INJECTION MOULDING

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Historical Background
A single-action hydraulic injection machine was
designed in the U.S.A. in 1870 by Hyatt
Heating-cylinder design was first recognised in a
patent issued to Adam Gastron in 1932.
Large-scale development of injection moulding
machinery design towards the machines we
know today did not occur until the 1950's in
Germany

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Injection Moulding Process

Over View
Solid Wide neck, Flat Product is made
like bucket, cabinets, Automobile &
Industrial parts
etc. by injecting
molten thermoplastic material in to a
closed mould which is relatively cool.
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Type of Injection Moulding

Machine
Hand Injection Moulding M/C
Plunger type Injection Moulding M/C
Reciprocating Screw Type Injection
Moulding M/C
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Hand Injection Moulding Machine

vertical machine consists of Barrel, Plunger,

Band Heaters along with energy regulator, Rack
& Pinion system for Injecting the material by the
plunger, a torpedo and nozzle.
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Plunger Type Injection

Moulding Machine

Vertical & Horizontal Plunger Type Injection Moulding Machine

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The Reciprocating Screw

The feeding zone
The compressing (or transition) zone
The metering zone

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Machine components

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The Injection Process

Plasticises the material by reciprocating Screw.
Injects the molten material to a closed mould
via a channel system of gates and runners.

Cools the Mould.

Refills the material for the next cycle.
Ejects the Product.
Closes the Mould for further cycle.

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Injection Moulded Items

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Injection Moulded Items

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Injection Moulded Items

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Advantages of Injection
Moulding Process

Parts can be produced at high production rates.

Large volume production is possible.
Relatively low labour cost per unit is obtainable.
Process is highly susceptible to automation.
Parts require little or no finishing.
Many different surfaces, colours, and finishes are
available.
Good decoration is possible.
For many shapes this process is the most economical way
to fabricate.
Process permits the manufacture of very small parts which
are almost impossible to fabricate in quantities by other
methods.
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Advantages of Injection
Moulding Process
Minimal scrap loss result as runners, gates, and rejects
can be reground and reused.
Same items can be moulded in different materials,
without changing the machine or mould in some cases.
Close dimensional tolerances can be maintained.
Parts can be moulded with metallic and non-metallic
inserts.
Parts can be moulded in a combination of plastic and
such fillers as glass, asbestos, talc and carbon.
The inherent properties of the material give many
advantages such as high strength-weight rates,
corrosion resistance, strength and clarity.
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Limitations of Injection Moulding

Intense industry competition often results in low profit
margins.
Mould costs are high.
Moulding machinery and auxiliary equipment costs are
high.
Lack of knowledge about the fundamentals of the
process causes problems.
Lack of knowledge about the long term properties of the
materials may result in long-term failures.
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Machine operation sequence

The mould closes and the screw begins moving forward for
injection.

The cavity fills as the reciprocating screw moves forward, as a

plunger.

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Machine operation sequence

The cavity is packed as the screw continuously moves forward.

The cavity cools as the gate freezes off and the screw begins to
retract to plasticize material for the next shot.

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Machine operation sequence

The mould opens for part ejection

The mould closes and the next cycle begins

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Injection Mould
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Mould system
A typical (three-plate) moulding system

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A two-plate mould.

A three-plate mould.

The moulded system includes a delivery system and moulded parts.

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Screw Used in Injection Moulding Machines

The screw has three zones with a ring-plunger assembly. The Feed Zone,
where the plastic first enters the screw and is conveyed along a constant
root diameter; the Transition Zone, where the plastic is conveyed,
compressed and melted along a root diameter that increases with a constant
taper; and the Metering Zone, where the melting of the plastic is completed
and the melt is conveyed forward along a constant root diameter reaching a
temperature and viscosity to form parts.
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L/D RATIO
The L/D ratio is the ratio of the flighted length (Effective
Length) of the screw to its outside diameter.
Most injection screws use a 20:1 L/D ratio. But it may
range from 18:1 to 24:1
In the case of Thermoset it may range from 12:1 to 16:1.

