Hot Runner & Control Systems

HOT RUNNER & CONTROL SYSTEMS

Table of Contents Hot Runner Systems

Hot Runner Systems

Temperature Control Systems SS TSP & TSP Plus

Stellar Micromolding...................................................29-32 Thermal Gate Hot Runner Systems Valve Gate Hot Runner Systems Smart One VG Hot Runner Systems..........................20-27 Customer Commitment........................................................4 Terms and Conditions of Sale. ...........................................5 Sales and Ordering Information. .......................................6 Hot Runner Warranty...........................................................7 Hot Runner Systems Overview...................................... 8-9 Custom Applications Engineered Hot Runner Systems Hot Runner Selection Guide.............................................11 Standard Global Manifold and Components..................12 Plastic Materials, Specs/Bushing Selection........... 13-14 Hot Runner Quote Request Form.....................................15 DME Hot Runner Technology. ..........................................18

TSP (Touch Screen Panel)......................................115-117 TSP Plus (Touch Screen Panel..............................118-119

Smart Series ® Typical System Configurations......................................124 Single Zone Controllers...........................................125-127 2-zone Controllers............................................................127 Single & 2-zone Accessories.................................128-129 Single Zone High Power Controller & Accessories...130 Smart Series 15 AMP Mainframe Configurations...........................................................131-132 Smart Series 30 AMP Mainframe Configurations..................................................................133 Digital Current/Voltage Monitor.....................................134 Floor Stand........................................................................135 Step-Down Transformer Kits..........................................135 Blank Panels, Fuses & Crimp Connectors...................135 Mainframe Connector Wiring.................................136-138 Mold Power & Thermocouple Cables..........................139 Mold Power Input Connectors.......................................140 Mold Thermocouple Connectors...................................141 Mold Connector Pocket Layouts............................142-143 Pre-wired Combination Terminal Mounting Boxes....144 Terminal Mounting Boxes...............................................145 SSM Modules............................................................146-147 TSM Modules............................................................148-149 TAS Temperature Alarm/System Modules...........150-151 Replacement Parts...................................................152-154 Input Wiring Diagram..............................................155-157 Alternate Cable Configurations..............................158-161 Stand Accessories..........................................................162

Standard Pre-Engineered Hot Runner Systems

The Hot One Technology.............................................34-52 Meteor Hot Runner......................................................51-60

Hot Sprue Bushings

D-MAX............................................................................64-69 Gate-Mate .....................................................................71-77 Straight-Shot ................................................................79-88 > High-Performance........................79-80 > S-Series ..............................................81 > E-Series .........................................82-83 > ER-Series ......................................84-85 > T-Series ..............................................86 > TR-Series ...........................................87 > Replacement Parts ..........................88 Integrally Heated Sprue Bushings ...........................89-94

Valve Gate Controller Products & Solutions

Hot Runner Services

Obsolete System Replacement Parts Gate-Mate...................................................................102-103 Cool One......................................................................104-111 Moldflow..........................................................................96-97 Moldflow Quote Request Form.........................................98 Hot Runner Service Center.........................................99-100

SVG Pneumatic Control Systems...........................164-165 SVG Hydraulic Control Systems.............................166-167 VCAP Air Valve Assemblies...........................................168 Compact 4-zone Pneumatic/Hydraulic controller......168 Single Zone Timer............................................................169

Technical Support....................................................170-171

Modular Components Deliver High Performance......112

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Hot Runner Systems

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Index

Index

Alternate Cable Configuration......................................... ..... 159 Alternate Cable Wiring Diagram. ......................................... 160 Blank Panels, Fuses & Crimp Connectors............................. 135 Bushing Selection....................................................................14 Cable Storage Baskets...........................................................162 Cartridge Heaters.................................................................... 47 Control Systems............................................................... ..... 121

Obsolete Hot Runner Replacement Parts......................... .... 101 Cool One & Micro Cool One............................................ 104 Gate-Mate Nozzles...........................................................102 Gate Shell Insulators........................................................103

Replacement Parts (Temp Control)........................................ 152

Sales and Ordering Information................................................ 6 Selection Guide, Hot Runner Technology. .............................. 10 Single & 2-Zone Controller Accessories........................ 125-130 Single Zone Controllers......................................................... 125 Single Zone High Power Controller & Accessories.............. 130 Single Zone Timer.................................................................. 169 SmartONE Hot Runner System. ......................................... 20-27 Smart Series 15 AMP Mainframe Configurations....................................................................... 131 Smart Series 30 AMP Mainframe Configurations....................................................................... 133 SSM Modules........................................................................ 146 Stellar Micromolding Hot Runner Systems. ........................... 28 Step-Down Transformer Kit................................................... 135 Straight Shot™ Hot Sprue Bushings....................................... 78 TAS Temperature Alarm/System Modules........................... 150 Technical Support Data (Temp Control). ............................... 170 Terminal Mounting Boxes. ............................................ 145, 161 Terms and Conditions of Sale................................................... 5 Thermocouple Cables............................................................ 139 Thermocouple Input Connectors. .......................................... 140 TSM Modules........................................................................ 148 TSP Temperature Controllers. ............................................... 114 TSP Plus Temperature Controllers......................................... 118 Tubular Heaters, Flexible......................................................... 41 Two Zone (2-Zone) Temperature Controllers. ....................... 127 Typical System Configuration (Temp Control)....................... 124 VCAP Air Valve Accessories.................................................. 168 Valve Gate Controls............................................................... 164 Valve Gate Single Zone Timer................................................169

