System Selection Guide

Your Complete Hot Runner

Configuration Guide

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 System Selection Guide

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System Selection Guide Contents

Contents pg
Standard Hot Runner Configuration 4
Hot Runner System Overview 5
Selection Overview 6
Nozzle Range and Series Options 8
Body Grade Selection 10
Nozzle Range Selection 11
Nozzle Series Selection 12
Typical Flow Length Ratios 13
Nozzle Flow Rates 13
Tip Grade Selection 14
Tip Style Selection 15
Tip Styles 16
Nut Grade Selection 17
Nut Type Selection 18
Nut Options 19
Nozzle Assembly Order Code for MJ and X-Range Series 20
Tip and Nut Options 21
Plastic Material and Tip and Nut Suitability 22
Gate Geometry Selection 23
Gating Options – MX / BX / SX / TX FlowLoc ™
24
Gating Options - YCN/Multi-Gates 25
YCN Nut 26
Multi-Gates 28
MJ Nozzle 30
MX Nozzle 32
BX Nozzle 34
SX Nozzle 36
FlowLoc Range
™
38
VeriShot Single Valve Gate System
™
40
MVG25 Headed Pin Valve Gate System 42
MVG40 Headed Pin Valve Gate System 44
MVG40 Threaded Pin Valve Gate System 46
MVG55 Headed Pin Valve Gate System 48
Cylix Headed Pin Valve Gate System 50
MVCH Valve Gate System 52
Manifold Components 54
Selecting a Manifold Configuration 55
Nexus™ Systems 56
Hot Half System 57
Additional Considerations 58
System Selection Example 60
Meticom TC5100 / TC5200 Temperature Control System 61
Meticom TC5H Temperature Control System 62
G-Series GTV8 Integrated Sequential Controller 63

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 Hot Runner System Overview System Selection Guide

Standard Hot Runner Configuration

KEY KEY
Valve Gate Assembly Back Plate**

Manifold Assembly Manifold Plate**

Nozzle Assembly Cavity Plate*

*Supplied by Customer
**Supplied by Mastip when hot half ordered

Locating Ring**

Valve Pin Actuator

Back Plate**

Manifold

Manifold
Plate**

Nozzle

Cavity
Plate *

Cooling Channels

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 System Selection Guide Hot Runner System Overview

Hot Runner System Overview

A Hot Runner System maintains a molten flow of plastic from the moulding machine nozzle to the gate of a plastic
injection mould.

Mastip Hot Runner System Benefits

• Efficient cycle times
• Improves part consistency and quality
• Minimised gate vestige
• Reduced injection pressure
• Valve gates allow for sequential filling and allow family part moulds
• Eliminates the cold runner that would be scrap or require re-grind
• Increased process control for fine tuning of mould and part

Hot Runner System Critical Areas of Performance

Manifold design considerations:

• Precise temperature control of the molten plastic
• Balanced flow to all cavities for even part filling
• Nozzle sizing for maintaining sufficient molten material flow
• Gate detail required to correctly fill the part and shut the gate
• No material traps or areas of flow hesitation to ensure quick colour change and prevent material degradation
• Minimum pressure drop across the Hot Runner System
• Reasonable melt residence time
• Maximum cooling of gate areas to ensure effective shut off to gates

Fully Hot Versus Semi Hot Configuration

Single Nozzle Gating Directly onto Part Single Nozzle Gating into a Cold Runner

Fully Hot advantages: Semi Hot advantages:

• No material wastage • Reduces cold runner weight
• Low cycle times • Reduces cost of mould
• Low part stress • Suitable for difficult gate locations

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 Selection Overview System Selection Guide

Selection Overview
The easiest way to select the correct hot runner system is to follow the ten steps below.

ONE
Fill in part and material details for later reference

Part Specification Value Unit

Part Description
Part Weight g
Cold runner weight (if applicable) g
Overall size of part L x W x H mm
Nominal Wall Thickness mm
Minimum Wall Thickness mm

Gate Requirements Value Material Specifications Value

Cosmetic? Y/N Material Type
Flat or recessed gate for label / printing? Y/N Filler or Glass Fibre %

Mould Specifications Value Manufacturer and grade OR

MFI - Value, Temperature & load
Number of Cavities?
Hot Half Construction? Y/N

TWO SIX CONT.

Using the flow chart “Body Grade Selection” on page 10 select Using the flow chart “Tip Style Selection” on page 15 and the
the required nozzle body steel grade. associated table on page 16 select the appropriate tip style.
For “Multi-Gate Selection” refer to page 28.
Body Grade F1 / F3
Tipless Nut
THREE Tip Style Y (No Tip)

Using the flow chart “Nozzle Range Selection” on page 11

select the required Nozzle Range. SEVEN

Nozzle Range MJ / MX / SX / BX / TX / BM / SM Using the flow chart “Nut Grade Selection” on page 17
and the associated table select the appropriate nut grade.

FOUR Nut Grade H1 / H2 / H3 / H5

Using the flow chart “Nozzle Series Selection” on page 12 and the
associated tables on page 13 select the appropriate nozzle series. EIGHT

Nozzle Series 09 / 13 / 16 / 19 / 27 Using the flow chart “Nut Type Selection” on page 18 and the
associated tables on page 19 select the appropriate nut style.
FIVE Thermal Gate
Using the flow chart “Tip Grade Selection” on page 14 Nut Style ONT / BN / BE / SN / SX / SL / RN / RSN / YCN
and the associated table select the appropriate tip grade.
Valve Gate
Tip Grade G1 / G2 / G5 Nut Style ONT / V1B / V2B / V1S / V2S

SIX
NINE
Using the flow chart “Tip Style Selection” on page 15 and the Using the flow chart “Gate Geometry Selection” on page 23
associated table on page 16 select the appropriate tip style. select the appropriate gate geometry.
For “Multi-Gate Selection” refer to page 28. units

Thermal Gate Gate Diameter (mm) mm

Tip Style TT / IT / OT Gate Land (0.2mm max) mm

Tip Extension (optional) +5 / +10

TEN
Multi-Gate
Tip Style 2A/3A/4A/1S/2S/3S/4S Based on the number of cavities and/or the injection points
required per part specify your manifold by attaching a drawing
Valve Gate showing the required positions or using the L & R references as
Tip Style TV / OV / GV per the manifold section of the Technical Guide.

Cap Insulator (optional) +C Number of nozzles on manifold

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System Selection Guide Notes

Notes

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 Nozzle Range & Series Options System Selection Guide

Nozzle Range and Series Options Key Suitability

 Available / Suitable
¤ Application dependant
Ï Not available / Not suitable

Valve Front Single

Nozzle Range Nozzle Series Gate Loading Nozzle
09 13 16 19 27
MJ Front loading heater for Hot Half use  Ï Ï Ï Ï Ï  Ï
Confined gate area
Close cavity pitching

MX Front loading heater for Hot Half use Ï    Ï   Ï

Close cavity pitching

BX Cost effective solution Ï      Ï ¤

Special length nozzles available
Robust heater design
Limited single nozzle use

SX Dedicated single nozzle solution Ï     Ï Ï 

Two heaters for optimum control

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 System Selection Guide Nozzle Range & Series Options

Nozzle Range and Series Options Key Suitability

 Available / Suitable
¤ Application dependant
Ï Not available / Not suitable

Valve Front Single

Nozzle Range Nozzle Series Gate Loading Nozzle
09 13 16 19 27
FlowLoc™ Heat conducting sleeves Ï Ï     Ï Ï
TX with embedded heaters
Threaded base for leak-proof operation

BM Multi-Gates manifold range Ï Ï Ï Ï  Ï Ï Ï

Close cavity pitching
Economical and robust coil heater

SM Multi-Gates single nozzle range Ï Ï Ï Ï  Ï Ï 

Two heaters for maximum temperature
control
Wide moulding window

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 Body Grade Selection System Selection Guide

Body Grade Selection

Body Grade Selection

Corrosion
resistant Yes F3
steel

No

F1

Bodies are manufactured in various grades designed for different applications and wear resistance.

Body Grade Steel Type

F1 H13 Steel

F3 420 Corrosion Resistant Steel

Nozzle Range F1 F3

MJ  Ï

MX  

BX  

SX  

TX Ï 

BM  

SM  

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 System Selection Guide Nozzle Range Selection

Nozzle Range Selection

Nozzle Range
Selection

Multi-Gate? Yes Single Nozzle? Yes Select SM

No No Select BM

Nexus™
Pre-Assembled Yes Select FlowLoc™
System TX Range

No

Does confined
Single Nozzle? No Yes
gate area require
MJ?