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High L/D Ratio results the following .

More shear heat can be uniformly generated in the

plastic without degradation;
Greater the opportunity for mixing, resulting in a better
homogeneity of the melt.
Greater the residence time of the plastic in the barrel
possibly permitting faster cycles of larger shots.

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COMPRESSION RATIO (CR)

The ratio of the first flight depth of feed zone to the last
flight depth of meter zone ,
Or,
First Channel Volume of feed zone to last channel
volume of metering zone,
Typically ranges from 1.5:1 to 4.5:1 for most
thermoplastic materials.
Most injection screws classified as general purpose have
a compression ratio of 2.5:1 to 3.0:1.
Thermo set screws have a 1:1 ratio.
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Higher the CR results the following .

Greater shear heat imparted to the resin
Greater heat uniformity of the melt
High Potential for creating stresses in some
resins
High energy consumption
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Back Pressure (Kg/Cm2 or bar)

Back pressure is the amount of pressure
exerted by the material ahead of the
screw, as the screw is pushed back in
preparation for the next shot.
Effect of Back Pressure
More Homogeneous Mix
Proper Melting
More compact
Sometime leads degradation
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Injection Speed (cm/Sec)

The injection speed is the forward
speed of the screw during its injection
operation per unit time.
Effect of Injection Speed
Easy Injection of Material
Avoid Short-Shot
Some times leads more orientation & burn
marks
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Screw Rotation Speed

The screw rotation speed (RPM) is the rate at which the
plasticizing screw rotates.
The faster the screw rotation result the following ..
Faster the material is compressed by the screw flights
Increasing the amount of shear heating
Low residence time, some less melting
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Cushion
The cushion is the difference in the final forward position
of the screw and its maximum allowable forward
position.
More Cushion results more residence time, some time
degrades.
If the screw were allowed to travel its full stroke and stop
mechanically against the nozzle, the cushion would be
zero.
With zero Cushion no hold on works.
Typically a cushion of 3 to 6 mm is used.
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Materials for Injection Moulding

Acrylonitrile butadiene styrene (ABS)

Acetal
Acrylic
Polycarbonate (PC)
Polyester
Polyethylene
Fluoroplastic
Polyimide
Nylon
Polyphenylene oxide
Polypropylene (PP) **
Polystyrene (PS)
Polysulphone
Polyvinyl chloride (PVC)
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Molecules lie in a definite fashion or regular arrangement

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Molecules fall in Crystalline & amorphous pattern

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Amorphous Polymer has

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While flowing in the channel or cavity of the Mould. As the melt

touches the surface of the mould its viscosity increases
because of lowering of melt temperature, So it slides on the
Surface and the Molecules gets oriented
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Non Newtonian Plastics

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Non Newtonian Plastics

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Newtonian Plastic

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Broad Molecular weight Distribution shows broad

Melting Points
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Narrow Molecular weight Distribution shows sharp Melting Points

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Plastic Product Properties can change 10% or more by

changing Process Conditions
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During Refilling

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During Injection

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Additive

Function

Examples

Filler

increase bulk density

calcium carbonate,
talc, limestone

Plasticizer

improve processability,
reduce product brittleness

phthalate esters,
phosphate esters

Antioxidant

prevent polymer oxidation

phenols, aromatic
amines

Colorant

provide desired part

application color

oil-soluble dyes,
organic pigments

Flame
retardant

reduce polymer flammability

antimony trioxide

Stabilizer

stabilize polymer against

heat or UV light

carbon black,
hydroxybenzophenone

Reinforcement

improve strength

E-glass, S-glass,
carbon, Kevlar fibers

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TOGGLE TYPE CLAMPING

A toggle is mechanically device to amplify force.
In a moulding machine, which consists of two bars
joined, together end to end with a pivot .
The end of one bar is attached to a stationary platen,
and the other end of a second bar is attached to the
movable platen.
When the mould is open, the toggle is in the shape of a
V.
When pressure is applied to the pivot, the two bars form
a straight line.

