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A
Air Shot
An air shot is the injection of polymer melt into the air, instead of into the mold. The main purpose of an air
shot is to act as a "test run," to make sure that the machine is operating properly.
The cylinder is pulled back from contact with the sprue bushing and the injection piston is moved forward,
forcing melted plastic from the nozzle. If the melt is caught in a metal cup, a pyrometer probe can be used to
check the temperature of the melt as it exits from the nozzle. This is one of the more accurate measurements of
the melt temperature.
Air Trap
An air trap is an air or gas bubble that has been trapped by converging flow fronts or trapped against the
cavity wall. This causes a surface blemish on the part. Air traps can be prevented by changing the gate
location or part thickness. Good practice is to place vents in the mold at the air trap location.
Amorphous Polymers
Amorphous polymers are a family of polymers that are characterized by entangled polymer chains that are
loosely bound. The term amorphous indicates that there is no preferred orientation of the molecules, relative
to each other, without external force. During injection molding amorphous polymers have orientation.
Amorphous polymers are in a super-cooled liquid state and generally shrink less than semi-crystalline
polymers. Amorphous polymers exhibit no x-ray diffraction pattern, because they are not crystalline in nature.
See also Crystalline Polymers, Semi-crystalline Polymers
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Anisotropic Shrinkage
Anisotropic shrinkage is shrinkage that has different magnitudes in different directions. Anisotropic
shrinkage occurs in filled materials due to the restriction of shrinkage along the fiber length, which tends to be
in the flow direction. It also occurs in un-filled materials when the molecules have insufficient time to relax
from the viscous elongation due to shear during flow.
Aspect Ratio
Aspect ratio normally refers to the relation between width and height of a mesh element. These are important
because they affect analysis accuracy. Aspect ratios are especially important in sensitive areas such as gates, or
gas channels in a gas-injection simulation.
The term aspect ratio is also used when describing fibers. In this context, aspect ratio is the ratio of the length of the fiber to the
diameter.
Automation
Automation is the science of machinery or mechanisms which are so self-controlled and automatic that
manual input is not required during operation. Automation is the technique of making a process automatic.
B
Back Pressure
Back pressure is pressure that opposes the screw as it returns.
The purpose of increasing back pressure is to make it harder for the screw to return. This increases the shear
heating and the mixing of the material, which results in improved polymer melt quality.

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Baffle
A baffle is a cooling system component which is constructed by inserting a metal plate in the cooling lines
which forces the coolant to flow up one side of the plate and down the other. It is used to regulate and direct
the passage of coolant fluid so that the coolant can travel into difficult areas for more efficient cooling. By
interrupting the flow in the cooling lines the baffles create turbulence around bends and improve the heat
transfer capability of the coolant.
See also Bubbler
Balanced Flow
Flow is balanced when the extremities of the mold fill at the same time and pressure, as shown in the
illustration below. Balanced flow leads to uniform orientation, uniform shrinkage and less internal stress and
warpage of the part. It also leads to cost savings with reduced material usage.
Gate location, runner system design and part thickness affect flow balance.

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Barrel
The barrel is the cylinder of the plasticating chamber of an extruder or injection molding machine. The
cylinder forms the chamber within which the plastic resin is converted from a solid form to a viscous melt.
Barrel Capacity
The barrel capacity is the maximum weight of material that a machine can produce from one forward motion
of the ram or screw.
See Shot size.
Barrel Effect
The barrel effect is the effect of material compressibility while the material is in the barrel of the injection
molding machine. This compressibility can be significant. A simulation that calculates and uses the barrel
effect will produce more accurate results.
See also Compressibility Model.
Batch
A batch is the quantity of polymer that is made in one operation. A batch is also referred to as a lot.
In CAE products, batch refers to the execution of consecutive analyses in one operation.
Bending Moment
A bending moment is the force or load applied to an entity that produces bending of that entity around an axis.
Boss
A boss is a raised projection in a molded part that usually has a hole in it to provide additional material for
supporting a mechanical fastener, such as a screw.

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Boundary Representation Solid

A boundary representation solid is a model format produced from a surface modeling CAD system. The solid
is defined as a list of surfaces that enclose a volume.
B-Splines
A b-spline is a mathematical function that defines free-form curves and surfaces. IGES files that use b-splines
instead of parametric splines are generally smaller in size.
Bubble
A bubble is a spherical, internal void caused by air or other gas trapped within a molded plastic product. A
bubble differs from a blister in that the bubble is contained within the part, whereas a blister is on or near the
surface of the part and generally causes deformation of the surface. A bubble also differs from a void, which is
developed as a vacuum during cooling.
Bubbler
A bubbler is cooling system component. It is a central circular channel that can be introduced into the mold
and is used to regulate and direct the passage of coolant fluid, so that the coolant can travel into difficult areas
for more efficient cooling. The coolant flows through the central channel and then out and around the outside
of the channel to the outlet point.
Both baffles and bubblers have the effect of increasing flow turbulence and thus increasing heat transfer due
to the inclusion of additional bends in the coolant flow system. Their geometrical shape also enables the
application of cooling to restricted areas.

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See also Baffle.
Buckling
Buckling is the conversion of in-plane membrane energy to bending energy and usually involves large
deformations of the part. It is the principle mode of failure of a planar thin structure under excessive in-plane
loading.
Burn Mark
A burn mark is a defect that appears as a brown or black mark on the part surface. A burn mark can be
caused by an un-vented air trap. This occurs when the trapped air is heated very quickly as it is compressed,
burning the surrounding plastic. Velocity profiling is often used to prevent this problem, by giving air more
time to escape from the mold.
C
CAD
Computer-Aided Design (CAD) is the process of using computer software programs to design parts, tools,
molds, and assemblies.
CAM
Computer Aided Manufacturing (CAM), is the use of computers and computer technology to control, manage,
operate, and monitor manufacturing processes.

