Common injection molding defects and solutions

Posted by linneasimone on February 18th, 2021

As we know that, injection molding is the most versatile manufacturing technique used to produce components made of glasses, polymer, metals, and other materials. First of all, the most critical step in the process is to design and construct moulds, tooling shaping parts, and other equipment required for the success of an injection molding process. The pellet of material chosen for making a particular component is melted and then injected into the mold with high pressure to form the desired product.

Injection molding manufacturing needs knowledgeable designers, engineers, and workers so that chances of costly mistakes can be reduced both in regard to time and budget.

Here are some common mistakes that lead to defect in the molding products and how it can be avoided simply adjusting some conditions-

Flow lines-Flow lines are often the result of variation in cooling speed, component material cooled at different rate in some areas leaving behind the flow lines. They are often appears as a wavy pattern with color variation. This impacts the looks of desired molded product that may not be accepted by customers. Flow lines can be avoided by adjusting the injection pressure, speed and temperature to the optimal level to ensure cavities can be filled properly.

Vacuum voids-Voids are air trapped bubbles formed due to uneven solidification between surface and inner sections of prototype. Switching to less viscous plastic, increasing mold pressure, adjusting gate at the thickest part, are some ways to avoid formation of vacuum void.

Burn marks-Burn marks are generally caused due to degradation of injection material, fast speed to processing, or by overheating. It looks patchy, discolored at the surface of molded components. Burn marks can be avoided by reducing the melting temperature and injection speed.

Flash-This kind of molding defect occur mostly when mold are not clamped together which allows the plastic to flow out. This can be seen in various type of bottle cap mould such as edible oil cap mold where molten plastic escape from the mold cavity and remain attached with finished products. This can be avoided by increasing clamp pressure and maintaining the molds before production.    

Likewise, there are many types of molding defects that can be prevented using appropriated mold design and identifying the required condition suitable for producing a prototype. These problems can be avoided by working with a reliable injection molding company. For best services, you can visit http://www.nicety-mould.com/

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