No

Series Range
Yes Front loading Yes MJ MX BX
required?
09 20
Easy fill applications1
PP - L/t < 125 MFI = > 15 13 24 31

PE - L/t < 125 MFI = > 15 No 16 26 34

PS - L/t < 75 MFI = > 15 19 36 36

27 45

Easy fill Close cavity

All measurements in mm
application? Yes Yes
pitching?
Sensitive materials
POM
No EVA
PVC Soft2

*Shot weight
No exceeds polymer in nozzle Sensitive Yes
or is an engineering material?
polymer

Yes
No

Select SX Select BX No Select MX Select MJ

Notes Warning: Check nozzle is

1. These examples are for typical applications only suitable for application
2. Rigid PVC is not recommended for X Range

* To calculate average mass of polymer in nozzle:

Nozzle flow bore diameter x nozzle length x density

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 Nozzle Series Selection System Selection Guide

Nozzle Series Selection

Select Nozzle Series Part weight

Overall size
Wall section
Special features

List part features

L/t ratio is the maximum length the material
has to flow divided by the wall section
Refer to table on page 13 - Typical Flow Length Ratios
This is a good measure of how difficult it
will be to fill the part
Determine maximum
flow length (L/t) Material type, grade
and typical L/t ratio

Determine material
characteristics Use shot weight and typical
L/t ratios for starting point

Estimate number and Flow analysis software and material

size of injection points grade is required to complete this stage

Perform fill and

pressure analysis

Increase number
Is
and/or size of
pressure and fill No
injection points
time OK?
Consider Valve Gate

Shot Weight
Flow Rate =
Yes (Fill Time * No Nozzles)
Refer to tables on page 13 - Typical Flow Length Ratios
+ Nozzle Flow Rates to select appropriate nozzle series
Use flow rate data
to select nozzle
The following may require
larger flow channels:
1. Shear sensitive material
2. Thin wall construction
3. Long flow lengths
4. Filled materials
Is flow
rate above 75% of Yes Thin wall part or
nozzle capacity? filled material? Yes

Select one series

No larger nozzle
No
Large flow rate
Sequential filling
Smooth gate

Is Valve Gate Yes Select Actuator

required?

No

Go to Tip Grade
Selection

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 System Selection Guide Nozzle Series Selection

Typical Flow Length Ratios (L/t)

Wall Section
Material
2.0 1.5 1.0 0.8 0.7 0.6 0.5 0.4
ABS 170 96 43 27 21 15 11 7
CA 150 84 38 24 18 14 9 6
EVA 175 98 44 28 21 16 11 7
SAN 120 68 30 19 15 11 8 5
PA 150 84 38 24 18 14 9 6
PC 100 56 25 16 12 9 6 4
HDPE 225 127 56 36 28 20 14 9
LDPE 275 155 69 44 34 25 17 11
PMMA 130 73 33 21 16 12 8 5
POM 150 84 38 24 18 14 9 6
PP 250 141 63 40 31 23 16 10
UPVC 100 56 25 16 12 9 6 4

All flow lengths greater than this must be considered thin wall and the nozzle series selected accordingly.

Nozzle Flow Rates

Use the table below to select the correct nozzle series based on the flow rate required and the material category.
If the material is a blend material (for example Medium-Difficult or Easy-Medium) always select the higher category to
ensure the part can be filled.

Nozzle Material Category 2

Material Specifications
Series Easy Medium Difficult
Thermal Gate Flow Rate g/s 1 15 7
09 Shot Weight g 1 0.5 - 15 0.5 - 10
Thermal Gate Flow Rate g/s 1 30 15 5
13 Valve Gate Flow Rate g/s 1 25 12
Shot Weight g 1 0.5 -45 0.5 - 30 0.5 - 15
Thermal Gate Flow Rate g/s 1 125 65 25
16 Valve Gate Flow Rate g/s 1 95 50 20
Shot Weight g 1 1 -200 1 - 125 1 - 60
Thermal Gate Flow Rate g/s 1 300 150 60
19 Valve Gate Flow Rate g/s 1 225 110 45
Shot Weight g 1 2 -625 2 - 300 2 - 150
Thermal Gate Flow Rate g/s 1 600 300 125
27 Valve Gate Flow Rate g/s 1 420 210 90
Shot Weight g 1 10 -2000 10 - 1200 10 - 800

1 Additives, flow length and thin wall sections all reduce the effective flow rate and shot weight.
To counter the reduced flow rate and shot weight select one nozzle series larger.
2 Refer to table on page 22 - Plastic Material and Tip and Nut Suitability.

For Multi-Gate Flow Rates refer to page 28.

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 Tip Grade Selection System Selection Guide

Tip Grade Selection

Tip Grade Selection

Minimum gate
Easy material? Yes vestige or long
life required?

Yes
No

Difficult
material or G2 tip
long life?

Yes No For best gate:

Use minimal gate land (q)
and gate diameter (G)

Yes Filled material?

No

No

Processing
Use G5 Yes temperature
> 300ºC

No

Use G1

Go toTip Style
Selection

Tip Grades

Tips are manufactured in various grades designed for different applications and wear resistance.

Tip Grade Recommended use Manufactured Material Tip Style Options

G1 Default grade suitable for easy materials Beryllium Copper with Nickel coating TT, IT, OT, TV, OV
Beryllium Copper tipped with Steel,
G2 Long life tip suitable for easy unfilled materials TT, IT
Nickel coating

Long life tip suitable for difficult and abrasive

G5 Carbide/Hard liner TT, IT, OT, OV, GV
materials

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 System Selection Guide Tip Style Selection

Tip Style Selection

Tip Style Selection

If gating onto a cold runner and it is suitable to follow the guidelines of

“Plastic Material and Tip and Nut Suitability” on page 22, then OT is the preferred choice.

No Use OT

Gating direct
No Valve Gate?
onto part?

No Use TV

Yes Yes
Shear
Yes Use OV
Sensitive?

Yes Cylindrical
Valve Gate?
Gate? No

No Filled
Yes No
Material?

Cosmetic gate Is Valve Gate Yes

Yes Yes
required? an option?
Use GV

No

No Use TT or IT
Is material
sensitive to
separation

Yes

No Crystalline material?
(i.e. narrow moulding Yes Use IT
window?)
Yes
Long fibre filled
material?
No Use OT

Go to Nut Type
No Use TT
Selection

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 Tip Styles System Selection Guide

Tip Styles

Thermal Gate Tip Styles Valve Gate Tip Styles

Multi Hole Extended Extended
Torpedo Tip (TV) Open Tip (OV)
Torpedo Tip (TT) Torpedo Tip (TT+5) Torpedo Tip (TT+10)

Single Hole Extended Single Hole Extended Single Hole

Guided Tip (GV)
Torpedo Tip(IT) Torpedo Tip (IT +5) Torpedo Tip (IT +10)

Open Tip (OT)

Multi-Gate Multi-Gate
Axial Tip (A) Side Tip (S)

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 System Selection Guide Nut Grade Selection

Nut Grade Selection

Nut Grade Selection

Abrasive
Polymers?

No

Yes

Corrosion
Resistance Yes Use H3
Required?

Use H5
No

Good
Thermal Gate Yes Use H2*
Control?

No

Go to Nut Use H1
Type Selection

Notes
*H2 nut only available in ONT nut
*MJ09 nut only available in H2

Nuts are manufactured in various grades designed for different applications and wear resistance.

Nut Grade Recommended use Manufactured Material Nut Style Options

Default grade suitable for unfilled H13 Steel ONT, BN, BE, SN, SL, SX,
H1
or lightly filled materials Medium Hardness V1B, V1S
Suitable for insulative properties Titanium
H2 ONT
and gate control Low Hardness
420 Corrosion Resistant Steel ONT, BN, BE, (Y)CN, SN
H3 Suitable for corrosive environments
Medium Hardness V1B, V2B, V1S, V2S
Vanadium Steel
H5 Wear resistant nut suitable for abrasive polymers BN, SN, V2B
High Hardness

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 Nut Type Selection System Selection Guide

Nut Type Selection

Nut Type Selection

If gating onto a cold runner a Sprue is recommended.

Gating
Select YCN Nut,
direct onto No
Sprue Nut SN, SX or SL
part?

Yes

Is witness
ring on part No Select Open Nut
acceptable? (ONT)

Yes

Is gate
cooling critical Yes
to cycle
time?

