Injection molding of micro parts demands advanced hot runner solutions to meet the specific needs of mold workers and manufacturers. The production of precision micro components, which typically weigh between 0.05g and 2g, requires high accuracy and tight tolerances. This makes the runner system's weight a critical factor in cost control. In fact, even small variations in the runner’s weight can significantly impact the final part price. A balanced runner system is essential to ensure uniform filling across all cavities. However, traditional systems often result in excessive runner weight, increasing material costs and requiring additional separation equipment, which raises the overall part cost. To overcome these challenges, a compact and balanced hot runner system is necessary, especially for molds with numerous cavities and limited space. The design of the hot runner tips plays a crucial role in minimizing the mold size. By tightly mounting the tips directly onto the manifold and using a specialized distribution device, a naturally balanced system can be achieved. Figure 1 illustrates a hot runner system with 4, 8, and 16 tips, showcasing how the melt is evenly distributed across multiple channels. Figure 2 displays a cylindrical manifold with external milling, designed to provide equal flow lengths to each tip. This configuration allows for a fully balanced system within a compact space. The use of technical resins, particularly those with flame-retardant additives, is vital to maintain short residence times and reduce pressure loss. These materials help optimize performance while ensuring consistent quality. Temperature distribution is another key factor in maintaining part quality. The material must not exceed its allowable temperature range, as overheating can lead to degradation. A balanced thermal distribution across the system ensures that all areas are properly heated without causing damage. Heat transfer occurs through radiation, convection, and conduction, and each method should be minimized to improve efficiency. Figure 3 highlights the power distribution of the heating elements in a 16-channel manifold. The use of titanium alloy components helps reduce heat transfer, while an optimized heater ensures even radiant heat distribution. The ends of the manifold require more heat than the center, so the heating elements are adjusted accordingly. In micro hot runner mold design, reducing the contact surface between the mold and the hot runner minimizes heat transfer. A front-seal melt chamber around a titanium alloy ring compensates for thermal expansion, preventing stress and tension. This design also reduces the load on the mold surface and facilitates rapid cooling, keeping the material in optimal condition. The manifold must be precisely centered to ensure uniform thermal expansion. A small pitch between the tips allows accurate calculation of thermal expansion, enabling injection ports as small as 0.4mm in diameter. Figure 4 illustrates a miniature hot runner mold, emphasizing the importance of precise engineering in micro-molding applications. High-performance materials, such as molybdenum alloys, offer a balance between wear resistance and thermal conductivity, making them ideal for hot runner tips. When all design guidelines are followed, a micro hot runner system can produce high-quality parts on small injection molding machines with minimal imprint. Micro hot runners are widely used in various mold configurations, including small injection molding machines and multi-branch manifolds (see Figure 5). Combining micro hot runners with standard manifold components offers flexible mold designs, reducing the number of control zones while ensuring reliable installation and operation. Advancements in hot runner technology have provided mold makers and injection molders with innovative solutions, helping them stay competitive in a rapidly evolving industry. With the right design and materials, micro hot runner systems continue to push the boundaries of precision and efficiency in modern manufacturing.

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