D-MAX High Performance Hot Sprue Bushings. .................... 63 Digital Current/Voltage Monitor........................................... 134

Flexible Tubular Heaters.......................................................... 41 Floor Stand (Temp Control).................................................... 135

Gate-Mate Hot Sprue Bushings.............................................. 71 Global Manifolds..................................................................... 12

Hot One Components & Accessories...................................... 35 Hot One Hot Runner Technology – Overview......................... 18 Hot Runner Modular Components. ....................................... 112 Hot Runner Quote Request Form......................................... 15 Hot Runner Services................................................................ 96 Hot Runner Selection Guide.................................................... 10 Hot Runner Warranty. ............................................................... 7 Hot Sprue Bushings, D-MAX High Performance. ................... 64 Hot Sprue Bushings, E-Series Straight Shot. ......................... 82 Hot Sprue Bushings, ER-Series Straight Shot........................ 84 Hot Sprue Bushings, High-Performance. ................................ 79 Hot Sprue Bushings, Integrally Heated................................... 89 Hot Sprue Bushings, Straight Shot Replacement................... 88 Hot Sprue Bushings, S-Series Straight Shot.......................... 81 Hot Sprue Bushings, Straight Shot™...................................... 78 Hot Sprue Bushings, T-Series Straight Shot........................... 86 Hot Sprue Bushings, TR-Series Straight Shot.........................87

Input Power Wiring Diagrams............................................... 155 Integrally Heated Hot Sprue Bushings.................................... 89

Mainframe Connector Wiring. .............................................. 136 Meteor Hot Runner Systems................................................... 53 Moldflow™ Services............................................................... 96 Mold Connector Pocket Layouts. .......................................... 142 Mold Filling/Mold Cooling Analysis Form. .......................... 98 Mold Power Cables............................................................... 139 Mold Power Input Connectors. ............................................. 140 Mold Thermocouple Connectors........................................... 141 Pre-Wired Combination Terminal Mounting Boxes.............. 144 Plastic Materials and Specifications......................................13

Warranty Information................................................................ 7

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Customer Commitment Hot Runner Systems

Application Engineering

Is there a hot runner application on your wish list that you don’t see here? DME can help. Our design and applications engineering group consists of professional engineers and experienced designers. Once you provide the information necessary for proper application design and analysis, the DME applications engineering team will go to work diligently analyzing, designing and manufacturing a hot runner system that will best suit your needs and requirements.

To take advantage of any or all of these services, or if you have any questions, problems, or ideas please call DME at: n 800-626-6653 (U.S.) n 800-387-6600 (Canada) Part prints or system design prints may be sent in the following ways:

n dme_appl_eng@dme.net n 248-544-5707 (U.S.) fax n 905-677-5280 (Canada) fax

Technical Service

DME is proud to say that it is an industry model for technical service coverage and response. The DME technical service department covers the entire United States and Canada, with additional service representatives in Europe, Asia and throughout the world. Because DME knows you need assistance starting, operating, and maintaining hot runner systems it has made a great effort to strategically staff a Technical Service Department that is responsible for the success of DME’s molding systems. When you need a knowledgeable person to help you order parts and components, DME has you covered. Our direct field sales force puts a local sales representative in your area. One who understands your business and can offer valuable assistance in helping you select the molding system best suited to your application and your budget. In addition, DME provides a customer service department that has been extensively trained on all of DME’s products and systems, making it easier for you to order and have your questions answered. We can provide you price and delivery information on all DME items quickly and accurately. Field Sales and Customer Service

DME offers you a wide range of services from component selection to on-site system installation. Our ever-growing list of services include the ability to:  n Analyze the best system to fit your needs n Assist in system design n Perform computerized system analysis and resin qualification before any metal is cut  n Marry your system to the mold base, plates and components required  n Provide quotations for and perform all of the special machining required n Assemble and wire the system  n Check mechanical fit of all components and perform electrical load testing n Assist with system start-up and maintenance All of which gives you ... more time to concentrate on cavities and cores!

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Terms and Conditions of Sale Hot Runner Systems

