{"id":7726,"date":"2025-09-01T09:00:00","date_gmt":"2025-09-01T08:00:00","guid":{"rendered":"https:\/\/uplastech.com\/clamping-force-tonnage-selection-2\/"},"modified":"2026-10-28T03:47:13","modified_gmt":"2026-10-28T03:47:13","slug":"clamping-force-tonnage-selection","status":"publish","type":"post","link":"https:\/\/uplastech.com\/ar\/clamping-force-tonnage-selection\/","title":{"rendered":"Clamping Force and Tonnage Selection: The Five-Step Calculation"},"content":{"rendered":"<style>\n.upl-blog{font-size:17px;line-height:1.78;color:#1f2937}\n.upl-blog p{margin:0 0 18px}\n.upl-blog h2{font-size:26px;line-height:1.3;color:#0b2b33;margin:46px 0 14px;font-weight:700;letter-spacing:-.015em}\n.upl-blog h3{font-size:19.5px;color:#0d3b47;margin:28px 0 10px;font-weight:700}\n.upl-blog ul,.upl-blog ol{margin:0 0 20px;padding-left:22px}\n.upl-blog li{margin:0 0 9px}\n.upl-blog figure{margin:0 0 34px}\n.upl-blog figure img{width:100%;height:auto;display:block;border-radius:10px}\n.upl-blog figcaption{font-size:13px;color:#6b7280;margin-top:10px;line-height:1.5}\n.upl-blog .toc{background:none;border:0;border-radius:0;padding:0;margin:0 0 34px}\n.upl-blog .toc .lwptoc{margin:0}\n.upl-blog .toc h4{margin:0 0 10px;font-size:13px;letter-spacing:.1em;text-transform:uppercase;color:#0d5563}\n.upl-blog .toc ol{margin:0;padding-left:18px;font-size:14.5px}\n.upl-blog .toc li{margin-bottom:6px}\n.upl-blog table{width:100%;border-collapse:collapse;font-size:14.5px;margin:0 0 10px}\n.upl-blog th{background:#0d3b47;color:#fff;text-align:left;padding:11px 13px;font-weight:600;font-size:13.5px;border:0}\n.upl-blog td{padding:11px 13px;border:0;border-bottom:1px solid #e8ebed;vertical-align:top}\n.upl-blog tbody tr:nth-child(even){background:#fafbfc}\n.upl-blog .tablecap{font-size:12.5px;color:#6b7280;margin:0 0 30px}\n.upl-blog .myth{background:#fff8ef;border:1px solid #f6ddbd;border-radius:8px;padding:16px 20px;margin:0 0 26px;font-size:15.5px}\n.upl-blog .myth b{color:#a85c10}\n.upl-blog .callout{background:#f2f8f9;border-radius:8px;padding:18px 22px;margin:0 0 26px;font-size:15.5px;border-left:3px solid #14707f}\n.upl-blog .faq h3{border-top:1px solid #eceff1;padding-top:22px;margin-top:0;font-size:18px}\n.upl-blog .faq h3:first-of-type{border-top:0;padding-top:0}\n.upl-blog .cta{background:linear-gradient(135deg,#0b2b33,#0d5563);color:#fff;border-radius:12px;padding:34px;margin:48px 0 30px}\n.upl-blog .cta h2,.upl-blog .cta .cta-h{color:#fff;margin:0 0 10px;font-size:24px;font-weight:700;line-height:1.3}\n.upl-blog .cta p{color:#c9dee3;margin:0 0 20px;font-size:16px}\n.upl-blog .btn{display:inline-block;background:#e07a1f;color:#fff;text-decoration:none;font-weight:700;padding:13px 26px;border-radius:8px;font-size:15.5px}\n.upl-blog .rel{border-top:1px solid #e8ebed;margin-top:40px;padding-top:26px}\n.upl-blog .rel h4{font-size:13px;letter-spacing:.1em;text-transform:uppercase;color:#6b7280;margin:0 0 14px}\n.upl-blog .rel ul{list-style:none;padding:0;margin:0}\n.upl-blog .rel li{padding:11px 0;border-bottom:1px dashed #e8ebed}\n.upl-blog .rel a{text-decoration:none;font-weight:600;font-size:15.5px}\n@media(max-width:640px){.upl-blog h2{font-size:22px}.upl-blog table{font-size:13px}.upl-blog .cta{padding:24px}}\n\/* \u5355\u7bc7\u9875\u9690\u85cf WhatsApp \u81ea\u52a8\u5c55\u5f00\u7684\u95ee\u5019\u5361\uff0c\u53ea\u4fdd\u7559\u5706\u5f62\u6c14\u6ce1\uff0c\u907f\u514d\u906e\u6321\u4fa7\u680f\u8be2\u76d8\u63d0\u4ea4\u6309\u94ae *\/\nbody.single-post .ht_ctc_chat_greetings_box{display:none !important}\n<\/style>\n<div class=\"upl-blog\">\n<figure>\n<img fetchpriority=\"high\" decoding=\"async\" src=\"https:\/\/uplastech.com\/wp-content\/uploads\/2026\/10\/clamping-force-tonnage-selection.jpg\" alt=\"Chart of cavity pressure by material and clamping force against projected area for injection molding\" width=\"1536\" height=\"909\"><figcaption>Clamping force is the one machine number that decides whether a tool runs clean or flashes, and it is arithmetic, not experience.