Setting process conditions

Importance of process conditions

The quality of the molded part is greatly influenced by the conditions under which it is processed. See,
for example, the process window shown in Figure 1. As you lower the temperature, higher pressure is
needed to deliver the polymer melt into the cavity. If the temperature is too high, you risk causing
material degradation. If the injection pressure is too low, a short shot could result. If the pressure is too
high, you will flash the mold.

FIGURE 1. Process window shows the influence of pressure versus temperature

After Dr. C-MOLD evaluates the sensitivity of a process to various design parameters, it can
produce a machine set-up sheet to assist process engineers in setting injection molding machine
controls. See Figure ?. The numbers in the Suggested Value column are parameters optimized by Dr.
C-MOLD. In the Set Value column, you may enter the actual machine control settings you used,
based on Dr. C-MOLD's values.

Setting machine process conditions

Before setting process conditions, you should make sure the molding machine is in proper working
order, and that the mold you plan to use was designed for the particular machine you plan to use.
Follow the step-by-step procedure provided below to control the settings on your machine.

1Set the melt temperature

2Set the mold temperature

 3Set the switch-over position

4Set the screw rotation speed

5Set the back pressure

6Set the injection pressure to the machine maximum

7Set the holding pressure at 0 MPa

8Set the injection velocity to the machine maximum

9Set the holding time

10Set ample remaining cooling time

11Set the mold open time

12Mold a short-shot series by increasing injection volume

13Switch to automatic operation

14Set the mold opening stroke

15Set the ejector stroke, start position, and velocity

16Set the injection volume to 99% mold filled

17Increase the holding pressure in steps

18Minimize the holding time

19Minimize the remaining cooling time Step 1

Step Set the melt temperature

Melt temperature is one of the most important factors in molding plastic parts. If it is too low,
the resin might not be completely melted or it might be too sticky to flow. If the melt
temperature is too high, the resin could degrade, especially if the resin is POM or PVC.
Suggested melt and mold temperatures for specific materials are available from the resin
supplier. Appropriate melt and mold temperatures for several materials are listed in Resin data
table. The resin table also contains links to descriptions of resins, their general properties, and
typical applications.

Setting heater band temperatures

Most melting of the resin occurs because of the frictional heating from the screw rotation inside
the barrel. The barrel heater bands serve mainly to keep the resin at the appropriate temperature.
Typically there are three to five temperature zones or heater bands on the cylinder. The rules for
setting the heater band temperatures are as follows:

 The temperature should gradually decrease from the nozzle zone to the zone nearest the
hopper.
 The last temperature zone, nearest the hopper, should be about 40º to 50ºC (72º to 80ºF)
lower than the calculated melt temperature, to give better transport of plastic pellets
during plasticization.

The heater band at the nozzle zone should be set to the calculated melt temperature, and should
keep the temperature uniform. Improper heater band temperature settings may cause drooling at
the nozzle, and degradation or color change, especially for PA materials.Following the rules
above, here is an example of how a process engineer would use Dr. C-MOLD's prediction of
melt temperature set heater band temperatures. Dr. C-MOLD predicts 235ºC (455ºF) as the melt
temperature for PS, as shown in Figure ?. A process engineer can use this melt temperature to
set the heater band temperature as follows:

 235ºC (455ºF) at the nozzle zone

 235ºC (455ºF) at the front zone
 210ºC (410ºF) at the first middle zone
 195ºC (383ºF) at the second middle zone
 180ºC (356ºF) at the rear zone

Air-shot temperature
The actual melt temperature, or air-shot temperature, is usually higher than the heater band
controller setting. This difference is due to the influence of back pressure and screw rotation on
frictional heating and the melt temperature, as mentioned above. (You can measure the actual
melt temperature by quickly sticking a probe thermometer into an air shot with the nozzle
backed away from the mold.)

Step 2

Step Set the mold temperature

Suggested melt and mold temperatures for specific materials are available from the resin
supplier. Appropriate melt and mold temperatures for many generic, base resins are listed
in Resin data table.
The mold temperature can be measured by using a thermometer. As illustrated below, the
average cavity surface temperature will be higher than the temperature of the coolant during
production. Thus, you should set the coolant temperature to be 10º to 20ºC (18º to 36ºF) lower
than the required mold temperature (provided on Dr. C-MOLD's setup sheet). If the mold
temperature is 40º to 50ºC (72º to 80ºF) or more, consider insulation plates between the mold
and the clamping plates, for energy savings and process stabilization.

FIGURE 2. Temperature-time curve at various locations in the mold. a) Mold cavity surface. b) Cooling
channel wall. c) Cooling channel outlet. d) Cooling channel inlet.

Use the lowest temperature setting to achieve the shortest cycle time. However, you might try
using higher temperatures to improve the appearance of the part. A higher mold temperature
produces a higher gloss and more crystallization.

Considering temperature difference

For parts with a deep core, a lower coolant temperature is needed for the core (moving plate) in
order to minimize the temperature difference between the mold surfaces on the core and cavity.
A lower surface temperature difference will produce parts with higher quality, at a lower cost.
By a rule of thumb, the coolant temperature for fixed and moving plates should not differ by
more than 20ºC (36ºF). This is related to thermal expansion, which can be determined only by
the user. A large temperature difference results in differential mold plate thermal expansion,
which may cause alignment problems in guide pins, especially in large molds. The mold will
sometimes lock up for this reason. The cycle time can be increased to reduce the required
coolant temperature difference.

Step 3

Step Set the switch-over position

The switch-over position is the ram position where the filling (injection) stage switches to the
post-filling (packing or holding) stage. The cushion distance is the distance from the switch-
over position to the farthest position that the end of the screw can reach, as shown in Figure 3.
Thus, the switch-over position determines the cushion distance. The cushion should contain
adequate material for post-filling the part. An insufficient cushion could cause sink marks. The
typical cushion distance is about 5 to 10 mm.

At this step, set the switch-over position to fill about two-thirds of the mold. This prevents
damage to the press or the mold. In Step 12, the injection volume will be increased to fill the
cavity.

FIGURE 3. Screw positions at various stages

Step 4

Step Set the screw rotation speed

Set the Screw rotation speed to the level required to plasticize the resin. Plasticizing should not
prolong the cycle time. If it does, increase the speed. The ideal speed causes plasticizing to
complete at the latest possible point in the cycle without prolonging the cycle time. Resin
vendors supply the suggested screw rotation speed for specific resins.

