LG PC

Processing Guide
Injection Molding

Alcom® LG PC are translucent, optically diffuse and entrapments in finished parts during subsequent
unfilled compounds based on Polycarbonate (PC). processing. If larger amounts of dust occur during material
handling or transport, the use of an additional dust removal
The special optical properties of Alcom® LG PC require
system is recommended. Contamination in injection
special attention during pretreatment and processing of the
molding units and mold cavities, e.g. due to residues of
materials, especially with regard to adherence to injection
foreign material, oil or other processing aids, must also be
molding parameters, as well as cleanliness and purity of the
avoided. Before using Alcom® LG PC, purge the injection
processing environment. The following processing
molding unit with clear polycarbonate until no impurities
instructions provide guide values for handling the materials.
(e.g. specks, streaks, color haze) are visible in the melt
The information on pretreatment and processing on the
cake.
technical data sheet of the product used must also always
be followed.
Processing Environment
As usual when processing thermoplastic molding
compounds into optical components, special care must be
taken to ensure cleanliness of machines and peripherals.
Contamination and dust in drying equipment, pellet feeders,
storage containers or other surfaces the pellets come into
contact with can lead to defects and impurities in the
finished part. Dust in particular causes cracking and black
Material Handling Nozzle: Open nozzles are preferred. Particularly for easy-
flowing materials (MVR >25 cm³/10min), valve gate nozzles
Alcom® LG PC is usually supplied in bags. This helps to
are used sometimes. However, due to their design, these
avoid contamination of larger granulate quantities during
nozzles may cause increased shear and possible zones
material handling and thus large reject quantities, as would
with increased residence time. Both can lead to component
otherwise be possible with octabin, BigBag or silo goods.
defects due to streaks or black specks. Purging during
Store unopened bags dry and protected from light. Opened
material changes is also more complex with valve gate
residual containers must be sealed airtight after opening
nozzles.
and checked for increased residual moisture and
contamination before processing. Residence time: Excessive residence time can lead to
material damage and color deviations (“yellowing”). Make
Pretreatment
sure the size of the plasticizing unit used matches the shot
PC is a hygroscopic polymer and absorbs moisture from volume of the injection mold used. The recommended
the ambient air which can lead to material damage and dosing volume is 1-3 times the screw diameter (1-3D).
surface defects during injection molding. Therefore, pre- Residence times of the material in the plasticizing should
drying, preferably in a dry air dryer, is necessary until a be 6 minutes maximum.
residual moisture of 0.02% maximum (Karl Fischer titration)
Processing temperatures: The processing temperatures
is reached. Ensure the drying equipment is clean and free
recommended on the technical data sheet must be
of dust in order to prevent contamination. The material must
followed. Temperatures too high can lead to significant
be processed immediately and continuously after pre-drying
color deviations and material degradation. Temperatures
as it absorbs moisture from the ambient air again in the
too low increase the injection pressure. This leads to
material supply of the injection molding machine. After
excessive shear and increased stresses in the component,
longer production stops it may be necessary to dry the
up to and including component failure. As a guide for initial
granules again if they have not been stored airtight
sampling it is recommended to start with the mean value of
Processing the processing temperatures specified on the technical data
sheet. In case of production interruptions residual material
Alcom® LG PC can be processed on all standard injection
in the aggregate should be purged and barrel temperatures
molding machines with 3-zone screw. Please follow the
should be lowered to 160°C - 180°C. Before re-starting
recommended process conditions given below, as well as
production, the plasticizing unit should be purged with
the recommendations on the technical data sheet of the
material until no more degraded/discolored melt is being
product used. In the following, some points are considered
extruded and the melt cake is free of streaks and black
which should be given special attention when processing
specks.
Alcom® LG PC.
Injection speed and holding pressure: The injection
Plasticizing: A screw speed and back pressure set
speed should ensure component filling with constant flow
correctly contribute significantly to a homogeneous melt
front speed. The holding pressure should be between 50 to
quality. However, both parameters should not be set too
70% of the maximum injection pressure. Uneven filling and
high in order to avoid damage to the molding compound
excessive pressures cause internal stresses in the
due to excessive shear energies. A screw circumferential
component, which can lead to warpage and damage to the
speed < 0.2 m/s and a specific back pressure between
component. At very high injection pressures (> 1500 bar),
50-100 bar are recommended.
the gating system should be checked and adjusted if
necessary (e.g. by larger gate diameter).