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Cavity
The cavity is the region within the mold that fills with plastic to form the part.
Center Gate
A center gate is a gate which is located in the center of the part. It can be a sprue (direct) gate or pinpoint gate.
See also: gate.
Centroid
A point whose coordinates are the average of the coordinates of a given set of points and which for a given
planar or three-dimensional figure (as a triangle or sphere) corresponds to the center of mass.
Charge Stroke
See Shot Size.

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Check Ring
A check ring is the sliding ring of the non-return valve on the front of the screw. The check ring allows melted
plastic to flow forward to the front of the screw during plastication, and prevents flow back into the screw
during injection. The check ring is a high wear item that can leak during injection, effectively reducing the
pressure that is applied to the melted plastic.
See Non-Return Valve.
Chiller
A chiller is a self-contained system comprised of a refrigeration unit and a coolant circulation mechanism
consisting of a reservoir and a pump. Chillers maintain optimal heat balance by constantly recirculating
chilled cooling fluids to injection molds.
Clamp Capacity
Clamp capacity is a measure of the largest projected area of cavities and runners that an injection molding
machine can safely hold closed at full molding pressure.
Clamp Force
Clamp force is the force required to hold the mold closed while an opposing pressure is exerted by the plastic
injected into the cavity.
Closed Loop Controller

A closed loop controller is one that responds to feedback from transducers that measure the value being
controlled. For example, cavity pressure can be controlled by placing a transducer in the cavity and using that
measurement to adjust the pressure on the plastic in the injection molding cylinder.

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Closed Volume
A closed volume is a group of surfaces connected together to form a polyhedron. A closed volume has no free
edges. The structure is used to form inserts and the mold boundary.
See also Free Edges
Compensating Phase
The period during the injection molding process when plastic is injected to compensate for the plastic in the
cavity shrinking as it cools.
Composite Curve
A group of curves that are joined end to end to form a single curve. Composite curves are discontinuous if the
start point of one curve is not the same as the end point of the previous curve.
IGES composite curves are:
Composite Curve (IGES Type 102)
Boundary Entity (IGES Type 141)
Curve on a Parametric Surface (IGES Type 142)
Compressibility Model
Heated plastics are compressible. The compressibility of a material affects the volume of plastic required to
produce a finished part.
A compressibility model describes the relationships between pressure, temperature, and the volume (PVT) of
the plastic material.
The compressibility model that the software uses is the 2-Domain Modified Tait PVT model with 13
coefficients.
Conic Arc
A mathematical form for representing ellipses, hyperbola and parabolas.

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Control Limits
Control limits are statistically determined values between which a control variable is allowed to range without
adjusting the process. Control limits provide an indication of the variation in the injection molding process.
Cooling Channel
A cooling channel is a passageway in a mold for circulating water or another cooling medium, in order to
control the temperature of the metal surfaces in contact with the plastic being molded.
Cooling channels are typically connected to form a circuit. Cooling channel configurations can be serial or
parallel.
Cooling Time
Gross cooling time is the time after the velocity phase until the part is sufficiently cooled to be ejected from the
mold. Therefore, gross cooling time is the sum of the pressure phase (packing and holding) and the net cooling
time.
The net cooling time is the time after the pressure phase and before the part is ejected from the mold.
Core
The core is the part of the mold which shapes the inside of a molded part.
Cracking

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Cracking is the formation of a narrow separation in a plastic component, usually by the rupture of chemical
bonds due to internal and external stress.
Crystalline Polymers
Crystalline polymers are a family of polymers that are characterized by an ordered arrangement of the
molecules which fit closely together. Typically, crystalline polymers are more dense than amorphous
polymers. A polymer in a crystalline state is a solid, due to its solid crystals, which have definite geometric
form.
Crystalline polymers display an X-ray diffraction pattern. The degree of crystallinity determines the intensity
of the pattern. The pattern can be used to identify the polymer.
See also Amorphous Polymers
Crystallinity
Crystallinity is a solid, molecular state of some polymers which denotes compactness of the molecular chains.
This characteristic is attributable to the existence of solid crystals with definite geometric form.
Crystallization
During cooling some polymers form an ordered molecular structure which are called crystals. The rate of

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crystallization is a function of both temperature and time. The level of crystallinity achieved is determined by
cooling rates. Rapid cooling rates are associated with lower levels of crystalline content and vice versa. The
level of volumetric contraction (shrinkage) is also affected by degrees of crystallinity, with higher crystallinity
resulting in greater shrinkage.
In injected molded parts, thick regions tend to cool slowly relative to thinner sections, and so have higher
crystalline content and hence higher volumetric contraction.
Cure
Cure is a stage reached by a thermosetting material that is sufficiently cross-linked to form a solid; the cross
linking is the result of a chemical reaction.
Sometimes this term is used to describe the solidification of thermoplastics; this is a physical process of
removing heat from the thermoplastic.
Curve
A line in three-dimensional space. A curve can be straight or contain bends.
This includes:
Line - a straight curve defined by two end points.