No

Is a sprue Select Sprue Nut

Yes
required? SN, SX, SL, V1S, V2S

No

Is part shaped Yes

at gate area?

No

Crystaline Select Bush Nut

Yes
material? BN, V1B, V2B

No

The BE bush nut has a larger contact

Select Bush Nut area that can be tuned to provide a
BE, V1B, V2B correct cooling rate for the application

Go to Gate Geometry
Selection

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 System Selection Guide Nut Options

Nut Options Key Value

 Yes
Ï No
Thermal Gate Nut Types
Witness Nut will leave a circular witness mark on part
Bush Nut
Bush Nut (BN) Dome Nut (BD) Modify Nut may require modification to suit application
Full Contact (BE)
Witness
 Witness
 Witness

Modify
 Modify
Ï Modify


For a Dome Nut supply

R1 and K dimensions

K
at time of order.

R1

Sprue Nut +5 (SN) Sprue Nut + 20 (SX) Sprue Nut + 35 (SL) Retro Sprue Nut (SN-R) YCN Nut (YCN)

Witness
 Witness
 Witness
 Witness
 Witness

Modify
 Modify
 Modify
 Modify
 Modify


Valve Gate Nut Types Thermal Gate and Valve Gate Nut Types
Valve Bush Nut Valve Sprue Nut
Open Nut (ONT) Retro Nut (ONT-R)
(V1B/V2B) (V1S/V2S)
Witness
 Witness
 Witness
Ï Witness
Ï
Modify
 Modify
 Modify
Ï Modify


Series Standard Nut Ød4 Retro Nut Ød4*

13 10 13.1
16 12 16.1
19 15 19.1
Ød4
27 23 27.1
* Finish to suit cavity d4 -0.015mm to +/-0.005mm

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Nozzle Assembly Code for MJ & X-Range Series System Selection Guide

Nozzle Assembly Order Code for MJ and X-Range Series

NOZZLE
NUT

NOZZLE
NOZZLE SERIES
TIP NOZZLE
LENGTH
NOZZLE TIP
RANGE EXTENSION
(OPTIONAL)
BODY TIP NUT GATE (BUSH & SPRUE
GRADE GRADE GRADE DIAMETER NUTS ONLY)

MX TT 13 075 +10 F1 G2 H1 -09

+5
+10 } Thermal Tip
With Open Nut
F1
F3
G1
G2
H1
H2
+C Valve Gate G5 H3
Cap Insulator H5

09
13
T (Open) 16 METRIC INCH
BN 19 045 (BX25 ONLY)
T BE 25 055 137
SN 27 065 187
I
O SX 075 237
MJ SL 085 287
G
MX SNR 095 337
4S
BX RN 105
4A
SX (Y)CN** 115
Y (No Tip)
TX V 130
BM V1B 145
SM V2B 160
V1S 175
V2S 200
225
250
275
300
350
400
450

* Multiple gate diameters are available as standard

** Refer to page 27 for order code diagram for YCN Nut

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 System Selection Guide Tip and Nut Options

Key Tip Suitability

Tip and Nut Options  Available
éééé Highest rating
1 Not Available in X13 3 Not Available in SX Series
2 Not Available in X27 4 Not Available in H5 Ï Not Available

Grades Nut Style Features Plastic (Refer to page 22)

TIPS SN/V1S 4
BN / BE Gate Flow Flow
G1 G2 G5 ONT SX 4 /(Y)CN .4 Easy Medium Difficult
V1B / V2B Quality Rate Marks
4 SL 4 /V2S
TT    ééé éé éé éééé éééé ééé
Multi Hole
Torpedo Tip

TT+5   Ï Ï Ï ééé éé éé éééé éé Ï

Extended
Torpedo Tip

TT+10   Ï Ï Ï ééé é éé éééé é Ï

Extended
Torpedo Tip

IT    ééé éé ééé éééé éééé ééé

Single Hole
Torpedo Tip
Thermal Gate

IT+5   Ï Ï Ï ééé éé ééé éééé éé Ï

Extended
Torpedo Tip

IT+10   Ï Ï Ï ééé é ééé éééé é Ï

Extended
Torpedo Tip

OT  Ï  éé ééé éééé éééé ééé é

Open Tip

Y Ï Ï Ï Ï Ï é éééé éééé éééé éééé ééé

No Tip

Multi-Gate  Ï Ï Ï Ï ééé éé éé éééé Ï Ï

(A)
Axial Tip
Multi-Gate  Ï Ï Ï Ï éé éé éé éééé Ï Ï
(S)
Side Tip
TV  Ï Ï éééé éééé éé éééé ééé é
Torpedo Tip
4 4
3 1 1 1
Valve Gate

OV  Ï  éééé éééé ééé éééé ééé é

Open Tip 4 4

3 1 1

GV Ï Ï  Ï éééé éééé ééé éééé ééé é

Guided Tip

YV Ï Ï Ï Ï éééé éééé ééé éééé ééé é

No Tip

3 4 4

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 System Selection Guide Plastic Material
System and Tip and
Selection Nut Suitability
Guide

Plastic Material and Tip and Nut Suitability Key Tip Suitability
 Suitable
G5 Very suitable with Grade 5 tips and H5 nuts only
¤ Application dependant
1 Not available in G5
G5 Application dependant and Grade 5 tip and H5 nuts only
2 Only available in G2
Ï Not suitable

Material Nozzle Series and Tip

Category 09 13 16 19 27
TT 1 2
TT OT TT OT TT OT TT OT A
IT OV IT OV IT OV IT OV S
TV 1 TV 1 TV 1

PP          
PE          
Easy

PS          Ï
SB          Ï
EVA          Ï
ABS ¤         Ï
AS ¤         Ï
POM ¤         Ï
Medium

SAN ¤         Ï
PA6 ¤  ¤  ¤  ¤  ¤ Ï
PMMA ¤  ¤       Ï
ASA ¤  ¤       Ï
TPE ¤  ¤       Ï
PA66 ¤  ¤  ¤  ¤  ¤ Ï
PBT Ï  ¤  ¤  ¤  ¤ Ï
PC Ï  ¤  ¤  ¤  ¤ Ï
PPS Ï  ¤  ¤  ¤  ¤ Ï
PPE Ï  ¤  ¤  ¤  ¤ Ï
PPU Ï  ¤  ¤  ¤  ¤ Ï
PET Ï  ¤  ¤  ¤  ¤ Ï
PES Ï  ¤  ¤  ¤  ¤ Ï
PPO Ï  ¤  ¤  ¤  ¤ Ï
LCP Ï  ¤  ¤  ¤  ¤ Ï
Difficult

PEI Ï  ¤  ¤  ¤  ¤ Ï
PP + FILL Ï G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 Ï
PA + FILL Ï G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 Ï
SAN + FILL Ï G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 Ï
PA66 + FILL Ï G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 G5/H5 Ï
PBT + FILL Ï G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ Ï
PC + FILL Ï G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ Ï
PPS + FILL Ï G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ Ï
PPE + FILL Ï G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ Ï
PPU + FILL Ï G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ Ï
PET + FILL Ï G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ G5/H5 ¤ Ï

22 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide Gate Geometry Selection

Nut Grade Selection

Gate Geometry
Selection
For Valve Gate the gate
diameter and land does
not affect gate quality
Use minimal land (q)
Minimal gate and gate diameter (G)
vestige required? Yes
For easy materials
use G2 TT/IT tip

No

Use standard land (q)

and gate diameter (G)

Finished

Thermal Gate Land Length (q)

Gate land Cosmetic Gate Gate Life Other Factors

(‘q’) Size
>0.20mm Not Recommended Increased injection pressure, premature gate freeze off
0.20mm * **** Recommended for materials with high % filler
0.15mm ** *** Recommended for materials with medium % filler
0.10mm *** ** Good balance between gate cosmetics and life
0.05mm **** * Strong cavity steel required. Cooled inserts required near to gate
<0.05mm Not Recommended Sharp edge breaks on first few shots, poor wear resistance
Limited cooling at gate can result in stringing

Recommended Thermal Gate Diameter (ØG)

Nozzle Series
Material Tip Grade
09 13 16 19 27
G1/H1 - 0.8 - 1.3 0.9 - 1.4 1.1 - 1.6 1.8 - 2.5
Unfilled G2/H1 0.7 – 0.8 0.7 – 1.3 0.8 - 1.4 1.0 - 1.6 1.6 - 2.5
G5/H1 - 0.9 – 1.3 1.0 - 1.4 1.2 - 1.6 2.0 - 2.5
G5/H1 - 1.0 – 1.4 1.2 – 1.5 1.5 - 1.8 2.4 - 2.8
Filled
G5/H5 - 1.4 –1.6 1.5 – 1.7 1.7 – 2.0 2.6 – 2.8

It is always recommended to start with a small gate and adjust as required.

