Innovative Gate Cutter by I-Mold: Automated Sprue Removal for Efficient Plastic Production

Demoulding Safe sprue separation in the closed tool

2024-12-02 Source: I-Mold 2 min Reading Time

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I-Mold’s innovative Gate Cutter automates the removal of sprues and runner channels directly within the closed mould, eliminating the need for manual post-processing. Compatible with various gate designs and materials, this hydraulic-driven system ensures clean, burr-free cuts while maintaining cycle times.

The new Gate Cutter from I-Mold separates sprues during demoulding in an automated and precisely positioned manner.(Source: I-Mold) — The new Gate Cutter from I-Mold separates sprues during demoulding in an automated and precisely positioned manner.
(Source: I-Mold)

Conventional plastic part production requires the sprues and distribution channels to be cut off after demoulding. Whether it is done manually with cutting pliers, by guillotine or milling cutter, this separate process always takes time and manpower. With the new Gate Cutter from I-Mold, this task is automated and carried out in the still closed tool. The system is suitable for a wide range of gate designs, including film, shield and tunnel gates, for tools with one or more cavities, as well as for moulded parts with several gates, such as those typically used for automotive reflectors. In every case, the cycle time remains unchanged when using the Gate Cutter.

Just as conveniently as with hot runner technology, the moulded parts can be removed automatically after opening and placed on a conveyor belt or pallet without further finishing. Sprues and runner channels drop out of the tool, ideally to be sent directly for grinding again.

The principle is the same for all types of mould: during injection, the cutter blade remains retracted in its rest position without obstructing the flow of molten material. At the end of the holding pressure phase, a space-saving hydraulic high-pressure mini-cylinder pushes the blade, precisely guided, into the cooling moulding compound. When the mould opens, the blade returns to its initial position. The blade is moved by an external hydraulic control unit designed for an operating pressure of 800 bar with a precise time control adapted to the filling process. Alternatively, the hydraulics of the injection moulding machine can also be used if necessary.

The result is a clean, burr-free cut, even with materials that are difficult to rework, such as PMMA or glass-fibre-reinforced PET. The cut is made exactly where it is needed, directly at the edge of laterally moulded parts or concentrically in the middle of concentrically moulded parts. All sources of quality-reducing errors that can occur with manual intervention are eliminated.

Andy Walter, Managing Partner of I-Mold, says: “When it comes to quality, there is no alternative to injection moulding. Moulds equipped with the Gate Cutter give processors even more certainty that they are meeting these requirements — absolutely reproducible, around the clock. And where no one has to work with the knife anymore, no one can get hurt with it either.”

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