Step 5

Step Set the back pressure

The recommended Back pressure is about 5 to 10 MPa. Back pressure that is too low can result
in inconsistent parts. Increasing the back pressure will increase the frictional contribution to the
melt temperature and decrease the plasticization time. Use a higher back pressure to achieve a
shot volume that is a larger percentage of the injection machine's capacity, in order to speed up
plasticization. Use a lower back pressure for a smaller percentage shot volume because the
material will remain in the barrel longer (for many cycles) before it reaches the screw head.

Step 6

Step Set the injection pressure to the machine maximum

The injection pressure is the pressure of the melt in front of the screw. The injection pressure
should be as low as possible to reduce part internal stress. On the machine, set the injection
pressure to the machine maximum. The purpose is to completely exploit the injection velocity
of the machine, so that the pressure setting valve does not limit the velocity. Because the
switch-over to holding pressure occurs before the mold is completely filled, no damage will be
done to the mold.

Step 7

Step Set the holding pressure at 0 MPa

For now, set the holding pressure at 0 MPa, so the screw will stop when it reaches the switch-
over position. This will prevent mold or press damage. In Step 17, the holding pressure is
increased to its final setting.

Step 8

Step Set the injection velocity to the machine maximum

With the highest possible injection velocity, you can expect less flow resistance, longer flow
length, and improved strength in weld lines. However, you may need to create vents once you
do this.

Proper venting minimizes defects

Insufficient venting causes compression of air trapped in the cavity. This results in very high
temperatures and pressures in the cavity, causing burn marks, material degradation, and short
shots. You should design a venting system to avoid or minimize the defects caused by trapped
air in the mold. C-MOLD shows you where weld lines, meld lines, and air trap locations will
occur; use these predictions improve your design. Remember that it is necessary to clean the
mold surface and venting system regularly, especially for PVC or ABS/PVC materials.
The filling time estimated by Dr. C-MOLD is based on the maximum injection velocity for the
selected machine size, part volume, and the injection pressure. A higher injection pressure
requirement will slow the injection velocity, thus resulting in a longer filling time.

The actual filling time on the shop floor may be shorter if there is a booster or accumulator
attached to the injection unit, or may be longer if the injection velocity is not set to the
maximum. Also note that the shop floor filling time often refers to "the time while the screw is
moving," which includes filling time and holding time. The actual filling time should stop at the
switch-over position.

Step 9

Step Set the holding time

The ideal holding time setting is the gate freezing (sealing) time or the part freezing time,
whichever is shorter. The gate and part freezing times can be calculated or estimated. For your
first trials, you can estimate the holding time to be 10 times the filling time predicted by C-
MOLD.

Dr. C-MOLD calculates the holding time for your design. The holding time calculated by Dr.
C-MOLD is the gate freeze time or the part freeze time, whichever is shorter. Use this as your
initial holding time setting. It can be further refined in Step 18.

Step 10

Step Set ample remaining cooling time

Cooling time can be calculated or estimated. The cooling time consists of the holding time and
the remaining cooling time, as shown in Figure 4. Your first estimate of the cooling time can be
10 times the filling time. For example, if the predicted filling time is .85 seconds, the initial
holding time would be 8.5 seconds and the additional cooling time would be 8.5 seconds. This
ensures that the part and runner system will be sufficiently solid for ejection.

Cooling time is estimated by Dr. C-MOLD and included on the machine setup sheet. The
cooling time consists of the holding time and the remaining cooling time. See Figure ?. Dr. C-
MOLD estimates the cooling times for the cavity. In practice, a part may have to wait until the
runner is solidified before ejection. Use the estimated cooling time from Dr. C-MOLD first.
Increase the cooling time if needed.
FIGURE 4. Cycle time and its components

Step 11

Step Set the mold open time

The mold open time is usually set at 2 to 5 seconds. This includes mold opening, ejection of
parts from the mold, then mold closing, as shown in Figure 4. The cycle time is the sum of the
filling time, cooling time, and mold open time.

Step 12

Step Mold a short-shot series by increasing injection volume

C-MOLD provides the part weight and sprue/runner/gate weight. From this information, along
with the screw diameter or barrel inner diameter, the total injection volume and the feeding
position (see Screw positions at various stages) can be estimated for each shot.

For now, fill only two-thirds of the mold. The holding pressure should already be set at 0 MPa,
so that mold filling stops when the screw reaches the switch-over position, thus protecting the
mold structure and the press. Next, increase the volume in increments of 5 to 10 percent, up to
95 percent of mold filling.
In order to prevent material from escaping from the open nozzle, relieve the back pressure
created during plasticizing by drawing back the screw a few millimeters, immediately after the
rotation has stopped.

Step 13

Step Switch to automatic operation

The purpose of an automatic operation is to obtain stability in the process.

Step 14

Step Set the mold opening stroke

The mold opening stroke is comprised of the core height, the part height, and the capsize space,
as shown in Figure 5. You should minimize the mold opening stroke. The mold opening speed
should be slow at the very beginning, then accelerate, then slow down again at the end of the
stroke. The sequence of the mold closing speed is similar to the mold opening speed: slow, fast,
slow.

FIGURE 5. Required mold opening

Step 15

Step Set the ejector stroke, start position, and velocity

Relieve any slides first. The ejector travel should be, at a maximum, the core height. If the
machine is equipped with a hydraulic ejector, set the start position at the point where the part is
clear of stationary mold parts. (When the ejector velocity is equal to the opening speed, the part
remains where it was in relation to the stationary mold part.)

Step 16

Step Set the injection volume to 99% mold filled

When the process has stabilized (when the same parts are produced each time), adjust
the switch-over position to 99 percent of filling. This will exploit the maximum injection speed
in as large a part of the injection as possible.

Step 17

Step Increase the holding pressure in steps

Increase the holding pressure in steps of approximately 10 MPa in the melt. If the first step does
not fill the mold completely, increase the injection volume.

De-mold and remove the part. Write the holding pressure on it. This holding pressure series
forms a good basis for a more thorough examination. You can then discuss the possibilities and
limitations with the customer.

Dr. C-MOLD provides a holding pressure that results in minimum shrinkage, without flashing
or demolding problems. This estimated holding pressure is typically the maximum value, and
you should not set holding pressure higher than the value provided by Dr. C-MOLD.

Choose the lowest acceptable holding pressure, as this minimizes the internal stresses in the
part and saves material, as well as operating costs. A high holding pressure can cause
excessive residual stresses that could warp the part. Molded-in residual stresses can be released
somewhat by annealing at around 10ºC (18ºF) below the heat deflection temperature.

