Troubleshooting Guide For Injection Molding
Troubleshooting Guide For Injection Molding
Troubleshooting Guide For Injection Molding
Cause Solution
3
Blisters
Blisters are areas of trapped gas seen as surface irregularities
or bumps on the surface of the molded part. They occur
during injection or cooling.
Cause Solution
Poor
Relocate gate to minimize any flow disruptions.
Gate Location
4
Blush
Blush often occurs near the gate or a flow disruptor such as a core pin
or shutoff. It is also noticed near sharp corners or severe wall thickness
transitions. It is the result of melt fracture. The part surface will appear
dull (low gloss) or discolored and some flow marks will be visible.
Cause Solution
Other Process
Increase melt & mold temperature.
Changes
5
Brittleness
Brittleness occurs from degrading the resin and results in a
reduction of physical properties. Brittleness can also be related to
moisture in some materials prior to melt processing.
Cause Solution
6
Bubbles
Regions within the molded part without plastic are referred
to as internal voids or bubbles. They can be caused by
differential cooling or air entrapment.
Cause Solution
Under
Increase injection & hold pressures and/or times.
Packing
7
Burns
Burned resin can be the result of several things. High barrel tem-
peratures, shear from screws or runner and gate systems, excessive
residence time and poor venting will all cause the resin to discolor.
Cause Solution
Lowering the injection speed will allow trapped air in
High Injection the mold to escape. It will also reduce shear
Velocity
heating of the resin.
Wet
Properly dry hygroscopic resin.
Material
8
Cloudiness/Haze
Cloudiness in transparent resins can be the result of
contamination. Other causes can be mold surfaces, mold
temperature or resin temperature.
Cause Solution
9
Contamination
Contaminants often show up as black specks or color streaks.
Cause Solution
10
Cracking/Crazing
Cracking and crazing can occur upon ejection from the mold. Many
simple changes will improve the part quality after molding.
Cause Solution
High shrinkage or low molecular weight resin may
Thick tend to crack or generate voids upon cooling. Using a
Wall Section higher molecular weight or lower shrink resin will help
eliminate this. Thin wall sections will tend to shrink less.
Small
Enlarge gate to reduce stresses.
Gate
11
Deformation
Upon ejection, parts can stick to the tool causing the geometry to
be deformed as the ejectors push forward. Deformation can also be
caused on mold opening if the part tries to stick to the wrong half.
Cause Solution
12
Delamination
Delamination is a separation of layers of the molded part. These
layers can develop from contamination or improper processing.
Cause Solution
Review resin handling system to ensure no foreign
materials are mixed with virgin or regrind. Switch to all
Contamination virgin to isolate source. Purge barrel and clean hopper,
dryer and hose lines. Clean grinders, filters and containers.
Ensure magnet is in place and no objects are attached to it.
13
Dimensional Instability
Dimensional instability or warpage in a molded part can be the
result of differential material shrinkage, molded-in-stress relief, or
an inconsistent injection molding process.
Cause Solution
14
Discoloration
Discoloration can be caused by several factors and can occur to the
actual pellets prior to molding as well as the final part.
Cause Solution
Long Residence Reduce cycle time, use small volume barrel. Use a
Time reverse temperature profile.
15
Flash
Flash is caused when resin flows out of the cavity at the parting
line. This can be a function of many machine, mold and material
variations and is typically easily corrected.
Cause Solution
Exceeding Increase clamp pressure set point. Lower pack and hold
Clamp Pressure pressures. Lower injection velocity.
Too Much
Reduce the shot size and/or increase the cushion.
Volume
Vents
Verify the proper vent depth for the material.
Too Deep
16
Flow Lines
Flow lines, weld lines, meld lines, knit lines and ripples or folds are
all a result of a disturbance in the flow path of the resin. When
smooth laminar flow is interrupted, the polymer may not accurately
reflect the surface of the tool.
Cause Solution
Poor Gate Locate gate to fill thickest section first and produce the
Location smallest amount of weld lines.
17
Jetting
Jetting or worming is caused by excessive injection force without
a barrier for the melt to hit. The material cannot develop a laminar
flow front unless it impinges on a wall or boss.
Cause Solution
Small
Increase gate size to reduce nozzle effects.
Gate
18
Mold Deposits
Under the high temperatures and pressures of the injection molding
process, additives and residual monomer can be volatized and separated
from the resin. These materials can end up as residue on the mold surface
and require cleaning or leave surface defects on the molded parts.
Cause Solution
Poor Verify vent sizes are correct for the given resin.
Venting Increase the number of vents at more locations.
19
Short Shots
A short shot occurs when insufficient material is injected and does
not completely fill or pack out all of the cavities in the mold. Shorts
can be caused by machine, mold or material.
Cause Solution
Low Injection
Raise injection pressure.
Pressure
Low Mold Increase mold temperature to aid flow and prevent too
Temperature thick of a solid skin from setting.
Air Clean vents and ensure they are the proper size.
Trap Burning may also accompany this.
Damaged
Verify clearances to prevent back flow.
Barrel/Screw
20
Sink Marks
Sink marks can be the result of a poor fill (short shot) or the result
of differential cooling when wall sections vary greatly in thickness.
Cause Solution
Increase shot size and/or decrease cushion to push
Insufficient
more resin into the cavity. Ensure consistent
Feed
cushion size.