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TOGGLE TYPE CLAMPING

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TOGGLE TYPE CLAMPING

ADVANTAGE
Low cost and lower horsepower needed to run.
Positive clamp of the mould

DISADVANTAGE
Do not read the clamp force.
Clamping is more difficult.
Higher maintenance as lubricant is provided.
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HYDRAULIC CLAMPING
A clamping unit actuated by hydraulic cylinder, which is
directly connected to the moving, closed the mould. In
this case ram of hydraulic system is attached to moving
platen. There are two halves in hydraulic cylinder, which
is actually inlet and outlet of oil.
When oil goes to the cylinder with pressure oil pushes
the ram to forward direction by which moving platen
moves and mould closed and when oil comes from the
cylinder the ram come back and mould is open.

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HYDRAULIC CLAMPING

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HYDRAULIC CLAMPING
ADVANTAGE

Clamp speed easily controlled and stopped at any point.

Direct a read out of clamp force.
Easy adjustment of clamped force and easy mould set
up.
Low maintenance as part is self lubricated.

DISADVANTAGE

It is higher cost and more expensive than toggle

system.
None positive clamp.
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TIE-BAR LESS CLAMPING

Tie-Bar less clamping system is basically Hydraulic
clamping system without any tie bar.
The platen is moved on a rail system.
The main advantage of this system there is no limitation of
mould platen size.
As there is no tie bar so the mould dimension is not so
important.
Also mounting of the mould is easy and it is very useful
when products eject from the mould is manual.
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TIE-BAR LESS CLAMPING

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TIE-BAR LESS CLAMPING

Much larger mould mounting area.

Larger stroke compared to the toggle type machines.
Full machine capacity can be utilised.
Smaller machines can mould larger components.
Saves floor space.
Saves electrical energy because of reduction in the size of machine.
Has the capacity to reduce weight of the moulded component because tiebar stretching is not there.
Machine becomes very flexible for future modification.
Easy access to mould cavity's because of the absence of the tie bars.
Robotic arm movement becomes easy.
Fewer moving parts so lesser wear and tear so longer life for machines.
Lower lubrication required.
Removal of mould plates much simple.
Greater stability.
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Theoretical Calculation

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Example 1: POM has an S.G. of 1.42. It is to be moulded in

an Injection Moulding Machine with a shot weight of 80 gms
(in PS).
This machine has a shot weight of 80 x 1.42 / 1.05 = 108.19
gms of POM.
Example 2: PP has an S.G. of 0.90. It is to be moulded in an
Injection Moulding Machine with a shot weight of 80 gms (in
PS).
This machine has a shot weight of 80 x 0.90 / 1.05 = 68.57
gms of PP.
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Example 3: Figurines made of UPVC (S.G. 1.38) with a

combined weight of figurine plus runners of 40 gms. are to
be moulded. What size of machine is sufficient?
Shot weight in terms of PS = 40 x 1.05/1.38 = 30.43 gms.
Using the 85% guide line, the machine shot weight needed =
30.43/0.85 =35.80 gms.
Example 4: The same figurine in example 3 is to be moulded
in a big machine. What is the biggest machine that could be
used?
Using the 35% rule, the biggest machine that could be used
has a shot weight = 30.43/0.35 = 86.94 gms.
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Determining Projected Area

Projected area is calculated by multiplying

length times width.
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Determining Clamping Force

(Tonnes)
Projected Area = Length x Width
and multiplying that area by a clamp factor of between 2 and 8. Most
commonly factor 5 is used.
Clamp Force = Projected Area x 5
For every inch of depth the clamp force must be increased by
10%.