If the material cushion is completely used (see Screw positions at various stages), the last part
of the holding pressure time will not be effective. This calls for a change in the injection stroke
position, in order to increase the injection volume.

Calculating injection pressure

The hydraulic pressure in the injection cylinder can be read on the machine manometer.
However, the injection pressure in front of the screw is more important. To calculate the
injection pressure you will need to multiply the hydraulic pressure by the resin/hydraulic
pressure ratio. (See Factors that influence injection pressure requirements.) This ratio is usually
found on the molding machine near the injection unit or in the instruction manual for the
machine. The ratio is usually in the range of 7 to 15, as shown in below.
FIGURE 6. Resin/hydraulic pressure ratio for a Ø 30 mm screw is 11.1

Step 18

Step Minimize the holding time

A quick way to find the minimum holding time is by setting a longer holding time, then
reducing the holding time until sink marks appear.

If consistent part dimensions are essential, use the following more accurate determination of the
holding pressure time. From a curve of part weight versus holding time, determine when the
gate or the part freezes. For example, Figure 7 shows that the holding pressure does not
influence the part weight after nine seconds. This is your minimum holding time.
 FIGURE 7. Determination of the gate/part freezing time by weighing parts manufactured at various
holding pressure times

Step 19

Step Minimize the remaining cooling time

Reduce the remaining cooling time until the maximum surface temperature of the part reaches
the heat deflection temperature of the material. The heat deflection temperature can be provided
by the resin supplier.

TECHNICAL BLOG

Injection Molding Process Parameters of 17

Most Common Plastics
Mar. 08, 2018

Abstract: it lists plastic injection molding process of 17 most common plastics include HDPE,
PP, PS, PVC, PA6, PA66, PBT, PET, PC, ABS, SAN, PMMA, POM, CA, PPO, etc. It
summarizes key process parameters setting based on experience. These process parameters
include temperature setting, pressure setting, stroke setting, etc. It will be very useful and
instructive to those plastic process engineers who work on plastics manufacturing.
Keywords: process parameter, common plastics, plastic injection molding

1.High density polyethylene (HDPE)

Description Process Parameter & advice

feeding area of barrel 30~50℃ (50℃)

Temperature of Area 1 160~250℃(200℃)

screw barrel Area 2 200~300℃ (210℃)

Area 3 220~300℃ (230℃)

 Area 4 220~300℃ (240℃)

Area 5 220~300℃ (240℃)

Nozzle 220~300℃ (240℃)

The temperature in the brackets is recommended as the basic set va

lue, the utilization rate of the stroke is 35% and 65%, the ratio of t
he flow length to the wall thickness is 50:1 to 100:1.

Material melt
220~280℃
temperature
Constant
temperature of 220℃
the barrel
Mould
20～60℃
temperature
Material has good flow performance, and avoid the high injection
Injection
pressure, advise to use 80 to 140MPa (800 ~ 1400bar). Some thin-
pressure
walled packaging containers except for 180MPa (1800bar)
The shrinkage is high and need to hold the product for a long time.
Holding pressure The size accuracy is the key factor, holding pressure is about 30%
~ 60% of the injection pressure.
5 ~ 20MPa (50 ~ 200bar), and the place with too low back
Back pressure pressure is easy to cause the uneven weight and dispersion of the
products.
requires high injection speed for thin-walled packaging containers,
Injection speed and medium injection speed is often more suitable for other types
of plastic products.
high screw speed (1.3m/s) is allowed. As long as the cooling time
Screw speed is finished, the plasticizing process is finished. The torque
requirement of the screw is low.
0.5 ~ 4D (minimum value to maximum), and the measurement
Metering stroke stroke of 4D is very important to provide enough long standing
time for the molten material.
from 2 to 8mm, depending on the measurement range and screw
Residual material
diameter
 It is not necessary to predry; if the storage condition is not good, it
Predry
can be dried at 80 degrees centigrade at the temperature of 1H.
Recovery rate can reach 100% recovery
1.2 to 2.5%; it is easy to twist; the shrinkage degree is high; after
Shrinkage rate
24h, no contraction (after forming contraction)
The point gate of the gate system; the heating type heat flow path,
the heat insulation type heat flow path, the inner cast-in-place
Gate system
sleeve; the cross section area is relatively small, it is sufficient for
the thin section products.
No other materials are needed for special cleaning in the machine
Shutdown period
shutdown period;
Standard three stage screw is used. For the packing container
products, the mixing section and the shear section have special
Barrel equipment
geometric shape (L:D = 25:1), straight through nozzles and
check valves

2. Polypropylene (PP)
Description Process Parameter & advice

feeding area of barrel 30~50℃ (50℃)

Area 1 160~250℃(200℃)

Area 2 200~300℃ (220℃)

Area 3 220~300℃ (240℃)

Temperature of Area 4 220~300℃ (240℃)
screw barrel
Area 5 220~300℃ (240℃)

Nozzle 220~300℃ (240℃)

The temperature in the brackets is recommended as the basic set v

alue, the utilization rate of the stroke is 35% and 65%, the ratio of
the flow length to the wall thickness is 50:1 to 100:1.
Material melt
220~280℃
temperature
Constant
temperature of the 220℃
barrel
Mould
20～70℃
temperature
Material has good flow performance, and avoid the high injection
Injection pressure pressure, advise to use 80 to 140MPa (800 ~ 1400bar). Some thin-
walled packaging containers except for 180MPa (1800bar)
The shrinkage is high and need to hold the product for a long time
Holding pressure ， around 30% of cycle time. Holding pressure is about 30% ~
60% of the injection pressure.
Back pressure 5 ~ 20MPa (50 ~ 200bar)
requires high injection speed for thin-walled packaging
Injection speed containers, and medium injection speed is often more suitable for
other types of plastic products.
high screw speed (1.3m/s) is allowed. As long as the cooling time
Screw speed
is finished, the plasticizing process is finished.
0.5 ~ 4D (minimum value to maximum), and the measurement
Metering stroke stroke of 4D is very important to provide enough long standing
time for the molten material.
from 2 to 8mm, depending on the measurement range and screw
Residual material
diameter
It is not necessary to pre-dry; if the storage condition is not good,
Pre-dry
it can be dried at 80 degrees centigrade at the temperature of 1H.
Recovery rate can reach 100% recovery
1.2 to 2.5%; it is easy to twist; the shrinkage degree is high; after
Shrinkage rate
24h, no contraction (after forming contraction)
Point gate or multi point gate; heated hot runner, heat insulation
Gate system hot runner, pouring sleeve; location of gate is the most thick point
of the product, otherwise large shrinkage can occur easily.
No other materials are needed for special cleaning in the machine
Shutdown period
shutdown period; Resistance to temperature rising.
 Standard three stage screw is used. For the packing container
products, the mixing section and the shear section have special
Barrel equipment
geometric shape (L:D = 25:1), straight through nozzles and
check valves

There’s a lot of room for

expensive errors when it comes to injection molding. Quality issues in injection-molded
products can range from minor surface defects to more serious problems that can affect the
safety, performance and function of the product. They can be caused by problems related to
the molding process, material use, tooling design or a combination of all three.