<\/figcaption><\/figure>\n<div class=\"toc\"><\/div>\n<h2 id=\"why\">Why tonnage is the first number to get right<\/h2>\n<p>Every injection moulding quotation starts with a machine size, and that size is set by clamping force. Get it too low and the tool flashes at the far corner of the parting line, no process setting fixes it, and the moulder spends a week blaming the tool. Get it too high and the mould vents are crushed shut, parts burn, and the tool wears out years early.<\/p>\n<p>The number is not a matter of judgement. It is projected area multiplied by cavity pressure, with a small safety margin. The difficulty is that cavity pressure is not the same as injection pressure, and the projected area is not the same as the part footprint.<\/p>\n<div class=\"callout\">\n<p><strong>Two mistakes cause most tonnage errors.<\/strong> Using hydraulic pressure instead of cavity pressure \u2014 they differ by a factor of five to ten. And forgetting the runner: on a multi-cavity tool the runner's projected area can add 30\u201350% to the total.<\/p>\n<\/div>\n<h2 id=\"formula\">The arithmetic<\/h2>\n<p>Clamping force has to exceed the separating force that the melt exerts on the mould faces. That force is cavity pressure times the projected area of everything the pressure acts on.<\/p>\n<p><strong>F (kN) = A (cm\u00b2) \u00d7 P (bar) \u00f7 100<\/strong><\/p>\n<p>Where <strong>A<\/strong> is the total projected area \u2014 parts plus runner plus overflow \u2014 and <strong>P<\/strong> is the peak cavity pressure during packing, not during fill. Then multiply by a safety factor of 1.1 to 1.2.<\/p>\n<table>\n<thead>\n<tr>\n<th>\u0627\u0644\u062e\u0637\u0648\u0629<\/th>\n<th>What to measure<\/th>\n<th>Common error<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>1. Projected area<\/td>\n<td>Outline of the part as seen from the nozzle, in cm\u00b2<\/td>\n<td>Using the flat base area, not the maximum outline<\/td>\n<\/tr>\n<tr>\n<td>2. Number of cavities<\/td>\n<td>Multiply per cavity<\/td>\n<td>Forgetting the runner and sprue<\/td>\n<\/tr>\n<tr>\n<td>3. Cavity pressure<\/td>\n<td>Peak pack pressure, from a sensor or a material table<\/td>\n<td>Using hydraulic or injection pressure instead<\/td>\n<\/tr>\n<tr>\n<td>4. Separating force<\/td>\n<td>A \u00d7 P \u00f7 100<\/td>\n<td>Mixing units \u2014 mm\u00b2 with bar gives nonsense<\/td>\n<\/tr>\n<tr>\n<td>5. Safety factor<\/td>\n<td>\u00d7 1.1 \u2013 1.2<\/td>\n<td>Using 2.0 and oversizing the machine<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 1 \u2014 The five steps of a tonnage calculation. Steps 1 and 3 are where the errors live; the arithmetic itself is trivial.<\/p>\n<p>A worked example. A flat ABS housing, 180 \u00d7 120 mm outline, one cavity, a runner with 40 cm\u00b2 of projected area. Total projected area is 216 + 40 = 256 cm\u00b2. ABS packs at around 500 bar. Separating force is 256 \u00d7 500 \u00f7 100 = 1,280 kN, or 128 tonnes. With a 15% margin, the machine needs 150 tonnes.<\/p>\n<h2 id=\"pressure\">Cavity pressure by material<\/h2>\n<p>Cavity pressure is a material property as much as a process setting. Viscous, fast-freezing, glass-filled or semi-crystalline resins need more pressure to fill and pack the same geometry.<\/p>\n<table>\n<thead>\n<tr>\n<th>\u0627\u0644\u0645\u0648\u0627\u062f<\/th>\n<th>Typical cavity pressure<\/th>\n<th>Note<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>PE, PP<\/td>\n<td>200 \u2013 400 bar<\/td>\n<td>Low viscosity, easy flow<\/td>\n<\/tr>\n<tr>\n<td>PS, HIPS<\/td>\n<td>300 \u2013 500 bar<\/td>\n<td>Fast freezing, short flow<\/td>\n<\/tr>\n<tr>\n<td>ABS<\/td>\n<td>400 \u2013 600 bar<\/td>\n<td>Common baseline for tonnage tables<\/td>\n<\/tr>\n<tr>\n<td>\u0643\u0645\u0628\u064a\u0648\u062a\u0631 \u0634\u062e\u0635\u064a<\/td>\n<td>500 \u2013 800 bar<\/td>\n<td>High viscosity, needs hot mould<\/td>\n<\/tr>\n<tr>\n<td>PA6 \/ PA66<\/td>\n<td>600 \u2013 1,000 