Tips on How to Trouble Shoot Injection Molding Defects

 

Plastic injection molding is an effective manufacturing process for making plastic products. However, in the making of injection molded components, it involves several steps that must be executed with accuracy to achieve the anticipated level of quality. At Creatingway, we acknowledge that there is room for expensive errors to occur when it comes to the injection molding process. It leads to material wastage and loss of money, for some of these errors are unrepairable. Despite these injection molding issues, there are several ways of rectifying the defects by executing several troubleshooting tips.

Troubleshooting does help avoid common problems met during the process of injection molding. It is a science and art of curing defects. Hence, the post discusses the different troubleshooting mechanisms incorporated in our industry.

 

How to Fix Trouble Shoot Injection Molding Defects: Problems, Causes, and Remedies

 

In the injection molding process, certain defects are unavoidable, which might put the entire production line in trouble. So, the following are a few amongst the several defects with their causes and the troubleshooting tips we employ at Creatingway.

 

Blisters

The following are some of the reasons leading to blister formation on injection molded parts.

• Why does it occur?

1. Faster heat-up rate oven temperature
2. Contamination by foreign objects
3. Tool deflection
4. Mold temperature out of spec
5. Improper vacuum

• How we fix the issue

1. We use the following troubleshooting techniques to avoid blisters on forming on any of your parts.
2. Check for contamination thoroughly in the material used for the process
3. Increase the mold temperature adequately.
4. Set a suitable vacuum.
5. Check for mold deflection.
6. Setting appropriate cure times.

 

Flow marks of injection molding parts

These are streaks, patterns, or lines that form on the surface of the plastic parts. It leaves an undesirable finish on the final product.

• Why does it occur?

1. The defect is due to the following:
2. Variations in the cooling speed
3. Too low injection speed
4. The molten plastic flowing at different speeds
5. Molten plastic flowing through sections with a varying wall thickness

• How we fix the issue

1. By implementing the following troubleshooting tips, flow lines, which appear as a wavy pattern we avoid by:
2. Increasing injection pressure and speed
3. Round the corners of the mold

 

Chip

The cause of the defect is the loss of small pieces from the plastic parts.

• Why does it occur?

1. The site commonly affected is near the edges of the plastic part. The following causes are the reasons for this type of defect:
2. Improper secondary fixtures
3. Rough handling and bypass

• How we fix the issue

  

What can we do in case we come across a chip on the part? Our team of engineers at Creatingway have come across several innovative ways, including:

1. Monitor part quality at every stage
2. Decrease molding pressure
3. Polish the tool surface at regular intervals
4. Ensure proper handling while shipping
5. Increasing compound viscosity
6. Slowing ejector speed

 

Deformation of injection molding parts

It is when plastic parts fail to maintain the shape of the designed mold after the injection molding process completes.

• Why does it occur?

1. The part deformation is a result of the following;
2. Too short after time pressure
3. Defects in the heating process
4. Too low injection pressure

• How we fix the issue

1. To avoid the production of deformed parts, our injection molders implement the following:
2. Increased injection pressure
3. Increased mold surface temperature
4. Increasing cooling time
5. Decreasing gate diameter

 

Burn Marks

These as seen on the surface or edges of plastic components as black or rust-colored discoloration. Generally caused by problems similar to blistering.

• Why does it occur?

1. The cause of burn marks are as follows:
2. Overheating resins in the mold cavity
3. Excessive injection speeds
4. Trapped air

• How we fix the issue

To a great extent, we avoid the development of burn marks to your plastic components by the implementation of the following troubleshooting tips.

1. Decreasing the molding temperature
2. Minimizing the injection speed
3. Enlarging gas gates and vents, so that the trapped air leaves the mold

 

Dull surface or gloss surface

• Why does it occur?

1. Several reasons exist for the formation of a dull surface on the plastic part made. They are as follows:
2. High shrinkage of the material
3. Loss of pressure
4. Unacceptable surface tool

• How we fix the issue

To nullify the problem of dull surface, the following are some of the tips our dedicated team of injection molders:

1. Choosing different shrink additives or levels
2. Increased mold temperature
3. Increased cure cycle
4. Increasing molding pressure
5. Polishing the surface of the tool

 

The troubleshooting techniques mentioned above do highly assist us in avoiding most of the injection molding defects. By troubleshooting injection molding problems effectively, So we not only save money and time for our esteemed customers but also minimize material wastage, which is eco-friendly. Hence, we are well versed in such troubleshooting techniques and wisely use them to produce high-quality parts without flaws It, in turn, helps produce parts without defects as specified by the customers.

 

Creatingway is concentrated on CNC machining manufacturing, prototype machining, low-volume manufacturing, metal fabrication and parts finishing services, provide you the best support and services. ask us one inquire now.

 

Any questions or RFQ for metal& plastic technology and custom machining, welcome to contact us below

Call +86-0(755)-89492523 or send an inquiry to us

Welcome visit us, any metal and plastic design and machining questions, we are here to support you. Our services email address:

: sales@creatingway.com