But as with any quality problems, knowing how molding defects arise is half the battle
(related: How Experienced Importers Limit Product Defects in 3 Stages [eBook]). As an
importer or manufacturer of injection-molded products, some knowledge of common
molding defects and how to avoid them can help you cut costs related to unsellable goods
and product returns.

Let’s look at the most common quality defects related to injection molding, what causes
them and what you can do to prevent them.

Molding defects often caused by process

problems
Some molding defects may be difficult or costly to address. Others can be prevented by
adjusting the molding process, without the need to redesign the mold tooling or replace
other production equipment. You can typically avoid these defects relatively easily simply by
adjusting the flow rate, temperature or pressure of your mold.
1. Flow lines
Flow lines appear as a wavy pattern often of a slightly different color than the surrounding
area and generally on narrower sections of the molded component. They may also appear
as ring-shaped bands on a product’s surface near the entry points of the mold, or “gates”,
which the molten material flows through. Flow marks won’t typically impact the integrity of
the component. But they can be unsightly and may be unacceptable if found in certain
consumer products, such as high-end sunglasses.

Causes and remedies for flow lines

Flow lines are most often the result of variations in the cooling speed of the material as it
flows in different directions throughout the mold. Differences in wall thickness can also
cause the material to cool at different rates, leaving behind flow lines.

For example, molten plastic, cools very

quickly during the injection process and flow marks are evident when the injection speed is
too slow. The plastic becomes partially solid and gummy while still filling the mold, causing
the wave pattern to appear.

Here are some common remedies for flow lines in injection-molded products:

 Increase the injection speed, pressure and material temperature to ensure the
material fills the mold before cooling
 Round the corners of the mold where wall thickness increases to help keep flow
rate consistent and prevent flow lines
 Relocate mold gates to create more distance between them and the mold
coolant to help prevent the material from cooling too early during flow
 Increase the nozzle diameter to raise flow speed and prevent early cooling
2. Burn marks
Burn marks typically appear as black or rust-colored discoloration on an edge or surface of

a molded plastic part. Burn marks generally don’t

affect part integrity, unless the plastic is burned to the extent of degradation.

Causes and prevention of burn marks

The usual cause for burn marks in injection-molded parts is trapped air, or the resin itself,
overheating in the mold cavity during injection. Excessive injection speeds or heating of the
material often lead to overheating that causes burns. Consider the following preventative
measures to avoid burn marks in molded components:

 Lower the melt and mold temperature to prevent overheating

 Reduce the injection speed to limit the risk of trapping air inside the mold
 Enlarge gas vents and gates to allow trapped air to escape the mold
 Shorten the mold cycle time so that any trapped air and resin don’t have a chance
to overheat

3. Warping
Warping is deformation that can occur in injection molded products when different parts of a
component shrink unevenly. Just as wood can warp when it dries unevenly, plastic and
other materials can warp during the cooling process when uneven shrinkage puts undue
stress on different areas of the molded part. This undue stress results in bending or twisting
of the finished part as it cools. This is evident in a part that’s meant to lie flat but leaves a
gap when laid on a flat surface.
Causes and prevention of warping in molded parts

One of the main causes for warping in injection-molded plastic and similar materials is that

cooling happens too quickly. Often

excessive temperature or low thermal conductivity of the molten material can worsen the
problem. Other times mold design can contribute to warping when the walls of the mold are
not of uniform thickness—shrinkage increases with wall thickness. Here are some common
ways to prevent warping in your molded parts:

 Ensure the cooling process is gradual and long enough to prevent uneven
stresses on the material
 Lower the temperature of the material or mold
 Try switching to a material that shrinks less during cooling (e.g. particle-filled
thermoplastics shrink much less than semi-crystalline materials or unfilled grades)
 Redesign the mold with uniform wall thickness and part symmetry to ensure
greater stability in the part during cooling

4. Vacuum voids / air pockets

Vacuum voids, or air pockets, are trapped air bubbles that appear in a finished molded
component. Quality control professionals typically consider voids to be a “minor” defect
(related: 3 Types of Quality Defects in Different

Products). But larger or more numerous

voids can weaken the molded part in some cases, as there’s air below the surface of the
part where there should be molded material.
Common causes of and steps to prevent vacuum voids in molded parts

One of the chief causes of voids is inadequate molding pressure to force trapped air out of
the mold cavity. Other times, the material closest to the mold wall cools too quickly, causing
the material to harden and pull the material toward the outside, creating an abscess. The
material itself may be especially vulnerable to voids if its density changes significantly from
the molten to hardened state. Voids are more difficult to avoid in molded parts which are
thicker than 6 mm. Common ways to prevent voids include:

 Raise the injection pressure to force out trapped air pockets

 Choose a grade of material with lower viscosity to limit the risk of air bubbles
forming
 Place gates close to the thickest parts of the mold to prevent premature cooling
where the material is most vulnerable to voids

5. Sink marks
Sink marks are small recesses or depressions in an otherwise flat and consistent surface of
a molded part. These can occur when the inner part of a molded component shrinks, pulling
material from the outside inward.

Causes and prevention of sink marks

Sink marks are similar to vacuum voids but are reversed in cause and effect.

Rather than the material cooling too rapidly

near the exterior of the part, the material cools too slowly. The resulting shrinkage pulls the
outside material inward before it’s had a chance to adequately cool, leading to a
depression. As with voids, sink marks are more likely to occur in thicker parts of a
component. Here are some steps you can take to prevent this defect:

 Increase holding pressure and time to allow the material near the part’s surface to
cool
 Increase cooling time to limit shrinkage
  Design your mold with thinner component walls to allow for faster cooling near
the surface

6. Weld lines
Weld lines can appear on the surface of a molded part where the molten material has
converged after splitting off into two or more directions in a mold. The hair-like weld line is
the result of weak material bonding, which lowers the strength of the part.

