Sensor-based efficiency gains for injection molders

Reliable and accurate sensors are the foundation for effective process monitoring in injection molding. Measuring where the process actually takes place is the key to detecting the process condition with maximum transparency. That's why our philosophy is to record the decisive process variables of pressure and temperature directly in the injection molding tool. You can immediately see possible deviations from the ideal state in the process curves, so you can reliably predict the quality of the molded part – shot by shot. Your benefits:

Efficient and targeted setup phase for new tools
Minimum time and effort for tool startup
Reliable monitoring of the process
Highly informative individual documentation for each manufactured part

To deliver these advantages, we offer a wide selection of sensors that meet the specific requirements for your processes and tools in every detail.

A unique portfolio of sensors for use in the injection mold

Kistler offers a wide range of sensors to match different applications, mold designs and special requirements such as high temperatures.

The 6183D cavity pressure sensor for direct measuring has a very compact design with a front diameter of only 1 mm.

What makes Kistler sensors special?

Learn about sensor location, and explore other interesting topics around the Kistler sensor portfolio

Sensor selection

Kistler offers a wide range of sensors for monitoring injection molding processes.

Kistler offers a wide range of different sensors – but selection of the right sensor is simple, because it is essentially based on the installation conditions in the mold. Piezoelectric measurement technology has a key advantage: it provides a sufficiently good signal over the entire measurement range (usually 0–2,000 bar). The measuring chain will only need to be adapted in case of very low pressures (in foaming processes, for example). To make installation as simple as possible, select the sensor with the largest possible geometric dimensions. The choice between a direct or indirect cavity pressure sensor depends on the basic design of the mold. For existing molds, a sensor behind an ejector is often the simpler option – but on the other hand, direct sensors offer more flexible positioning.

Sensor positioning

Sensor positioning is essentially dependent on the quality criteria to be monitored, or on the overall quality monitoring strategy.

For characteristics that are significantly influenced by the filling of the cavity, a post-gate sensor position is recommended because this is the only way to visualize the mold filling. If a local quality criterion such as a weld line or complete filling is targeted, the sensor should be installed close to this critical position. When monitoring short shots, end-of-fill positioning offers significantly better resolution for failure detection.

Transfer based on cavity pressure

Sensors and systems based on cavity pressure determine whether or not a part is scrap at the earliest possible moment.

If the transfer to holding pressure is based on cavity pressure, a sensor position close to the sprue is recommended: at 1/3 of the flow path, for example. With this position, a clear switching point can usually be identified so a corresponding pressure threshold can be set. Cavity pressure-dependent switching offers higher process reproducibility as compared to other methods such as screw position-dependent transfer: this is because the actual flow behavior of the melt in the cavity is considered, rather than just a machine component. Influences from the nonreturn valve are compensated effectively. The same applies to overmolding of inserts with the higher tolerances that are well-known in this context.