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How does the mould temperature controller contribute to the longevity of molds?

2025/01/03 By Topstar

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In injection moulding production, properly managing temperature during the moulding process is one key factor in extending mould life and reducing the risk of damage. We can use a mould temperature controller to achieve mould temperature regulation throughout the injection moulding process. In this article, we will share the role of mould temperature controllers in extending mould life. By combining scientific principles and practical experience, we will gradually explore how effective temperature regulation can help prevent mould damage, reduce wear, and improve mould efficiency and output.

How does stable mould temperature prevent thermal stress?

Thermal stress is a primary factor leading to long-term mould damage. Because the mould heats up during the injection process and cools after each injection, uneven temperature distribution or rapid temperature changes can cause stress in the mould material. This can cause problems, including cracking, warping, and accelerated wear on the mould surface.

The mould temperature controller can maintain a constant mould temperature through mould load adaptive temperature intelligent control brought by the PID algorithm, with a temperature control accuracy of ±0.1℃, thereby reducing mould temperature fluctuations and ensuring that the mould temperature is evenly distributed on all surfaces to prevent deformation caused by local overheating or cooling. By effectively managing the heat transfer process, the mould temperature controller reduces the rate at which the mould expands and contracts, thereby reducing the likelihood of cracks forming.

Minimize mould corrosion and erosion with a mould temperature controller

Another key factor that causes mould wear is corrosion and erosion, which can significantly shorten the mould’s life. Corrosion usually occurs when moisture, chemicals, or other contaminants interact with the mould surface. Erosion is the physical wear of the mould surface due to friction or repeated movement of the injected material.

Mould temperature controllers can indirectly help minimize corrosion and erosion. Continuously controlling the mould temperature helps maintain the integrity of the mould material and prevents excessive exposure to high temperatures, which increases the rate of oxidation or rust. In addition, the pure water series of mould temperature controllers have their water tanks, use pure water as the circulating medium, and use a closed circulation system to avoid corrosion of metal ions on the mould and blockage of the mould by scale. Reduce the requirements for water quality and prevent mould rust and corrosion.

Reduce the risk of mould cracking by controlling the temperature cycle.

Rapid heating and cooling cycles are often required to meet production and cycle time requirements in the injection moulding process. However, these rapid temperature changes can also put much stress on the mould, especially when the mould is not designed to handle such changes. Repeated thermal cycling without adequate temperature control can cause mould cracking, and the cost of repairing and replacing the mould can be high.

The mould temperature controller reduces this risk with a combination of PID temperature control algorithms and solid-state relays, ensuring that the mould does not suffer sudden temperature changes but a smooth and uniform temperature transition. In addition, heat medium recovery technology completely replaces the residual medium in the mould with high-pressure gas, thereby preventing mould damage and further improving product yield.

Shorten cycle time and extend mould life

Proper cooling ensures that the plastic material solidifies at the correct rate, thereby reducing defects such as warping, under-injection or surface unevenness. By regulating the cooling temperature and providing a consistent cooling rate across the mould surface, the mould temperature controller helps prevent local overheating or cold spots. These temperature differences can cause part defects or permanent damage to the mould. More importantly, a well-regulated cooling process helps to shorten cycle times and increase productivity without sacrificing mould integrity. Shorter cycle times reduce the time the mould spends in the moulding environment, which decreases the number of thermal cycles the mould undergoes, extends its life, and helps maintain the mould’s dimensional stability.

Extended mould life brings cost benefits.

When plastic product manufacturers frequently repair or replace their moulds, they face a financial burden. Manufacturers who invest in quality mould temperature controllers can avoid the high cost of replacing damaged moulds and instead focus on maximizing production efficiency and output. In the long run, using mould temperature controllers will not only help extend the life of the mould but also help improve the overall profitability of the business. With fewer mould failures, shorter production cycles, and improved part quality, manufacturers can achieve significant savings while remaining efficient and competitive.

Better mould life extension

Mould temperature controllers are key to ensuring mould life during injection moulding. By regulating and maintaining the optimal mould temperature throughout the production cycle, manufacturers can minimize thermal stress, corrosion, erosion, and cracking, which can damage the mould and shorten its life. For manufacturers in Europe and beyond, investing in mould temperature controllers can bring both short-term and long-term benefits.

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