LB ABS

Processing Guide
Injection Molding

Alcom® LB ABS are inorganically filled compounds finished part. Dust in particular causes cracking and black
with high light reflectance and light blocking properties entrapments in finished parts during subsequent
based on ABS. 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® LB ABS 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® LB ABS, purge the injection
processing environment. The following processing
molding unit with pure ABS until no impurities (e.g., specks,
instructions provide guide values for handling the materials.
streaks, color haze) are visible in the melt cake.
The information on pretreatment and processing on the
technical data sheet of the product used must also always
be observed.
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
Material Handling Nozzle: Open or valve gate nozzles can be used. However,
due to their design, valve gate nozzles may cause
Store unopened bags dry and protected from light. Opened
increased shear and possible zones with increased
residual containers must be sealed airtight after opening
residence time. Both can lead to component defects due to
and checked for increased residual moisture and
streaks or black specks. Purging during material changes is
contamination before processing.
also more complex with valve gate nozzles.
Pretreatment
Residence time: Excessive residence time can lead to
ABS is a hygroscopic polymer and absorbs moisture from material damage and color deviations (“yellowing”). Make
the ambient air which can lead to material damage and sure the size of the plasticizing unit used matches the shot
surface defects during injection molding. Therefore, pre- volume of the injection mold used. The recommended
drying, preferably in a dry air dryer, is necessary until a dosing volume is 1-3 times the screw diameter (1-3D).
residual moisture of 0.02% maximum (Karl Fischer titration) Residence times of the material in the plasticizing should
is reached. Ensure the drying equipment is clean and free be 8 minutes maximum.
of dust in order to prevent contamination. The material must
Processing temperatures: The processing temperatures
be processed immediately and continuously after pre-drying
recommended on the technical data sheet must be
as it absorbs moisture from the ambient air again in the
followed. Temperatures too high can lead to significant
material supply of the injection molding machine. After
color deviations and material degradation. Temperatures
longer production stops it may be necessary to dry the
too low increase the injection pressure. This leads to
granules again if they have not been stored airtight.
excessive shear and increased stresses in the component,
Processing up to and including component failure. As a guide for initial
sampling it is recommended to start with the mean value of
Alcom® LB ABS can be processed on all standard injection
the processing temperatures specified on the technical data
molding machines with 3-zone screw. Please follow the
sheet. In case of production interruptions residual material
recommended process conditions given below, as well as
in the aggregate should be purged and barrel temperatures
the recommendations on the technical data sheet of the
should be lowered to 130°C - 150°C. Before re-starting
product used. In the following, some points are considered
production, the plasticizing unit should be purged with
which should be given special attention when processing
material until no more degraded/discolored melt is being
Alcom® LB ABS.
extruded and the melt cake is free of streaks and black
Plasticizing: A screw speed and back pressure set specks.
correctly contribute significantly to a homogeneous melt
Injection speed and holding pressure: The injection
quality. However, both parameters should not be set too
speed should ensure component filling with constant flow
high in order to avoid damage to the molding compound
front speed. The holding pressure should be between 50%
due to excessive shear energies. A screw circumferential
to 70% of the maximum injection pressure. Uneven filling
speed < 0.5 m/s and a specific back pressure between
and excessive pressures cause internal stresses in the
50-100 bar are recommended..
component, which can lead to warpage and damage to the
component. At very high injection pressures (> 1500 bar),
the gating system should be checked and adjusted if
necessary (e.g. by larger gate diameter).

Mold1 Barrel temperature1

IV III II I

50 - 80 240 - 250 235 - 245 230 - 240 220 - 230 40 - 60

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 Use of regrind
Temperature control: Uniform mold surface temperature Alcom® LB are materials for highest technical and optical
is mandatory for optimum component quality. The best requirements with narrow color tolerances. The use of
appearance is met by choosing mold temperatures in the ground production waste (e.g. sprues) is not recommended.
upper range. Special attention must be taken to inserts and Dust, impurities and also the increased thermal load due to
sliders in complex molds. We recommend checking the re-melting mean that the optical quality of the components
temperature control by measuring the mold surface cannot be ensured. Please feed production waste into the
temperature (e.g. with a contact thermometer). Insufficient recycling circuit instead.
or uneven mold temperature control can cause component
defects, such as increased warpage.
Gating: The gate should be located in an area of highest
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. In general, all common types of gates can be
used. Point and tunnel gates can be used but minimum
diameter of the gate should not be less than 1.0 mm. Gate
diameters that are too small can lead to high injection
pressures, insufficient filling behavior or surface defects.
Hot runner: The use of hot runner systems for processing
Alcom® LB ABS 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. 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: The highest surface gloss is achieved by high
mold temperatures as well as high injection speeds.
 Properties

Polymer ABS
Density (ISO 1183) 1.10 - 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 4-8h 2-4h
Drying temperature 80 °C 80 °C
Max. moisture content < 0.02 % < 0.02 %

Processing Conditions

Melt temperature 220 - 260 °C (for type-related values please see technical data sheet)
Tool temperature 60 - 80 °C
Coolant Water
Coolant throughput A turbulent flow is to be achieved
Screw circumferential speed 100 - 500 mm/s
Back pressure (specific) 50 - 100 bar
Residence time < 8 min
Injection speed Profile for constant melt flow front

Shrinkage2

ABS, inorganically filled

Shrinkage, 24 h (ISO 294-4) 0.3 - 0.6 %

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 | [email protected] confirming the suitability of the product for a particular application, its utilization and processing and must
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NO EXPRESS OR IMPLIED RECOMMENDATION OR WARRANTY IS GIVEN WITH REGARD TO THE
www.mocom.eu SUITABILITY OF THE PRODUCT FOR A PARTICULAR APPLICATION, SUCH AS, BUT NOT LIMITED TO,
SAFETY-CRITICAL COMPONENTS OR SYSTEMS.
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