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DME COMPANY LLC (“SELLER”) TERMS AND CONDITIONS OF SALE

1. ACCEPTANCE OF TERMS: Seller’s offer is expressly conditioned upon Buyer’s acceptance of these Terms and Conditions, and Seller expressly objects to any ad- ditional or different terms proposed by Buyer. Any subsequent purchase order issued by Buyer shall constitute Buyer’s agreement to these Terms and Conditions. Any contrary terms and conditions contained in any purchase order, facility entry form, or other instrument issued by the Buyer are expressly rejected and shall not apply to this transaction. Unless otherwise specified in the quotation, Seller’s quotation shall expire 30 days from its date and may be modified or withdrawn by Seller before receipt of Buyer’s conforming purchase order. 2. PAYMENT TERMS: Payment is due in accordance with any applicable progress, advance or other agreed upon payment schedule, or, if no such schedule has been agreed to, no later than 30 days from the date of invoice. Buyer shall pay a late payment charge computed at the lower of 1.5% per month on any overdue balance, or the maximum rate permitted by law. No cash discount is provided. If at any time Seller reasonably determines that Buyer’s financial condition or payment history does not justify continuation of Seller’s performance, Seller shall be entitled to require full or partial payment in advance or otherwise restructure payments, request additional forms of payment security, suspend its performance or terminate the order. 3. DELIVERY 3.1 In the United States, products are sold FCA Incoterms 2020 point of origin; for export sales, terms are FCA Incoterms port of export. Unless otherwise agreed in writing, title and risk of loss shall pass at the time of shipment. Buyer is responsible for all taxes, duties, fees, or other governmental charges related to its purchase of goods, with the sole exception of taxes on Seller’s income. Unless otherwise agreed, Buyer shall pay all packing and delivery costs. 3.2. Seller’s quoted lead times and targeted delivery dates are good faith estimates and are not binding on Seller. Buyer’s acceptance of delivery of Seller’s products from the carrier shall constitute a waiver of any claim for delay. If Seller notifies Buyer that the products are ready for shipment and Buyer delays delivery, then Seller may charge Buyer a storage fee equal to 1.5% of the contract price per month for each month of delay. Such storage fees are in addition to any other remedies Seller may have. 3.3. Buyer shall have a reasonable opportunity to inspect any products prior to ship- ment. Products shall be deemed to be accepted upon the earlier of: (i) inspection at Seller’s plant (provided that no reasonable objection is then raised by Buyer), or (ii) if no inspection is requested, then at shipment. If an objection is made during inspection, then Products shall be deemed accepted upon resolution of the objection by Seller. 4. WARRANTY: 4.1. Seller’s express product warranty be as stated in DME’s order specification documentation and shall run from the date of shipment (the “Warranty Period”). During the Warranty Period, Seller warrants that the products and services sold hereunder will be free from material defects in material, workmanship and title (the “Warranty”). 4.2. If, during the Warranty Period, Seller reasonably determines that the products do not meet the Warranty, then Seller shall, at its option, repair or replace the defective product or component thereof, reperform any defective services at Seller’s expense, or refund or credit to Buyer its purchase price for the defective products or services. 4.3. The Warranty will be void and will not apply: (i) when Buyer fails to promptly notify Seller of any alleged defect, (ii) when Buyer fails to properly install, maintain, or operate the products, (iii) to any product or parts thereof with a useful life, under normal operating conditions, inherently shorter than 1 month, or (iv) to products which were not made by Seller or any of Seller’s affiliates, provided that in such cases Seller shall use reasonable efforts to pass on to Buyer the manufacturer’s warranty. 4.4. If Seller provides any parts or services to repair a product that is not under War- ranty, then such parts and services will be billed to Buyer at Seller’s prevailing rates for time and materials. 4.5. The Warranty set out above is the sole and exclusive warranty provided by Seller for its products and is in lieu of, and Seller expressly disclaims, all other war- ranties, express or implied, oral, written or statutory. THERE ARE NO WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PURPOSE FOR SELLER’S PRODUCTS. 5. LIMITATION OF LIABILITIES: 5.1. Seller’s total liability to Buyer arising out of or resulting from this Contract or related in any way to Seller’s products or parts thereof shall not exceed the contract price for such products. 5.2. Seller shall not be liable for loss of profit or revenues, loss of use of products, interruption of business, downtime costs, increased operating costs, or any special, consequential, incidental indirect or punitive damages, whether incurred by Buyer or Buyer’s customers. 5.3. Because the conditions of actual production in each end user’s plant vary con-

siderably, Buyer assumes all risk for the results obtained by use of Seller’s products in the practice of any process, whether in terms of operating costs, general effectiveness, success or failure, and regardless of any oral or written statements made by Seller related to the use of its products. 6. SECURITY INTEREST. Buyer agrees that the Seller shall have and retain a purchase money security interest in the Products securing the payment of all sums becoming due hereunder. Such security interest shall attach, upon completion of manufacture, to the Products and to any parts or accessories attached to the Products and to the proceeds of any sale thereof. Buyer represents that the Products are being acquired for use in its business and that such Products will not, without prior written consent of the Seller, be sold or removed from the Buyer’s place of business to which delivery is made. Buyer agrees upon Seller’s request to execute any financing statements or other documents required to perfect, continue or renew Seller’s security interest in the Products. 7. CANCELLATION: Unless otherwise agreed, Buyer may cancel all or any part of the order by written notice received by Seller before the completion of the order. On receipt of such cancellation notice, all work on the order or part thereof canceled will be stopped as promptly as is reasonably possible. Buyer will then be invoiced for and will pay to Seller as liquidated damages a cancellation charge. For completed items, the charge will be equal to their established prices. For items not completed, the charge will be equal to 135% of Seller’s full cost as determined by Seller in accordance with Seller’s standard accounting practices (which includes burden and overhead), plus a charge for any packing and storage, less a credit for the balance of the material as scrap. 8. RETURNS: All returned items require a Return Merchandise Authorization (RMA) number from DME. Returns are subject to a quality inspection to validate whether it can be returned to inventory. Mold bases, plates, special components, made-to-order products and other date-sensitive products are non-returnable items. Items returned to DME without prior authorization(RMA)may be returned to sender. Items returned for stated defect or non- conforming reason require detailed explanation. No products are returnable beyond 30 days after receipt. 9. CONFIDENTIALITY. Any nonpublic information, including without limitation, Seller’s pricing information and the contents of Seller’s quotation or proposal and Buyer’s purchase order, exchanged between the parties is deemed confidential (“Confidential Information”). Each party agrees to maintain the other party’s Confidential Information in confidence, to not disclose the same to any third parties, and to use it only in connection with this sale. These restrictions shall expire two (2) years after the date of disclosure. This provision does not modify or supersede any separate confidentiality or nondisclosure contract signed by the parties. 10. FORCE MAJEURE: Seller shall not be liable for any delay in performance or nonperfor- mance which is due to war, fire, flood, pandemic, acts of God, acts of third parties, acts of governmental authority or any agency or commission thereof, accident, breakdown of prod- ucts, differences with employees or similar or dissimilar causes beyond Seller’s reasonable control, including but not limited to, those interfering with production, supply or transporta- tion of products, raw materials or components or Seller’s ability to obtain, on terms Seller deem reasonable, material, labor, products or transportation. 11. MERGER CLAUSE: This Contract entirely supersedes any prior oral or written representa- tions, correspondence, proposals, or contracts between the parties regarding the products. This writing constitutes the final and total expression of such contract between the parties, and it is a complete and exclusive statement of the terms of that contract. 12. ASSIGNMENT: Neither party may assign this Contract without the written consent of the other party, except that Seller may assign this Contract to a third party that acquires substantially all of Seller’s assets and Seller may assign the flow of funds arising out of this Contract. 13. COMPLIANCE WITH LAWS. Each party agrees to comply with all applicable laws in the performance of its obligations; Buyer shall not trans-ship, re-export, divert or redirect Products outside of the original country of delivery without Seller’s prior written consent. 14. GOVERNING LAW: This Contract shall be governed by and construed in accordance with the laws of the State of Michigan, without regard to the Convention for the International Sale of Goods (CISG), which shall not apply.