Mold1 Barrel temperature1

IV III II I

80 - 110 280 - 290 280 - 300 270 - 290 260 - 270 70 - 90

Temperatures in degree Celsius (°C) 1Orientationvalues. For the start-up process, mean values are recommended first, please note the
information on recommended processing temperatures on the current technical data sheet of the
product used.
Injection Mold demolding problems may occur due to surface adhesion.
These can be counteracted by suitable mold coatings. For
Temperature control: Uniform mold surface temperature
further information please contact your technical
is mandatory for optimum component quality. The best
representative.
appearance is met by choosing mold temperatures in the
upper range. Special attention must be taken to inserts and Use of regrind
sliders in complex molds. We recommend checking the
Alcom® LG PC are materials for highest technical and
temperature control by measuring the mold surface
optical requirements with narrow color tolerances. The use
temperature (e.g. with a contact thermometer). Insufficient
of ground production waste (e.g. sprues) is not
or uneven mold temperature control can cause component
recommended. Dust, impurities and also the increased
defects, such as increased warpage. PC is susceptible to
thermal load due to re-melting mean that the optical quality
stress cracking in general which is favored by high internal
of the components cannot be ensured. Please feed
stresses in the component.
production waste into the recycling circuit for polycarbonate
Gating: The gate should be located in an area of highest instead.
wall thickness in order to ensure the optimum effect of the
holding pressure to reduce sink marks. The position of the
gate should support uniform cavity filling with short flow
paths. The type of gate chosen must ensure gentle material
processing. Point and tunnel gates can be used but
minimum diameter of the gate should not be less than
1 mm. Excessive shear stress on the molding compound
can lead to color changes under certain circumstances.
Hot runner: The use of hot runner systems for processing
Alcom® LG PC is possible and has been proven for a long
time. Care should be taken to a hot runner design without
dead angles and with the smallest possible volume to
reduce the residence time. At the same time, the hot runner
system should introduce as little shear stress as possible to
the molding compound. Torpedo tips should be avoided.
Hot runner nozzles with valve gates are possible but extend
purging time and cause streaks more frequently. Please
follow the maximum processing temperatures of the
material used in the hot runner system as well.
Surface: Due to the special formulation of Alcom® LG PC,
optimum light diffusion is achieved even on polished
surfaces. Structuring is not necessary. In the case of large-
area components with (mirror-bright) polished surfaces,
 Properties

Polymer PC
Density (ISO 1183) 1.18 - 1.20 g/cm3 (see technical datasheet)

Injection Molding Machine

Screw stroke Dosing stroke between 1 x D and 3 x D (D = screw diameter)

Screw type Three-zone screw with L/D-ratio 18:1 to 23:1
Nozzle type Open or needle valve nozzle
Hopper type Standard

Pretreatment

Storage Dry, protected from heat and UV radiation

Dryer Air circulating dryer Dry air dryer
Drying time 4 - 12 h 2-4h
Drying temperature 120 °C 120 °C
Max. moisture content < 0.02 % < 0.02 %

Processing Conditions

Melt temperature 270 - 300 °C (for type-related values please see technical data sheet)
Tool temperature 80 - 110 °C
Coolant Water
Coolant throughput A turbulent flow is to be achieved
Screw circumferential speed 50 - 200 mm/s
Back pressure (specific) 50 - 100 bar
Residence time < 6 min
Injection speed Low to medium, profile for constant melt flow front

Shrinkage2

PC, unfilled
Shrinkage, 24 h (ISO 294-4) 0.5 - 0.9 %

2Shrinkage is not a pure material property, but is influenced by fillers, the component geometry, its wall thickness and the position and size of the gate. Processing
parameters, such as mold wall and melt temperature, also play a decisive role. Please also refer to the separate guide on shrinkage.

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technical advice on applications, whether verbally, in writing or by testing the product, is given to the best of our
Mühlenhagen 35 | 20539 Hamburg knowledge and in good faith and does not exempt the buyer from carrying out their own investigations and tests
in order to ascertain the product‘s specific suitability for the purpose intended. The buyer is solely responsible for
T +49 40 78105-720 | sales@mocom.eu confirming the suitability of the product for a particular application, its utilization and processing and must
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