Decoupled injection molding separates the molding process into independently controlled stages (fill, pack, hold). Hansen Plastics uses pressure sensors inside the mold and RJG software to monitor and adjust each stage in real time. The result: more precise, repeatable parts with fewer defects compared to traditional single-phase injection molding.

A decoupled process breaks injection molding into 3 separate, controlled stages:

1. Fill – rapidly fill the mold cavity
2. Pack – Push in extra material to compensate for shrinkage
3. Hold – maintain low pressure while part cools

Each stage is controlled independently using real-time pressure data, allowing fine-tuned optimization of every shot.

Decoupled molding reduces defects (sink marks, warpage, dimensional variation) by controlling pressure precisely at each stage. Real-time sensor feedback allows instant corrections. Fewer rejected parts means less waste and faster effective throughput. Hansen Plastics integrates RJG software with their ERP system for continuous process optimization.

Decoupled Molding solves:

• Part-to-part variation – eliminated by repeatable pressure control
• Shrinkage issues – pack stage compensates precisely
• Dimensional errors – real-time adjustments keep parts in spec
• Defects (sink marks, warpage) – reduced through stage separation
• Material waste – optimized process uses only what’s needed

3 stages of decoupled molding:

1. Fill Stage – molten plastic fills the mold cavity at controlled speed
2. Pack Stage – additional plastic is pushed in under controlled pressure to prevent shrinkage
3. Hold Stage – low pressure is maintained while the part cools and solidifies

Each stage is independently managed using Hansen Plastics’ RJG software and in-mold pressure sensors.

Yes, decoupled molding is the best choice for tight-tolerance parts. By controlling fill, pack, and hold separately with real-time pressure data, Hansen Plastics minimizes shrinkage and dimensional variation. Every shot follows the same precise profile, so parts consistently hit tight specs. Ideal for industries like automotive, life safety, and precision industrial components.