In order to improve the consistency of molded products as viscosity shifts throughout a run, a controller of an injection molding machine executes a calibration cycle in accordance with a mold cycle. The controller analyzes a plurality of sensed melt pressure values during the calibration cycle to determine one or more calibration metrics. The controller then uses the calibration metrics when executing each mold cycle of the run. More particularly, during each mold cycle of the run, the controller detects a plurality of sensed melt pressures prior to and during a fill phase of the mold cycle and compares the plurality of sensed melt pressures to the one or more calibration metrics to predict cavity pressure for a pack and hold phase of the mold cycle. The controller then adjusts a set point pressure for the pack and hold phase based on the predicted cavity pressure.

Systems and methods describe supplementing a native controller of an injection molding with a remote controller, via a retrofitting of the remote controller the injection molding machine. The remote controller may thereby modify control of an injection molding process based upon a control strategy of the remote controller, e.g., by providing a modified feedback signal to be used by a control algorithm of the native controller in lieu of a feedback signal previously used by the native controller. The remote controller may generate the modified feedback signal based upon its own control algorithm and control strategy. Furthermore, the remote controller may be configured to robustly account for behavior of the native controller so as to provide stable control of a control variable of the process according to a setpoint defined by the remote controller.

Component manufacturing methods and systems and methods are provided for six degree of freedom control of a component prior to molding. A method involves obtaining measurement data from a measurement device indicative of a measured orientation of a component mounted to a surface of a tool associated with a molding assembly, determining an orientation adjustment based on a relationship between the measured orientation of the component and a reference orientation associated with the molding assembly, determining an actuation command for operating an actuation arrangement coupled to the tool based at least in part on the orientation adjustment, and providing the actuation command to the actuation arrangement to actuate the tool to rotate the surface in accordance with the orientation adjustment prior to forming a molding compound on an exposed surface of the component using the molding assembly.

An injection molding apparatus (10) comprising an actuator (940, 941, 942) comprised of a driver (940dr, 941dr, 942dr) receiving electrical energy or power from an electrical drive (940d, 941d, 942d), the electrical drive (940d, 941d, 942d) comprising an interface that receives and controllably distributes electrical energy or power in controllably varied amounts during the course of an injection cycle to the driver (940dr, 941dr, 942dr), the electrical drive (940d, 941d, 942d) being housed within or by an actuator housing (940h, 941h, 942h) or being mounted on or to the housing (940h, 941h, 942h), the housing (940h, 941h, 942h) and the electrical drive (940d, 941d, 942d) being mounted on, to or in close proximity to the heated manifold (40), a cooling device (940mc, 940mc1, 940mc2, 941mc, 942mc) disposed between the heated manifold (40) and the housing (940h, 941h, 942h) adapted to substantially isolate or insulate at least the electrical drive (940d, 941d, 942d) from substantial communication with heat emanating or emitted from the heated manifold (40).

An injection molding apparatus and method of fabricating a molded part are provided. The apparatus may include a barrel, a nozzle enclosing an end of the barrel and defining an opening in fluid communication with an inside of the barrel, and an extrusion screw positioned at least partially inside the barrel and rotatable relative to the barrel. The extrusion screw may include a screw tip. Relative axial movement between the barrel and the extrusion screw may open or close the opening of the nozzle to permit or prevent, respectively, material flow through the opening of the nozzle. The method may include clamping a mold, opening a nozzle, rotating the extrusion screw to pump a molten material into the mold until the mold is filled, closing the nozzle, and unclamping the mold to release a molded part.

An injection molding apparatus comprising: An actuator having a driver receiving electrical energy or power from an electrical drive, the electrical drive comprising an interface, the electrical drive being housed within or by and actuator housing or being mounted on or to the housing, the housing and the electrical drive being mounted on, to or in close proximity to the heated manifold, a cooling device disposed between the heated manifold and the housing adapted to substantially isolate or insulate at least the electrical drive from communication with heat emanating from the heated manifold or to heat sink or absorb heat communicated or communicable to the electrical drive from the heated manifold or both.

A device for assisting molding condition determination includes a molding state data adjustment amount obtaining unit and a molding condition element adjustment amount obtaining unit. The molding state data adjustment amount obtaining unit obtains, using a first learning model, a molding state data adjustment amount having a value equivalent to a difference between molding state data detected by a sensor and a molding state data target value. The molding condition element adjustment amount obtaining unit obtains, using a second learning model, an adjustment amount for a molding condition element corresponding to the molding state data adjustment amount.

The disclosure is directed to an injection molding device comprising at least one injection mold with a first and second mold half during operation being displaceable with respect to each other in a first direction (z) between a closed position and an open position. The first and second mold halves forming in the closed position at least one cavity therebetween for receiving melted plastic material from an injection nozzle. The at least one cavity comprises first and second cavity sections which are by a constriction. Melted plastic material is injected into the first cavity section and travels from there via the constriction into the second cavity section. A first sensor arrangement is arranged in a cavity wall of the first cavity section and a second sensor arrangement is arranged in a cavity wall of the second cavity section to determine relevant parameters in relation to the constriction.

An injection molding apparatus and method of fabricating a molded part are provided. The apparatus may include a barrel, a nozzle enclosing an end of the barrel and defining an opening in fluid communication with an inside of the barrel, and an extrusion screw positioned at least partially inside the barrel and rotatable relative to the barrel. The extrusion screw may include a screw tip. Relative axial movement between the barrel and the extrusion screw may open or close the opening of the nozzle to permit or prevent, respectively, material flow through the opening of the nozzle. The method may include clamping a mold, opening a nozzle, rotating the extrusion screw to pump a molten material into the mold until the mold is filled, closing the nozzle, and unclamping the mold to release a molded part.

The present disclosure provides a molding machine and a method of molding a part. The molding machine may include multiple molding systems (e.g., extruders) for pumping molten material into one or more mold cavities. The multiple molding systems may pump the same material or different materials into the one or more mold cavities. The multiple molding systems may be individually and/or collectively controlled. A method of molding a part may include pumping material into one or more mold cavities via multiple molding systems, ceasing pumping material into the one or more mold cavities when one or more pressures associated with the multiple molding systems are achieved, and releasing a molded part from the one or more mold cavities after the one or more pressures are achieved.