bar<\/td>\n<td>Crystalline, fast setting<\/td>\n<\/tr>\n<tr>\n<td>POM<\/td>\n<td>800 \u2013 1,200 bar<\/td>\n<td>Very high, narrow process window<\/td>\n<\/tr>\n<tr>\n<td>PC\/ABS<\/td>\n<td>500 \u2013 800 bar<\/td>\n<td>Blend, between the two parents<\/td>\n<\/tr>\n<tr>\n<td>Glass-filled (30%)<\/td>\n<td>Add 30 \u2013 50%<\/td>\n<td>Viscosity rises with filler loading<\/td>\n<\/tr>\n<tr>\n<td>Thin wall (under 1 mm)<\/td>\n<td>Add 50 \u2013 100%<\/td>\n<td>Flow length to thickness ratio dominates<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 2 \u2014 Cavity pressure ranges. These are pack pressures, not fill pressures; a thin-walled part can need double the table value.<\/p>\n<p>The table values assume a reasonably balanced wall thickness and a flow length to thickness ratio under about 150. A part with a 0.8 mm wall running 120 mm from the gate has a ratio of 150 and sits at the limit; a 0.6 mm wall over the same distance needs pressures well outside the range and is usually a tooling problem rather than a tonnage problem.<\/p>\n<h2 id=\"area\">Projected area: what actually counts<\/h2>\n<p>Projected area is the shadow the mould cavity casts on the parting plane. It is not the surface area of the part, and it is not the area of the part's largest flat face.<\/p>\n<table>\n<thead>\n<tr>\n<th>\u0627\u0644\u0645\u064a\u0632\u0629<\/th>\n<th>Counts toward projected area?<\/th>\n<th>\u0644\u0645\u0627\u0630\u0627<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Part outline at the parting line<\/td>\n<td>\u0646\u0639\u0645<\/td>\n<td>This is what the pressure pushes apart<\/td>\n<\/tr>\n<tr>\n<td>Runner and sprue<\/td>\n<td>\u0646\u0639\u0645<\/td>\n<td>They carry the same pressure<\/td>\n<\/tr>\n<tr>\n<td>Side actions, sliders<\/td>\n<td>Only the projected face<\/td>\n<td>Sliders have their own force balance<\/td>\n<\/tr>\n<tr>\n<td>Deep ribs, bosses<\/td>\n<td>No extra<\/td>\n<td>Inside the outline<\/td>\n<\/tr>\n<tr>\n<td>Undercuts formed by lifters<\/td>\n<td>No extra<\/td>\n<td>Within the outline<\/td>\n<\/tr>\n<tr>\n<td>Overflow wells<\/td>\n<td>\u0646\u0639\u0645<\/td>\n<td>They fill with melt at pressure<\/td>\n<\/tr>\n<tr>\n<td>Hot runner manifold<\/td>\n<td>\u0644\u0627 \u064a\u0648\u062c\u062f<\/td>\n<td>It is behind the stationary platen, not between the halves<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 3 \u2014 What belongs in the projected area. The runner is the item most often left out, and on small parts it is often larger than the part itself.<\/p>\n<p>On a 16-cavity tool making a 3 cm\u00b2 part, the parts contribute 48 cm\u00b2 and the runner can contribute 30 cm\u00b2 or more. Ignoring the runner understates the tonnage by 40%, which is exactly the margin that separates a clean part from a flashed one.<\/p>\n<h2 id=\"toolow\">What too little clamping force looks like<\/h2>\n<p>Flash is the obvious symptom, but it is the last one to appear. The earlier signs are more diagnostic.<\/p>\n<table>\n<thead>\n<tr>\n<th>Symptom<\/th>\n<th>What it tells you<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Flash at the furthest point from the sprue<\/td>\n<td>Parting faces are deflecting, not opening evenly<\/td>\n<\/tr>\n<tr>\n<td>Part weight varies shot to shot<\/td>\n<td>Melt is escaping, so pack is inconsistent<\/td>\n<\/tr>\n<tr>\n<td>Flash appears only at high pack pressure<\/td>\n<td>Tonnage is marginal \u2014 it is a pressure limit, not a tonnage limit<\/td>\n<\/tr>\n<tr>\n<td>Flash on one side only<\/td>\n<td>Platen parallelism or mould face wear, not tonnage<\/td>\n<\/tr>\n<tr>\n<td>Short shots that come and go<\/td>\n<td>Operator is raising pack pressure to compensate, which makes flash worse<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 4 \u2014 Reading the symptoms. Flash on one side only is a parallelism problem and adding tonnage will not fix it.