Runner & Increase runner and gate sizes to get best pressure
Gate Size transfer to the part in the cavity of the mold.
21
Splay
Three types of splay are often encountered in injection molding. Splay
due to moisture usually results in silver streaks on the surface and slight
delaminating of a film layer. Heat splay, caused by degradation or hang-
up, looks similar but is often accompanied by black specks or yellowness.
Splay due to contamination is often accompanied by severe delamination.
Cause Solution
High Melt Verify barrel set points and measure purge shot
Temperature with a pyrometer. Lower if necessary.
Clogged Clean and inspect all vents. Verify venting is the proper
Vents depth for the given resin.
22
Surface Finish
A dull surface finish or poor reflection of mold surface
can be easily corrected.
Cause Solution
Raise melt temperature to decrease resin viscosity
Cold
and allow easier packing. This will better reflect
Material
the mold surface.
High Injection Slow injection speed to allow air and volatiles to escape
Velocity rather than get caught in the flow front.
23
Voids/Bubbles
Internal voids on a part are simply gaps or pockets with no material.
The are often invisible but can greatly reduce the strength. These
are caused by under packing or shrinkage.
Cause Solution
Thick Wall Design part with uniform wall thickness. Ensure ribs
Sections are on 50% of nominal wall thickness.
24
GENERAL POLYMER
PROCESSING GUIDE INTRO
Polymer families tend to have a wide range of processing condi-
tions so supplier specific information and grade specific information
should be used whenever possible when designing molds or setting
up processing conditions.
The mold shrinkage values provided are general ranges and are only
intended to be used to allow comparisons to other materials and
should only be used as a general guide. The mold shrinkage values
provided are the “flow-direction” shrinkage and are based on 1/8”
thick injection molded test specimens tested per ASTM D955.
Actual material shrinkage is based on a number of factors including
part design, wall thickness, tool configuration, mold cooling layout
and processing parameters. Entec’s recommendation would be to
use shrinkage values observed in other molds currently running the
material that produce parts with a similar geometry and wall thick-
ness, and proceed to machine the mold cores and cavities in a “steel
safe” manner.
25
GENERAL POLYMER
PROCESSING GUIDE
Drying Parameters Mold Melt Mold
Specific
RResin Temperature Temperature Temperature Shrinkage
Gravity
(F)/Time (F) (F) (in./in.)
ABS Flame
1.18 180 / 3 hrs 105 - 160 345 - 365 .003 - .007
Retardant
ABS/TPU 1.1 170 / 4 hrs 80 - 100 390 - 415 .005 - .007
ASA 1.07 175 / 2-4 hrs 105 - 175 465 - 535 .004 - .007
EVA .920 - .970 None Required 60 - 105 300 - 425 .001 - .016
LCP Reinforced 1.50 - 1.90 250 - 300 / 4 hrs 175 - 250 555 - 650 .000 - .004
PA 6 (Nylon 6) 1.13 165 / 2-4 hrs 160 - 200 460 - 520 .010 - .015
PA 6
1.18 - 1.49 165 / 2-4 hrs 160 - 220 515 - 565 .0015 - .003
Reinforced
PA 6/6 (Nylon
1.14 165 / 2-4 hrs 175 - 200 520 - 530 .012 - .020
6/6)
PA 6/6
1.22 - 1.49 165 / 2-4 hrs 175 - 220 540 - 570 .003 - .005
Reinforced
PBT 1.31 250 / 3-4 hrs 100 - 200 460 - 500 .017 - .023
PBT Reinforced 1.52 250 / 3-4 hrs 140 - 220 480 - 525 .003 - .006
PC Reinforced 1.25 - 1.52 250 / 6 hrs 190 - 250 600 - 650 .001 - .005
PC/ABS 1.08 - 1.22 250 / 3 hrs 150 - 190 460 - 500 .005 - .007
PET Reinforced 1.58 - 1.73 250 / 3 hrs 180 - 250 540 - 580 .002 - .006
PMMA
1.19 170 / 3 hrs 85 - 160 350 - 450 .004 - .006
(Acrylic)
POM (Acetal) 1.41 180 / 1 hr 170 - 200 370 - 390 .015 - .022
PPO 1.04 - 1.28 220 - 250 / 6 hrs 160 - 220 550 - 620 .004 - .007
PPS Reinforced 1.4 - 2.0 265 - 285 / 3-4 hrs 285 - 320 560 - 650 .002 - .007
SAN 1.06 175 / 3 hrs 105 - 175 390 - 480 .003 - .007
TPU 1.01 - 1.23 160 - 220 / 3 hrs 50 - 110 365 - 435 .005 - .01
26
The information presented in this document was assembled from literature of the
resin product producer(s). The information is believed to be accurate however
Entec Polymers (“Entec”) makes no representations as to its accuracy and assumes
no obligation or liability for the information, including without limitation its content,
any advice given, or the results obtained. ENTEC DISCLAIMS ALL WARRANTIES,
EXPRESSED OR IMPLIED, INCLUDING FITNESS FOR A PARTICULAR PURPOSE.
The customer shall use its own independent skill and expertise in the evaluation of
the resin. product to determine suitability for a particular application and accepts
the results at its sole risk.
ENTEC POLYMERS
1900 Summit Tower Blvd., Suite 900
Orlando, FL 32810
EntecPolymers.com
833.609.5703
3/14/2019