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Hot Runner Systems Sales and Ordering Information

U.S.A. TERMS AND CONDITIONS OF SALE: See previous page.

PHONE ORDERS – TOLL FREE: 800-626-6653. DME’s Customer Service Dept. operates Monday through Friday from 8 a.m. to 6 p.m. E.S.T. Calls can be made from anywhere in the continental U.S. and Puerto Rico (Puerto Rico: use “137” prefix instead of “1”). Our Customer Service Representatives will be happy to answer your questions on DME products or services, provide on-the-spot feedback on product availability and shipping details, or take any messages you wish relayed to your local DME sales, manufacturing or technical service representatives. MAIL ORDERS: If you prefer to order by mail, please address your order to: n DME Company, 29111 Stephenson Highway, Madison Heights, Michigan 48071-2330, FAX: 888-808-4363 ATTN: Customer Service Dept. FAX: You may fax your order to: • DME Customer Service • 248-544-5113 or 888-808-4363 CHECKS OR MONEY ORDERS: When paying invoices by check or money order, please make payable to DME Company. include remittance copy of invoice and mail to: DME Company, PO Box 854867 Minneapolis, MN 55485-4867 WALK-IN ORDERS, PICK-UPS AND RETURNS: If desired, ordered products in stock at your nearest DME Service Center can be picked up rather than shipped. Walk-in orders at Service Center locations can also be processed while you wait. Products being returned for repair or exchange should be processed through Customer Service prior to being returned. SPECIAL MACHINING SERVICES: Prints for quotation on special machining work can be sent by EDI to dme_cad@dme.net or mailed to the Estimating Department of the DME manufacturing location nearest you. Call our toll-free number if desired to clarify location which serves your area. Estimating locations are: • DME Company, 29111 Stephenson Highway, Madison Heights, Michigan 48071-2330, FAX: 888-808-4363

• 117 Fairplains Street, Greenville, MI 48838, Tel. 616-754-4601, FAX: 616-225-3924 • 3275 Deziel Drive, Windsor, Ont N8W 5A5, Tel. 519-948-5001, FAX: 519-948-4652

Please add “DME Company” and “Attn: Estimating Dept.” to above addresses when mailing prints. To obtain prices and delivery on special mold base orders or to check status of special work in progress please contact Customer Service.

CANADA TERMS AND CONDITIONS OF SALE: See previous page.

PHONE ORDERS: Contact our Mississauga, Ontario office at 800-387-6600, FAX: 800-461-9965. MAIL ORDERS: Send to: DME Company, 6210 Northwest Drive, Mississauga, Ontario L4V 1J6. CHECK OR MONEY ORDERS: Make payable to DME Company. Include remittance copy of invoice and mail to Mississauga address above. WALK-IN ORDERS, PICK-UPS, RETURNS, AND SPECIAL MACHINING: Contact our Mississauga office.

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Hot Runner & Temperature Control Warranty Hot Runner Systems

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DME Company 29111 Stephenson Highway, Madison Heights, MI 48071 Tel. 248/398-6000 n FAX 248/544-5113

