Double-Entry Forklift Leg Hollow Double-Face Blow-Molded Pallet Mold — Product Introduction (Motek Pallet Mold Series)
Double-Entry Forklift Leg Hollow Double-Face Blow-Molded Pallet Mold — Product Introduction (Motek Pallet Mold Series)
Product Positioning
Motek introduces dedicated blow mold solutions for double-entry, leg-supported hollow double-face blow-molded pallets. These pallets feature flat decks on both top and bottom surfaces, an independent leg (foot) structure on the bottom, and a two-way forklift entry design, formed integrally through the hollow blow molding process. Compared with single-face pallets, the double-face structure allows for alternate use on both sides; compared with legless double-face pallets, the bottom leg design increases ground clearance, facilitating quick two-way forklift entry while enhancing compatibility with automated storage and retrieval systems (AS/RS) and conveyor lines. The core challenges in mold development lie in synchronous blow-forming of the double-face decks and leg structures, precision forming of the two-way forklift entry openings, and wall thickness uniformity control under complex hollow structures. Motek configures dedicated solutions around double-face cavity layout, leg blow-forming structures, and cooling systems, helping customers achieve stable mass production of these pallets.
Core Specifications
| Item | Specification |
|---|---|
| Applicable Plastics | HDPE (High-Density Polyethylene, preferred for blow molding, low-temperature resistant, impact-resistant) |
| Mold Material | P20 / 718H (pre-hardened steel) for cavity and core; surface hardness up to HV800–1000 after nitriding |
| Number of Cavities | 1×1 (single cavity for large double-face leg-supported parts) |
| Molding Process | Hollow blow molding (extrusion blow molding), parison inflation for synchronous double-face + leg forming |
| Entry Method | Two-way forklift entry (insertion from both long and short sides) |
| Applicable Specifications | 1200×1000mm, 1200×1200mm, 1300×1100mm, etc. standard sizes |
| Load Capacity Reference | Dynamic load approx. 1.5–2 tons / Static load approx. 4–6 tons (depending on specific wall thickness and leg structure design) |
| Cooling System | Double-face zoned circulating water channels + targeted cooling layout for deep leg cavities |
| Demolding Method | Mold opens for removal, coordinated with demolding mechanisms |
Product Features
Synchronous Blow-Forming of Double-Face Decks and Leg Structures.
This pallet combines the dual characteristics of double-face usability and bottom leg support. During blow molding, the parison must be uniformly inflated between the upper/lower decks and the six or nine bottom legs. Motek optimizes parison dimensions and blow ratios to ensure the material forms a continuous, uniform hollow structure across the double-face decks, peripheral side walls, and leg interiors—preventing excessive thinning at leg roots due to over-stretching. The wall thickness consistency of the double-face structure ensures the pallet has equal load-bearing capacity regardless of which side faces up.
Precision Forming of Two-Way Forklift Entry Openings.
The two-way entry design allows forklifts to insert from both the long and short sides of the pallet, placing extremely high demands on the height, width, and inner wall smoothness of the fork openings. Motek forms the entry openings through precision inserts or sliders in the mold, ensuring precise opening dimensions and smooth, flash-free inner walls for quick and smooth forklift fork insertion. Entry opening edges are chamfered to prevent fork scratching and enhance structural strength at the opening.
Wall Thickness Uniformity Control Under Complex Hollow Structures.
The leg-supported double-face pallet has a more complex structure than single-face flat or nine-leg pallets, with numerous thick-thin transition areas (such as deck-to-leg connections and entry opening peripheries). Motek evaluates wall thickness distribution across regions through blow molding simulation, optimizing parison design for areas prone to thinning (such as leg corners) and adjusting blow parameters and cooling rates for areas prone to thickening (such as solid intersections) to avoid local over-thickness leading to shrinkage or stress concentration.
Mold Clamping Precision and Appearance Consistency of Large Double-Face Cavities.
Upper and lower double-face cavities must be precisely aligned; otherwise, the double faces will misalign or have uneven thickness. Motek adopts high-precision guide pin and guide bushing fit to ensure accurate alignment during mold closing. Parting line positions are optimized to be placed at pallet edges or non-contact areas of legs wherever possible, reducing flash trimming processes. Double-face anti-slip textures or grid structures are subject to consistency control to ensure coordinated appearance and texture on both faces.
Cooling Efficiency Optimization for Deep Leg Cavity Areas.
As support structures, legs have relatively thicker walls and cool more slowly after blow molding, which can easily lead to extended production cycles or demolding deformation. Motek designs targeted cooling water channels inside and around the legs, using high-thermal-conductivity inserts where necessary to accelerate heat dissipation in leg areas. The cooling channel layout covers both the double-face decks and legs, ensuring uniform cooling of the entire pallet—shortening cycle time while preventing warpage.
Automated Warehousing Compatibility and Structural Rigidity.
The leg-supported double-face pallet creates higher ground clearance at the bottom, suitable for automated conveyor lines, roller lines, and AGV robot operation requirements. Motek reinforces the structure at leg-to-deck connections, ensuring legs do not fracture or collapse under full-load (dynamic load approx. 1.5–2 tons) stacking and frequent handling, maintaining the pallet's overall squareness and dimensional stability.
Applicable Specifications Reference
| Pallet Specification (mm) | Structure Type | Load Reference | Entry Direction | Application Scenarios |
|---|---|---|---|---|
| 1200×1000×150 | Double-face with legs | Dynamic approx. 1.5-2T / Static approx. 4-6T | Two-way entry | General warehousing logistics, automated AS/RS |
| 1200×1200×150 | Double-face with legs | Depends on wall thickness design | Two-way entry | High-load stacking, large cargo turnover |
| 1300×1100×150 | Double-face with legs | Depends on wall thickness design | Two-way entry | Export standard pallets, container transport |
Applications
Motek double-entry forklift leg hollow double-face blow-molded pallet molds are suitable for:
- Double-face blow-molded pallets for automated storage and retrieval systems (AS/RS)
- Double-face leg-supported dunnage pallets for warehousing logistics
- Double-face blow-molded pallets for cold-chain/freezer storage (HDPE low-temperature resistant)
- Two-way entry blow-molded pallets for export transport
- Warehousing turnover pallets requiring frequent two-way forklift operation
Service Process
After the customer provides 3D product drawings, load requirements (dynamic/static/rack load), leg structure plans, entry direction, and blow molding machine model, Motek completes blow molding simulation (including parison size evaluation, double-face and leg wall thickness distribution prediction, and cooling optimization) and mold structure confirmation; cavity steel is selected per blow molding process requirements (P20/718H, nitrided); progress and key milestones are regularly reported during processing. During trial molding, Motek cooperates with the customer's blow molding machine for parison adjustment, inflation parameter optimization, and wall thickness inspection, with emphasis on verifying double-face forming completeness, two-way entry opening precision, leg structural strength, and pallet flatness. Before shipment, molds undergo anti-rust treatment and action testing, with water circuit diagrams, consumable parts lists, and blow molding process parameter recommendations provided. Technical support is available during the warranty period, with lifetime maintenance consultation.
Motek — From single-face nine-leg to double-face leg-supported blow-molded pallets, supporting various entry methods and custom sizes, providing reliable mold solutions for blow molding of logistics and warehousing plastic pallets.