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 23

 Gating Options – MX/BX/SX/FlowLoc™ System Selection Guide

Gating Options - MX/BX/SX/TX FlowLoc™

Standard Sealing Diameter

Series 13 16 19 27
Ød4 10 12 15 23

ONT ONT +5 ONT +10

13 16 19 27 13 16 19 27 13 16 19 27
       Ï    
L (nozzle)

Ød4
Ød4
5.0

Ød4

10.0
SN +5 SX +20 SL +35
13 16 19 27 13 16 19 27 13 16 19 27
       Ï    
L (nozzle)

20.0

Ød4
35.0
5.0

Ød4

Ød4

BN / BE V1B/V2B V1S/V2S
13 16 19 27 13 16 19 27 13 16 19 27
    Ï    Ï   
L (nozzle)

Ød4 Ød4
Ød4
5.0

24 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide Gating Options – YCN/Multi-Gates

Gating Options - YCN Thermal

Standard Sealing Diameter

Series 13 16 19 27
Ød4
5.0

Ød4 Ød4 10 12 15 23

10.0
YCN +20 YCN +35
13 16 19 27 13 16 19 27
   Ï Ï Ï Ï 
20.0

35.0

Ød4

Ød4

Gating Options - Multi Gates

Axial Gate* Side Gate*

13 16 19 27 13 16 19 27
Ï Ï Ï  Ï Ï Ï 
Ød4
Ød4
5.0
L (nozzle)
L (nozzle)

* Pocket dimensions to be supplied by Mastip

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 25

 YCN Nut System Selection Guide

YCN Open Tipless Nut

YCN Nut is designed for X-range nozzles, providing open flow moulding. An ideal moulding solution
for indirect-feed via a cold runner. Ideal for Thermal Gate applications.

YCN Nut Gating Options

Features
• Internal nut profiles to suit different materials 3
and temperature requirements
• No high-conductivity tip insert required
• Tipless nut provides open flow moulding
• Minimises melt shear
• Lowers the overall pressure drop through the gate 7 4
• Provides a broad repeatable moulding window

Applications P7 P4 N3
• Moulding applications that suit open flow injection Easy material/ Gate is located 7mm forward E.g. PP, PE, ABS,
• Cosmetic gate is not required on moulded part P7 Low temperature of the heat source ASA, SAN
• Ideal for indirect-feed via a cold runner
Gate is located 4mm forward
• Moulding applications where a moulded P4 Mid-Range
of the heat source
E.g. PC, POM, PMMA
sprue is acceptable
• Thermal Gate applications N3
Difficult material/ Gate is located 3mm behind E.g. PA, PBT, PET, PPS
High temperature the heat source PEI, PPO

YCN Nut Extension

YCN Nuts are stocked with a standard extension length

X13 X16 X19 X27

20mm 20mm 20mm 35mm

Gate Diameter
X-Range YCN Nuts are stocked with standard gate diameters according to the nozzle series, nut
style and filled or unfilled material.

Unfilled X Range – YCN Nut Style Filled X Range – YCN Nut Style
Series P7 P4 N3 Series P7 P4 N3
13 Ø1.2 Ø1.3 Ø1.3 13 Ø1.6 Ø1.8 Ø1.8
16 Ø1.4 Ø1.5 Ø1.5 16 Ø1.8 Ø2.0 Ø2.0
19 Ø1.8 Ø2.0 Ø2.0 19 Ø2.2 Ø2.5 Ø2.5
27 Ø2.2 Ø2.5 Ø2.5 27 Ø2.7 Ø3.0 Ø3.0

Custom gate and taper available on request.

Standard sprue taper is 6º

26 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide YCN Nut

YCN Nut Selection

YCN Nut
Selector

Yes Cosmetic
Gate

No

Moulded
No Sprue
Acceptable

Yes

Moulded sprue In-Direct

Yes on part requires No Feed via
repeatable forms Cold Runner

Yes

No

Valve Gate
Yes and/or Sequential
Filling

No

Select Alternative YCN Nut

Option 

Nozzle Order Code for X-Range YCN Thermal Nut Series

NOZZLE YCN NOZZLE NOZZLE BODY NUT GATE POLYMER GATE

RANGE NUT SERIES LENGTH GRADE GRADE PROFILE CLASSIFICATION DIAMETER

BX YCN 27 175 F1 H3 P4 F -30

MX YCN 13 045 160 F1 H3 P7 U (Unfilled)

BX 16 055 175 F3 P4 F (Filled) EXAMPLE OF A
SX 19 065 200 N3 SP FINAL ORDER CODE
075 225
TX 27 085 250
095 275
105 300
115 350
130 400
145 450

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 27

 Multi-Gates System Selection Guide

Multi-Gates

Mastip’s Multi-Gate solutions are engineered specifically for challenging applications requiring close
pitch gates in restricted areas where conventional gating methods aren’t possible.

Multi-Gates Gate Styles

Features Axial Gate

• Axial multi-gates allow close cavity pitching with
a pitch circle diameter (PCD) from 10.00 to 22.00 2 Gates 3 Gates 4 Gates
with the ability to offer 2 to 4 gates per tip 2A 3A 4A
• Side multi-gate allowing close cavity pitching PCD PCD PCD
with a gate well diameter from 22.30mm to
26.80mm with the ability to offer 1 to 4 gates
per tip
• Highly conductive tip allowing for precise
thermal control
• Tip flow channels designed to optimise Side Gate
and balance the thermal profile
• The M-Range nozzles are designed specifically 1 Gate 2 Gates 3 Gates 4 Gates
for multi-gate solutions incorporating BX/SX 1S 2S 3S 4S
proven technology Gate Well Gate Well Gate Well Gate Well
Diameter Diameter Diameter Diameter

Applications
• Multiple part direct injection gating with one
nozzle either in an Axial or Side gate tip style
• Side multi-gates allow internal side gating on Axial Side
single complex round parts that need a highly
balanced fill
• Axial multi-gates allow for direct gating on single
complex round parts that need a highly balanced fill
L

LL

• Only polymers that are easy to process such as

L

polyolefins with long residence times to be

processed through the multi-gates

BM / SM Standard Gate Lengths

Gate Nozzle Series L (Nozzle)

Axial BM 27 75 95 115 145 175 225 275
Gate SM 27 75 95 115 145 175 225 275
Side BM 27 69 89 109 139 169 219 269
Gate SM 27 69 89 109 139 169 219 269

Multi-Gate Flow Rates

Nozzle Series Material Specifications Material (Polyolefin)

Flow Rate g/s/gate 15
Shot Weight g 0.5 - 15
M27 Gate Size – Axial mm 0.7 - 1.0

0.5 - 1.0
Gate Size – Side mm
(max 70% part wall thickness)

28 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide Multi-Gates

Multi-Gates Selection

Multi-Gate
Thermal Gate No
Selection

Yes

No Polyolefin

Yes

Axial Gate Side Gate

Yes Yes

2-4 Gates 1-4 Gates

No per Axial tip* per Side tip* No

Yes Yes

Multi-Gate – 2A, 3A, 4A Multi-Gate – 1S, 2S, 3S, 4S

Alternate Solution

* Number of gates required not included in flow chart, contact Mastip.

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 29

 MJ Nozzle System Selection Guide

MJ Nozzle Overview

MJ nozzle, specifically designed for close cavity pitching.

1.MJ FEATURES

Mould design
• Nozzle pocket profile for improved cooling
performance and gate strength
• Optimal flow characteristics for ease of moulding
1 Dowel Pin
• Close cavity pitching

Operation
• Wide moulding window 2 Body
• Excellent temperature profile and thermal stability
• Operates at low moulding pressure and temperature
• Short cycle times

Installation and maintenance

• Simple installation
• Front loading for ease of servicing
• Improved reliability

3 Tip

4 Heater

5 Thermocouple

6 Snap Ring

30 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide MJ Nozzle

MJ Nozzle Series

Ø4.0
A/F = 20

Ø2
4.0
12.0
L (nozzle)

MJ Standard Lengths
L (nozzle)*
09 Series 75 95 115 130 145 175

* Custom lengths available on request

Ø7.0

Ø14.0

MJ Gating Options

ONT ONT +5 ONT +10

L (nozzle)

5.0

10.0

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 31

 MX Nozzle System Selection Guide

MX Nozzle Overview

MX nozzle, specifically designed for multi cavity manifold systems and hot halves.

