New part challenges directly translate into new tooling challenges. While many hot runner system suppliers have responded with new designs,

there are always new processing challenges and learning curves to navigate. This includes the design, location and consistency of heaters, thermocouples, flow channels, gate tips, water channels, manifolds and plates. Some basics to consider when evaluating your hot runner system design are:

Are any of the manifold flow channels directly crossing perpendicular underneath a tubular heater? These can cause burning.

Are any of the manifold thermocouples placed directly opposite of each other? These can cause zones to provide false feedback.

Are the thermocouples on the nozzles optimally located for the nozzle’s heat profile? They should be at a point of stable heat loss.

Do all nozzles have a thermocouple? This provides optimal system control when using the proper type of hot runner controller.

Is the entire system thermally balanced and managed with proper water channel size and location?

Have the gate geometries been proven on similar materials, parts and mold configurations?
Once these basics are in place, you will be able to learn the nuances of your new hot runner and mold design. Keep in mind that all of these factors can be negatively exaggerated, positively compensated for or just left to do their job by the hot runner temperature controller.