Arc - a section of a circular curve defined by one of two methods:
A center point and arc and angle
Three points on a plane.
Spline - a cubic spline interpolation. on a supplied set of points.
Cushion
The cushion is the distance between the forward screw position and the zero screw position, and contains
polymer left in the barrel after the cavity is filled. Most of the melt in the cushion is then used for
compensation flow during the packing stage.
Cycle Time

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Cycle time is the time from the ejection of one part to the ejection of the next part. Cycle time is the sum of:
Filling time.
Packing time.
Cooling time.
Mold open time.
D
Decompression
Decompression is the movement of the screw away from the nozzle (without rotation) and is used to prevent
drooling. Decompression may be used for low viscosity materials (for example, PA-66), where the nozzle does
not have a valve gate to prevent drooling.
Delamination
Delamination is a localized separation of the surface of the part. The most common cause of delamination is
excessive injection velocity.
Density
The density of a plastic part is measured by dividing its mass by its volume. A denser part has more plastic
molecules and more weight per volume. A part can have some regions with higher density than others.
Design of Experiments (DOE)
Design of Experiments (DOE) is an engineering method which determines which variables in your design have
the most, and least, effect on final part quality. DOE also analyzes how part quality changes as input variables
change. Engineers use DOE early in the design stage to improve designs.

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Disc Gate
A disc gate is a mold gate used in an identification of a molded part, generally having the same cross-section as
the mold runner.
Dominant Flow Path

The dominant flow path is the flow path of least resistance (the smallest pressure drop) from the polymer
injection location to the last place to fill. In the graphic below, the cone indicates the injection location and the
X indicates the last place to fill.
The dominant flow path is normally, but not always, the longest flow path.
Draft Angle
The angle included in the part design to allow the part to be easily ejected from the mold.
Drooling
Drooling is leakage of polymer from the nozzle, sprue, or gate. This creates thin strands of plastic that can get

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caught in the mold.
Dwell
Dwell is a pause in the mold closing cycle of a compression molding operation to permit gas to escape from the
molding material.
Dynamic Flow
Dynamic flow is the flow before the cavity is actually full, when a flow front still exists towards the end of the
cavity. This results in an area within the mold without plastic.
E
Ejection
Ejection is the removal of molded parts from the mold by mechanical means, or with compressed air.
Ejection Temperature
Ejection temperature is the averaged temperature of the part at the time it is ejected from the mold.
A molded part should be ejected only when it has enough strength to undergo the force of ejection, without
excessive warpage or marks from ejector pins. The ejection temperature depends on the resin, part thickness,
application, and shop floor practice. A part ejected at a higher temperature can reduce the cooling time, but
may increase warpage.
Ejection Time
Ejection time is the moment when the mold opens to eject the part. For example, an ejection time of 42
seconds indicates that 42 seconds elapsed from the moment the mold closes for injection until the moment the
mold opens for ejection.
Ejector Pins

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Ejector pins are located on the mold and push the part out of the mold when the clamp is open.
Element
A single sub-domain of a finite element mesh. Elements typically used in molding simulation are:
Two-node linear elements, used to represent runners, cooling channels and connectors.
Three-node triangular elements, used to represent surfaces.
Four-node tetrahedral elements, used to represent solids.
The properties of the element are assumed to be homogeneous.
End of Fill
The end of fill occurs when the polymer has reached the extremities of the mold cavity and the mold is
volumetrically filled.
Extensional Viscosity
When a polymer flows through a large cross-section to a smaller one, it will extend longitudinally. This will
result in a pressure drop that will be dependent upon the extensional viscosity of the particular material.
In practical injection molding situations, this pressure drop due to extensional effects is often seen when a
material flows from a large runner into a very small gate. The change in cross-section is sudden and severe,
resulting in a large pressure drop across the gate.
F
Family abbreviation
This is the shortened version of a material family name. For example, PC is the family abbreviation for the
family name Polycarbonate.

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Some families contain subsets, and there is an abbreviation for each subset. For example, TPE, TPO, TPU,
and TPR are family abbreviations within the Thermoplastic Elastomer family.
Family name
This is the name of a family of materials, for example, Polycarbonate. Each material is a member of a family of
materials.
The shortened version of a family name is the family abbreviation. For example, PC is the family abbreviation
for Polycarbonate.
Some families contain subsets, and there is an abbreviation for each subset. For example, TPE, TPO, TPU,
and TPR are family abbreviations within the Thermoplastic Elastomer family.
Fan Gate
The fan gate is the opening between the mold runner and the mold cavity which has the shape of a fan. This
shape helps reduce stress concentrations in the gate area by spreading the opening over a wider area.
Feasible Molding Window

A feasible molding window is represented by a set of boundaries that define a window-like shape. For the
process setting ranges inside the window boundaries, the molding process is feasible; outside the window
boundaries, the molding process is not feasible.
Fiber Orientation
Fiber orientation is the direction of the fibers' major axis, relative to the flow direction.
In the illustration below:
1. Random fibers are found at the entrance.
2. Flow-aligned fibers are found in the converging flow area.

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3. Transversely aligned fibers are found in the diverging flow area.
4. Fibers parallel to the flow direction are found in the restricted flow area.
Filler
Fillers are materials that can be added to a polymer for injection molding. Adding a filler to a polymer can
increase the strength of the polymer and ensure that good quality parts are produced.
Fillet
A fillet is a rounded interior corner of a part that makes the part stronger.
Filling Phase
The period during the injection molding process when plastic is injected to fill the cavity.
Filling Time
The time required for the injection molding machine to fill the part.
Finger Gate
The finger gate is used when presentation is important and you want to avoid disfiguring the top face of a
part. It tunnels down from the parting plane and comes up on the underside of the part (see below).

