D-M-E Hot Runner Services. Total support for your hot runner systems

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1 D-M-E Hot Runner Services Total support for your hot runner systems

2 46 Hot Runner Services Moldflow Services Optimize Part and Mold Design Comprehensive Analysis and Modeling With today s shrinking time-to-market window, development speed is essential. As part of its commitment to the molding industry, D-M-E is now offering Moldflow analysis to help optimize part and mold design especially for hot runner molds. D-M-E is the first mold technologies supplier to earn Moldflow s silver certification in this advanced technology. A Competitive Advantage Hot Runner Services Moldflow Services Optimize Part and Mold Design Grill stack mold Predictive analysis, utilizing Moldflow software, yields tremendous benefits, including: Optimize part design Reduce time-to-market Save cost and time on mold tryouts Lower development and production costs Provide a framework to establish reputable processes Improve product quality Decrease cycle times What is Moldflow? D-M-E uses Moldflow Plastics Insight (MPI) software which is an integrated suite of analysis tools that utilize CAD files and apply advanced Finite Element Analysis (FEA) techniques to quickly and easily enable a virtual what if design environment before initiating mold construction. MPI provides in-depth part/mold design and process parameter optimization. This is in contrast to Moldflow Plastics Advisor (MPA) which is primarily useful for parts with low to medium complexity, conceptual designs, and quick part design validation. D-M-E is a certified, licensed provider of Moldflow analysis services. Mold Fill Analysis The Mold Fill module uses predictive technology to simulate the filling process. Key analyses include: Optimize the number, size, and location of gates Balance the runner system design Reduce material stress levels

3 Hot Runner Services 47 Moldflow Services Optimize Part and Mold Design Predict weld line locations Validate pressure and temperature distribution within the mold Optimize processing conditions including melt temperature, injection rate, and cavity pressure Mold Pack Analysis Building on the results of a Mold Fill analysis, the Mold Pack module optimizes the packing phase to ensure a uniform packing condition. As an indication of part warpage, volumetric shrinkage is evaluated and the pack pressure profile is optimized. The result is minimized warpage with an improved surface appearance. Mold Cool Analysis The Cool Analysis module assesses an existing cooling layout to determine potential molding problems. Steel types, cooling channel sizes, bubblers, baffles, coolant temperatures, and flow rates are all evaluated. Using this analysis, the Mold Cool module recommends practical tooling design changes to ensure uniform cooling. Mold Cool takes into account: Number, location, depth, and pitch of cooling channels Steel types Cooling circuit layouts Coolant temperatures and flow rates Cycle times Warp Analysis Using the results from the Fill and Cool analyses, the Warp Analysis module enables prediction of plastic part shrinkage and warpage. Warp Analysis diagnoses the cause(s) of warping and recommends the appropriate solution, such as gate location changes, design parameter changes, and reduction of wall thickness variations. MPI 3D MPI 3D addresses a class of problems previously unsolvable using traditional finite element analysis techniques. In thick-walled parts, molten plastic can flow in all directions. Using a proven methodology based on a solid tetrahedral, finite element volume mesh, MPI 3D enables true, threedimensional simulations on thick-walled parts. Where Do I Start? Contact your D-M-E representative for more information regarding MoldFlow Services. The D-M-E Applications Engineering Department is available to provide a customized MoldFlow analysis and assist you in maximizing the results of your next application. Hot Runner Services Moldflow Services Optimize Part and Mold Design

