IntelliGate-Header2-LP-2025

Smart Hot Runner System

IntelliGate

Automotive
Packaging FMCG
Electronics

The worldwide first intelligent hot runner with integrated sensor technology included – for your sequential injection molding process.

Sequential (Cascade) molding processes are usually controlled by the screw position, time or cavity sensors. The exact timing of the nozzles is determined by experienced operators during mold sampling. Depending on the component and mold, this process can take several hours.

Save time and money by using sensor technology that automatically leads to an optimized injection molding process. Have you been avoiding the use of sensor technology because tool processing and installation are too time-consuming?

We have the solution: Introducing IntelliGate, the first plug-and-play system of its kind. In Synventive's new system (patent pending), the pin provides a fully integrated sensor technology that locates the melt front. The valve pin in the relevant nozzle then fully opens automatically. The ideal process is thus quick, efficient, and virtually risk-free, since IntelliGate comes fully pre-installed, wired, and tested.

IntelliGate Hot Runner for Cascade Molding

Cascade Molding: Why You Need Control

Cascade injection molding is primarily used for producing large, complex parts with long flow paths, high aesthetics and structural requirements. Instead of opening all gates at once, the gates open one after the other. The injection usually starts with a single gate, with further gates opening as the melt front reaches the nozzles position. During the filling study the operator determines the timing for the nozzle opening one by one. Our sophisticated IntelliGate hot runner assists in establishing the filling sequence and eliminates the need for trial and error. Furthermore, the system automatically adapts to process changes, ensuring precise gate opening timing.

Synventive's IntelliGate Hot Runner
- Detects melt flow in front of the nozzle
- Sends signal to the control box
- Opens the valve pin in the relevant nozzle at the optimal time
- Automatic viscosity compensation - no manual adjustments required
- No separate Sequential Controller required
- Fully wired and tested
- Save considerable costs due to quick set-up, resulting in less time and less waste of material

What You Can Expect

Automatic Melt Front Detection
- Enables autonomous injection molding
Automatic Viscosity Compensation
- No manual adjustment required
Automatic Process Control
- Up to 90% less setup time