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This gate is also known by the following names: banana, winkle, cow-horn, bent-tunnel gate and cashew.
Flash
A flash occurs when the polymer is not totally contained within the mold cavity. The most common causes of
flash are an excessive velocity stroke, injection velocity, packing pressure, and a low clamp force.
Remove flash by either reducing the injection velocity or increasing the clamp force.
Flow Leaders and Deflectors

Flow leaders and deflectors are surfaces with thicknesses designed to direct the flow front, either by attracting
it (leaders) or by deflecting it (deflectors). Flow leaders are thicker parts of the cavity (indicated by the yellow
arrow in the figure below) which attract the flow. Deflectors are thinner parts of the cavity (indicated by the
red arrow) which constrict the flow and slow it down.
Flow Path
A flow path is a route along which molten plastic moves within the cavity.

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Free Edge
A free edge is an element edge that is not shared by other elements. A free edge has an element attached to
only one side. An edge is a line segment that connects two mesh nodes.
In Fusion and 3D meshes, free edges should be corrected because they indicate elements which have not been
correctly attached.
See also Manifold edge and Non-manifold edge
Free-form Curves and Surfaces

These curves and the surfaces that are formed from them follow no mathematical relationship.
Friction
Friction is a force which acts against motion. When a part is being ejected, if there is high friction between the
part and the mold walls, then the part may be impossible to eject, or it may be damaged during ejection.
G
Gate

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The gate is the channel through which the molten polymer flows from the runner into the cavity. Generally,
the gate is small and solidifies first.
Gate Freeze
Gate freeze is the moment during the packing phase when polymer at the gate has frozen solid and no more
polymer can be packed into the mold cavity.
Gloss Mark
Gloss is the shiny appearance of a molded part's surface. Differences in the gloss finish of a part are caused by
different projection behaviors of the plastic at the mold wall, due to different cooling conditions and shrinkage
differences. You can remove dull surface patches by drying the material, decreasing the injection speed or
increasing back pressure.
H
Hesitation
In a part with multiple flow paths, the flow can slow down or hesitate in thin regions. This allows the melt to
cool in thin regions and in some cases freeze before filling is complete, causing short shots. Flow hesitation is
most likely to occur in parts containing thin diaphragms, ribs and hinges.
High Cushion
High cushion occurs when the cushion is too large and the material is kept in the barrel for too long. This can
result in defects such as short shot.

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Hopper
The hopper is the molding machine container that holds the polymer and feeds it to the injection molding
screw.
Hydraulic Pressure
Hydraulic pressure is the pressure applied to the injection ram during the injection phase. Setting hydraulic
pressure is one way of specifying the velocity phase for the molding cycle. The hydraulic line pressure is the
pressure in the main supply line from the pump; typically measured by means of a gauge in the hydraulic line.
There is a direct relationship between the injection pressure and the hydraulic line pressure called the
machine intensification ratio.
I
Injection Location
The injection location is the place where the molten plastic is forced into the mold cavity.
Different injection locations can have different effects on the appearance and quality of the part.
Injection Pressure
The injection pressure is the pressure that is applied to the ram during the injection phase, causing the
material to flow, and can be measured approximately by a transducer located in the nozzle. There is a direct
relationship between the injection pressure and the hydraulic line pressure called the machine intensification
ratio.

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Injection Time
The injection time is the time it takes to fill the cavity.
Injection Velocity
The injection velocity is the speed at which polymer is injected into the mold cavity during the injection phase.
If the injection velocity is too high, it can cause part defects such as flash and delamination.
Injection Volume
The injection volume is the amount of polymer injected into the mold cavity during the velocity phase.
Insert
An insert is a component that is placed into the mold before the injection phase and is anchored into the
plastic part by being partially or wholly surrounded by the injected plastic. Typical inserts may have threads,
may be electrically conductive, or may be a different plastic material.
Intersecting Mesh Elements

Intersecting mesh elements are mesh elements that lie on different planes and intersect each other.
Illustration 1) shows the elements joined at their edges. This is common for ribs. These mesh elements are
acceptable.
Illustration 2) shows intersecting elements which cut through each other. This is not acceptable. Remove
intersecting elements before you run an analysis.

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Isotropic Material
An isotropic material has material properties that are the same in all directions. There are no directional
effects of orientation or crystallinity.
J
Jetting
Jetting is the snake-like stream of polymer melt that occurs when the melt is pushed at a high velocity through
restrictive areas (such as the nozzle, runner, or gate), into open, thicker areas, without forming contact with
the mold wall.
In the jet, contact points form between the folds of melt, creating small welds. Jetting can lead to part
weakness, surface blemishes, and internal defects.
K
L
Loop
A group of connected curves that form a complete boundary of a surface.
M
Manifold Edge
A manifold edge is a mesh edge that has two entities attached to it. An edge is a line segment that connects two
mesh nodes.

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In a Fusion mesh, manifold edges are the only type of edges which are correct. All other types should be
corrected.
A = Free Edges
B = Manifold Edge
C = Non-Manifold Edge
See also Free Edge and Non-Manifold Edge.
Masterbatch
A masterbatch is a concentration of filler or additives in a polymer. The mixture is added in small amounts to
create the desired mix.
Meld Line
A meld line is a weakness or visible flaw created when two or more flows meet and converge while filling a
part. A meld line is typically formed by parallel flows, whereas weld lines are formed by flows meeting at
higher angles, often head-on. Meld lines tend to be less weak than weld lines. The quality of the meld line is
dependent on the material type, the type and amount of fillers, and the pressure and temperature at the meld
line.
Melt Density
Melt density is a single point density value of a polymer at its average processing temperature, and at zero, or
near zero, pressure.
Melt Temperature
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The melt temperature is the temperature of the polymer as it starts to flow into die.
Mesh
Injection molding simulation involves solving the governing equations of mass, momentum, and energy
numerically over the physical domain. The numerical implementation involves discretizing the physical
domain into a number of sub-domains, or elements. The dependent variables (velocity, pressure, temperature)
are approximated within each element. In short, the continuous domain is broken into many connected sub-
domains and the dependent variables are approximated over the whole domain.
Mesh density is the number of elements per unit area. In general, the more elements in the mesh, the more
accurate the analysis results, at the expense of longer calculation times.
Mesh - Midplane
Consists of three-node triangular elements located at the half-thickness of the part surface.
Creating a Midplane mesh from a solid model involves extracting the mesh and the element thickness from the
model. The two-dimensional Midplane mesh represent the solid model, using the thickness information,
during a molding analysis.
Mesh - Surface (Fusion)