Common causes of weld lines and how to prevent them

Two or more fronts of polymer or other molten material need to maintain a certain

temperature when colliding. Otherwise, they

become partially solidified and won’t sufficiently bond where they meet, resulting in weld
lines. Common remedies for weld lines in molded parts include:

 Increase material temperature to prevent partial solidification

 Raise injection speed and pressure to limit cooling before the material has filled
the mold
 Redesign the mold to eliminate partitions
 Switch to a material with a lower melting temperature or viscosity to allow
faster flow and prevent early cooling

7. Jetting
Jetting refers to a kind of deformation in a molded component that can occur when there’s
an initial “jet” of molten material injected into the mold cavity that starts to solidify before the
cavity is filled. Jetting often appears as a squiggly line in the surface of the finished
component, typically leading from the initial gate of injection. This visible flow pattern can
result in part weakness.
Causes and remedies of jetting in molded parts

The chief cause for jetting is excessive injection

pressure. When molten polymer or other

material is injected through a small gate at high pressure it often squirts rapidly through the
gate, rather than filling the mold cavity gradually. As this initial line of material cools against
the mold walls and starts to harden, the remaining mold material pushes it, leaving
impressions in the surface of the finished part. Avoid jetting in molded parts by:

 Reducing injection pressure to prevent rapid squirting of the material into the mold
cavity
 Increasing material and mold temperature to keep the initial jet of material from
solidifying early
 Designing the mold with the injection gate located such that the material is
directed across the mold, rather than lengthwise

Defects typically related to material use or

storage
Injection molding defects can often originate from the material itself or how the
manufacturer stores and handles the material prior to the production process. These
defects can range from minor aesthetic issues to compromised strength of the finished
component. Serious safety concerns may also result, depending on the intended application
of the product affected.

8. Discoloration
Discoloration, or “color streaking”, occurs when a molded part is a different color than
intended. Often the discoloration is limited to a localized area or a few streaks of abnormal
color on a molded part. This defect typically affects the appearance of the part without
reducing its strength.
Causes of discoloration in molded products and how to prevent it

A common cause of discoloration is leftover pellets in the hopper or residual resin in the
nozzle or mold from a previous production

run. Poor thermal stability of the coloring

agent or improper mixing of the masterbatch are other potential causes. Take the following
precautions to limit the risk of discoloration in your injection-molded products:

 Ensure that workers properly clean the hopper, nozzle and mold between
production runs to eliminate any residual pellets or base material
 Consider using a purging compound to remove excess color from the machine
 Ensure you or your supplier is using a color agent with adequate thermal
stability
 Ensure that the masterbatch is evenly mixed for consistent color output

9. Delamination
If you find thin layers on the surface of a molded part are easily separating or peeling off the
underlying material, you’re seeing a molding defect called delamination. Delamination is a
defect characterized by a flaking surface layer, similar to what you’d commonly find on flake
mica. This is generally regarded as a relatively serious defect because it reduces the
strength of the component.

Causes and prevention of delamination in injection molding

The most common cause of delamination is contamination of the resin pellets or other base
material with a foreign material. Flaky separation results when the two materials cannot
properly bond to each other. For example, you might combine a common base plastic like
acrylonitrile butadiene styrene (ABS) with an incompatible plastic, such as polypropylene
(PP). The resulting loss of strength of the material would be very dangerous if your part is

intended for a safety-critical use.

Aside from material fed into the hopper, the contaminant could also be any excess release
agents coating the mold for easier component separation. Excess moisture on the material,
due to improper drying prior to use, can also cause delamination. Consider the following
corrective actions to prevent recurrence if you discover delamination affecting your molded
parts:

 Increase the mold temperature or pre-dry the material properly if excess

moisture is an issue
 Ensure workers are properly storing and handling the resin pellets or base
material to prevent contamination
 Consider redesigning the mold with a focus on the injection nozzle to limit your
dependence on release agents

Injection molding defects caused by poor

mold design or maintenance
Defects can be introduced into molded products by issues with the mold tooling itself.
Certain defects are likely to occur when the mold is poorly maintained or designed.
Especially in the latter case, these defects can be difficult or costly to address in future
production runs when it’s necessary to completely overhaul the mold.

10. Short shot

A short shot occurs when the flow of molten material doesn’t completely fill the cavities in a
mold. The result is that the molded component is incomplete after cooling. Short shot might
appear as incomplete compartments in plastic shelves of a display or missing prongs on a
plastic fork, for example. Short shots are typically classified as a major defect that can
inhibit the function or appearance of the molded part.

Causes and remedies of short shot in molded products

The most common cause of short shots is flow restriction resulting from narrow or blocked
gates. Sometimes the material is too viscous or the mold is too cold to allow the molten
material to completely fill the mold before cooling. And other times trapped air pockets may
be hindering proper flow or injection pressure may be inadequate. Consider the following
steps to prevent short shot:

 Redesign the mold with wider channels or gates for better flow
 Increase injection speed or pressure or choose a thinner base material to improve
flow
 Increase mold temperature to prevent material from cooling too rapidly
 Add additional air vents or enlarge existing vents in the mold to allow trapped air
to escape

11. Flash
Flash, also called “spew” or “burrs”, is an excess of molding material that appears as a thin
lip or protrusion at the edge of a component. Flash appears because material has flowed
outside of the intended flow channels and into the space between the tooling plates or at

the injector pin. Flash is usually subtle but

might be considered a major defect if particularly obvious on a product. The process for
reworking a molded product with flash often includes trimming the excess material.
 Common causes of flash and prevention in molded products

A poorly-designed or worn and degraded mold is the most common contributor to flash.
Excessively high mold temperature or injection pressure can also cause flash. Material
flowing through the mold cavities can force its way between plates when plate clamping
force is inadequate. Common methods for addressing flash in molded products include:

 Retool or redesign the mold if plates don’t fit together properly or allow material to
flow outside the channel
 Increase plate clamping force to confine material flow to the channel
 Adjust mold temperature, injection pressure and ventilation to improve material
flow

Conclusion
Manufacturing using injection molding typically requires significant upfront investment in
tooling. That’s why it’s especially important to design your mold right the first time, rather
than having to start again after finding serious defects. Defects related to the molding
process or material tend to be easier and less costly to solve. But no matter the cause,
defects in molded products can hurt your bottom line tremendously.