DME Hot Runner Systems and Temperature Controllers are warranted pursuant to DME Company’s standard terms and conditions (see page 5) for the time periods set forth below. The warranty (i) covers items sold and shipped [supplied in accordance with orders placed by the customer with DME on or after JULY 1, 2003], (ii) applies only to the original DME customer and, (iii) is not transferable to subsequent owners of the product except as specifically set forth herein (see Transferability below for conditions). WARRANTY PERIODS APPLICABLETO SPECIFIED DME PRODUCTS; COVERAGE STARTS UPON DATE OF SHIPMENT: Item Coverage DME Stellar and Hot One Hot Halves (plates designed, machined & assembled by DME, excluding Electrical Parts) DME-Global Blue Warranty tag installed on Hot Half Plastic leakage, due to manufacturing defect, within hot runner plates covered for Two (2) years; excluding Gate Detail. DME SMARTOne Fixed and Valve Gate Hot Halves (plates designed, machined & assembled by DME, excluding Electrical Parts) DME-Global Blue Warranty tag provided with components Plastic leakage, due to manufacturing defect, within hot runner plates covered for ONE (1) year; excluding Gate Detail. DME Hot One, Stellar & SMARTOne Fixed and Valve Gate Manifold and Components (neither plates nor assembly supplied by DME, excluding Electrical Parts) DME-Global Blue Warranty tag provided with components One (1) year on components only. DME-CN Smart Fixed Gate and Valve Gate Hot Halves and Manifold & Components (excluding Electrical Parts) DME-Global Black Warranty tag provided with components No warranty outside of Country of Manufacture. Contact Country of Manufacture for local warranty coverage. Warranty Coverage is not transferrable outside of country of origin. DME Electrical Parts (all heaters and thermocouples) One (1) year DME Mold Controls and Valve Gate Controls ( excluding Fuses & Triacs, Power Packs & Trolley as appropriate ) One (1) year - Pumping systems, Valves & Solenoids Two (2) years - Smart Series Mainframes & Modules TSP, TSP Plus & SVG Electronic Controllers Replacement or repair will be made at the election of DME; implemented at a DME facility and/or by shipment of replacement parts to the customer for installation and/or return of defective parts to DME for repair. Transferability: This warranty may be transferred by the original DME Customer to a subsequent owner of the product if all of the following conditions exist: (i) the original DME Customer purchased the product for purposes of re-sale or other immediate transfer and DME was made aware of these purposes at the time of purchase in writing, (ii) within thirty (30) days from the date of invoice, DME is notified in writing of the transfer and provided with the name of the new owner (hereafter “Transferee”), the contact person of the Transferee and the Transferee’s address. Exclusions: • Normal wear of the system and components including, but not limited to: Nozzle Tips, Nozzle Seal Rings, and Electrical connectors • Damage to the critical seal-off areas on the manifold, nozzle bodies, or in the mating cavities or cavity inserts caused by improper assembly, operation, disassembly and maintenance • Wear or damage resulting from corrosion or processing of abrasive/aggressive resins • Damage due to failure to follow recommended operation and maintenance procedures specified in the DME Hot Runner Manual, Hot Runner Nameplate, Service Bulletins, User Manuals or failure to follow standard industry operation and maintenance procedure • Damage caused by abuse, neglect, and failure to adhere to DME instructions and operational recommendations • Damage caused by improper installation, operation and maintenance • Damage resulting from modifications to the product or component parts, abuse or neglect • Failure caused by modifications made to the product without the prior written approval of DME • Damage resulting from operation of products at injection pressures greater than 20,000 psi (1360 bar) on Hot One, Stellar & Smart One VG Systems;

unless specifically designed and manufactured for higher pressure applications in agreement with manufacturer • Damage or failure caused by the product’s inability to perform as a component of a system design not supplied by DME • Operator absence or operator error • Operator maintenance and training capability • Electrical interruptions

• Events beyond the control of DME • Errors or actions by a third party • Non-compliance with local laws, codes, ordinances or regulations codes or bylaws unless DME is informed of them by our customer at the time of order placement

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DME Hot Runner Overview Hot Runner Systems

DME : Your essential resource for hot runner solutions

Whether your application requires best-in-class components or a turnkey hot-half system, DME has a hot runner solution that meets your needs.

®

DME: An Essential Resource for Hot Runner Productivity Moldmakers, molders and mold designers worldwide look to DME for essential hot runner solutions — whether that is a single, best-in-class component or a complete, fully functioning hot half system. Offering the industry’s broadest range of hot runner products and services as well as an unsurpassed knowledge and expertise, DME is committed to helping customers achieve maximum productivity, reliable operation, and better performance.

System Solutions DME offers a comprehensive family of hot runner systems built on our modular architecture making custom configuration easy and quick. Systems include: • Stellar ® Micromolding Systems engineered for tight pitch molding • The Hot One 250, 375 and 625 series

A wide range of DME nozzles allows versatility in system selection

Stellar Micromolding Nozzles provide application flexibility

U.S. 800-626-6653 • Canada 800-387-6600 • dme.net • store.dme.net

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9 …from components and manifolds to turnkey hot halves Hot Runner Systems

Our goal is simple: to be an essential resource for your molding challenges. Every step of the way.

®

Specialized Systems As one of the world’s leading hot runner manufacturers, we recognize that some application challenges demand specialized solutions. Offerings include: • Stellar Manifold and Components • Stellar Hot Halves • Hot One Manifold and Components • Hot One Hot Halves

Knowledge That Gives You an Advantage

Service and Support to Keep You Productive DME provides essential support to keep your hot runner systems in-service. Our dedicated hot runner service center is staffed by trained, experienced technicians who support DME systems, as well as other brands, to provide help when and where you need it, every step of the way.