A mesh consisting of surface (double-skin) shell elements. Surface mesh elements can be 3 or 6 noded planar,
straight-edged triangles.
A surface mesh analysis simulates the flow of the melt on both the top and bottom parts of the mold cavity.
Consistency between the results on the opposite sides is maintained by using connectors - elements with zero
flow and heat resistance. The connectors are inserted automatically at locations determined by the geometric
features of the model.

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A surface mesh can include Midplane areas.
Mesh - Volume (3D)

A volume mesh consists of solid, tetrahedral shaped mesh elements. Each tetrahedral element consists of four
Midplane mesh elements joined to create a solid tetrahedron. Tetrahedral elements have four nodes, four
faces and six edges and allow an accurate 3D flow simulation to be calculated.
Mesh Intersection
See Intersecting Mesh Elements
See also Overlapping Mesh Elements
Model
A mathematical description of the relationships of the physical entity being described. For example, a
geometry model is a mathematical description of the physical shape and characteristics of the part. Other

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models include viscosity model, process model, etc.
Mold
The mold is the steel tool used on the injection molding machine. The mold acts as a heat exchanger in which
the molten thermoplastic solidifies to the shape defined by the cavity.
Mold Open Time

Mold open time is the duration of time during which the mold is open. Mold open time begins when the mold
opens for part ejection and ends when the mold closes so that the screw can begin moving forward for
injection.
See also Cycle Time.
Mold Temperature
The mold temperature is the temperature of the steel mold.
Molding Window
A process window or molding window, defines the limits of molding conditions under which an acceptable
part can be produced. If molding conditions fall within this region, then a good part can be made.
On the graph below, a good quality part (labeled with a checkmark), is encircled by the boundaries of the
process window. A poor quality part (marked "X"), is outside the process window.

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Node
In the context of model geometry
A node is a special coordinate position in space. Nodes are saved with a model.
When modeling, you typically create nodes and then use nodes to create curves and regions.
Nodes take on special significance when you assign attributes to them. For example, you might assign an
injection location, a coolant inlet, a constraint, or a load to a model node.
In the context of mesh

When you mesh a model, model nodes are converted to mesh nodes and additional mesh nodes are generated.
Mesh nodes are the vertices of Midplane, Fusion, and 3D mesh elements and the ends of beam elements. The
graphic below shows mesh nodes at the vertices of a triangular element and a beam element.
When you run an analysis, certain results are recorded at mesh nodes.
No-flow Temperature
The no-flow temperature is the temperature at which a polymer ceases to flow inside the mold cavity after
injection.
Nominal Part Thickness

Nominal part thickness is the thickness of the part at the thickest section.
Non-manifold Edge

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A non-manifold edge is a mesh edge with more than two entities attached to it. An edge is a line segment that
connects two mesh nodes.
On a Fusion mesh, non-manifold edges should be corrected because they indicate elements which have not
been correctly attached.
A = Free Edges
B = Manifold Edge
C = Non-Manifold Edge
See also Free Edge and Manifold Edge.
Non-return Valve
The non-return valve is located in front of the injection screw on an injection molding machine. It allows
material to flow in one direction and closes to prevent back flow.
Normalized Thickness
Normalized thickness is a measurement of part thickness. The normalized thickness value ranges from -1 to 1,
where 0 is the center of the part and 1 and -1 are the plastic/metal interfaces, or mold walls.
Nozzle Pressure
Nozzle pressure is the pressure applied to the polymer at the nozzle. Setting nozzle pressure is one way of
specifying the injection pressure of the polymer.
O
Open Loop Controller
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An open loop controller does not respond to measurements of the value being controlled.
See Closed Loop Controller
Optimization
Optimization is the process of finding the best conditions for molding a particular part. The part geometry,
the material selection, the injection location, and the processing conditions can all be optimized.
Orientation
During shear flow, polymer molecules align themselves in the direction of flow. The extent of this orientation
depends on the shear rate to which the material is subjected and the temperature of the melt. When the
material stops flowing, the induced molecular orientation begins to relax at a rate dependent on the material's
relaxation time and temperature. If the material freezes before relaxation is complete, the molecular
orientation is "frozen in".
Frozen-in orientation affects the mechanical properties of the material and also the shrinkage in the direction
of material orientation. For a given element, the mechanical properties and the amount of shrinkage are
different in directions parallel and perpendicular to the direction of material orientation.
Orthotropic Material
An orthotropic material consists of either oriented fibers or oriented polymer chains. Mechanical properties in
the direction parallel to the orientation are different from those in the perpendicular direction.
Overlapping Mesh Elements

Overlapping mesh elements are mesh elements that overlap in the same plane. Remove overlapping elements
from a mesh because they interfere with accurate analyses.
Overlapping elements are shown in the illustration below.

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1) Mesh elements do not overlap.

