Every shot.
Measured.
In-mold sensors and process monitoring on every cycle. Cavity pressure, melt temperature, cycle integrity — all logged, all controllable. Move from "we think it's stable" to "we know."
Sensor placement, wiring routes, and connector are engineered into the insert from the start. Compatible with Kistler, RJG, and Priamus systems — and the cooling-AI tool on conformalcooling.info.
Sensors that
see every shot.
A conventional mold runs blind — you set parameters, hope they stay correct, and inspect the parts that come out. A smart mold tells you what's actually happening inside the cavity, shot by shot, in real time.
Embedded pressure and temperature sensors at strategic cavity locations feed live data to a controller that can adjust holding pressure, injection profile, or cooling time on the fly. Industry 4.0, real.
Sensors inside.
Wires outside?
No.
Sensors are flush-mounted at cavity surface positions chosen by simulation. Wiring is routed through internal printed channels, exiting at a single connector port on the mold side — like RJG Lynx, but engineered into the insert geometry from the start.
- Cavity face — mirror-polished
- Conformal channels — serpentine, ⌀ 3–8 mm
- Water ports — threaded, in/out
- Mounting bolts — M6 × 4 corners
- Ejector pin clearances
Closes the loop
around your process.
Each sensor zone independently monitored. Pressure peaks, temperature drift, cycle anomalies — all logged with timestamp and shot number. The controller can tune injection speed, holding pressure, or cooling time per zone, per shot, based on the live data.
Works on conformal-cooled or conventional molds. Compatible with Kistler, RJG, Priamus, and the AI cooling assistant on conformalcooling.info.
Why open-loop molding
leaves yield on the table.
You set, you hope, you inspect
FIG.A · Open loop
- You set holding pressure once and hope it stays stable
- Drift in melt temperature is invisible until parts fail QC
- Reject rate climbs after the first 1,000 shots
- Traceability requires manual logging — error-prone, slow
Closed loop, every shot
FIG.B · Closed loop
- Cavity pressure + temp logged at 10 kHz per shot
- Controller adjusts injection / hold / cooling on the fly
- <2% reject rate target — validated across plastic packaging, medical, automotive, white-goods, and defense programs
- Every shot timestamped — full production traceability
From data
to decision.
Engineering
specifications.
| Sensor systems | Kistler 6182BB · RJG Lynx · Priamus Sigmasoft (configurable) |
| Pressure range | 0–2,000 bar, ±0.5% full-scale accuracy |
| Temperature range | 0–450°C, ±0.1°C accuracy with Type-K thermocouples |
| Sampling rate | 10 kHz max per channel · 1 kHz standard |
| Sensor count | 1–8 per insert · multi-zone configurations supported |
| Connector standard | Lynx LE-CON / Kistler / OPC-UA compatible |
| Data export | CSV, JSON, OPC-UA, MQTT — connects to MES/SCADA systems |
| Compliance | Plastic packaging · Medical (FDA part traceability) · Automotive OEM · White goods · Defense-grade production |
See inside your cycle.
Bring us your part and your sensor preference. We'll engineer the instrumented insert, integrate with your existing control system, and commission it on-site.