IntelliGate | Synventive | Barnes Molding Solutions

Sequential 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.

2-Component Actuator
Industrial Part
Sealing Ring
Power Socket
Frame for Power Socket
Frame for Switch Socket
Industrial Cap
Belt Winder
Hermetical Closure
Bullet Base
Battery Cover

2-Component Actuator

Material: TPV Santoprene 111-55
Part Weight: 17.8 g
Speciality: overmolded on PP+GF30% base
Shot Weight: 35.6 g

Industrial Part

Material: PP
Part Weight: 5.5 g
Speciality: overmolded on PP+GF30% base
Wall thickness: 0.9 mm

Nozzles: THS18-R4
System: SS230361
Cavities: 4
Gate Diameter: 1 mm

Sealing Ring

Material: PA 66 + 30% glass sphere
Part Weight: 0.35 g
Wall thickness: 2.55 mm
Shot Weight: 1.4 g

Nozzles: THS12-R2
System: SS230972
Cavities: 4
Gate Diameter: 0.9 mm

Power Socket

Material: PC Lupillon S-3000R
Part Weight: x
Speciality: x
Shot Weight: x

Nozzles: 3xTH18-R2 independent tip control
System: SS210815 (HH)
Cavities: 6
Gate Diameter: 1 mm

Frame for Power Socket

Material: ABS HF380LK
Part Weight: 17.3 g
Wall thickness: 1.8 mm
Shot Weight: 34.6 g

Nozzles: THS18-R2
System: SS220739
Cavities: 2
Gate Diameter: 1 mm

Frame for Switch Socket

Material: PC - Makrolon 2407
Part Weight: 31.2 g
Wall thickness: 2.1 mm
Shot Weight: 124.8 g

Nozzles: 4xTHS24-R1
System: SS240275
Cavities: 4
Gate Diameter: 1.2 mm

Industrial Cap

Material: PA 6
Part Weight: 0.24 g
Wall thickness: 0.8 mm
Shot Weight: 3.84 g

Nozzles: 2xTHS12-L4+4
System: SS230361
Cavities: 16
Gate Diameter: 0.7 mm

Belt Winder

Material: PS
Part Weight: 5.5 g
Wall thickness: 1.0 mm
Shot Weight: 22 g

Nozzles: 2xTHS24-R2 independent tip control
System: SS230850
Cavities: 4
Gate Diameter: 1 mm

Hermetical Closure

Material: PP
Part Weight: 2.4 g
Wall thickness: 1.5 mm
Shot Weight: 19.2 g

Nozzles: THS12-L4+4
System: SS210585
Cavities: 16
Gate Diameter: 0.7 mm

Bullet Base

Material: TPE Uteksol TH 36 D
Part Weight: x
Wall thickness: 1.09 mm
Shot Weight: 0.068 g

Nozzles: 2xTHS12-L4+4
System: SS200906
Cavities: 16
Gate Diameter: 0.7 mm

Battery Cover

Material: PP
Part Weight: 320 g
Wall thickness: 2.5 mm
Shot Weight: 640 g

Nozzles: 6xTHS24-R1
System: SS230334
Cavities: 2
Gate Diameter: 1.5 mm

Why You Need Control

Cascade Molding

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