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Example 5: What is the residence time of UPVC (S.G. 1.38) in a machine

with screw diameter of 55 mm, injection stroke of 250 mm, shot weight
(PS) of 567 g, and a cycle time of 10 s moulding shots weighing 260 g?
Volume of melt in the barrel is estimated to be two times the injection
volume = 2 * 3.1416 * 5.5 * 5.5 * 25 / 4 = 1188 cm3
Barrel residence time = 1188 * 1.38 * 10 / 260 = 63 s
Example 6: A GPPS cup of diameter 79 mm is to be moulded. The cup is
0.6 mm at its thinnest section. Find a conservative clamping force which
would be sufficient.
The projected area of the cup (and runner) is 3.1416 * 7.92 / 4 = 49 cm2.
This cup belongs to the thin wall domain. The conservative clamping force
is 0.62 * 49 = 30.4 tonnes.
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Example 7: The same GPPS cup has a flow path length of 104 mm. Find
a more accurate clamping force needed.
Flow path to thickness ratio (L/T Ratio) = 104 / 0.6 = 173. From Figure 2,
at 0.6 mm wall thickness, the cavity pressure is 550 bar.
1 bar = 1.02 kg/cm2. The clamping force = 550 * 1.02 * 49 = 27,500 kg =
27.5 tonnes.
The above calculation has not accounted for viscosity. It turns out to be
still correct as the viscosity factor for GPPS is 1.0.
Example 8: The same cup as in the above example is to be made out of
ABS. Find the clamping force needed.
Using the viscosity factor of 1.5, the clamping force needed = 1.5 * 27.5
tonnes = 41.3 tonnes.
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Plastic flow

(a) Simple shear flow.

(b) Simple extensional flow.

(c) Shear flow in cavity filling.

(d) Extensional flow in cavity filling.

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where

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When Plastics flow in the cavity, the pressure decreases along

the delivery system and the cavity
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Injection pressure as a function of melt viscosity, flow length,

volumetric flow rate, and part thickness
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Setting Machine Process Conditions

1

Set the melt temperature

Set the mold temperature

Set the switch-over position

Set the screw rotation speed

Set the back pressure

Set the injection pressure to the machine maximum

Set the holding pressure at 0 MPa

Set the injection velocity to the machine maximum

Set the holding time

10

Set ample remaining cooling time

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Setting Machine Process Conditions

11

Set the mold open time

12

Mold a short-shot series by increasing injection volume

13

Switch to automatic operation

14

Set the mold opening stroke

15

Set the ejector stroke, start position, and velocity

16

Set the injection volume to 99% mold filled

17

Increase the holding pressure in steps

18

Minimize the holding time

19

Minimize the remaining cooling time

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Basic Process Factors in Injection

Moulding

Material Parameters

Amorphous, Semicrystalline, Blends and Filled Systems

Pressure-Volume-Temperature (PVT) Behaviour
Viscosity

Geometry Parameters

Wall Thickness of Part

Number of Gates
Gate Location
Gate Thickness and Area
Type of Gates: Manually or Automatically Trimmed
Constraints from Ribs, Bosses and Inserts

Manufacturing Parameters

Fill Time
Packing Pressure Level
Mold Temperature
Melt Temperature

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Residual stress

The development of residual flow stresses due to frozen-in molecular

orientation during the filling and packing stages. (1) High cooling, shear,
and orientation zone (2) Low cooling, shear, and orientation zone
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Process Controls
Injection Moulding cycle can be broken down into four
phases:
Fill,
Pack,
Hold, and
Cooling/plastication
These phases can be controlled by following variables:
Injection Speed,
Plastic Temperature,
Plastic Pressure,
Cooling Temperature and Time.
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Cycle time in injection moulding

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Post Moulding Operation

Heat inserting
Chrome Plating
In Mould Insert Moulding
Post Mould Inserting
Drilling
Polishing
Assembly
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Secondary operations

Bonding
Welding
Inserting
Staking
Swaging
Assembling with fasteners

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Secondary operations
Appliqu: a surface covering applied by heat and
pressure
Printing: a process of making a mark or impression onto
a substrate for decorative or informational purposes.
Painting
Hard coating
Metallizing/shielding
Surface treatment
Annealing
Machining

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Benefits of Post Moulding Operations

