Method for evenly distributing plastic melt in a hot runner system using strain gauges

A method of evenly distributing molten thermoplastic material to multiple cavities using a hot runner system in a molding apparatus comprising:

• creating, by one or more processors, a target strain profile for a molding process of a molding apparatus;
• receiving, by the one or more processors, strain readings reflecting changes in strain during a molding process as an output from at least one strain gauge in each of a plurality of temperature zones of the molding apparatus,
• monitoring, by the one or more processors, the strain readings for each temperature zone in order to detect a deviation from the target strain profile by a temperature zone;
• if a deviation is detected, determining, by the one or more processors, whether the deviation exceeds a deviation limit;
• if the deviation exceeds a deviation limit, adjusting heat produced by one or more heaters in the deviating temperature zone in order to correct the deviation,
• and amplifying the changes in strain sensed by at least one of the at least one strain gauge in each of the plurality of temperature zones using an alternative material insert filling an aperture in which the at least one of the at least one strain gauge in each of the plurality of temperature zones is located.