Hot-Runner Technology in Mass Production Wago manufactures sprue-free parts using a
48-cavity mold

Wago is transitioning the production of its electrical installation terminals from lateral direct injection molding to a sprue-free process. An Ewikon hot-runner system in a 48-cavity mold reduces cycle time by up to 40% and cuts CO₂ emissions by 45%. This was made possible through close coordination between R&D, toolmaking, and production.

In the mass production of electrical components, plastic processors face the challenge of combining high component quality with cost-effective process management. Wago, a manufacturer of connection technology based in Minden, first became aware of Ewikon’s side direct injection technology in 2022. Together with Ewikon, Wago evaluated this technology for its 2273 series of electrical installation terminals.

An orange-colored polycarbonate (PC) was used as the reference material, which places high demands on flow properties, demolding behavior, and surface finish. The tests conducted at the Ewikon Technical Center confirmed flawless melt flow, stable demolding without a sprue, and high part quality under conditions close to those of mass production.

Validation using an 8-in-1 test tool at three locations

Based on the test results, the Wago Tooling International division in Minden designed a near-production 8-cavity test mold in 2022. Following successful approval at the main facility, the company deployed the mold at its production sites in Sondershausen and Domdidier, Switzerland. This cross-site validation ensured that the new hot-runner technology guarantees consistently high process stability even under fluctuating production conditions. All participating plants attested to its high reliability.

Scaling up to a 48-cavity mold for high-volume production

Following the successful test phase, production moved to high-volume manufacturing. The Portuguese mold maker GLN/Famolde, based in Marinha Grande, took over the production of a 48-cavity production mold based on the design specifications from Wago’s pre-development team. Coordination between the developers, the toolmaker, and the hot-runner manufacturer took place well in advance in close collaboration with the future production team.

Tool development was largely led by the Wago development team (Alexander Sudermann, Viktor Löwen, Sebastian Meyer, and Eduard Wallmann), GLN/Famolde (Rui Gomes), Ewikon (Jens Hartwig), and Euro-Cumsa (Marcio Felicio), whose expertise made a decisive contribution to the project’s success. As a result, the ramp-up phase at the Wago plant was significantly shortened after delivery.

Production Success: Performance Data from Production

The switch to side direct injection completely eliminates sprue material, thereby eliminating post-processing steps and reducing material consumption. In mass production, the 48-cavity mold reduces cycle time by up to 40% compared to conventional mass-production molds. By eliminating sprues, part-specific CO₂ emissions are reduced by approximately 45%.

The mechanical robustness of the hot runner system is evident even during continuous operation: During a proactive inspection after more than 3,000,000 shots, all nozzle components were found to be in perfect condition.

Technology Meets Teamwork

The project between Wago and Ewikon impressively demonstrates that technological innovation and successful collaboration must go hand in hand. Side direct injection not only enables sprue-free manufacturing but also opens up entirely new possibilities for cost-effective mass production. At the same time, the project demonstrates how important close coordination between development, toolmaking, and production is.