Meusburger Smartflow Helix Boosts Valve Gate Moulding

For valve gate applications Precise melt flow for stable injection moulding processes

2026-05-14 Source: Meusburger 2 min Reading Time

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Meusburger has expanded its hot runner portfolio with Smartflow Helix, a solution for valve gate applications designed to improve melt homogenisation directly in the nozzle area. The technology supports stable mould filling, reduces injection defects and helps processors achieve consistent part quality, especially in complex, thin-walled or visually demanding injection moulded components.

Meusburger recommends Smartflow Helix particularly for frequent colour changes, applications with high visual quality requirements, multi-cavity moulds and technical plastics.(Source: Meusburger) — Meusburger recommends Smartflow Helix particularly for frequent colour changes, applications with high visual quality requirements, multi-cavity moulds and technical plastics.
(Source: Meusburger)

In the demanding world of injection moulding, optimal melt flow in the hot runner system is a decisive factor in process stability, part quality and production costs. With Smartflow Helix, Meusburger is expanding its hot runner portfolio with a solution specifically designed for valve gate applications. The technology optimises flow control in the nozzle area and helps users process challenging plastics reliably.

Smartflow Helix is based on the Smartflow manifold technology and has been specifically developed for use in valve gate hot runner systems. At the core of the solution is a special flow geometry that generates a defined vortex — a helical flow — within the nozzle. This geometry homogenises the melt flow immediately before it enters the cavity. Differences in temperature and pressure within the melt are reduced, promoting uniform filling. Particularly in the case of complex geometries or thin-walled items, optimised flow control helps to ensure stable filling of the mould.

Optimisation of valve gate applications

Valve gate systems place high demands on flow control in the gate area. Conventional systems can, for example, lead to so-called ‘pin shadows’ in the injection area. The unique geometry of Smartflow Helix eliminates these effects. The targeted mixing of the melt in the nozzle area promotes uniform material distribution, which minimises injection defects and improves the visual quality of the items.

Rheologically designed flow channels and diffusion-welded manifolds

In addition to its specialised flow technology, Meusburger uses diffusion-welded hot runner manifolds, which ensure uniform melt flow thanks to their rheological design. This is optimally aligned with the flow properties of the plastics. Diffusion welding enables the creation of complex channel layouts with high dimensional accuracy and surface quality. This helps to reduce pressure losses and localised hotspots.

Added value for sophisticated applications

Meusburger recommends Smartflow Helix particularly for frequent colour changes, applications with high visual quality requirements, multi-cavity moulds and technical plastics. Improved homogenisation of the melt helps to ensure consistent part quality and stable processes. The technology also offers advantages in standard applications: Consistent filling reduces the risk of unusable parts and improves process reliability in serial operation.

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