Smart Molding International 2-2025

32 smart_molding international 2/2025 molds and tooling Servoelectric cold runner molds for LSR injection molding are learning to think for themselves The pioneering “I” technology is based on online rheometry for continuously optimizing the process and determining the actual material viscosity in the shear rate range of relevance to injection molding. T he patent-pending SMARTshot I cold runner measurement and control concept incorporating servoelectrically actuated nozzle nee- dles, currently under development by LSR mold specialist ELMET, is an in- telligent variant of the SMARTshot E system. Once deployed in a practical setting, entirely automatic startup will be possible as will controlled family molds with cavities of differing volumes that do not require additional sensor systems. This will enable cascaded in- jection processes with time-delayed opening and closing movements as well as injection processes with par - tially open needles for simultaneously filling cavities with different volumet - ric flow rates per nozzle. ELMET gave an update of this new concept at LSR 2025 (took place 16 to 19 June 2025 in Irvine, California). At its launch at Fakuma 2021, SMARTshot E was one of the first all-electric, servomotor-driven cold runner system for processing liquid silicone rubbers (LSR). The SMARTshot-I development concept is based on the same technology. However, additional rheology-based features will be able to further improve controllability of the injection molding process by using AI with self-learning functionality. It will be possible to set up or retrofit this upgrade on any existing SMARTshot E mold. In combination with compatible injection molding machines that have a suitable interface, it will then be available to any user. SMARTshot I will be the ideal add-on to the type E in future. ELMET’s range of valve gate cold runner systems also includes the pneumatic SMARTshot P and the hybrid SMARTshot PE with pneumatic needle movement and electric stroke adjustment. Getting there faster and more reliably with self-learning The pioneering “I” technology is based on online rheometry for continuously optimizing the process and determining the actual material viscosity in the shear rate range of relevance to injection molding. This technology uses a mathematical relationship between the volumetric flow rate of the injection molding machine, the geometric constraints of the cold runner, and the shear force at the needle to identify and quantify batch-to-batch fluctuations. This turns the cold runner into rheological measuring instrument. In learning mode, the system automatically detects the volume of material required to fill a cavity, so facilitating setup and optimization, especially with family molds with a number of cavities of differing sizes. Ready for integrating artificial intelligence (AI), the system is set in future to be able to support self- controlled injection molding machines if SMARTshot I control is integrated into the machine at a later date. Micrometer-range precision In type E and I systems, servoelectric drives perform the tasks carried out by the pneumatic pistons that were until recently used as standard. This is achieved using a highly responsive, brushless 24 V, 50 W DC motor that generates minimal waste heat and can withstand three times the rated load for short periods.