4 48 Hot Runner Services D-M-E Hot Runner Service Center Ensuring the Productivity of every Hot Runner System Full-Service Hot Runner Support Mold technology leader D-M-E known for our innovative family of hot runner systems including Galaxy, Meteor, and Stellar now also provides total support for your hot runner systems. Whether it s a D-M-E system or not, we can repair, reconfigure even totally rebuild it to help ensure maximum uptime and performance of your system. Hot Runner Services D-M-E Hot Runner Service Center A Dedicated Center for Hot Runner Systems Our new Hot Runner Service Center, located in Madison Heights, Michigan, is exclusively dedicated to supporting your hot runner systems. Staffed by a team whose sole focus is hot runner systems, we re quickly able to get your system operating at maximum efficiency. This group has over three decades of experience installing, assembling, and repairing hot runner systems. And, because we re centrally located, we can get your system back in your shop quickly and costeffectively. If appropriate, we can also perform many basic operations in one of our D-M-E regional centers further speeding turnaround. A Wide Range of Services D-M-E recognizes the value of your time that s why we ve developed a comprehensive suite of hot runner services to provide a single source for maintenance and optimization of your system. Key services include: Repairs including expedited service System cleaning including complete bake-out Total system rebuild Re-configuration Operator training Mold tryouts Repairs Get You Back Up Quickly Time is money. When a critical tool is out of commission, productivity is lost and production schedules can be threatened. We understand this at D-M-E. That s why our team of hot runner repair specialists are always available to get you back in service. Whether you re experiencing leaks, heating issues, flow problems, or would simply like a system bake-out, we ll repair your system quickly and cost-effectively. Standard turnaround for repairs on systems from 1-12 drops (depending on parts availability for non-d-m-e systems) is 5 working days or less. If your system has over 12 drops, contact us for an estimated turnaround time. And, we offer emergency 24-hour turnaround service.

5 Hot Runner Services D-M-E Hot Runner Service Center Ensuring the Productivity of every Hot Runner System 49 Rebuilds Ensure Performance After tens of thousands of cycles you may have noticed your system just doesn t perform the way it used to. Or maybe you ve run high-temperature engineered materials and the tolerances just aren t as tight. Key benefits of system rebuilds include: Cost savings of at least 40% as compared to new systems Extended life for your tool Maximizing system uptime and performance Improved finished part quality Whether you need a total system rebuild, or a simple cleaning and inspection D-M-E can help. System rebuilds can be performed on any brand of hot runner system and typically include: Complete bake-out cleaning Check and replace heaters and thermocouples Inspect and correct wiring Replace seals and bushings Clean or replace nozzle components Check all dimensions and re-assemble system Cost-Effective Reconfiguration When your process needs change, without a significant tooling change, we can adapt your hot runner to the new process. Whether it s a material switch, or a part design change, D-M-E can help reconfigure your existing system. Training Maximizes Productivity, Speeds Set-Up Hot Runner Services D-M-E Hot Runner Service Center The D-M-E Hot Runner Service Center can provide comprehensive operator training in start-up or prototyping. Our hands-on programs help your operators get up-to-speed, or stay current on hot runner technology. Mold Tryouts We also offer mold tryouts at the Hot Runner Service Center. Injection molding machines from 110 to 1,000 tons are available to run your mold and ensure proper performance.

6 50 Hot Runner Services Hot Runner Services Overview Hot Runner Services Hot Runner Services Overview Unrivaled Support When and Where You Need It Since the 1970s, D-M-E has developed and marketed a full spectrum of hot runner systems and components. From Moldflow analysis to turnkey hot half systems and everything in between, the D-M-E family of hot runner products and services offers a comprehensive array of solutions for a wide range of applications. Whether your need is for standard, off-the-shelf components, customer engineered manifolds, or fully assembled systems ready for bolt-on installation, D-M-E has a proven solution to match your application. Moldflow Services As the first mold technologies supplier to earn Moldflow s silver certification, D-M-E is highly adept at applying Finite Element Analysis (FEA) techniques to help optimize part and mold design. Whether you need Mold Fill, Mold Pack, Mold Cool or Warp analyses, D-M-E can assist you in maximizing the results of your next application. Applications Engineering and Technical Service Our dedicated and experienced team of mold designers and applications engineers assists D-M-E customers with product selection, system design, performance analysis and technical advice. D-M-E technical service representatives are globally located for complete coverage and quick availability no matter where your hot runner production takes place. Technical experts employed worldwide are available for start-ups, personnel training or system service. Research and Development Expertise The D-M-E Technology Center features a development lab that tests hot runner systems, manifolds and modular components within a real-world environment to validate that your D-M-E hot runner system performs efficiently at peak performance levels. Comprehensive Hot Runner Service Staffed by a team whose sole focus is hot runner systems, the D-M-E Hot Runner Service Center offers a single source for hot runner system optimization and maintenance. Our services include expedited repairs, system cleaning, system rebuilds, re-configuration and mold tryouts for virtually any type of hot runner system.