Pressure-Controlled Runner Optimization and Filling Balance Analysis in Multi-Cavity Injection Molds

In this study, the effects of runner-system design on filling balance and pressure distribution in multi-cavity injection molds were investigated through Moldex3D simulations. Four runner configurations—H-type, Symmetrical-type, Star-type, and Fishbone-type—were evaluated using the material SCHULAMID® 6 MV14 FR4 K1681. The simulation results revealed that runner geometry has a decisive influence on filling uniformity, and they further demonstrated the effectiveness of a pressure-controlled runner approach in improving overall product quality. The findings highlight the importance of rheology-based optimization in runner-system design. This study differentiates itself from previous research by providing a comparative analysis of multiple runner types and by demonstrating that balanced filling can be successfully achieved not only in molds with 2ⁿ cavity counts but also in intermediate cavity numbers such as 12 and 14. The rheology-based pressure-controlled methodology presented here introduces a new optimization perspective for multi-cavity injection mold design.