Reduced costs by carrying out post moulding operations in

house, and utilising lean manufacturing tools, we can greatly reduce
component costs and the complexity of work that our customers
would ordinarily undertake.
High level of quality performing post-moulding operations on
products helps ensure that a high level of quality is maintained. By
checking parts from the moment they leave a press, to final
assembly, quality levels can be maintained and ensure that
components are only assembled to the highest standards.
Reduction of Customers stock holding Assembly of
components will reduce the cost of customers stock holding due to
delivery of an assembly rather than a range of components.
Reduced production times post moulding operations mean there
is very little time between the production of components and their
assembly. This means that a great deal of time can be saved when
components would normally be transported, or stored, in between
moulding and assembly operations.
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Heat inserting is the addition

of inserts into a part
increases the functionality of
a part by which components
can be assembled.

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Benefits of Heat Inserting

Increased functionality by adding inserts to
mouldings the part can more easily be used for its
designed purpose. For example by adding threaded
inserts parts can be easily be screwed to their fixings or
other parts, increasing their functionality.
Low part degradation the process of heat inserting
means that the heating/melting of the part is very
localised to where the insert will be pressed in. this
means that parts do not suffer warping, or any other
distortion effects, due to being heated again.
High level of quality due to the known challenges
with heat inserting extra measures are taken to ensure
the processes is repeated to as high a level as possible,
meaning part quality is kept very high.
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Chrome Plating

Due to the chrome plating process requiring the

part to be electrically conductive, a series of steps
are required before the chrome can be deposited
onto the surface of the product.
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Benefits of Chrome Plating

Metal finish - Metal finishes can be very popular and, by
coating plastics, advantage can be taken of characteristics
from both materials.
Wear resistant as chrome is a metal rather than a plastic
its wear resistance properties are much greater than those
of the plastic it covers. This means for applications where a
part might be handled repeatedly, such as a shower
handset, a chrome finish is likely to wear better than its
plastic counterpart.
Electrically conductive parts by chrome or nickel
plating a part it is possible to give a plastic component the
ability to conduct electricity. This gives the advantage of
being able to create electrical components that are light
weight and less costly to produce than completely metal
parts.
Attractive mouldings by applying chrome finish to
mouldings a
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In Mould Insert Moulding

In mould insert moulding is the process by

which a metal, or preformed plastic, insert is
incorporated in to the component during the
moulding stage.
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Benefits Of In Mould Insert Moulding

Reduced post-moulding operations With in mould insert moulding the

need for post moulding operations is greatly reduced. This helps with ease
of assembly and reduces the labour necessary for products.
Increased part consistency Insert Moulding has major benefits in the
consistency of parts produced. As the inserts are placed in the same
locations in tools for every cycle each of the mouldings produced will be
exactly the same. This helps reduce costs, as rejected parts will be kept to a
minimum.
Ease of assembly Due to inserts being incorporated into parts during the
moulding stage this eases the assembly of the part. Instead of having to
place fittings to attach parts fittings can be incorporated during the moulding
stage so that parts can be simply clipped together.
Reduced production time when vertical moulding machines, that are
equipped with a rotary table, are used for production there is the opportunity
to have two halves of the lower part of the tool. This means that production
is almost constant with mouldings being formed at the same time as fresh
inserts are being loaded into the second half of the tool. This lowers overall
production times and can also reduce the amount of labour needed.

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Post Mould Inserting

Post mould inserting is the process by which a

metal, or preformed plastic, insert is
incorporated into a moulding by means of a
secondary process once the component has
already been moulded.
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Benefits of Post Mould Inserting