Now that you’re familiar with common injection molding defects to look out for, you can take
steps to prevent them in the future and ensure your products meet your customers’ quality
standards

13 Possible Injection Moulding Defects

And How To Avoid Them
 Priyanka
 July 5, 2019
 Tricks
 0 Comments
Injection moulding is one of the most common processes by which plastic parts are
manufactured.
In the injection molding process, a vast variety of components of various sizes, shapes, and
complexities can be created.
 Injection
molding

The three main requirements of this process are:

 An injection moulding machine,
 Raw plastic material, and
 A mould
The whole process, in short, is this: the plastic material is first melted in the machine with hot
runners, and then poured into the mould. There, it cools and solidifies into the desired
component.
Injection moulding is used to create a variety of thin-walled plastic parts for use in household
appliances, electronic goods, toy manufacturing, etc.
Errors made during the process of injection molding or due to the materials used in the
process can turn out to be very costly for your business. Defects in the final product could
range from harmless and superficial quality issues to bigger problems that could affect the
safety and efficacy of the product.
If proper care is not ensured during the molding process, there can be many defects that are
formed on the finished plastic product. In this article, we are going to discuss all the possible
injection moulding defects, what causes them, and how they can be avoided.
Understanding what the possible defects could be and what causes them is the first step in
ensuring that the products developed in the process consistently reach acceptable standards.
This could reduce losses incurred due to products that cannot be sold, or products that are
returned after sale due to the defects.
Here are some of the most common injection moulding defects, along with their causes and
what can be done to avoid them.
Defects In Injection Moulding
Possible Defects Caused Due To Process Problems
Sometimes, the problem lies not in the raw materials or the tools used in the process, but in
the injection molding process itself. When you are sure that the defects are being caused by
the process, all you need to do is adjust certain important factors like the wall thicknesses, and
they can be easily avoided.

Injection molding machine

Some of these factors could be the flow rate, the pressure, or the temperature settings
of plastic injection molding.
Let’s take a look at some defects that are caused purely due to faults in the injection mould
process.
1. Flow Lines Or Flow Marks
What it is:
Flow lines (also called flow marks) are waves, streaks, or lines that are discoloured when
compared to the area surrounding them.
 These are usually observed near the ‘gate’ points or gate locations of the mould, where
molten plastic enters it through plastic injection. They do not affect the functionality of the
finished product, but are unpleasant, especially when found on products that need to be
aesthetically pleasing.
What causes it:
Flow lines are caused by variations in the cooling rate of the melt plastic as it flows through
the heated barrel and mould and solidifies. This also happens if there are thin walls and thick
walls instead of uniform wall thickness, as the material cools at different speeds.
A slow injection speed or low pressure injection molding can also cause flow lines, as the
plastic cools very quickly and becomes thicker, forming molding defects like wavy patterns or
streaks.
How to rectify it:
 The simplest answer to this problem would be to increase the injection speed of the injection
molding cycle.

 The pressure and temperature of the material injected into the mold can also be adjusted so that the
type of plastic is able to completely fill the mould before solidifying.

 If flow lines appear due to sharp contours or lack of uniform wall thickness in the molding
machine, it would help to round the corners of the mold cavities so that the pressure injection flow
is consistent.

 Another strategy would be to change the location of the mould gates of the injection units where
the molten plastic begins to flow in during the manufacturing process.

 Increasing the size of the nozzle can help increase the flow rate and avoid premature solidification
of the plastic material by increasing the cooling time.

 Applying a lubricant to the surface will also assist the flow of the molten thermoplastic material in
the runner system.

2. Burn Marks
What it is:
Burn marks are dark coloured (either black or rust coloured) marks on the edges or on the
surface of the moulded product that are not part of the product design. They are usually
harmless unless the burn has degraded the plastic.
What causes it:
The most common cause behind burn marks is the overheating of either trapped air bubbles or
resin in the mould cavity during cycle times. This could be due to high injection speeds or
overheating of the material.
How to rectify it:
 Burn marks can be avoided by reducing the injection speed and holding pressure of the molding
tool. This will prevent air bubbles getting trapped inside the mould of the injection machine.

 Gas vents can be enlarged in order to facilitate easy escape of trapped air during low pressure
injection.

 Reducing the temperature of the mould and hydraulic cylinders can also help prevent burn marks.
3. Warping
What it is:
Warping occurs when different parts of a product cools and solidifies unevenly during plastics
processing. The resultant compression molding product is disfigured with bends and twists.
What causes it:
The main reason warping occurs in plastic products is due to premature cooling rates of the
raw material. This could be either due to overheating or no and no uniform walls of the
mould.
How to rectify it:
 Make the cooling process gradual so that there is no stress on the molten plastic material as it
cools.

 Adjust the mould temperature during mass production.

 Use materials that do not shrink excessively during cooling.

 Ensure that the mould has a uniform thickness of its walls so that there is uniform cooling
throughout the metal casting and clamping units.

4. Vacuum Voids / Air Pockets

What it is:
These are trapped air bubbles in the finished product. Although this is not considered to be a
major defect, it could lead to a weakening of the final product during product development.
What causes it:
One of the most common reasons for vacuum voids in plastic products is insufficient pressure
in the mould during lowvolume production. The air bubbles that are trapped in the mould are
thus not pushed out while the plastic cools and solidifies in the insert moulding process.
How to rectify it:
 The blow molding injection pressure needs to be increased in order to force trapped air bubbles out
of the mould.

 Select a material with low viscosity so that air bubbles are not formed in it easily.

 Ensure that there are gates near the thickest parts of the mould so that the plastic does not cool too
soon.

5. Sink Marks
What it is:
These are small depressions formed in the plastic product. This usually takes place when the
inner part of the component solidifies fast and shrinks, and the outer material is forced inward
due to shot weight.
What causes it:
Sink marks occur because the molten plastic material cools too slowly in the mould. Thus, the
outward material is pulled inward before it has a chance to cool completely, causing a
recession in the material.
This usually occurs in the thickest parts of the mould due to uneven cooling of the plastic
material.
How to rectify it:
 A simple way to rectify this problem would be to increase the pressure so that there is more time
for the material to cool and shrinkage is limited.

6. Weld Lines
What it is:
These are lines that appear on the surface of the plastic product.
What causes it:
It happens when molten plastic converges from different channels at a certain point in the
mould and bonds weakly to each other. This results in a weakening of the plastic component
at the weld line.
How to rectify it:
 The material temperature needs to be increased so that there is uniform solidification of the
material throughout.

 The injection speed and pressure can be increased to ensure that there is no premature cooling
inside the mould.

 A material with lower viscosity can be chosen as the raw material so that it flows easily and does
not cool prematurely.