<\/p>\n<p>The trap is that raising pack pressure to fix a short shot increases the separating force, so a marginal tool starts flashing. The operator backs off the pressure, the short shot returns, and the job runs in a narrow band between two defects. That is the signature of a machine that is one size too small.<\/p>\n<h2 id=\"toohigh\">What too much clamping force costs<\/h2>\n<p>Oversizing is the more common error because it feels safe. It is not free.<\/p>\n<table>\n<thead>\n<tr>\n<th>Effect<\/th>\n<th>Mechanism<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Crushed vents<\/td>\n<td>Vent depth is 0.02\u20130.05 mm; tonnage closes it<\/td>\n<\/tr>\n<tr>\n<td>Burns and dieseling at the end of fill<\/td>\n<td>Air cannot escape, so it compresses and ignites<\/td>\n<\/tr>\n<tr>\n<td>Higher energy consumption<\/td>\n<td>Tonnage is a direct power draw<\/td>\n<\/tr>\n<tr>\n<td>Mould wear and fretting on the parting line<\/td>\n<td>Repeated elastic deflection of the faces<\/td>\n<\/tr>\n<tr>\n<td>Difficulty setting up<\/td>\n<td>Small adjustments produce large pressure changes<\/td>\n<\/tr>\n<tr>\n<td>Tie bar strain and platen deflection<\/td>\n<td>Especially on older machines without force monitoring<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 5 \u2014 The cost of oversizing. Vent crushing is the one that turns a good tool into a tool that burns parts for the rest of its life.<\/p>\n<p>A mould built for 100 tonnes run on a 250-tonne press will usually work, because most presses can be set to a lower clamp force. The real risk is a moulder who does not set it down, or a press without a clamp force display, where the machine simply closes at full tonnage.<\/p>\n<h2 id=\"verify\">Verifying the number on the machine<\/h2>\n<p>The calculation gives a starting point. The machine gives the answer. Three checks confirm it.<\/p>\n<p>First, the flash test: reduce clamp force in 10% steps until flash just appears at the furthest point, then add back 15\u201320%. That is the true minimum for the tool at that pressure.<\/p>\n<p>Second, the vent check: with the calculated tonnage applied, inspect the vents. If they are bright and polished, they are being crushed. If they hold a faint witness mark, they are working.<\/p>\n<p>Third, the platen check: on a large mould, place pressure-sensitive film or lead wire at the four corners of the parting line and close at production tonnage. Uneven impressions mean the platens are not parallel and the tonnage is not distributed, whatever the display says.<\/p>\n<h2 id=\"machine\">Choosing the machine, not just the tonnage<\/h2>\n<p>Tonnage is necessary but not sufficient. Three other numbers decide whether a machine can run a tool.<\/p>\n<table>\n<thead>\n<tr>\n<th>Machine parameter<\/th>\n<th>Rule of thumb<\/th>\n<th>What goes wrong<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Shot size<\/td>\n<td>Part + runner between 25% and 75% of barrel capacity<\/td>\n<td>Below 25%: long residence time, degradation<\/td>\n<\/tr>\n<tr>\n<td>Injection pressure<\/td>\n<td>Cavity pressure \u00d7 2 at the nozzle, minimum<\/td>\n<td>No headroom, process drifts through the shift<\/td>\n<\/tr>\n<tr>\n<td>Tie bar spacing<\/td>\n<td>Mould width plus 50 mm each side<\/td>\n<td>Mould will not fit, or fits with no room for hoses<\/td>\n<\/tr>\n<tr>\n<td>Daylight and stroke<\/td>\n<td>Part depth \u00d7 2 plus 100 mm<\/td>\n<td>Part cannot be ejected<\/td>\n<\/tr>\n<tr>\n<td>Screw diameter<\/td>\n<td>Matches shot size, not tonnage<\/td>\n<td>Oversized screw, long residence time<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p class=\"tablecap\">Table 6 \u2014 Machine selection beyond tonnage. Shot size below 25% of barrel capacity is the most common hidden problem on small parts run on large presses.<\/p>\n<p>The shot size rule is worth emphasising. A 20 g part on a machine with a 500 g barrel spends twenty-five times as long in the barrel as it should, and the material degrades. The part may pass inspection and still fail in service because the molecular weight has dropped. A smaller barrel on the same tonnage is almost always the better machine.