Ease of assembly by adding inserts to a moulding the ease by

which it can be assembled is greatly increased. Inserts such as clips
or screw bolts can be incorporated into mouldings which greatly
assist assembly operations and subsequent product performance.
Increased part functionality besides adding inserts to aid
assembly inserts that improve a parts functionality can also be used.
For example, terminal fittings for wires, or seals to make parts
watertight.
Increased component value any second operation carried out on
a part will add value to it. By adding inserts to help assembly or
increase functionality, product value will be raised. This helps to
compensate for the extra time involved in second operations and
ensure products remain cost effective.
Good part consistency to carry out post mould inserting jigs are
used to hold mouldings while they are inserted. This means that the
repeatability of the operation is very good and all parts inserted will
be of the same quality.
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Drilling
The drilling of parts is used to remove any
unnecessary polymer that may have been
necessary in the moulding process. By
removing this extra material in house it
means a ready-to-assemble moulding can
be provided to the customer, or the part can
be assembled with other mouldings.
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Polishing
For products that have a high quality gloss finish a
post moulding polishing operation is often a useful
extra process. Even though the finish produced by
the moulding tool may be of a very high quality, a
polishing operation to remove any dust from the
product before final packaging gives a part the
high gloss finish that will have been specified..
Polishing operations are carried out on a softpolishing wheel with high quality wax to ensure
that a part is polished to a perfect finish without
leaving any marks.
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Assembly
For products that require assembly we are able to
carry out this operation in our assembly facility. We
can demonstrate examples of assemblies where
we mould all the separate components in house
and assemble the parts either as a whole in the
assembly facility or as a step by step process on
the press as each part is produced. By carrying out
assembly in house we can reduce costs for our
customers while still producing products to a high
standard.
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Faults & Remedies

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Sink Marks
Depression in a moulded part caused
by shrinking or collapsing of the resin
during cooling.
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Sink Marks - Problems

Resin feed inadequate

Improper mould design.
Parts cool too rapidly
Rib section in part too wide.
Temperature of mould
surface opposite rib too hot.
Entrapped gas.
Nozzle too restrictive,
land length too long.

Pressure too low.

Mould temperature too low
or high
Stock temperature too high
Gate too small
Improper gate location
Nozzle and metering zone
temperatures too high.
Excessive cooling time in
mould
Unbalanced flow pattern.
Bad check valve.

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Jetting
Turbulence in the resin melt flow caused
by undersized gate, abrupt change in
cavity volume, or too high injection
pressure.
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Jetting - Problems

Excessive injection speed.

Melt temperature too high.
Melt temperature too low.
mould Temperature too low.
Nozzle opening too small.
Gate and length too long.
Sprue, runner, and/or gate size too small.
Nozzle heating band malfunction.
Inefficient gate location.
CORPORATE TRAINING
AND PLANNING

Splay Marks (Silver

Streaking, Splash Marks)
Marks or droplet type imperfections
formed on the surface of a finished
part.
CORPORATE TRAINING
AND PLANNING

Splay Marks (Silver Streaking,

Splash Marks) - Problems

Obstruction in nozzle.
Screw rpm too high.
Back pressure too low.
Melt temperature too
high.
Nozzle too hot.
Nozzle too small.
Gates too small.
Sprue too small.
Insufficient venting.

Burr in runner or gate.

Cracked mould.
Trapped volatiles.
Excessive moisture.
Resin contaminated.
mould cavity
contamination.
Excessive shot size.

CORPORATE TRAINING
AND PLANNING

Blush
Discoloration generally appearing at
gates, around inserts, or other
obstructions along the flow path. Usually
indicates weak points.
CORPORATE TRAINING
AND PLANNING

Blush - Problems

mould temperature too cold

Injection fill speed too fast
Melt stock temperature too high or too low.
Improper gate location
Sprue and nozzle diameter too small.
Nozzle temperature too low.
Insufficient cold slug well.
Sharp Corners in gate area
Resin excessively moist.
Inadequate injection pressure.
CORPORATE TRAINING
AND PLANNING

Burn Marks
Black marks or scorch marks on surface
moulded part; usually on the side of the
part opposite the gate or in a deep cavity.
CORPORATE TRAINING
AND PLANNING

Burn Marks - Problems

Excessive Injection speed

Excessive injection
pressure.
Inefficient mould
temperature.
Excessive amount of
volatiles due to improper
Venting.
Improper gate location
Front zone temperature too
high.
Screw speed too high.
Excessive back pressure.
Compression ratio of screw
too high.

