{"id":12462,"date":"2026-04-08T12:31:57","date_gmt":"2026-04-08T10:31:57","guid":{"rendered":"https:\/\/ikv-aachen.de\/rp\/kaskare-hot-runner-pressure-control\/"},"modified":"2026-05-20T10:55:08","modified_gmt":"2026-05-20T08:55:08","slug":"kaskare-hot-runner-pressure-control","status":"publish","type":"cpt_ikv_rp","link":"https:\/\/ikv-aachen.de\/en\/rp\/kaskare-hot-runner-pressure-control\/","title":{"rendered":"KaskaRe &#8211; Hot runner pressure control"},"content":{"rendered":"<style type=\"text\/css\">\n    #single-header-block_52ab02e124bd0f99b484c51b24c3211b .swiperThumbsNavi .swiper-slide {\n        opacity: 0.4;\n    }\n\n    #single-header-block_52ab02e124bd0f99b484c51b24c3211b .swiperThumbsNavi .swiper-slide-thumb-active {\n        opacity: 1;\n    }\n<\/style>\n    <section id=\"single-header-block_52ab02e124bd0f99b484c51b24c3211b\" class=\"block-single-header theGridWrapper \">\n        <div class=\"theGrid12\">\n            <div class=\" col-start-2 col-span-10 md:col-start-3  md:col-span-8\">\n                <h2 class=\"font-serif font-semibold text-blue text-sm w-4\/5\">\n                    Control strategy for cascade injection moulding with servo-electric hot runner pins                <\/h2>\n                                    <div class=\"mt-base text-blue text-sm font border-l-8  border-blue pl-base my-12 leading-normal \">\n                        Cascade injection moulding is the preferred method for manufacturing parts with long flow paths and no visible weld lines. To compensate for process fluctuations, such as the processing of different material batches, the KaskaRe project resulted in the development of a cavity pressure control system. This regulates the pressure transfer into the cavity at each gate. The pressure transfer is adjusted by means of variable opening strokes of the hot runner valve pins.                    <\/div>\n                                            <\/div>\n        <\/div>\n    <\/section>\n\n\n\n<p class=\"wp-block-paragraph\"><br>To improve control quality, the geometries of the pin guide and the valve pin were numerically optimised in a first step, so that the correlation between opening stroke and pressure loss was linearised (Fig. 1). The optimisation was based on a physical process model describing the system behaviour. The improved control quality allows further increases in process consistency.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">The pin movement was designed first for the development of the internal cavity pressure control for cascade injection moulding. Since filling is performed via several gates, the pressure transfer into the cavity can also be individually influenced at each of the gates. Injection moulding simulations were used to analyse the influence of individual pin movements on the pressure and temperature distribution in the cavity. Since the pin movements only influence the process conditions in areas close to the nozzle due to material cooling during sequential filling, all pins are moved equally for control purposes. The application of the control system increases process consistency in cascade injection moulding.<\/p>\n\n\n<figure class=\" relative flex flex-col gap-2xs mb-xs md:mb-l xl:mb-xl\"><img decoding=\"async\"  class=\" w-full  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/IGF-22805-N-scaled.jpg\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/IGF-22805-N-748x363.jpg 748w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/IGF-22805-N-1536x745.jpg 1536w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/IGF-22805-N-768x373.jpg 768w\" sizes=\"auto, (max-width: 1536px) 100vw, 1536px\" width=\"1536\" height=\"745\" alt=\"IGF 22805 N\" loading=\"lazy\" \/><span class=\" text-copyright order-3 justify-end text-right w-full  w-full \">&copy; IKV<\/span><figcaption class=\" w-full  text-figcaption justify-end text-right \">Fig. 1: Numeric optimisation of the geometries of pin guide and valve pin (left) and linearisation of the correlation between opening stroke and pressure loss (right).<\/figcaption><\/figure>\n\n\n<details class=\"wp-block-details is-layout-flow wp-block-details-is-layout-flow\"><summary>Project data and funding<\/summary>\n<p class=\"wp-block-paragraph\">We would like to thank the BMWE for funding the IGF project (funding code 22805 N) and the project partners for their cooperation.