Our team of trained, experienced experts can help you with needs analysis, design, configuration, operation, and all the other services that enable you to focus on your core business. • Applications engineering • Moldflow analysis

Stellar & Hot One Systems are custom configured for your application

Moldflow predictive analysis optimizes part design and lowers costs

DME Hot Runner Service Center provides total support for your hot runner system

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JUNE 2021

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DME Hot Runner Technology Selection Guide

The values expressed in grams are for reference only and are determined by using a nominal wall thickness of 1.8mm (.070") and unfilled poly- propylene Part dimension, wall thickness, length of fill within part, mold

GENERIC PLOYMER NAME (TRADE NAME) [A=AMORPHOUS or C=CRYSTALLINE]

NOTE: THE CHART BELOW SHOWS COMMODITY RESINS IN ORANGE TYPE; ALL OTHERS ARE ENGINEERING RESINS.

Good Contact DME Not recommended Resin Application Key

conditions and molding parameters must also be considered.

Recommended

Flow Capacity

NOTE: If flame retardant is present in the desired resin grade, please contact DME for product suitability or application guidance.

Polymer Viscosity Key L=Low M=Medium H=High

Gate Diameter Range

(Grams)

Viscosity

Min (mm)

Max (mm)

Min (inch)

Max (inch)

Low MFI.16

Medium MFI 7-16

High

MFI

NOZZLES

TIP

.02-7 L L H M H M L M H M M M H H M L H H H H H H H L H H M H H L L H H H M

Sprue Tip

1.0 2.0 0.040 0.080 20

15

10

SmartONE-04 Thermal Gate

Point Gate Tip

1.0 1.9 0.040 0.075 10

10

7

Sprue Tip

2.0 3.0 0.080 0.125 500

400

225

SmartONE-06 Thermal Gate

Point Gate Tip

1.5 2.5 0.060 0.100 175

125

80

Sprue Tip

2.5 4.0 0.100 0.160 625

575

325

SmartONE-08 Thermal Gate

Point Gate Tip

1.5 3.1 0.060 0.125 250

175

125

Sprue Tip

2.5 5.0 0.100 0.200 850

700

425

SmartONE-10 Thermal Gate

Point Gate Tip

1.5 3.1 0.060 0.125 310

200

150

Sprue Tip

3.0 6.0 0.125 0.236 1000 775

475

SmartONE-12 Thermal Gate

Point Gate Tip

2.0 3.1 0.080 0.125 500

375

275

Sprue Tip

3.0 8.0 0.125 0.315 1500 1100

750

SmartONE-16 Thermal Gate

Point Gate Tip

2.5 4.4 0.100 0.175 800

550

400

Sprue Tip

1.5 2.0 0.600 0.800 400

300

150

SmartONE-06 Valve Gate

Direct Valve Gate Tip 1.5 2.0 0.600 0.800 225

150

90

Sprue Tip

2.5 2.5 0.100 0.100 500

450

250

SmartONE-08 Valve Gate

Direct Valve Gate Tip 2.5 2.5 0.100 0.100 450

300

220

Sprue Tip

2.5 3.0 0.100 0.125 775

625

375

SmartONE-10 Valve Gate

Direct Valve Gate Tip 2.5 3.0 0.100 0.125 610

460

280

Sprue Tip

4.0 5.0 0.160 0.200 900

725

425

SmartONE-12 Valve Gate

Direct Valve Gate Tip 4.0 5.0 0.160 0.200 725

525

315

Sprue Tip

5.0 7.0 0.200 0.275 1200 950

600

SmartONE-16 Valve Gate

Direct Valve Gate Tip 5.0 7.0 0.200 0.275 940

640

475

www.dme.net

JUNE 2021

DME Hot Runner Technology Selection Guide

GENERIC PLOYMER NAME (TRADE NAME) [A=AMORPHOUS or C=CRYSTALLINE]

The values expressed in grams are for reference only and are determined by using a nominal wall thickness of 1.8mm (.070") and unfilled poly- propylene Part dimension, wall thickness, length of fill within part, mold conditions and molding parameters must also be considered.

NOTE: THE CHART BELOW SHOWS COMMODITY RESINS IN ORANGE TYPE; ALL OTHERS ARE ENGINEERING RESINS.

Good Contact DME Not recommended Resin Application Key

NOTE: If flame retardant is present in the desired resin grade, please contact DME for product suitability or application guidance.

Recommended Gate Diameter Range

Flow Capacity

Polymer Viscosity Key L=Low M=Medium H=High

(Grams) Viscosity

High

MFI

Min (mm)

Max (mm)

Min (inch)

Max (inch)

Low MFI.16

Medium MFI 7-16

NOZZLES

.02-7 L L H M H M L M H M M M H H M L H H H H H H H L H H M H H L L H H H M

TIP

2.0 2.0 0.080 0.080 20

15

10

Sprue Tip

Stellar High Performance Heater

10

10

Standard Point Gate Tip

0.7 1.9 0.028 0.075 10

Wear Resistant Point Gate Tip 1.3 1.9 0.050 0.075 10

10

10

475

315

Sprue Tip

2.0 3.1 0.080 0.125 625

Hot One 250 Series

(Coil Heater)

150

100

Standard Point Gate Tip

0.7 2.5 0.028 0.100 200

475

315

Sprue Tip

2.0 3.1 0.080 0.125 625

Hot One 250 Series (Cast-in Heater)

Wear Resistant Point Gate Tip 0.7 2.5 0.060 0.100 200

150

100

Sprue Tip

3.2 4.7 0.125 0.187 1000 750

450

Hot One 375 Series (Coil Heater)

Standard Point Gate Tip

0.7 3.1 0.028 0.125 310

200

150

Sprue Tip

3.2 4.7 0.125 0.187 1000 750

450

Hot One 375 Series (Cast-in Heater)

