machine ejector
or/and,incaseofmechanicaloperation,thereturnpinsofthemould.

Core

Sliding
sleeve

Ejectorpin

Latchlockingdevice

Ejectionmotionofmouldopening

Ejectionmotionofthehydraulic
systems of the machine

Core

Sliding
sleeve

Ejectorpin

Figure17

TwoStageejection:concept(left)andapplicationexample(right).

Twostageejection

Twostage ejection can be supported by the application of latches devices (see last Latchesdevices
figure) however, latches are often used on injection molds with two mold parting

[Link] ontheoutsideofthe
[Link],onepartinglevelopensfirst;aftertravelingaprede
termined distance, the locking mechanism of the latch is released and the second
[Link]
platemoldsinwhichonepartinglevelmustopenforthesprueandrunnersandthe
[Link]
a latch unit is shown in the following figure a). A hinged latch bar remains in its
[Link]
themouldisclosed,[Link]
tionofthisspringmustbecheckedwhenassemblingthisunit.

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CAEDSMouldDesign
Another design of a latching unit is shown in following figure b). Both the housing
[Link]
latch bar on the movable mould half and the control bar on the fixed half. During
mould opening, parting plane I opens first, until the slope S of the control bar (2)
disengagestheslidinglock(3).[Link]
pulledplateistobelimitedinthisposition,e.g.,[Link]
the slope corresponds to the minimum stroke of the latchlocking unit. In this area,
onlylow
Duringmouldopeningmovement,ifthereisanothermotionwithinthemouldbefore
the opening of parting plane I starts, a third parting plane must be provided as re
quired. In this case the latch bar travels the delayed stroke Hv before the actual
hookingstarts.

a)

b)

c)

Figure18
Standardlatchpullers:a)latchpullerwithslidehingedlatchbar;b)Latch
device;c)Latchlickingunitandoperatingsequence:I,II,IIIMouldpartinglines1Latchbar
2Controlbar3SlidingboltSSlopeHvLostmotion
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CAEDSMouldDesign
Althoughtheabovementionedlatchingunitsaremountedfromtheoutside,thereare Frictionpuller
[Link]
calledfrictionpullersmaybeusedtoadvantageformediumpullingforcesandwhere
positioning accuracy is not important. They transmit axial forces through friction
between a plastic sleeve and the bore wall. The friction force is infinitely adjustable
withatapered,[Link]
threeplatemolds;theycanalsobeusedasabraketoslowdownamotionorasa
[Link]
be limited in the direction of pulling, e.g., by shoulder screws. Note that when the
mouldisbeingclosed,themouldprotectionmechanismofthemachineisaffectedby
[Link].

Figure19

Frictionpuller

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CAEDSMouldDesign

References
Moldmakinghandbook,[Link],2ndedition,Hanser/GardnerPublish
ing,Inc.,ISBN1569902615,1998
Moldengineering,HerbertRees,Hanser/GardnerPublications,Inc.,ISBN156990131
7,1995
UnderstandinginjectionMoldDesign,HerbertRees,HanserPublishers,ISBN1

569903115,2001
Injectionmolds:108provendesigns,HansGastrow,[Link],
2ndeditionrevisedwithnewmolddesigns,HanserPublishers,ISBN3446156828

,1993
Howtomakeinjectionmolds,GeorgMenges,WalterMichaeliePaulMohren,3rded.,
Munich:Hanser,ISBN3446212566,2001
Plasticsmoldengineeringhandbook,JohnHarryDubois(Author),[Link]
ble(Editor),KluwerAcademicPub;4thedition,ISBN0442218974,1987
EngineeringPolymers,partandmolddesignadesignguide,BayerCorporation,
Pittsburgh,2000
HASCO,DMEandCUMSAelectroniccatalogues

Ejectorpinsandsleeves18