Synventive: Simulation-Based Hot Runner Technology for Illuminated Two-Component Front Grille

Two-component front grille – (Photo: Synventive).

Synventive, a brand of Spectrix, has developed a hot runner system tailored to the part geometry of a large, illuminated front grille for a premium electric SUV. The two-component part consists of transparent polycarbonate (PC) and black acrylonitrile butadiene styrene (ABS) and is manufactured on a KraussMaffei injection molding machine using the company's "SpinForm" swivel-platen technology. The technical design focuses on filling the thin-walled geometry and preventing optical defects on visible and light-transmitting surfaces.

Swivel-Platen Technology for Large-Scale Components
The "SpinForm" technology uses two parting planes and molds arranged one behind the other. Both plastic components can be injected simultaneously. According to KraussMaffei, this enables twice the output compared with rotary-table technology at the same clamping force. The concept thus provides the machine technology required to manufacture the large two-component part.

Advert

Mold Filling Simulation and Gate Positioning
During the hot runner design process, Synventive used "Moldflow" simulations to investigate the interaction between gate positions, flow paths, and part geometry. By precisely controlling the melt flow fronts, the aim is to move weld lines away from optically critical areas and minimize impairments to light transmission.

Due to the low wall thickness, the design incorporates a large number of gates to shorten the flow paths. The melt channel geometry had to be designed and manufactured with corresponding precision to ensure that the simulated filling balance could be achieved in the actual production process.

Direct Gating from the Rear and Temperature Control
The melt is injected directly from the rear of the part to prevent gate marks on the Class-A visible surface. Valve gates enable the precisely timed opening of individual injection points. The system also incorporates multi-zone heating for particularly long nozzles. Controlled temperature management is important when processing transparent polycarbonate, as thermal stress and contamination can adversely affect optical quality.

The actual component will be on display at the Spectrix booth at Fakuma 2026, Hall A1, Booth 1208. Spectrix brings together technologies for moldmaking, hot runner systems, as well as sensor and control technology.

Fakuma 2026
Friedrichshafen, Germany
October 12–16, 2026
Hall A1, Stand 1208

Synventive Molding Solutions GmbH, Bensheim, Germany

back to news list