Wear Resistant Point Gate Tip 0.7 3.1 0.060 0.125 310

200

150

Sprue Tip

4.7 7.9 0.187 0.312 1500 1100

750

Hot One 625 Series (Coil Heater) (Cast-in Heater) Hot One 625 Series

Standard Point Gate Tip

3.2 4.4 0.125 0.175 800

550

400

Sprue Tip

4.7 7.9 0.187 0.187 1500 1100

750

Wear Resistant Point Gate Tip 3.2 4.4 0.125 0.175 800

550

400

S-Series & T-Series

4.1 4.1 0.160 0.160 700

500

300

E-Series

1.5 1.5 0.060 0.060 300

150

50

Raduis Hot Sprue Bushings

ER-Series & TR-Series

3.2 3.2 0.125 0.125 500

300

200

1.6 1.6 0.062 0.062 300

150

50

High Performance Series

3.2 3.2 0.125 0.125 500

300

200

Sprue Tip

2.0 3.1 0.080 0.125 700

500

350

D-MAX 250 Series

Standard Point Gate Tip

1.3 2.5 0.050 0.100 250

175

125

High Performance

Wear Resistant Point Gate Tip 1.5 2.5 0.060 0.100 250

175

125

Sprue Tip

3.2 4.7 0.125 0.187 1100 800

500

D-MAX 375 Series High Performance

Standard Point Gate Tip

1.3 3.1 0.050 0.125 350

250

200

Wear Resistant Point Gate Tip 1.5 3.1 0.060 0.125 350

250

200

850

Sprue Tip

1.7 7.9 0.187 0.312 1600 1200

D-MAX

625 Series High Performance

Standard Point Gate Tip

3.0 4.4 0.125 0.175 900

650

500

Wear Resistant Point Gate Tip 3.0 4.4 0.125 0.175 900

650

500

Available only as a DME Designed and Manufactured Manifold & Components or Fully Assembled and Wired Hot Half Available from the catalog as Components only or a DME designed and manufactured Manifold & Components or Fully Assembled and Wiored Hot Half

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Standard Global Manifold Hot Runner Systems

DME Global Manifolds and Components are standardized worldwide to ensure that even the smallest detail provides operational excellence regardless of where DME hot runner products are used. Whether you’re relying on a quick-delivery manifold or an applications-engineered, custom manifold, the DME Global Manifold Standard ensures optimal hot runner performance no matter where in the world it was built. Key Features of the DME Global Manifold Include: • Flexible tubular heaters • Locating rings that fit virtually any injection press platen hole diameters • Heated Manifold Extension Nozzles available • High-tolerance, press-fit heaters • Upper and center Manifold supports constructed of high-strength, low-heat conductive titanium that minimizes heat loss and maintains an even heat profile • J-type thermocouples are black-and-white, coinciding with the IEC 584-3 International Standard • Flow channel sizes range from 6mm to 16mm DME customers are assured that DME Manifold Systems are designed and built with a global standard that ensures efficient molding anywhere in the world. And, since replacement parts are identical worldwide, they are readily available wherever your mold is operating, not just where it was built. All DME nozzles, including, Stellar and the Hot One, perform flawlessly with the DME Global Manifold Standard.

Heated “MEN“ From Machine Nozzle to Manifold

U.S. 800-626-6653 • Canada 800-387-6600 • dme.net • store.dme.net Available in all balanced design layout patterns up to 24 nozzle drops*, including inline, X, Y, H, Double H & Multiple Level Systems. *Contact DME for Higher Cavitation MANIFOLD DESIGN, SPECIFICATION & TOLERANCE STANDARDS HARMONIZED FOR GLOBAL PRODUCT OFFERING AMERICAS – EUROPE – ASIA – AUSTRALIA / NEW ZEALAND – INDIA – AFRICA

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Plastic Materials and Specifications

PLASTIC MATERIAL PROCESS CONDITIONS

PROCESS TEMPERATURE

MOLD TEMPERATURE

HOT RUNNER TEMPERATURE

DENSITY MELTING

SOLID DENSITY

STANDARD RESIN SYMBOL

MATERIAL

[°C]

[°F]

[°C]

[°F]

[°C]

[°F]

[g/cm 3 ] [Ibs/inch 3 ] [g/cm 3 ] [Ibs/inch 3 ]

SB

210 220 230 210 300

410 428 446 410 572

70 45 80 45 80

158 113 176 113 176

230 240 255 230 330

446 464 491 446 626

0.93 0.93 0.99 0.95 1.08

0.0366 1.02 0.0366 1.11 0.0358 1.08 0.0343 1.05 0.0390 1.20

0.0369 0.0401 0.0390 0.0379 0.0434

Styrene Butadiene

PUR SAN

Polyurethane

Styrene-acrylonitrile

PS PC

Polystyrene

Polycarbonate

PPO

260

500

80

176

300

572

0.99

0.0358 1.13

0.0408

Polyphenylene Oxide-Styrene

PE PP

200 225 330 300 265 220 255 240

392 437

25 40

77

225 245 370 330 290 250 280 265

437 473 698 626 554 482 536 509

0.74 0.73 1.13 1.53 1.44 0.98 1.09 0.78

0.0267 0.96 0.0264 0.91 0.0408 1.37 0.0553 1.70 0.0520 1.57 0.0354 1.14 0.0394 1.26 0.0282 0.90