2) Partially overlapping mesh elements.
3) Fully overlapping mesh elements.
See also Intersecting mesh elements
Overpacking
Overpacking occurs when extra material is compressed into one flow path while other flow paths are still
filling. The shortest and thickest flow paths fill first, resulting in overpacking.
Overpacking can cause warpage, flashing and excessive cycle time and part weight.
Overpacking generally occurs in sections with the shortest fill time.
P
Part
The part is the object that will be made. It is the finished product of the molding process.
Parting Plane

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The parting plane is the surface of the two mold halves that separates when the mold opens.
Pinpoint Gate
A pinpoint gate is a small gate, generally 0.75mm or less in diameter. In multi-cavity molds, the dimensions of
pinpoint gates must be held within very tight tolerances in order to fill all cavities at the same time.
The advantage of such a small gate is that it leaves a small, easily-removed mark on the part.
Disadvantages include the following:
The melt tends to freeze early in a pinpoint gate, as the flow slows. For this reason its use is limited to
small parts and to resins with good fluidity.
Pinpoint gates often require a third plate (for part removal), increasing mold expense.
Pinpoints gates can lead to very high shear rate and high entrance pressure loss.
An indirect gate is a variant of a pinpoint gate. Indirect gates are used when the injection location must be
transferred from center of part.
Plastication
Plastication is the process in which raw material is changed to melt and pushed to the front of the screw
through a rotational action.
Point

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A point is a position in space. The first stage of creating a model is usually the creation of points, which are
then joined together to create surfaces.
Poisson's Ratio
The Poisson's ratio (n12) pertains to a material under tensile stress, and is defined as the ratio of lateral (or
transverse) contraction strain (in the second principal direction) to the longitudinal strain (in the first
principal direction).
Polymer
A polymer is a natural or synthetic compound, usually of high molecular weight. Its long-chained structure
consists of repeated linked molecular units called monomers (or mers). Monomers are relatively light and
simple. A chemical polyermization process builds polymers from monomers.
Although the term plastics is often used as a synonym for polymer, plastics are actually one type of polymeric
compound. Plastics are generally formulated with plasticizers, stabilizers, fillers, and other additives for the
purpose of processing and performance.
Non-plastic polymeric systems include rubbers, fibers, adhesives, and surface coatings.
Processing polymers into end products mainly involves physical phase change such as melting and
solidification (for thermoplastics) or a chemical reaction (for thermosets).
Preferred Molding Window

A preferred molding window is a refinement of a feasible molding window. It is represented by a set of
boundaries that define a window-like shape. For the process setting ranges inside the preferred molding
window boundaries, the molding process is optimal; outside the window boundaries, the molding process is
not optimal, but it may be feasible.
See also Feasible Molding Window
Pressure Gradient
The pressure gradient in the molten polymer is the pressure drop per unit of length along the flow path. The
pressure drop from one location to another is the force that pushes the molten polymer to flow during filling.
Polymer always moves from higher pressure to lower pressure, akin to water flowing from higher elevations
to lower elevations.

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Filling with a more uniform pressure gradient is desirable. Non-uniform pressure gradients often indicate
problems such as flow hesitation, over-packing (resulting in flash) and under-packing (resulting in excessive
shrinkage).
Pressure Profile
A pressure profile is a graph made up of set points joined by lines. The set points determine the pressure to be
applied at specific time intervals. The pressure profile controls how the part is packed out during the pressure
stage of a cycle.
Pressure Stroke
The pressure stroke is the proportion of the total stroke performed under pressure control. This is the
distance between the velocity to pressure change-over position and the screw forward position in an injection
molding machine.
Pressurization Phase
The pressurization phase is the period during the injection molding process when extra plastic is injected to
ensure all corners and edges of the mold cavity are full of plastic.
Process Control
Process control is the monitoring and correction of production.
Process Parameters
Process parameters are variables that typically correspond to molding machine settings. Commonly used
process parameters include:
Maximum injection pressure.
Screw cushion.
Pressure stroke.
Cycle time.

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Charge stroke.
Mean injection pressure.
Process Window
A process window or molding window, defines the limits of molding conditions under which an acceptable
part can be produced. If molding conditions fall within this region, then a good part can be made.
On the graph below, a good quality part (labeled with a checkmark), is encircled by the boundaries of the
process window. A poor quality part (marked "X"), is outside the process window.
Processing Conditions
Processing conditions are the variables that control the molding process. These include:
The injection velocity.

The pressure applied to the melt.
The mold and melt temperatures.
The material grade being used.
Production Run
A production run is a series of parts made under a particular set a process conditions, for example, a
particular set velocity and pressure profiles.
Purging
Purging is the cleaning of one color or type of material from the injection molding machine. This can be done
by forcing the material out with a new color, a new material, or with another purging material.
PVT

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Pressure-Volume-Temperature (PVT) data describes the specific volume (1/density) of a material as a

function of temperature and pressure. It describes the temperature/pressure relationship for polymers over
the entire processing range.
Q
R
Racetrack Effect
The racetrack effect occurs when molten plastic flows into thicker regions more easily than thin regions. The
flow divides and then fills thicker sections before combining again to fill the thinner sections. The recombined
flow can reverse to meet the oncoming flow in the thinner section.
The racetrack effect can cause air traps, weld lines and regions of high internal stress.
Ram
In the injection molding process the ram (or screw) is the part of the injection molding machine that pushes
the polymer into the mold.
See also Screw.
Record Groove
The appearance of this surface defect is similar to the grooves on a record. Record grooves are formed when a
high flow resistance exists in the mold, thus leading to a repeated temporary stagnation of the flow fronts.
To prevent this defect, the mold and melt temperatures should be increased while decreasing the injection
time.