7. Jetting
What it is:
Jetting is a sort of deformation in the plastic product that can lead to weakness of the part.
What causes it:
Jetting, as the name suggests, is caused by a sudden jet of molten material entering the mould
and cooling faster than the rest of the material.
This could be due to high injection pressure, resulting in the material squirting in through the
gate into the mould instead of filling it in gradually.
This jet of molten plastic starts to cool before the rest of the cavity is filled, leading to wavy
formations on the surface of the finished product.
How to rectify it:
 One way to rectify jetting in plastic components is to reduce the injection pressure. This will
prevent squiring of the molten material into the mould.

 The temperature of the mould and material can be increased so that the jet stream does not solidify
faster than the rest of the material.

 Optimal designing of the mould and reciprocating screw so that jetting does not occur is another
solution.

Possible Defects Caused Due To Material Use Or Storage

Sometimes, defects in the injection moulding process can occur due to the material being
used.
 plastic molding
material

Here are some of the defects related to the plastic resins used or its storage prior to use.
8. Discolouration
What it is:
Discolouration is when the finished plastic product is a different colour than it is supposed to
be.
The discolouration is usually present in one part of the product or as just a few streaks of a
different colour on the surface of the component.
Discolouration is purely superficial and does not affect the strength or functioning of the
finished product.
What causes it:
One probable cause of discolouration could be left over pellets of plastic material from a
previous run in the machine. It could also be due to some residual material stuck in the nozzle
or mould due to low pressure.
Other reasons could be that the colouring agent has not mixed well with the raw material.
How to rectify it:
 Make sure that all parts of the injection moulding machine like the hopper, nozzle, mould, etc. are
thoroughly cleaned before you run a fresh batch.

 Purge the machine regularly to remove any excess colour or residual material.

 Make sure that your supplier uses colouring agents with sufficient thermal stability and that your
raw material is properly mixed with the colouring agent.

9. Surface Delamination
What it is:
Delamination is when thin layers from the finished product start to peel away from its surface.
This is a relatively serious problem, as flaking of the surface material would eventually cause
the product to weaken and lose its functionality.
What causes it:
Usually, surface delamination occurs because of the contamination of the raw materials with
particles of a foreign substance like sheet metal.
The surface of the product starts flaking when the material cannot properly bind together.
This is especially the case when two or more different plastics are combined to create a
product.
This is very dangerous if the finished product is a crucial component in terms of safety.
 Another reason for surface delamination could be that the material has not dried properly
prior to use and has moisture on its surface.
How to rectify it:
 Make sure that the material has been dried properly before loading it into the hopper of the
machine.

 You can also increase the mould temperature to ensure that the material is dried.

 Be very careful in the storage and handling of the raw material to avoid possible contamination.

 Redesigning of the nozzle also would help to make sure contaminants do not enter the mould
easily.

Possible Defects Caused Due To Faults In The Mould

There are some defects that occur in finished products due to poor design or improper
maintenance of the mould.
10. Short Shot
What it is:
During a run, if the molten plastic material doesn’t fill in the mould cavity completely, the
final product will have defects and be incomplete after it cools and solidifies. This is short
shot. It is a crucial defect that greatly affects the functionality of the product and increases
production cost.
What causes it:
Blocked passages or gates in the machine are one of the main causes of short shot. This could
especially take place when the gates are narrow.
If the material is too viscous, or if the mould is not at a high enough temperature, the mould
will not be completely filled up before the material solidifies.
Trapped air in the material can also affect the flow of the molten resin. Another reason could
be insufficient pressure during injection of the material.
How to rectify it:
 The best way to rectify short shot is to redesign the mould with larger gates so that the resin can
flow in easily.

 The injection speed and pressure can also be adjusted to improve the flow.

 Adding a thinner base material will aid in the movement of the hot fluid plastic throughout the
mould.

 The mould temperature can be increased to prevent premature cooling of the material.

 Increasing the number of air vents can facilitate the escape of any trapped air inside the material.
11. Flash
What it is:
Sometimes, there is a small flap of thin extra plastic material at the edges of the finished
product. This is called flash, or spew, or burrs.
The reason for flash occurrence is that the plastic material has flown outside of the mould and
solidified there.
Flash is usually not a serious issue unless it affects the aesthetics of the finished product. It
can be easily trimmed off from the component.
What causes it:
A low cost mould that is not properly designed, or that has been worn out due to over-usage
could be the problem behind flash.
A very high mould temperature or pressure during injection can also cause it.
Another contributor to flash is the insufficient clamping force of the plates containing the
resin.
How to rectify it:
 The mould may need to be redesigned if it is faulty or worn out. The temperature and pressure can
be adjusted to prevent flash.

 Sometimes, the clamping force of the plates needs to be increased to prevent it.

12. Silver Streaking

What it is:
Silver streaking can be described as streaks of silver or white in the finished product. They
usually occur in the direction of the material flow.
What causes it:
These silver streaks are usually caused by excess water that is absorbed in the material.
It could also be due to contamination of the material with a foreign substance or air bubbles
that are trapped inside it. Excess additive in the plastic material could also cause this.
How to rectify it:
 Ensure that the mould is thoroughly cleaned before starting a new run.

 Pre-dry the raw material and investigate any possible contamination.

 Reducing the injection speed, increasing mould temperature, and applying a back pressure can also
help avoid formation of silver streaks.

 You could also try adjusting the size of the gates or their positions.

13. Product Stuck in The Mould

What it is:
This occurs when the finished product does not separate from the mould parts.
Usually, after a product has been moulded, it sticks to the moving part of the mould and is
removed using ejector pins when the mould is opened. When that does not happen, it could
lead to broken ejector pins.
What causes it:
This could happen due to any of the following reasons:
– The residual pressure of the mould is too high,
– There is shrinkage in the product,
– The mould draft is not large enough, or
– The mould finish is at an irregular angle
These reasons could cause malfunctioning of the ejector pins, and the product gets stuck
inside the mould.
How to rectify it:
 Decreasing the temperature and pressure settings could help get the finished product unstuck.

 Increasing the size of the mould draft or redesigning the mould to have a better finishing could
prevent this from happening.

 Sometimes, mould parting agents are used to avoid this problem.

