Cav-Bal®PRO

What Is Cav-Bal®?

Cav-Bal® is proprietary cavity balance software developed by Moulding Optimisation Ltd for correcting hot runner cavity imbalance in multi-cavity injection moulds. It is used during mould qualification, process validation, and troubleshooting to establish uniform cavity filling and stable production conditions.

Precision Cavity Balance for Multi-Cavity Injection Moulds

In multi-cavity injection moulding, small differences in fill time between cavities create measurable variation in part weight, dimensions and cosmetic quality.

Even the best hot runner systems can produce significant cavity imbalance out of the box.

Cav-Bal® is specialist software developed to scientifically calculate the hot runner tip adjustments required to balance cavities.

 

What Cav-Bal® Does

Cav-Bal® analyses short-shot cavity weight data and calculates:

• Required hot runner tip temperature corrections

• Cavity-to-cavity imbalance percentage

• The optimum ΔT for the balanced tip profile

Cav-Bal® can achieve a measurable <1% cavity imbalance on your hot runner moulds; results are limited only by the resolution of the hot runner controller.

Why Cavity Balance Matters

Unbalanced moulds can result in:

• Dimensional variation

• Cosmetic differences between cavities

• Uneven packing

• Gate freeze inconsistency

• Increased scrap

• Extended mould trials

• Ongoing “tuning” during production

Traditional tip tuning is often iterative and experience-based.

Cav-Bal® converts cavity weight data into calculated adjustments using a structured Design of Experiments methodology — removing guesswork and reducing trial time.

Where Cav-Bal® Is Used

Cav-Bal® is suitable for:

• Initial mould qualification

• Scientific Injection Moulding studies

• Medical validation (IQ / OQ / PQ support)

• Routine maintenance re-balance

• Troubleshooting cosmetic or dimensional variation

• High cavity count hot runner systems

It is particularly effective on:

• Valve-gated hot runners

• Multi-cavity tools (4–32 cavities)

• Engineering polymers

• Medical and high-tolerance applications

How It Works

1. Conduct a structured short-shot study.

2. Input cavity weight data into Cav-Bal®.

3. The software calculates required tip temperature settings.

4. Apply adjustments.

5. Re-confirm balance.

The process typically reduces balancing time from multiple trial iterations to a single structured correction cycle.

Key Features

• Stand-alone Windows application

• No in-cavity sensors required

• No external subscriptions

• Designed specifically for hot runner cavity balancing

• Uses proprietary balancing algorithm based on DoE

• Simple operator interface

• Fast implementation during trials

The Engineering Philosophy Behind Cav-Bal®

Cav-Bal® was developed from real-world injection moulding experience.

It does not replace scientific injection moulding. It strengthens it.

Cav-Bal® integrates naturally into a structured SIM approach and supports validation-driven environments.

Versions

Cav-Bal®PRO
Full functionality for professional mould trials and production support, balances up to 64 cavities.

Cav-Bal®FREE / Trial
Limited online version for evaluation, balances up to 8 cavities.

 

Enquire About Cav-Bal®

If you are running multi-cavity hot runner tools and want to do it better, Cav-Bal® provides a structured, engineering-driven solution. Contact us for further information, Cav-Bal®FREE access or technical discussion or register and download the Cav-Bal® white paper.

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