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Region
A planar space defined by a consistent set of curves. The curves connect but must not intersect.
Restricted Gate
A restricted gate is a small opening between the cavity and runner in an injection mold. The gate breaks
cleanly after each part is made to assist part recovery.
Reynolds Number
The Reynolds Number is a ratio that defines the rate of fluid flow in pipes. The onset of turbulence in water is
between 2300-4000. The Reynolds Number is assigned to cooling circuits when the flow rate is not known. A
Reynolds Number of 4000 is considered fully turbulent but we recommend using a Reynolds Number of
10,000 to represent turbulent flow when running an analysis.
Rib
A rib is a long, thin intersecting wall that is used to reinforce the outer walls of the plastic part.
Run
See Production Run.
Runner / Runner System

Runners are the channels that feed the polymer from the sprue to the gates of each cavity in the mold.
A runner system includes the following:
Runners, shown in red.

Sprue, shown in green.
Gates, shown in yellow.

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S
Screw
The screw is the part of the injection molding machine that pushes the polymer into the mold, that is, the shaft
that rotates within the barrel of the injection molding machine to process and prepare the material for
injection.
Screw Back Position

The screw back position is the position that the screw is brought back to before the start of the next cycle.
Screw Displacement
Screw displacement is the distance the screw has moved during the injection phase.
Screw Forward Position

The screw forward position is the furthest forward position of the screw during a cycle.
Screw Velocity
Screw velocity is the speed with which the screw has moved during the injection phase.

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Semi-Crystalline
A plastic in a mixed state of crystalline and amorphous conditions. Most plastics are semi-crystalline. The
crystalline content determines the physical properties or the part.
See also Crystalline
Set Points
Set points are the defining points on the velocity and pressure profiles. For the velocity profile, it is a discrete
injection velocity and time/displacement coordinate. For the pressure profile, it is a discrete injection pressure
and time/displacement coordinate.
Shear
Shear is a type of deformation caused by friction between the moving plastic and the mold wall.
Shear Rate
Shear rate is the rate of change of shear strain with time.
Shear Strain
The shear strain of the polymer is the ratio of the deformed state compared to the original state, when a
polymer has been deformed due to an applied load.
Shear Stress
Shear stress is caused by friction between the moving plastic and the mold wall and between the layers of
plastic moving at different rates. High shear stress can cause the plastic to degrade or to fail, due to stress
cracks.
Shell
A group of connected surfaces that form an open shell.
Short Shot
A short shot is the incomplete filling of a mold cavity which results in the production of an incomplete part.

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Shot Size
The shot size is the distance between the screw back position and the zero screw position of an injection
molding screw. This is a measure of the polymer available for injection for each part.
Shot size is also known as charge stroke.
Shot Weight
In injection molding, the shot weight is the mass of plastic delivered in one complete filling of the mold,
including the molded parts, sprue, runners, and flash.
Shrinkage
Shrinkage is the reduction in the dimensions of a plastic part, compared with the mold dimensions. Shrinkage
occurs as the polymer cools. Shrinkage can vary in different directions.
Crystalline and semi-crystalline materials are particularly prone to thermal shrinkage; amorphous materials
tend to shrink less. Excessive shrinkage can be caused by the following factors:
Low injection pressure.

Short pack-hold time or cooling time.
High melt temperature.
High mold temperature.
Low holding pressure.
Sink Mark
A defect on the surface of a molded part. Sink marks are caused mainly by thermal contraction (shrinkage)

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during packing, if the temperature and pressure are not controlled correctly. They can occur on the opposite
side from ribs or bosses because the additional thickness causes increased contraction.
Solid
A set of connected surfaces that form a closed shell, enclosing a volume of material, assumed to be
homogeneous in properties.
Specific Heat
The specific heat (Cp) of a material is the amount of heat required to raise the temperature of a unit mass of
material by one degree Centigrade. It is essentially a measure of a material's ability to convert heat input to an
actual temperature increase. It is measured at zero pressure and a range of temperatures, or averaged across
the temperature range of 50C to the material's maximum processing temperature.
The unit of measure for specific heat is J/kg-C, Joules per kilogram celsius.
Sprue
The sprue is the main feed channel that connects the mold cavity with runners leading to each cavity gate.
Start of Fill
The start of fill is the time at which melted polymer starts to flow. This happens after the screw has started to
move and corresponds to the start of the pressure rise in the nozzle.

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STL File
STL (stereolithography) is a tessellated representation of the surfaces of a solid, using triangles. STL was
initially used in rapid prototyping. STL files can be in either ASCII or binary format. All major CAD/CAM
systems can generate an STL file of a solid model.
Streak Mark - Color

Usually occurs because of different orientation of the pigments in the flow, or poor blending in
the plastication stage.
Streak Mark - Dark

Dark colored brown or silver streaks can be caused by thermal damage to the material during
filling, or inadequate tool venting. Rectify the venting system, or reduce the injection speed or
pressure to avoid dark streaks.
Streak Mark - Glass Fiber

Rough and mat streaks can be caused by differential shrinkage or premature freezing of glass-
filled material against the mold wall. Using shorter glass fibers, increasing melt temperature, or
increasing mold wall temperature may help solve the problem.
Streak Mark - White

Also shown as silver streaks. There are a few different types:
Moisture - Streaking occurs opposite the flow direction, due to a high residual moisture content.
Drying the material properly will remove this defect.
Air - Air is trapped and cannot escape while the mold is filling. The air is drawn to the surface and
stretched in the direction of the flow causing streak marks.
Stroke
The stroke is the distance between the screw back position and the screw forward position of an injection
molding screw. This provides a measure of the amount of polymer injected during a cycle.