Faulty temperature
controllers.
Frictional burring--gates too
small
Dead material hung up on
screw or nozzle.
Melt stock temperature too
high or too low.
Nozzle diameter too small
Over-heated heater band
Incorrect screw rpm.

CORPORATE TRAINING
AND PLANNING

Poor Weld Lines (Knit Lines)

Inability of two melt fronts to knit together
in a homogeneous fashion during the
moulding process, resulting in weak areas
in the part of varying severity.
CORPORATE TRAINING
AND PLANNING

Poor Weld Lines - Problems

Material too cold.

Injection speed too slow
Entrapment of air at weld
line.
Improper mould design.
Contamination of poorly
dispersed pigments.
Core shifting.
mould temperature to low.
Injection speed too slow.
Melt stock temperature to
low.
Injection pressure too low.

Insufficient mould venting

Cylinder temperature too low.
Injection back pressure too
low.
Nozzle diameter too small.
Excessive screw flights in
metering zone.
Improper gate locations
and/or size.
Distance from gate
excessive.
Ineffective flow pattern.
mould release agent (brittle
weld lines).
Inadequate flow.

CORPORATE TRAINING
AND PLANNING

Voids (Bubbles)
An unfilled space of such size that it
scatters radiant energy such as light.

CORPORATE TRAINING
AND PLANNING

Voids - Problems

Injection pressure too low

Packing time too short
Insufficient feed of material
mould temperature too low.
Injection speed too high
Excessive cushion
At the side of a rib; rib too thick.
Runners or gate too small or badly
positioned.
CORPORATE TRAINING
AND PLANNING

Delamination (Skinning)
Surface of the finished part separates or
appears to be composed of layer of
solidified resin. Strata or fish scale type
appearance where the layers may be
separated.
CORPORATE TRAINING
AND PLANNING

Delamination - Problems
Contamination of resin by additives or other
foreign materials.
Resin temperature too low.
Non-uniformity of resin temperature.
Wrong mould temperature.
Excessive material moisture.
Inadequate injection speed.
Sharp corners at gate.
Incompatible polymers.
CORPORATE TRAINING
AND PLANNING

Flow Lines and Folds

Mark visible on the finished item that
indicate the direction of flow in the cavity.
CORPORATE TRAINING
AND PLANNING

Flow Lines and Folds - Problems

Stock temperature too low.

Runners too small
Improper gate size and/or location.
mould temperature too low.
Inadequate cold slug well.

CORPORATE TRAINING
AND PLANNING

Excessive Warpage/
Shrinkage
Excessive dimensional change in a part
after processing, or the excessive
decrease in dimension in a part through
cooling.
CORPORATE TRAINING
AND PLANNING

Warpage / Shrinkage -Problems

mould closed time too short.

Inefficient injection forward
time.
Ram speed too high or too
low.
Injection and holding
pressure too high or low.
Melt temperature
inadequate.
Excessive nozzle and
metering zone temperatures.
mould temperature too high
(for thick wall sections).

Parts cool unevenly.

Parts underpacked.
Improper gate location.
Gate too restrictive
Unequal temperature
between mould halves.
Non-uniform part ejection.
Parts mishandled after
ejection.
Unbalanced gates on
multiple gated part.
Too many stresses in part.

CORPORATE TRAINING
AND PLANNING

Black Specks
Particles in the surface of an opaque part
and visible throughout a transparent part.