0.0347 0.0329 0.0495 0.0614 0.0567 0.0412 0.0455 0.0325

Polyethylene Polypropylene

104 329 230 140 194 194

PEEK PPS PBT PA 6 PA 66

626 165 572 110

Polyether-etherketone Polyphenylene Sulfide

509 428 491 464

60 90 90 35

Polyebutylene Terephthalate

Polyamide 6 Polyamide 66

TPE

95

Thermal Plastic Elastomers

POM

180

356 100

212

200

392

1.16

0.0419 1.42

0.0513

Polyoxymethylene (Polyacetal)

PMMA

235

455

70

158

250

482

1.09

0.0394 1.18

0.0426

Polymethyl Methacrylate

ABS

225

437

70

158

250

482

0.95

0.0343 1.08

0.0390

Acrylonitrile Butadiene Styrene

NOTE: Temperature and density values shown above are general, and may not apply to your application. Please refer to proper processing data for the resin grade intended for your specific application. Failure to use temperature settings appropriate to the specific resin and resin grade intended for your application may result in poor part quality, or inability to produce acceptable molded parts.

U.S. 800-626-6653 • Canada 800-387-6600 • dme.net • store.dme.net

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Bushing Selection

HOT SPRUE BUSHING TIP STYLE

For use where gate vestige is allowed. Provides low resistance to flow with excellent flow rates. Extended style provides additional stock for machining profiles or part contours.

SPRUE GATE TIP STANDARD / EXTENDED

Ideal for low vestige commodity and engineering grade resin applications. The Ring Gate features a sealed tip for efficient shut-off at the part surface. Available with standard or wear resistant needles. Extended style provides additional stock for machining profiles or part contours.

RING GATE TIP STANDARD / EXTENDED

Suitable for high viscosity resins, engineering plastics and applications requiring optimum gate cosmetics with minimal gate vestige. Available with standard or wear resistant needles.

POINT GATE TIP

BUSHING TIP AND PLASTIC MATERIAL COMPATIBILITY

THERMOPLASTIC RESIN TYPE

AMORPHOUS

SEMI-CRYSTALINE

NOZZLE

SPRUE GATE TIP STANDARD / EXTENDED

RING GATE TIP STANDARD / EXTENDED

POINT GATE TIP

Green Yellow Red

– Works well with this resin – Contact DME Engineering for guidance – Not recommended

U.S. 800-626-6653 • Canada 800-387-6600 • dme.net • store.dme.net

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Hot Runner Quote Request Form Hot One Hot Runner Technology

EMAIL TO DMEUS_AE_QUOTE@DME.NET OR FAX United States: 888-808-4363 • Canada: 800-461-9965 • International: 248-398-7394

DME 29111 Stephenson Highway Madison Heights, MI. 48071-2383

Applications Engineering QUOTE REQUEST FORM Email to: mailto: DMEUS_AE_Quote@dme.net

Tech Service Approval, Final Drawings and In-House Due Date Required for Firm Quote - QUOTE TYPE

Preliminary

Firm

Customer’s In-House Date Requirement

Date

Sales Rep Contact

Company Address Address

Phone

Fax

City State

E-Mail

Zip

Acct#

End User Melt Temp

Molding Material Manufacturer Flame Retardant Color Changes Filler

deg. (min)

Range

(max)

None

Glass

Other Percent

%

Yes Yes

No Melt Flow Index

No

Mold Temp

deg.

New Mold

Retrofit

DME Mold Base to be Quoted Mold Base Drawings Supplied

Mold Base Size

Gating Into

Part

Dimple

Runner

Stellar / Hot One / SmartONE (Fixed Point/Sprue Tip only)

SmartONE (Valve Gate)

Gate Style

Sprue Other

Ext Sprue

Tip/Point

WR

VG–Bodiless VG-Sprue

VG–Full Body

VG–Full Body Ext’d

Number of Drops

Number of Cavities

Part Name

Part Number

Job #

Part Drawing Supplied Wall Thickness of Part

Yes

No

Sample Supplied CAD Data Supplied Total Shot Weight

Yes Yes

No No

Part Weight Runner Weight

Grams Grams

Ounces Ounces

Grams

Ounces

Type of Quote Requested

M&C (system)

Hot Half – Plate Steel

#2 (standard)

420SS

Drop Spacing

A= A1= B= B1=

Drop Spacing

Plate Width Plate Length

X= Y= L=

Molding Elevation

# of Columns # of Rows

NOTES:

U.S. 800-626-6653 • Canada 800-387-6600 • dme.net • store.dme.net

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page content text Table of Contents

Hot Runner Technology.............................................17-19 The best solution for precision thermoplastic micromolding

Smart One Hot Runner System................................20-27 Cost efficient and capable, the DME SMART ONE gives you all you need in a melt delivery system at an economical price.

Stellar Micromolding Hot Runner Systems...........28-33 The best solution for precision thermoplastic micromolding.

Hot One Nozzles......................................................34-60 A long-standing industry standard in user-friendliness and affordability.

Components: Heaters & Thermocouples.......47-52 Custom-configured manifolds, manifold and component systems, and complete hot half assemblies for quick delivery.

Meteor ® Hot Runner Systems..................................54-60 Custom-configured manifolds, manifold and component systems, and complete hot half assemblies for quick delivery.

U.S. 800-626-6653  Canada 800-387-6600 n dme.net n store.dme.net

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