<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Project duration: 01.03.2023 &#8211; 31.07.2025<\/p>\n\n\n\n<p class=\"wp-block-paragraph\">Promotion:<\/p>\n\n\n<section id=\"logo-bar-block_f267303b5bef0556ea141bfe2e9e1e84\" class=\"block-logo-bar py-2xl  clear-both\">\n    <div class=\"theGridWrapper overflow-hidden  \">\n        <div class=\"grid grid-cols-[repeat(auto-fill,minmax(140px,1fr))] gap-base\">\n                            <figure class=\" relative h-full  \"><img decoding=\"async\" fetchpriority=\"low\"  class=\" object-contain w-full h-full mb-base  \"  src=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo.png\" srcset=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo.png 500w, https:\/\/ikv-aachen.de\/wp-content\/uploads\/2024\/10\/BMWE-Logo-335x335.png 335w\" sizes=\"auto, (max-width: 748px) 100vw, 748px\" width=\"500\" height=\"500\" alt=\"BMWE-Logo\" loading=\"lazy\" \/><\/figure>                                <\/div>\n    <\/div>\n<\/section>\n<\/details>\n","protected":false},"excerpt":{"rendered":"<p>Cascade injection moulding is the preferred method for manufacturing parts with long flow paths and no visible weld lines. To compensate for process fluctuations, such as the processing of different material batches, the KaskaRe project resulted in the development of a cavity pressure control system. This regulates the pressure transfer into the cavity at each gate. The pressure transfer is adjusted by means of variable opening strokes of the hot runner valve pins.<\/p>\n","protected":false},"featured_media":12104,"parent":0,"template":"","tags":[837,1552,921,1471,860],"research_fields":[813,1529],"class_list":["post-12462","cpt_ikv_rp","type-cpt_ikv_rp","status-publish","has-post-thumbnail","hentry","tag-cascade-injection-moulding","tag-hot-runner-sealing-needle","tag-injection-moulding","tag-mould-optimisation","tag-process-control","research_fields-injection-moulding","research_fields-process-control"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.4 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>KaskaRe - Hot runner pressure control | IKV-Aachen<\/title>\n<meta name=\"description\" content=\"Cascade injection molding is the preferred process for the production of components with long flow paths without visible weld lines. To compensate for process fluctuations, such as the processing of different material batches, a cavity pressure control system for cascade injection molding was developed in the KaskaRe project. The pressure transfer into the cavity is regulated at each gate by adjusting the pressure transfer using variable opening strokes of the hot runner valve pins.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/ikv-aachen.de\/en\/rp\/kaskare-hot-runner-pressure-control\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"KaskaRe - Hot runner pressure control | IKV-Aachen\" \/>\n<meta property=\"og:description\" content=\"Cascade injection molding is the preferred process for the production of components with long flow paths without visible weld lines. To compensate for process fluctuations, such as the processing of different material batches, a cavity pressure control system for cascade injection molding was developed in the KaskaRe project. The pressure transfer into the cavity is regulated at each gate by adjusting the pressure transfer using variable opening strokes of the hot runner valve pins.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/ikv-aachen.de\/en\/rp\/kaskare-hot-runner-pressure-control\/\" \/>\n<meta property=\"og:site_name\" content=\"IKV-Aachen\" \/>\n<meta property=\"article:publisher\" content=\"https:\/\/www.facebook.com\/profile.php?id=523026911193540&amp;_rdr\" \/>\n<meta property=\"article:modified_time\" content=\"2026-05-20T08:55:08+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/ikv-aachen.de\/wp-content\/uploads\/2026\/04\/IGF-22805-N-scaled.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"2560\" \/>\n\t<meta property=\"og:image:height\" content=\"1242\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<meta name=\"twitter:label1\" content=\"Estimated reading time\" \/>\n\t<meta name=\"twitter:data1\" content=\"2 minutes\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/kaskare-hot-runner-pressure-control\\\/\",\"url\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/kaskare-hot-runner-pressure-control\\\/\",\"name\":\"KaskaRe - Hot runner pressure control | IKV-Aachen\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/#website\"},\"primaryImageOfPage\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/kaskare-hot-runner-pressure-control\\\/#primaryimage\"},\"image\":{\"@id\":\"https:\\\/\\\/ikv-aachen.de\\\/en\\\/rp\\\/kaskare-hot-runner-pressure-control\\\/#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/ikv-aachen.de\\\/wp-content\\\/uploads\\\/2026\\\/04\\\/IGF-22805-N-scaled.jpg\",\"datePublished\":\"2026-04-08T10:31:57+00:00\",\"dateModified\":\"2026-05-20T08:55:08+00:00\",\"description\":\"Cascade injection molding is the preferred process for the production of components with long flow paths without visible weld lines. 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