Stargate HRS: Innovative Hot Runner System by Oerlikon HRS Flow

Pinless hot runner design Oerlikon HRS Flow presents needle-free Stargate HRS hot runner system

2025-10-14 Source: Oerlikon HRS Flow 1 min Reading Time

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Presented at K 2025, Oerlikon HRS Flow’s Stargate HRS hot runner system introduces a diaphragm-based gate design that replaces traditional needles, offering a more compact layout, shorter cycle times, and easier maintenance.

left: the standard valve gate solution; right: the Stargate HRS technology, which reduces cycle time and requires significantly less installation space than conventional needle valve systems. (Source: Oerlikon HRS Flow) — left: the standard valve gate solution; right: the Stargate HRS technology, which reduces cycle time and requires significantly less installation space than conventional needle valve systems.
(Source: Oerlikon HRS Flow)

At K 2025, Oerlikon HRS Flow unveiled its patented Stargate HRS hot runner technology, featuring a completely redesigned gate unit. Unlike conventional designs with axially moving needles, this news technology uses a diaphragm-like element in the gate plane to manage melt flow into the cavity. Eliminating the need for needles provides numerous processing and cost advantages.

Thanks to its diaphragmatic concept delivering optimal cooling performance, Stargate HRS offers a significant reduction in cycle time as a key advantage, resulting in higher productivity. The absence of components required for guiding and moving the needle also streamlines manufacturing, assembly, and maintenance operations. Its innovative design eliminates the need for actuator installation space, which is typically positioned axially above the needles in conventional systems, allowing for thinner back plates. Additionally, the innovative pinless configuration allows for smaller nozzle diameters and reduced mold pocket sizes, making the Stargate HRS an exceptionally compact solution.

Gallery

Oerlikon HRS Flow's new Stargate HRS hot runner technology uses a diaphragm-like element in the gate plane to manage melt flow into the cavity.(Source: Oerlikon HRS Flow)

The combination of smooth plastic flow and a reduced stagnation area enables faster colour changes, lower scrap quantities, and lower pressure losses. Additionally, the easily replaceable gate insert reduces maintenance costs. The external position of the actuator contributes to lower energy consumption because it does not require cooling.

Experience at the Oerlikon HRS Flow R&D Technical Center shows that the new Stargate HRS technology is ideal for injection moulding medium-to-large parts with reduced holding and cycle times. For these types of applications, the cycle time can be up to 20 percent shorter than with conventional gate systems.

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Date: 08.12.2025

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