Kistler Instrumente AG is currently professional fitting two 96-cavity molds for the production of insulin pen components with pressure sensors manufacturers for quality assurance. Each of the 96 cavities and each of the 16 manifolds will be equipped with a sensor, such that each mold will come with a total of 112 detection. The objective of using mold cavity pressure sensors in injection moulding these polypropylene components is to establish automatic 100 % quality assurance and thus to ensure zero-defect production.

With a front diameter of only 1 mm, the Type 6183A… sensors are the smallest so far used for cavity pressure measurement. The mold maker adapts the front ends of the sensors to the contours of the cavity wall, using erosion technology to fit both the sensors and the mold inserts.

It is only due to Kistler's single-wire technology that 112 sensors can be integrated into such a compact and complex mold. The cut-and-grip technique permits the sensor cables to be fitted and removed quickly and easily without any additional tooling.
Specially developed high channel charge amplifiers transmit the measurement data digitally to the Dataflow process analysis system, which offers functions for the visualization, monitoring and documentation of injection molding processes based on the cavity pressure curve. As with other Kistler systems, Dataflow professional monitors changes in cavity pressure in all cavities cycle by cycle. Parts that are identified as defective or non conforming are removed through activation of reject diverters or industrial robots.