TOP INJECTION MOLDING PROBLEMS AND THEIR COUNTERMEASURES

1. FLOW LINES

Flow lines are streaks, patterns, or lines - commonly off-toned in color - that show up on the prototype part
as a consequence of the physical path and cooling profile of the molten plastic as it flows into the injection
mold tooling cavity. Injection molded plastic begins its journey through the part tooling via an entry section
called a gate. It then flows through the tool cavity and cools (eventually hardening into a solid).

CAUSE:

Flow line defects are caused by the varying speed at which the molten plastic flows as it changes
direction through the contours and bends inside the mold tool. They also occur when the plastic flows
through sections with varying wall thickness, or when the injection speed is too low causing the plastic to
solidify at different speeds.

COUNTERMEASURES:

Increase injection speeds and pressure to the optimal level, which will ensure the cavities are filled
properly (while not allowing the molten plastic time to start cooling in the wrong spot). The temperature
of the molten plastic or the mold itself can also be elevated to ensure the plastic does not cool down
sufficiently to cause the defect.
Round corners and locations where the wall thickness changes to avoid sudden changes in direction
and flow rate.
Locate the gate at a spot in the tool cavity with thin walls.

2. SINK MARKS
Sink marks or shrink marks are hollows or indentations that occur on the outer surfaces of molded
components.

CAUSE:

Sink marks are often caused when the cooling time or the cooling mechanism is insufficient for the
plastic to fully cool and cure while in the mold. They can also be caused by inadequate pressure in the
cavity, or by an excessive temperature at the gate. All else being equal, thick sections of the injection
molded part take longer to cool than thin ones and so are more likely to be where sink marks are located.

COUNTERMEASURES:

Mold temperatures should be lowered, holding pressure increased, and holding time prolonged to allow
for more adequate cooling and curing.
Reducing the thickness of the thickest wall sections will also ensure faster cooling and help reduce the
likelihood of sink marks.
3. VACUUM VOIDS

Vacuum voids are pockets of air trapped within or close to the surface of an injection molded prototype.

CAUSE:

Vacuum voids are often caused by uneven solidification between the surface and the inner sections of
the prototype. This can be aggravated when the holding pressure is insufficient to condense the molten plastic in
the mold (and thereby force out air that would otherwise get trapped). Voids can also develop from a part that is
cast from a mold with two halves that are not correctly aligned.

COUNTERMEASURES:

Locate the gate at the thickest part of the molding.

Switch to a less viscous plastic. This will ensure that less gas is trapped as air is able to escape more
rapidly.
Increase holding pressure as well as holding time.
Ensure that mold parts are perfectly aligned.

4. SURFACE DELAMINATION

The term "delamination" is used to refer to a condition where a thin micaceous layer develops on the
molded product and then becomes separated.

CAUSES:

Inclusion of a plastic which has poor compatibility with ABS (i.e., PP or PS, etc.)
When the die and plastic temperatures are extremely low, the difference in temperatures between
he outer walls and the fluid layer results in the development of a thin hard coating which then
peels.

COUNTERMEASURES:

Carry out cleaning in

- Inside the cylinder
- Inside the hopper
- Inside the air feed lines
- Inside the dryer
Standardize the resin temperatures.
- Raise the temperature of the resin
- Raise the temperature of the die
5. WELD LINES

The material splits off and flows in two or more directions. When the divergent flow fronts converge again,
hair-like lines appear where they meet. This results in reduced strength, as well as burn-mark and bubble
defects.

CAUSES:

Material splits and flows in separate directions, then converges again.

Polymer temperature is too low. Polymer is not fully melted.
Difficulties in venting gas and air.

COUNTERMEASURES:

Raise the resin temperature

Increase the injection pressure.
Increase the injection speed.
Provide a cold slug well where weld lines occur.
Provide a gas vent.
Change the gate locations. Or increase the number of gates.
Stop using mold parting agents.
Change the gate locations so that the weldlines occur in locations less susceptible to external forces if
weld strength is an issue.
Choose a low-viscosity high flow type material.

6. SHORT SHOTS

A molded product that is incomplete because the mold cavity was not filled completely.

CAUSES:
Insufficient injection-molding machine performance (shot capacity, plasticizing capacity, etc.)
Poor material flowability
Gate cross-section surface area is too small. Molded product thickness is too thin.
Poor gas venting.