1.MX FEATURES

Mould design
• Efficiently designed profile to allow closer cavity pitching
• Shares the same gate profiles as BX and SX 1 Dowel Pin
• Available in both thermal and valve gate options
• Consistent nozzle lengths across the range
• Ability to mould large parts with smaller nozzles
due to optimum flow characteristics 2 Body

Operation
• Wide moulding window
• Excellent temperature profile and thermal stability
• Operates at low moulding pressure and temperature
• Optimum cycle times due to superior thermal insulation
• Uses an advanced micro coil heater with integrated
heat deflection tube 3 Heater Sleeved

Installation and maintenance

• Front loading capability for easier servicing of tips,
heaters and thermocouples
• Simple machining and installation requirements
• Improved reliability due to the use of advanced materials
• Common tip and nut options provide ready availability of
spare parts

4 Tip

5 Thermocouple

6 Thermocouple Clip

7 Heater Cap

8 Snap Ring

9 Nut

32 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide MX Nozzle

MX Nozzle Series

.0
.0 Ø8
0 Ø7
Ø6.

A/F = 26

A/F = 36
A/F = 24

Ø28 Ø30
.0 .0
Ø4
0.0

15.0
12.0

12.0

L (nozzle)
L (nozzle)

L (nozzle)

Ø10.0 Ø12.0 Ø15.0

Ø22.9 Ø24.9 Ø31.5

MX13 MX16 MX19

MX Nozzle Body Lengths**

Series Steel 45 55 65 75 95 115 130 145 175

13 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1

420 (SS) F3* F3* F3* F3 F3 F3* F3* F3* F3*

16 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1

420 (SS) F3* F3* F3 F3 F3 F3 F3* F3* F3*

19 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1

420 (SS) F3* F3* F3 F3 F3 F3* F3* F3*

* Length not currently stocked, available on request

** Custom lengths available on request, BX recommended
Available in H13 and 420 steel

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 33

 BX Nozzle System Selection Guide

BX Nozzle Overview

BX nozzle is designed to provide cost sensitive solutions for low to medium cavitation
applications, not requiring hot half construction.

1.BX FEATURES

Mould Design
• Ability to easily order special length nozzles 1 Dowel Pin
• Shares the same gate profiles as MX and SX
• Available in both thermal and valve gate options
• Consistent nozzle lengths across the range 2 Body
• Ability to mould large parts with smaller nozzles
due to optimum flow characteristics

Operation
• Wide moulding window
• Excellent temperature profile and thermal stability
• Operates at low moulding pressure and temperature
• Optimum cycle times due to superior thermal insulation
• Uses an economical and robust coil heater
3 Heater
Installation and Maintenance
• Simple machining and installation requirements
• Improved reliability due to the use of advanced materials
• Common tip and nut options provide ready availability of
spare parts

4 Heater Cover

5 Tip

6 Thermocouple

7 Thermocouple Clip

8 Heater Cap

9 Snap Ring

10 Nut

BX Nozzle Body Lengths**

Series Steel 45 55 65 75 85 95 105 115 130 145 160 175 200 225 250 275 300 350 400 450

13 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1* F1*

420 (SS) F3* F3* F3 F3 F3* F3 F3* F3* F3* F3* F3* F3* F3* F3*
16 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1* F1* F1*
420 (SS) F3* F3* F3 F3 F3* F3 F3* F3 F3* F3* F3* F3* F3* F3* F3*
19 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1* F1* F1* F1* F1*
420 (SS) F3* F3* F3* F3 F3* F3 F3* F3 F3* F3* F3* F3* F3* F3* F3* F3* F3*
27 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1* F1* F1* F1*
420 (SS) F3 F3* F3 F3* F3 F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3*

* Length not currently stocked, available on request

** Custom lengths available on request
Available in H13 and 420 steel

34 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide BX Nozzle

BX Nozzle Series

.0 0
Ø6 Ø7. Ø8.
0

A/F = 34

A/F = 36
A/F = 31

Ø34
.0 Ø38
.0 Ø40
.0
12.0

15.0
12.0
L (nozzle)

L (nozzle)

L (nozzle)
Ø10.0 Ø12.0 Ø15.0
Ø27.0 Ø30.0 Ø33.0

BX13 BX16 BX19

2.0
Ø1
A/F = 45

Ø50
.0
20
L (nozzle)

Ø23.0
Ø43.0

BX27

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 35

 SX Nozzle System Selection Guide

SX Nozzle Overview

With two heaters the SX nozzle is perfectly suited for all single nozzle applications.

1.SX FEATURES
1 Circlip

Mould Design
• Ability to easily order special length nozzles 2 Sprue Heater Cover
• Shares the same gate profiles as MX and BX
• Consistent nozzle lengths across the range
3 Sprue Heater
• Ability to mould large parts with smaller nozzles
due to optimum flow characteristics

Operation 4 Sprue Thermocouple

• Separate heater for the nozzle head for
maximum temperature control
• Wide moulding window
• Excellent temperature profile and thermal stability
• Operates at low moulding pressure and temperature 5 Dowel Pin
• Optimum cycle times due to superior thermal insulation
6 Body
• Uses economical and robust coil heaters

Installation and Maintenance

• Simple machining and installation requirements 7 Heater
• Improved reliability due to the use of advanced materials
• Common tip and nut options provide ready availability of
spare parts

8 Heater Cover

9 Thermocouple

10 Tip

11 Thermocouple Clip
12 Heater Cap
13 Snap Ring

14 Nut

SX Nozzle Body Lengths**

Series Steel 45 55 65 75 85 95 105 115 130 145 160 175 200 225 250 275 300 350 400 450

13 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1* F1*

420 (SS) F3 F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3*

16 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1* F1* F1*

420 (SS) F3 F3 F3 F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3*

19 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1* F1* F1* F1* F1*

420 (SS) F3* F3 F3 F3 F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3*

27 H13 (Std) F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1 F1* F1* F1* F1*

420 (SS) F3 F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3* F3*

* Length not stocked, available on request

** Custom lengths available on request
Available in H13 and 420 steel
To suit machine nozzle orifice and radius

36 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide SX Nozzle

SX Nozzle Series

A/F = 46
A/F = 36

A/F=36
Ø40 Ø50
Ø4
0
Ø32 Ø32
Ø24 Ø24 Ø38
Ø3*
Ø6 Ø4* Ø30
Ø7 Ø4*
Ø8
5
7

5
7
26

5
7
26

26
18

18

20
L (nozzle)

L (nozzle)

L (nozzle)
Ø10 Ø12 Ø15
Ø27 Ø30 Ø33

SX13 SX16 SX19

A/F = 46

Ø50

Ø38
Ø30
Ø5*
Ø12
5
7
25
25
L (nozzle)

Ø23
Ø43

SX27

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 37

 TX Nozzle System Selection Guide

TX - FlowLoc™ Nozzle Overview

FlowLoc™ Technology Range are designed to provide a secure, leak-proof solution for multi-cavity manifold systems.

1.
FLOWLOC ™
FEATURES

Design
• Available in 16, 19 and 27 Series nozzle in a variety of
lengths with the ability to order special length nozzles
• Features a threaded base to attach securely
to the manifold 1 Stainles Steel
• Available in thermal gate Body
• Suitable for low to high cavity applications
• Shares the same gate profiles as existing X-Range nozzles

Operation
• Incorporates advanced heating technology with
embedded heaters for exceptional thermal performance
• Threaded nozzle screws directly into the manifold
providing a secure, leak-proof solution
• Capable of processing a wide range of polymers
including abrasive fillers
• Excellent thermal profile along the entire length
of the nozzle ensures a wide moulding window
2 Heater
• Suitable for high pressure applications

Installation and Maintenance

• Simple installation via threaded base
• Utilises Mastip’s proven X-Range tips and nuts
• Individual components are readily available on 3 Thermocouple
express order from our service team

4 Thermocouple Clip

5 Heater Cap

6 Circlip

7 Tip

8 Nut

TX Nozzle Body Lengths**

Series Steel 75 85 95 105 115 130 145 160 175 200 225 250 275 300 350 400 450

16 420 (SS) F3 F3 F3 F3 F3 F3 F3 F3 F3 F3* F3* F3*

19 420 (SS) F3 F3 F3 F3 F3 F3 F3 F3 F3 F3* F3* F3* F3* F3*

27 420 (SS) F3 F3 F3 F3 F3 F3 F3 F3 F3 F3 F3 F3 F3 F3* F3* F3* F3*

* Custom lengths available on request

Available in 420 steel

38 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide TX Nozzle

TX FlowLoc™ Nozzle

Ø12.0
Ø8.0
Ø7.0

20.00
20.00
20.00

L (nozzle)
L (nozzle)
L (nozzle)

A/F = 27
A/F = 30 A/F = 36

TX16075 - TX16200 TX19075 - TX19200 TX27075 – TX27200

Ø8.0

Ø12.0
Ø7.0

Ø12.0
20.00

20.00
20.00
L (nozzle)

(nozzle)
LL(nozzle)

A/F = 27 A/F = 30
A/F == 36
A/F 36

TX16225 – TX16250 TX19225 – TX19300 TX27225 – TX27450

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 39

 VeriShot™ Single Valve Gate System System Selection Guide

VeriShot™ Single Valve Gate System

Mastip’s VeriShot™ is an extremely compact, adjustable single valve gate system. The VeriShot™ incorporates
advanced heating technology for exceptional thermal performance in applications requiring high cosmetic finish,
high flow rates and dimensional accuracy.

