The flow front is one of the most critical—and at the same time least transparent—phases in the injection molding process.
The switching point is often defined indirectly based on pressure curves or empirical values. To avoid short shots or flash, the settings are chosen conservatively.
This increases the cycle time.
Why this patent is relevant
Indirect switching strategies result in safety margins.
Typical consequences in production:
- Longer cycle times
- Unstable filling processes for complex geometries
- Rejected due to material or temperature drift
- Extended sampling periods
Even an increase of just 0.5 seconds per cycle can result in a several-percent drop in output for production tools.
The patented process replaces estimates with a defined trigger signal as soon as the melt reaches a specified position.
The switching point becomes reproducible.
Typical applications
- Cascade injection molding
- PUR flooding
- Monitoring the flow front velocity
- Precise definition of the switching point
- Trigger for venting or needle closure
Direct flow front measurement ensures stability in the filling process, particularly when dealing with reactive materials or multiple injections.
Technological progress
The patented measurement principle enables:
✔ Real-time transparency in the filling process
✔ Reproducible switching points
✔ Reduced cycle times
✔ Faster mold validation
This isn't about sensor technology.
It's all about production levers: measurable stability, shorter cycles, and predictable output.