CORPORATE TRAINING
AND PLANNING

Black Specks - Problems

Contamination of material.
Holdup of molten resin moulding machine or mould
runner system.
Press Contamination.
Local over-heating in the injection cylinder.
Defective closure of the nozzle.
Oxidation by occluded air or inadequate air venting
mould contains grease.
Trapped air
Inefficient injection speed.
CORPORATE TRAINING
AND PLANNING

Brittleness
Tendency of a moulded part to break,
crack, shatter, etc. under conditions which
it would not normally do so.
CORPORATE TRAINING
AND PLANNING

Brittleness - Problems

mould temperature too high

Inadequate cooling in gate area
Gate section of item too thin (gate brittleness)
Resin too cold.
Non-uniformity of resin temperature.
Undried material.
Contamination.
Poor part design.
Material degraded.
Non-compatible mould release.
Packing the mould.
Melt temperature too cold.
Excessive amounts of regrind.
CORPORATE TRAINING
AND PLANNING

Brittleness - Problems

Inadequate mould temperature

Excessive screw rpm
Excessive back pressure
Insufficient venting.
Improper gate location.
Excessive injection speed.
Excessive residence timed
Melt temperature too high.
Nozzle too hot.
Injection pressure too low (weld lines).
Runners and gates in adequate (weld lines).
Dwell time in the injection cylinder too long (material degraded).
Material degraded during drying or pre-heating
CORPORATE TRAINING
AND PLANNING

Flash
Excess plastic around the area of the
mould parting line on a moulded
part.
CORPORATE TRAINING
AND PLANNING

Flash - Problems
mould parting surfaces do not seal properly.
Injection pressure too high.
Clamp pressure set too low or projected area
or item too large for clamp pressure of the
machine.
Injection temperature too high.
Feed needs adjustment.
Hold time too long.
Inadequate mould supports.
Oversize vents.
CORPORATE TRAINING
AND PLANNING

Blister
Defect on the surface of a moulded part
caused by gases trapped within the part
during curing.
CORPORATE TRAINING
AND PLANNING

Blister - Problems

Screw rpm too high

Back pressure too low
mould temperature too low.
Gate improperly located
Insufficient venting.
Regrind too coarse

CORPORATE TRAINING
AND PLANNING

Crazing
Fine cracks in part surface. May
extend in a network over the surface
or through the part.
CORPORATE TRAINING
AND PLANNING

Crazing - Problems
Insufficient drying of the material.
Contamination.
Injection temperature too high (crazing
accompanied by dis-coloring or yellowing).
mould surface contaminated
Inadequate injection speed.
Inefficient injection forward time.
Excessive injection pressure.
mould temperature too low.
Gate too large.
CORPORATE TRAINING
AND PLANNING

Cracking
Fracture of the plastic material in an
area around a boss, projection, or
moulded insert.
CORPORATE TRAINING
AND PLANNING

Cracking - Problems
Parts cool too quickly
moulded-in stress
Wall thickness too heavy for compound.

CORPORATE TRAINING
AND PLANNING

Low Gloss
Surface roughness resulting from high
speed fill which causes surface wrinkling
as the polymer melt flows along the wall of
the mould.
CORPORATE TRAINING
AND PLANNING

Low Gloss - Problems

Inadequate polish of mould surface.

Material or mould too cold.
Air entrapment.
Melt index of material too low.
Improper mould design.
Wrong injection pressure.
Excessive injection speed.
CORPORATE TRAINING
AND PLANNING

Low Gloss - Problems

Inadequate flow.
Contamination
Resin excessively moist
Sprue, runners, and/or gate size too
small.
Pigment agglomerates.
Oil or grease on knockout pins.
CORPORATE TRAINING
AND PLANNING

Short Shot
Injection of insufficient material
to fill the mould.
CORPORATE TRAINING
AND PLANNING

Short Shot - Problems

Insufficient feed, cushion.

Inadequate injection pressure.
Inadequate injection speed.
Insufficient booster or injection highpressure time.
Inefficient screw delay.
Inadequate injection back pressure.
Melt temperature too low.
Cylinder temperature inadequate.
mould temperature too low.
CORPORATE TRAINING
AND PLANNING

Short Shot - Problems

Gates, sprues, and/or runners too small.

Excessive screw flights in metering zone.
Insufficient venting.
Improper gate location.
Melt index of resin too low.
Excessive clearance between non-return
valve and barrel.
Screw bridging.
Injection press of insufficient capacity.
CORPORATE TRAINING
AND PLANNING

THANK YOU

CORPORATE TRAINING
AND PLANNING