1. ™ FEATURES
VERISHOT 1 Locating Ring
Cap Screw M6
(metric option)
or ¼ UNC
2
Design
(inch option)
• Available to suit TX16, TX19 &
TX27 series threaded nozzles 3 Dowel Pin Ø6 x 20
• Compact annular design
• Reduced mould height 4 Cap Screw M8 x 90
• Multiple gate profiles to suit
a broad range of applications
• VeriShot™ functions as a locating 5 Striker Plate
ring for mould alignment 6 Dowel Pin Ø5 x 28
• Locating ring supplied in metric and
imperial sizes 7 Upper Manifold

Operation
• Advanced heating technology 8 Pin Locking Screw
9a
• Exceptional thermal performance 10 Valve Pin
• Capable of processing a wide range Valve Pin 9b
of polymers Adjustment 9c
• Adjustable valve pin Packers 11 Wear Strip Top
9d
• Incorporates superior FlowLoc™ 12 O-Ring ID 79 x 3
Technology providing a secure,
leak-proof solution 13 Piston

Installation and Maintenance 14 O-Ring ID 100 x 3

Wear Strip 15
• Simple Installation Bottom
• Utilises proven X-Range tips and nuts 16 O-Ring ID 79 x 3
Dowel Pin 17
Ø6 x 20 18 O-Ring ID 115 x 3
19 O-Ring ID 5 x 1.5
20 Cylinder
21 Cap Screw M5 x 40
22 O-Ring ID 6 x 1.5
Button Cap Screw 23
M4 x 8

24 VeriShot™ Heater

25 Dowel Pin Ø5 x 28
26 Valve Pin Seal
Lower Manifold 27
28 Dowel Pin Ø3 x 12

Thermocouple 29
30 FlowLoc™ Nozzle

40 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide VeriShot™ Single Valve Gate System

VeriShot™ Single Valve Gate System

Ø170.00
Ø140.00
92.0
146.0

ØD
17.00
54.00

76.00 Min
L (nozzle)

FlowLoc™ (nozzle)

Metric Inch
ØD 100-125mm 4”- 5”

VeriShot™ Nozzle Compatibility

Description FlowLoc™ Nozzle Supplied Pin Size L (nozzle)
VeriShot 16 ™
TX16 Ø2.5 x 350 75 - 200
VeriShot 19 ™
TX19 Ø3.0 x 400 75 - 300
VeriShot™ 27 TX27 Ø5.0 x 600 75 - 450

Note
1. Lengths can be customised to suit your requirements on request
2. Multiple diameter locator ring sizes now come as standard to suit your requirements.

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 41

 MVG25 Headed Pin Valve Gate System System Selection Guide

MVG25 Headed Pin Valve Gate System

1.
MVG25 FEATURES

1 Blanking Plate Screw

Mould Design
• Available to suit MX and BX Nozzles
2a Blanking Plate 2b
• Standard minimal pitching is
55mm – can be modified to fit 43mm
• Backplates 50mm minimum 3 Blanking Plate Seal
• Conical or Cylindrical shut off
• Easy machining of the pockets 4 Pin Locking Screw
• Pneumatic circuit integrated with
5 Pin Head Seal
the backplate
6a Valve Pin Adjustment Packer
Moulding Benefits
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results
in better part quality
• Reduced gate cooling requirements

Installation and Maintenance 7 Valve Pin

• Easy machining and installation
• Easy seal replacement
• Valve pin height is adjustable
• Comes with Headed Pin design,
with incremental adjustment

6b
6c Valve Pin Adjustment Packers
6d

8 Piston Main Seal

9 Piston

10 Piston Rod Seal

11 Circlip

12 Cylinder

13 Cylinder End Seal

14 Locating Spacer

15 Valve Pin Seal

42 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

 System Selection Guide MVG25 Headed Pin Valve Gate System

MVG25 Headed Pin Valve Gate System

MVG25 Blanking Plate

Ø54.0

MVG25 Cylinder Assembly

50.0 Min
MVG25 Spacer

MVG25 Valve Pin

10.0

MVG25 Nozzle Compatibility

Description Nozzle Nozzle Length Supplied Pin Size
MX13 45 – 175 Ø2.0
MVG25-P1 Headed Pin BX13 45 - 225
MX16 45 - 175 Ø2.5
BX16 45 - 250

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 43

 MVG40 Headed Pin Valve Gate System System Selection Guide

MVG40 Headed Pin Valve Gate System

1.
MVG40 FEATURES

1 Blanking Plate Screw

Mould Design
• Available to suit MX and BX Nozzles
• Standard minimal pitching is 75mm
2a Blanking Plate 2b
- can be modified to fit 58mm pitching
• Backplates 55mm minimum
• Conical or Cylindrical shut off 3 Blanking Plate Seal
• Easy machining of the pockets
• Pneumatic circuit integrated with the backplate 4 Pin Locking Screw

5a Valve Pin Adjustment Packer

Moulding Benefits
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results
in better part quality
• Reduced gate cooling requirements

Installation and Maintenance

6 Valve Pin
• Easy machining and installation
• Easy seal replacement
• Valve pin height is adjustable
• Comes with Headed Pin design,
with incremental adjustment

5b
5b Valve Pin Adjustment Packers
5b
7 Piston Main Seal

8 Piston

9 Piston Rod Seal

10 Circlip

11 Cylinder

12 Cylinder End Seal

13 Locating Spacer

14 Valve Pin Seal

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 System Selection Guide MVG40 Headed Pin Valve Gate System

MVG40 Headed Pin Valve Gate System

MVG40 Blanking Plate

Ø75.0

MVG40 Cylinder Assembly

55.0 Min
MVG40 Spacer

MVG40 Valve Pin

10.0

MVG40 Nozzle Compatibility

Description Nozzle Nozzle Length Supplied Pin Size
MX13 45 - 175 Ø2.0
BX13 45 - 225
MVG40-P1 Headed Pin MX16 45 - 175 Ø2.5
BX16 45 - 250
MX19 45 - 175 Ø3.0
BX19 45 - 300
BX27 75 - 450 Ø5.0

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 MVG40 Threaded Pin Valve Gate System System Selection Guide

MVG40 Threaded Pin Valve Gate System

1.
MVG40 FEATURES

Mould Design 1 Blanking Plate Screw

• Available to suit MX and BX Nozzles
• Standard minimal pitching is 75mm
- can be modified to fit 58mm pitching
2a Blanking Plate 2b
• Backplates 55mm minimum
• Conical or Cylindrical shut off
• Easy machining of the pockets 3 Blanking Plate Seal
• Pneumatic circuit integrated with the backplate
4 Pin Locking Screw
Moulding Benefits
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results 5 Valve Pin
in better part quality
• Reduced gate cooling requirements

Installation and Maintenance

• Easy machining and installation
• Easy pin adjustment and seal replacement
while the mould remains assembled 6 Piston Main Seal
• Comes with Threaded Pin design fully adjustable
7 Piston

8 Piston Rod Seal

9 Circlip

10 Cylinder

11 Cylinder End Seal

12 Locating Spacer

13 Valve Pin Seal

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 System Selection Guide MVG40 Threaded Pin Valve Gate System

