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Brazed Cores and Cavities
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Polyshot Corporation has developed its own in-house technology to join manifold plates for state-of-the-art hot runner construction. This technology is now available to molders and mold makers to allow them to manufacture conformally cooled mold cores and cavities. This technology can reduce the cycle times in injection molds as much as 60%.

The view at left, is an exploded view of an mold core assembly for a consumer closure application. It is shown separated for clarification. Polyshot uses its exclusive plate fusion technology to braze the sections back into a one piece assembly.
 
These sections come to Polyshot from the mold maker as rough "blanks" with the conformal cooling channels already machined into them.
After brazing, the customer can finish machine the core as any other piece of steel, EDM, jig grinding, milling, drilling and heat treat are done just as they normally would be.
 
The right hand view shows the completed mold core assembly fused with the conformal cooling channels now embedded into the core.

 Some Typically Asked Questions for Fusing Cores and Cavities by Polyshot:

Question: With a typical Fused Core like you show here, what is my expected cycle time savings?  
 
Answer: In this particular core, a 39% reduction in cooling time was realized compared with a typical center cooled water baffle.
 
Question: Is there technical data on material temperature at end of pack and cooling phases? Are there any studies that you can provide to support the results of this technology and the savings it provides?
 
Answer: Yes, Polyshot has had a independent study commissioned by Shadow Polymer Industries, Inc. You can access a full technical presentation by clicking here.
 
 
Question: Can I heat treat the fused assemblies after I get them back from Polyshot?
 
Answer: Yes, the fused assemblies can be annealed and or hardened by a typical heat treat process. The only limit is the heat treating temperatures should not exceed 1800 degrees F. or 982 degrees C. This typically allows a maximum Rockwell hardness of about 45 RC.
 
Question: What steel types are acceptable to use with your process?
 
Answer: Polyshot brazes H13, 420 Stainless, S7, most of the typical mold steels. Other steels can be reviewed for brazing by contacting Polyshot Engineering.
 
Question: How hard are the assemblies after Polyshot fuses them together.
 
Answer: The hardness after fusing can be anywhere form totally soft to about 30RC. This depends on the mass of the assembly to be brazed and the time Polyshot uses to cool them. Many times the customer goes straight to machining after Polyshot ships them to the customer and other times the customer introduces a heat treat step before machining. This is either an anneal or a hardening process if they prefer to machine them hard.
 
Question: How do I prepare plates for Polyshot to braze? What machining needs to be done to them before I send them to Polyshot?
 
Answer: Plates to be fused are shipped to Polyshot in the rough finish on the outside of the cores or cavities. The mating surfaces are to be precision ground (surface ground) to a maximum flatness of .0005" (.012mm), to their finished thicknesses. The plates will have the cooling channels machined into them also. Each mating surface will have dowel holes and pins installed to align the plates also. The dowel holes need to be larger than the dowels by .004" (.10mm). Polyshot also has a guide that can be downloaded by clicking here: General Preparation for Fusing
 
Question: How long does Polyshot need to fuse my cores and cavities.
 
Answer: Polyshot likes to schedule larger projects 4-6 weeks in advance. After we receive the customers cores or cavities typical turn around time is 2 weeks for small orders to as much as 6 weeks for large multi-cavity programs.
 
Question: What do I need to do to see if I can use Polyshot's conformal cooling technology services?
 
Answer: For all projects, contact Polyshot Sales for technical assistance.
 
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Polyshot is pleased to announce a significant price reduction on its industry leading Single
Nozzle Valve Gate System, patent pending. Due to its extreme success in the marketplace
we have been able to increase our manufacturing volumes and lower the price with no impact
to its quality or performance.

In addition to the M11 Polyshot Single Nozzle Valve Gate price reduction, we have
also lowered the M15, higher capacity Version to $4,490.00.

Power – 400 lbs of pin force, 4 times the pin force of any pneumatically operated single nozzle
valve gate in the industry.

Size – The entire system fits within the mold locating ring.

Capabilities – Can process resins up to 700 degrees F. (370 degrees C.).
Excellent for clear medical parts.


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