Injection moulding machine

As you can see, there are many possible defects that can take place due to faults in the
moulding machine, the various tools, and the raw material that is introduced into the injection
moulding machine.
It is important to ensure that your mould is designed and finished properly to avoid the
additional costs of redesigning a faulty mould.
Ensuring the quality of all finished products will guarantee their safety and efficiency.
TAGS: INJECTION MOULDING

Injection Molded Part

Defects and
Remedies
Posted by Kyle Keiser on Jun 19, 2019 11:00:00 AM

 Share

There are several variables in the injection molding process and mold design.
All of which have implications on part quality. It's important to know the
potential defects, how to prevent them, or process them out. Here you will find
a list of common molding challenges and their remedies

 Brown / Black Marks

 Burning
 Cracking
 Flashing
 Flow lines
 Jetting
 Short Shot
 Sink Marks
 Voids
 Warping
 Weld / Knit Lines

Assumptions

When assessing issues with injection molded parts we want to make sure
some core aspects of molding are checked. Below is a list of items that should
be checked both during normal molding operations and if defects are
detected. Material contamination, for example, can cause a number of
molding issues. Therefore, it's important to check these things first before
digging deeper into the potential issues or changing machine settings.

 Material is free from contamination

 Material has been properly dried
 Material handling equipment is functioning correctly and has been properly cleaned
 Processing parameters including drying time, drying temperature, and regrind limits are
within specification for the selected material
 The proper material has been selected for the application
 The molding machine is functioning properly and has been properly maintained.
 Auxiliary equipment such as temperature controllers and dryers are functioning
correctly
 Mold surfaces are cleaned
  Mold water channels are clean and flowing properly
 Previous processing parameters have been recorded and checked

Brown / Black Marks

Description

Brown or black marks or streaks are present on the surface of the molded
part.

Cause - Remedies

 Material from previous runs are stuck in the barrel / screw assembly, nozzle, or hot
runner system. Degrading material can also be caused be high resonance time in the
barrel.
o Purge the barrel and hot runner system
o If possible increase cycle time to reduce material resonance time. Running the
mold in molding machine with less barrel capacity is also possible
o Remove and inspect the check ring
o Remove the barrel assembly and thoroughly check for damage or ware
 Melt temperature of the plastic is too high
o Lower the rear zone temperatures
 Material is being injected too fast causing excessive shear heating
 Screw RPM is too high
 Gates are too small
 Check for uniform wall thickness to avoid high shear areas
o Make varying wall thicknesses uniform

Burning
Description

Yellow / black marks at the end of fill on a molded part. Burning is most likely
cause by air traps in the mold. As plastic fills the mold the air needs to
escape. If the air gets trapped it will compress and overheat the plastic.
Causes - Remedies

 Injection Speed too High

 Material is too hot
o Reduce melt temperature
 Excessive clamping force
o Reduce clamping force if possible
 Not enough venting in the mold
o Check for restricted venting and air traps
 Dirty Vents
o Clean the mold surfaces, parting lines, and vent pins

Cracking
Description

The components crack on ejection or during handling.

Causes - Remedies

 Injection speed is too slow

 Degraded material
o Adjust cylinder temperatures
o Reduce back pressure
 Melt temperature is too low
o Increase rear zone temperature
o Increase nozzle temperature
 Mold surface is too cold
o Increase the mold temperature
 Gate size or runners are too small
 Excessive regrind present

Flashing
Description

Extra plastic around parting lines and other shut off areas.
Causes - Remedies

 Injection pressure too high

o Slow down the injection speed
o Raise the volume-pressure switch over point
o reduce shot size
 Material is too hot
o Reduce the melt temperature
 Low or uneven clamp force
o Make sure sufficient clamp force is available
o Make sure mold is clamping squarely and fully
o Make sure tooling assemblies / actions have proper support to resist material
pressure
 Clogged or small venting
o Check that venting is sufficient

Flow Lines
Description

A rippled surface finish usual around a gate but can also be at the end of fill
on the parts

Causes - Remedies

 Slow injection speed

o Increase the injection speed
 Low melt temperature
o Increase the temperature in the front two zones of the barrel
 Runner and gates are too small
o Increase the size of the runners and gates
 Surface temperature of the mold is too low
o Increase the mold temperature

Jetting
Description

A swirled line coming from the gate of the part

Causes - Remedies

 Mold surface temperature too low

o Increase the mold temperature
 Gate size too small
o Increase gate size

Short Shot
Description

The molded part is not completely filled out

Causes- Remedies

 Injection speed to slow

o Increase injection speed
 Shot size too small
o Increase shot size if screw position continuously goes to 0
 Non return valve / check ring damaged or worn
o Check for ware or damage if consistent cushion cannot not be accomplished
 Inadequate mold venting
o Air traps causing material flow to stop. Check for proper venting
 Long flow length / thin wall sections
o Check for consistent wall thickness and make sure gate location is optimized for
material flow.

Sink Marks
Description

Sinks or voids in the plastic part. Usually located around thick wall sections.

Causes - Remedies

 Inadequate shot volume

o Make sure cushion is consistent
 Inadequate injection pressure
o Increase injection pressure to flow more material into the mold
 Inadequate hold time
o Add more hold time to allow part to fill out
 High melt temperature
o Lower the melt temperature
  Too small of a gate
o Gate size should allow for proper fill of the part with out freezing off
 Gate position not optimized
o Gate should feed into larger areas of the part to ensure they fill

Voids
Description

Bubbles trapped inside a part. May not be seen on colored parts.

Causes - Remedies

 Air traps in the melt / barrel

o Increase back pressure
o Reduce screw RPM
o Reduce decompression
 Inadequate packing pressure
o Increase injection pressure
 High fill speed
o Slow down the injection speed

Warping
Description

Part shape is warped after it's ejected from the mold

Causes - Remedies

 Cycle time too short

o Increase the cooling time to allow the part to be cooled more thoroughly by the
mold
 Insufficient shot size
o Increase the shot size
 Melt temperature too low
o Increase the melt temperature
 Insufficient mold cooling
o Check for proper cooling flow through the mold
o Increase the amount of cooling in the mold
 Feed systems to small or misplaced
o Gates should feed into thicker wall sections of the part and allow for enough
material to flow and cool
 o Runner system should be able to feed enough material into the cavities without
excessive pressure or freezing

Weld / Knit Lines

Description

Locations where material is "reconnected" during the injection molding

process. This is inevitable with holes in plastic parts and multiple gate
situations. These can be failure points on the molded parts if not remedied
properly

Causes - Remedies

 Low melt temperature

 Flow speed too fast or too slow
 Mold surface is too cold
o Increase the mold temperature
 Mold is not vented properly causing slow flow at knit lines

o Add or increase vents as needed

Topics: Injection Molding, Tool Building, Mold Design & Analysis