MVG40 Threaded Pin Valve Gate System

MVG40 Blanking Plate Ø75.0

MVG40 Cylinder Assembly

55.0 Min
MVG40 Spacer

MVG40 Valve Pin

10.0

MVG40 Nozzle Compatibility

Description Nozzle Nozzle Length Supplied Pin Size
MX13 45 - 145 Ø2.0
BX13 45 - 145
MVG40-P2 Threaded Pin MX16 45 - 145 Ø2.5
BX16 45 - 145
MX19 45 - 175 Ø3.0
BX19 45 - 300
BX27 75 - 400 Ø5.0

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 47

 MVG55 Headed Pin Valve Gate System System Selection Guide

MVG55 Headed Pin Valve Gate System

1.
MVG55 FEATURES

1 Blanking Plate Screw

Mould Design
• Available to suit BX Nozzle in 27 Series
• Standard minimal pitching is 95mm 2a Blanking Plate 2b
can be modified to fit 74mm
• Backplates 55mm minimum
3 Blanking Plate Seal
• Easy machining of the pockets
• Pneumatic circuit integrated with 4 Pin Locking Screw
the backplate
5a Valve Pin Adjustment Packer
Moulding Benefits
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results
in better part quality
6 Valve Pin
• Reduced gate cooling requirements

Installation and Maintenance

• Easy machining and installation
• Easy seal replacement
• Valve pin height is adjustable
• Comes with Headed Pin, with
incremental adjustment

5b
5c Valve Pin Adjustment Packers
5d

7 Piston Main Seal

8 Piston

9 Piston Rod Seal

10 Circlip

11 Cylinder

12 Cylinder End Seal

13 Locating Spacer

14 Valve Pin Seal

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 System Selection Guide MVG55 Headed Pin Valve Gate System

MVG55 Headed Pin Valve Gate System

MVG55 Blanking Plate

Ø95.0

MVG55 Cylinder Assembly

55.0 Min
MVG55 Spacer

MVG55 Valve Pin

10.0

MVG55 Nozzle Compatibility

Description Nozzle Nozzle Length Supplied Pin Size
MVG55-P1 Headed Pin BX27 75 – 450 Ø5.0

© Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com 49

 Cylix Headed Pin Valve Gate System System Selection Guide

Cylix Headed Pin Valve Gate System

1.
CYLIX FEATURES
1 Blanking Retaining Screws

Mould Design
• Available to suit TX, FlowLoc™ Nozzle 2 Blanking Plate
• Standard minimal pitching is 60mm
• Backplates 65mm minimum
• Conical (1) or Cylindrical (2) shut off 3 Lid Seal
• Easy machining of pockets
4 Pin Locking Screw
Moulding Benefits 5a Valve Pin Adjustment Packer
• Reduced moulding pressure
• Wide moulding window
• Low mould filling stress results
6 Valve Pin
in better part quality
• Reduced gate cooling requirements

Installation and Maintenance 5b

• Cylix pneumatic actuator pre-assembled 5c Valve Pin Adjustment Packers
to manifold 5d
• Actuator has integrated cooling circuit to
maintain integrity of seals 7a Piston Seal
• PTFE/stainless braided hose supply
pneumatics and cooling 7b Piston Seal O-Ring
• Easy seal replacement
• Valve pin height is adjustable 8 Piston
• Comes with Headed Pin (P1), with
incremental adjustment
9 Bearing Strip
10 Rod Seal

11 Cylinder Retaining Screws

12 Cylinder

13 Flange Plug

14 Base Mounting Screws

15 Base

16 Valve Pin Seal

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 System Selection Guide Cylix Headed Pin Valve Gate System

Cylix Headed Pin Valve Gate System

Y
10
X
Pin Length
L (nozzle)

figure. 9

Cylix Nozzle Compatibility

Description Nozzle Nozzle Length Supplied Pin Size
PVB40-P1 Headed Pin TX16 75 – 250 Ø2.5
PVB40-P1 Headed Pin TX19 75 - 300 Ø3.0
PVB40-P1 Headed Pin TX27 75 - 450 Ø5.0

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 MVCH Valve Gate System System Selection Guide

MVCH Valve Gate System

1.
MVCH FEATURES
1 Back Plate Screw
Mould Design
• Available to suit MX 16, 19 and BX 16, 19 and 27 series
• Standard minimal pitching is 58mm
2 Back Plate
• Backplates 86mm minimum
• Easy machining of pockets
• Hydraulic actuation

Moulding Benefits
• Improved part quality 3 Cylinder
• Reduced moulding pressure
• Increased moulding window
• Lower mould filling stress results in better part quality
• Reduced gate cooling requirements

Installation and Maintenance

• Adjustable pin length 4 Cylinder Screw

5 Lock Nut

6 Pin Holder

7 Pin

8 Pin Holder Cap

9 Steel Spacer

10 Insulation Spacer

11 Seal

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System Selection Guide MVCH Valve Gate System

MVCH Valve Gate System

80x58
54x54

86 MVCH2505
96 MVCH2510
15.0
L (nozzle)

MVCH Nozzle Compatibility

Description Stroke Supplied Pin Size Nozzle L (nozzle)
MVCH2505-2.5 5
MX16 45 - 145
MVCH2510-2.5 10
Ø2.5
MVCH2505-2.5 5
BX16 45 - 145
MVCH2510-2.5 10
MVCH2505-3 5
MX19 55 - 145
MVCH2510-3 10
Ø3.0
MVCH2505-3 5
BX19 45 - 145
MVCH2510-3 10
MVCH2505-5 5
Ø5.0 BX27 75 - 250
MVCH2510-5 10

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 Manifold Configuration System Selection Guide

Manifold Components
Exploded view of a Standard 2 Drop Hot Runner System

1 Spacer Assembly

2 Sprue Bush & Heater

Manifold Heater
4
Thermocouple 3 & Ceramic Connector

5 Manifold

End Plug Assembly 6

7 Locator

9 Nozzle

Orientation Dowel Pin 8

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 System Selection Guide Selecting a Manifold Configuration

Selecting a Manifold Configuration

When deciding on a manifold layout it is important to consider the following:

• The number of injection points required per cavity
• The number of cavities in the mould
• Minimum distance between nozzles
• Balancing of the manifold
• Spacing of cavities to provide adequate room for cooling
• Gate and cavity
• Strength of the mould
• Sufficient steel between cavities
• Mould size versus machine platen size
• Total shot weight

For multi-cavity moulds balancing is critical to achieve consistent dimensions, cosmetic appearance and processing
conditions across cavities. It is therefore strongly recommended that for multi-cavity moulds a manifold layout providing
natural balancing is used.

Natural Balancing: In order to achieve natural balance, the material must flow through identical geometry from the
machine nozzle to each of the gates.
This means identical:
• Flow distance
• Runner diameters
• Number and angle of bends
This ensures that every gate receives material in exactly the same condition. With natural balance, the balance is
inherent in the design, and is not based on a specific material or processing temperature.

Rheological balancing: Is a method of balancing by using different runner sizes to artificially provide identical pressure
drop at each gate. To accurately predict this, the flow properties of the material must be known, along with the flow rate
and anticipated processing temperature. Any variation from the processing conditions used during design will result in
an unbalanced system.

Some drop configurations can not be naturally balanced unless the drops are on a PCD and must therefore be
rheologically balanced. E.g. 3, 5, 7, 9, 10, 11, 13, 14, 15, 17-23 etc
All standard Mastip manifolds (except 3 Drop 3x1) are naturally balanced.

Best Configuration Poor Configuration

Equal and symmetrical drop positions Unbalanced drop positions
L

R2
L

R1

L L

Refer to the Manifold Guidelines Section for standard drop configurations.

L1 L2

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 Nexus™ Systems System Selection Guide

Nexus™ Systems
Mastip’s Nexus™ Pre-Assembled and Pre-Wired hot runner systems are designed for fast, simple installation out of the box without
requiring any further technical assembly. Nexus™ Systems incorporates superior FlowLoc™ technology providing a secure, leak-
proof solution. The FlowLoc™ range ensures an excellent thermal performance using the latest heating technology.

1. ™ SYSTEMS
NEXUS

• Fully customised to suit

your application requirements
• Thermal and Valve Gate configurations
• Able to process commodity and
engineering grade polymers
• Fast, simple installation out of the box
• Advanced heating technology with
embedded heaters
• FlowLoc™ nozzles connect securely
to manifold via threaded base
• Cylix™ Valve Cylinders mount directly
to the manifold system
• Stainless steel nozzles
• Proven performance of X-Range
nozzle technology
• Customised trunking for wiring
• Advanced heating technology for
superior thermal performance
• Leak-proof solution via screwed
in nozzles
• Accidental cold starting will not
result in polymer leakage
• User-friendly maintenance
• Excellent thermal profile
ensures a wide moulding window
• Unit removes easily from mould
facilitating quick, easy service and
maintenance

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 System Selection Guide Hot Half System

Hot Half System

All Mastip’s Hot Half solutions, from low to high cavity thermal or valve gate systems,
are delivered as a complete solution to integrate seamlessly with your completed mould.