<\/p>\n<div class=\"faq\">\n<h3>How do I calculate clamping force?<\/h3>\n<p>Projected area in cm\u00b2 multiplied by peak cavity pressure in bar, divided by 100, gives kilonewtons. Divide by 9.81 for tonnes, then add 10\u201320% margin. Include the runner and every cavity.<\/p>\n<h3>What cavity pressure should I use?<\/h3>\n<p>200\u2013400 bar for PE and PP, 400\u2013600 for ABS, 500\u2013800 for PC, 600\u20131,000 for nylon, up to 1,200 for POM. Add 30\u201350% for glass-filled grades and up to 100% for walls under 1 mm.<\/p>\n<h3>Is tonnage the same as clamping force?<\/h3>\n<p>In practice yes \u2014 \"tonnage\" is shorthand for clamping force expressed in metric tonnes. A 150-tonne machine can apply about 1,470 kN of clamp force.<\/p>\n<h3>Why does my part flash even though the tonnage is correct?<\/h3>\n<p>Usually one of three things: the parting faces are worn or not parallel, the projected area was underestimated because the runner was left out, or the pack pressure is higher than the value used in the calculation. Check parallelism before adding tonnage.<\/p>\n<h3>Can I use a bigger machine and just turn the tonnage down?<\/h3>\n<p>Yes, if the machine has a working clamp force setting and the shot size still falls in the 25\u201375% band. On a small part in a large barrel, the residence time problem is worse than any tonnage benefit.<\/p>\n<h3>How much safety margin should I add?<\/h3>\n<p>10\u201320%. More than that and you start crushing vents and wasting energy. The margin is there to cover material batch variation and temperature drift, not to cover a wrong projected area.<\/p>\n<h3>Does the number of cavities change the tonnage?<\/h3>\n<p>Yes, linearly for the parts, and it also adds runner area. An 8-cavity tool needs eight times the part area plus the runner, which is why multi-cavity tools move to larger presses quickly.<\/p>\n<h3>What is a safe minimum shot size?<\/h3>\n<p>25% of barrel capacity. Below that the melt residence time becomes long enough to degrade heat-sensitive materials, and the process becomes sensitive to any interruption in the cycle.<\/p>\n<\/div>\n<div class=\"cta\">\n<p class=\"cta-h\">Not sure which press a tool needs?<\/p>\n<p>Send us the part drawing, the resin and the cavity count. We will come back with the projected area, the cavity pressure, the tonnage and the machine specification \u2014 before you commit to a tool.<\/p>\n<p><a class=\"btn\" href=\"https:\/\/uplastech.com\/ar\/injection-molding\/\">Talk to an injection molding engineer<\/a>\n<\/div>\n<div class=\"rel\">\n<h4>Continue reading<\/h4>\n<ul>\n<li><a href=\"https:\/\/uplastech.com\/ar\/injection-molding-tolerances\/\">Injection Molding Tolerances: What Is Actually Achievable<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/ar\/injection-molding-design-guidelines\/\">Injection Molding Design Guidelines: 12 Rules That Cut Part Cost<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/ar\/injection-molding-cost-per-part\/\">Injection Molding Cost per Part: How the Price Is Really Built<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/ar\/scientific-molding-five-tests\/\">Scientific Molding: The Five Studies and Why the Order Matters<\/a><\/li>\n<li><a href=\"https:\/\/uplastech.com\/ar\/injection-molding-defects\/\">Injection Molding Defects: 12 Problems, Their Causes and Fixes<\/a><\/li>\n<\/ul>\n<\/div>\n<\/div>","protected":false},"excerpt":{"rendered":"<p>Clamping force is projected area times cavity pressure, plus a safety factor. Where each number comes from, and what both too little and too much tonnage cost you.<\/p>","protected":false},"author":1,"featured_media":7718,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Clamping Force and Tonnage Selection: The Five-Step Calculat","_seopress_titles_desc":"Clamping force is projected area times cavity pressure, plus a safety factor. 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