COUNTERMEASURES:
Increase the amount of material feed. If material feed is still insufficient at maximum material feed
capacity, change to a larger capacity machine.
Install a screw with a back-flow check valve.
Increase injection pressure
Raise the cylinder temperature setting. Raise the nozzle temperature, too.
Make sure there are no severed lines to the heater.
Make sure the nozzle is not clogged. If the nozzle clogs frequently, raise the mold temperature or
shorten the cycle time.
Increase injection speed
Raise the mold temperature.
Increase the mold gas release.
Increase gate cross section surface area.
 Increase the molded product thickness.
Add ribs to the molded product design to improve flowability.
Choose a low-viscosity high flow material type.
Apply surface lubricant. (Add 0.05-0.1% by weight.)

7. WARPING
The molded product warps immediately following or at some time following molding where the mold cavity
should be straight.

CAUSES:

Residual stress from the molding process is released, causing deformation.

COUNTERMEASURES:
Decrease the injection pressure.
Lower the cylinder temperature setting.
Lengthen the cooling time.
Make the thickness of the molded product uniform.
Eliminate undercuts.
Operate the knock out pins in a uniform fashion.
Provide multiple knock out pins.
Change the gate locations.
Lower the mold temperature.

8. BURN MARKS
Discoloration or dark reddish brown streaks in the molded product.

CAUSE:

Heat decomposition of the material.

COUNTERMEASURES:

Lower the cylinder temperature setting.

Shorten the intermediate time (dry cycle time).
The ram is recessed for too long of a time duration.
Slow down injection speed.
Provide a larger gas vent.
Increase the gate sizes.

9. JETTING

The term "jetting" is used to describe the phenomenon where plastic passing through a gate does not
adhere and where flow patterns are formed on the surface of the molded product.
 Plastic at a relatively low temperature is injected from the nozzle during the initial stage of molding, upon
coming into contact with the mold wall, this plastic becomes highly viscous and swirling takes place;
furthermore, as hotter plastic is continually injected into the die, the original material is pushed deeper into
the die and leaves flow marks.

CAUSES:

When the plastic temperature is low, the viscosity of the molten material is high, and this become
higher in the case of plastic which has been injected into the die; consequently, the resistance to
flow is large and jetting occurs.
When the die temperature is low, the material injected into it will be rapidly cooled, and the
corresponding increase in viscosity leads to the occurrence of this problem.
When gates are small, the speed of plastic injected into the cavity will be relatively fast, and this
leads to the occurrence of jetting in many cases. (Gate sectional area x flow speed = Fixed
injection amount)

COUNTERMEASURES:

Increase the temperature of the plastic to lower its viscosity.

In the case of amorphous plastics, the ideal temperature of the die is between 20deg.C and 30deg.C
lower than the plastic's thermal deformation temperature.
It is also beneficial to reduce the injection speed.
Dies
It is advantageous to increase the sectional area of the gates so that the speed of the material passing
through the gates becomes slower.

10. FLASH

Flash is a molding defect that occurs when some molten plastic escapes from the mold cavity. Typical
routes for escape are through the parting line or ejector pin locations. This extrusion cools and remains
attached to the finished product.

CAUSE:
Flash can occur when the mold is not clamped together with enough force (a force strong enough
to withstand the opposing forces generated by the molten plastic flowing through the mold), which allows the
plastic to seep through. The use of molds that have exceeded their lifespan will be worn out and contribute
to the possibility of flash. Additionally, excessive injection pressure may force the plastic out through the
route of least resistance.

COUNTERMEASURES:

Increase the clamp pressure to ensure that the mold parts remain shut during shots.
Ensure that the mold is properly maintained and cleaned (or replaced when it has reached the end
of its useful lifespan).
Adopt optimal molding conditions like injection speed, injection pressure, mold temperature, and
proper gas venting.
TECHNOLOGICAL INTITUTE OF THE PHILIPPINES MANILA
363 P. CASAL ST., QUIAPO, MANILA

COLLEGE OF ENGINEERING AND ARCHITECTURE

CHEMICAL ENGINEERING DEPARTMENT

CHE 512

PLASTICS TECHNOLOGY

ASSIGNMENT

SUBMITTED BY:

ALDA, GLADYS M.

SUBMITTED TO:

ENGR. LINA D. DELA CRUZ

MARCH 16, 2017