1. HALF FEATURES
HOT

Applications
• Fully customised to suit
your application requirements
• Able to process commodity
and engineering grade polymers

Features
• Plates available in high quality
P20 steel or 420 stainless steel
• Proven performance of X-Range
nozzle technology
• Delivered fully assembled and
fully wired

Benefits
• Advanced heating technology for
superior thermal performance
• Easy servicing of nozzles, tips,
thermocouples and heaters
• Heaters are front loading
• Excellent thermal profile ensures
a wide moulding window
• 3-year leak proof guarantee

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 Additional Considerations System Selection Guide

Additional Considerations

To select a Hot Runner System to match your part and material specifications consideration must
be given to the following:
• Gate type
• Gate size
• Nozzle range and series
• Nozzle tip style
• Nozzle nut type

Selecting Material

There are three broad categories of materials each relating to its moulding characteristics:
• Easy
• Medium
• Difficult
When selecting material consider the following:
• Materials with large percentages of filler (for example, >15%) or very low MFI, the material classification moves up a grade (for
example, easy to medium).

Selecting a Gate Type

The following factors must be considered when selecting a gate type:

• Shot size of part • Required cycle time

• Material to be moulded
• Material
• Viscosity
• Additives
• Glass fibre
• Flame retardant
• Gate surface finish
• Thickness of part walls
• Longest flow length of part

When designing an injection mould, the type, size and location of the gate is one of the most important consideration
for correct moulding of the part. Incorrect gate position can result in uneven filling, over packing, and dimensional
instability.
Available gate types include:
• Direct gating
• Valve gating
Direct gating is the most common gate type as it offers simple construction and reliability.
Refer to the Nozzle Section for more information about Gate Types

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 System Selection Guide Additional Considerations

Gate Size
The correct gate size ensures a good thermal gate is achieved and minimises the pressure drop across the gate while
maintaining its structural integrity. Parts with very thin wall sections or very long flow lengths need a larger nozzle and
gate to achieve proper filling, this may require increasing the nozzle by one to two series.

The gate sizes effects the:

• Flow rate
• Pressure drop through the system
• Cycle time
• Thermal gate shut off after filling
• Cosmetic impact of the gate on the part
• Cooling in the gate area
The gate size is dependent on the:
• Material
• Material viscosity
• Part wall thickness
• Gate cooling*
* Gate cooling is a complex variable and consideration must also be given to cycle time, gate profile, and land length.

Gate Size Variables

gate size vs
gate size vs material gate size vs MFI part wall thickness gate size vs gate cooling

large gate
large gate
large gate

large gate

small gate
small gate
small gate

small gate

amorphous crystalline low MFI high MFI thin thick cold gate hot gate
material material material material part wall part wall cooling cooling

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 System Selection - Example System Selection Guide

Working Example of a System Selection

To calculate the number and size of nozzles required to fill a part an initial estimate of the number of nozzles or injection
points must be made. A good starting point is to limit the flow length / part thickness (L/t) ratio to the
typical values for that type of material. Refer table on page 13 - Typical Flow Length Ratios.

1 Part Details 3 Hot Runner System Initial Estimates

Description Fluorescent Light Base Number of Nozzles (N) 4
Overall Size 700 x 150 x 40 mm L/t 87.5 with 4 Nozzles
Wall thickness (t) 1.5mm
Part Volume (V) 220ml

2 Material 4 Hot Runner System Analysis Results

Type ABS Injection Pressure 93.65MPa
Grade Cycolac T-XS 30001 Injection Time (T) 1.36
Flame retardant Yes Total Flow Rate (F) (V*SG)/T=(220*1.3)/1.36=210g/s
Specific Gravity (SG) 1.3 Flow Rate per Nozzle (F/N)=210/4=52.5g/s
L/t for wall thickness 96
Material Category Medium - due to flame
retardant move up one
grade to difficult.

Part Model - Fluorescent Light Base

Nozzle Series Selection

19 Series Nozzle is best suited due to the required flow rate of 52.5 g/sec. and the ABS material fitting the
medium to difficult material category.

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 System Selection Guide Temperature Control System

Meticom TC5100 / TC5200 Temperature Control System

1.
METICOM TC5100 / TC5200 FEATURES

Features
• TC5100 accommodates 12 to 36 zones
• TC5200 has 24 to 72 zones and can
accommodate up to 120 zones in a
network
• The modularized design allows for easy
maintenance and configuration
• Soft Start function to protect heaters
during startup
• Idle mode after power failure, to protect
hot runner system and mold
• Self test on startup
• CE certified
• Easy to use touch screen interface
• Mould and module diagnostics
• Quick multi-zone setup
• Power usage display
• Synchronous heating and cooling
• Automatic heater and thermocouple
detection and monitoring

Technical Specifications

Module input power 230Vac ± 10% (50/60 Hz)

Power consumption 230Vac, 3W per module
Output power 3450W, 15A/230Vac per zone
Storage temperature range -20ºC to 70ºC (-4ºF to 158ºF)
Operating temperature range -10ºC to 50ºC (14ºF to 122ºF)
Operating humidity 10-80% RH (non-condensing)
Control accuracy ± 0.25% FS
Measurable accuracy ± 0.25% FS
Temperature control range 0ºC to 600ºC (32ºF to 999ºF)
Fuse 250Vac, 20A 30mm

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 Temperature Control System System Selection Guide

Meticom TC5H Temperature Control System

1. TC5H FEATURES
METICOM

• Blown Fuse
• Display function of current and output
ratio
• Smart SOFT START function
• Auto/Manual Selection function
• PID Automatic Temperature Control
• Output percentage limit setting
• LCD display module
• One-key start (stop)/standby (boost)
function
• Built-in alert alarm
• CE Certified
• Over-voltage protection
• Heater short-circuit protection
• Automatic detection of wire breakage of
heater
• TRIAC short-circuit protection
• Detection for reverse troubleshooting
sensor wiring temperatures

Technical Specifications

Module input power 230Vac ± 10% (50/60 Hz)

Power consumption 230Vac, 3W per module
Output power 3450W, 15A/230Vac
Storage temperature range -20ºC to 70ºC (-4ºF to 158ºF)
Operating temperature range -10ºC to 50ºC (14ºF to 122ºF)
Operating humidity 10-80% RH (non-condensing)
Control accuracy ± 0.25% FS
Measurable accuracy ± 0.25% FS
Temperature control range 0ºC to 600ºC (32ºF to 999ºF)
Fuse 250Vac, 20A 30mm

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 System Selection Guide Sequential Control System

G-Series GTV8 Integrated Sequential Controller

1.
GTV8 FEATURES

• Regulation of the injection quantity from

each individual gate
• Quality of the moulded part can be
improved by removing or repositioning of
weld lines
• Injection is performed with minimum
clamping force due to the gates not all
opening simultaneously
• Optimum control over part fill
• Pneumatic only
• Standard GTV8 cabinet configurations
are 8 zones compact design

Technical Specifications

Mains input power Single phase AC 220V (50/60 Hz)

Injection signal input power supply 24VDC, 220VAC
Solenoid output power supply Signal voltage, 100mA/Zone
Operating temperature range -10 ºC to 50 ºC
Operating modes Two modes (Continuous Sequence and Intermittent Sequence)
Timer Increment 0.1 seconds
Timer Range 0 - 999 seconds
Automatic input voltage Yes
Manual override Yes

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 Notes System Selection Guide

Notes

64 © Copyright Mastip Technology Limited. Information subject to alteration. V3.24 www.mastip.com

Mastip Head Office New Zealand
Physical Address
558 Rosebank Road, Avondale
Auckland 1026, New Zealand
Postal Address
PO Box 90651, Victoria St West
Auckland 1142, New Zealand
Phone: +64 9 970 2100
Email: [email protected]
Mastip Regional Office Europe
Phone: +33 0 809 400 076
Email: [email protected]
Mastip Regional Office North America
Phone: +1 262 644 9400
Email: [email protected]
Mastip Regional Office China
Email: [email protected]
For a full list of Distributors,
please visit www.mastip.com

© Copyright Mastip Technology Limited. Information subject to alteration. 40-000-070 V3.24