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Suck Back
Also known as decompression or pull-back, suck back is a technique used to clear polymer from the injection
nozzle by moving the screw away from the nozzle.
Surface
A rectangular surface defined by a grid of points which represent the control points of a NURBS definition of
a surface. (NURBS is a Non-Uniform Rational B Spline, a common mathematical representation in the CAD
industry.)
NURBS surfaces are not often used, because they are limited to a rectangular shape. Trimmed surfaces are
more useful and common. More?
Surfaces provide important information for meshing operations, which allow much better meshes to be
achieved than via facet-based mesh input.
See also Trimmed Surface
Switch-Over
Designates the transition from one phase to another, for example, the transition from the filling phase to the
packing phase. Various switch-over methods can be used.
For example, fill-to-pack switch-over can be initiated when the injection time or pressure reaches a
specified value, when a specified percentage of the volume is filled, or when other conditions are met.
T
Tensile Strength
Tensile strength is the maximum nominal stress sustained by a material being pulled from both ends, at a
specified temperature and at a specified rate of stretching.
Thermal Conductivity
The thermal conductivity of a material is the rate of heat transfer by conduction per unit length per degrees
Celsius. It is expressed in units of W/m.C. It is essentially a measure of the rate at which a material can
dissipate heat, and is determined under pressure and averaged across the material's melt temperature range.

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Thermal Degradation
Thermal degradation is a break down of material quality, resulting in poor parts. Thermal degradation may
occur if the barrel temperatures are too high, the rotational speed of the screw is too fast, or the nozzle
diameter is too small.
Tooling Noise
Excessive tooling noise may occur due to molding problems where the injection pressure is too high toward
the end of the velocity phase. Excessive tooling noise may lead to tool damage after repeated usage.
Transducer
A transducer is a mechanical or electrical device that is used to measure a value and transmit the
measurement to a recorder, or to a device that can compare the measurement with a desired value.
Transition Temperature
The transition temperature is the polymer freeze temperature. At this temperature, the melt-to-solid
transition occurs.
The transition temperature corresponds to the glass-transition temperature (Tg) for amorphous materials and
to the crystallization temperature (Tc) for semi-crystalline polymers.
Translator
A utility that converts mesh or models from one CAD format to another.
Trimmed Surface
A trimmed surface is a NURBS surface with a set of curves defined in the UV space of the surface. This
provides an easy way to define non-rectangular representations (patches) of surfaces.

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(NURBS is a Non-Uniform Rational B Spline, a common mathematical representation in the CAD industry.)
U
Unbalanced Flow
Unbalanced flow occurs when polymer melt completely fills some flow paths in the mold before other flow
paths have filled.
Underflow
Flow fronts from 2 directions meet, then pause momentarily, long enough for a frozen layer to develop, then
the polymer in one of the flows reverses direction and flows back between the outer frozen layers. When the
flow reverses the frozen layer partly re-melts due to frictional heating. This flow reversal gives poor part
quality, both from surface appearance and structural viewpoints.
To avoid underflow balance all flows so that their flow fronts meet at the end of fill.
Uni-directional Flow
Uni-directional flow is flow in one direction, with a straight flow front, during the filling phase. This is
desirable because it improves the mechanical properties and quality of the part. Flow direction is determined
by polymer injection location.
V
Valve Gate

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A valve gate is a component of a hot runner system. The sprues from the hot runner drop through the cavity
plate to the part(s). Each sprue has a rod that can be moved forward to cut off flow through the sprue. The
opening of the sprue is timed to be just after the melt front has passed that location. The lower pressure drop
through the hot runner system is passed on to the gate, allowing lower filling pressures and reduction in the
number of weld lines in the part.
Velocity Profile
The velocity profile is a graph made up of set points joined by lines. The set points determine the velocity to be
used at specific displacement measurements. The velocity profile controls how the part is filled during the
injection stage of a cycle.
Velocity Routines
Routines are complete processes within Setup Xpert that optimize one aspect of a profile. There are six
velocity routines that are used to optimize the velocity phase of the cycle, including the velocity stroke and the
velocity profile. While the velocity profile routines are being used, the pressure profile is set to zero.
Velocity Stroke
The velocity stroke is the distance between the screw back position and the velocity to pressure change-over
position in an injection molding machine. This is the proportion of the total stroke performed under velocity
control.
Velocity to Pressure Change-Over

This is the position of the screw when the machine switches the screw displacement control from velocity
control (used in the filling stage), to pressure control (used in the packing stage).
Vent
A vent is a small channel at the end of a flow path that allows air to escape the cavity.

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Venting
When air is trapped within the cavity, for example, at the last point to fill in the mold or at weld lines,
blackening or "dieseling" of the part can occur. Venting involves making a minor modification to the mold in
the problem area so that entraped air can escape.
Viscosity
The viscosity of a material is a measure of its resistance to flow within a mold cavity.
Viscosity Index
The viscosity of the material at 1000 1/s shear rate and at a specified temperature.
For example, VI(240)125 means that the material has a viscosity of 125 Pa.s at a shear rate of 1000 1/s and
a temperature of 240C.
The viscosity index is used to compare the viscosity of one material to another.
Viscosity Model
The viscosity of polymers is dependent on temperature, pressure and shear rate. The relationship of the
variables can be described by one of several equations, called models. For this product you can use either the
Cross-WLF or the Second Order model.
Voids
Voids are caused by the plastic pulling away from the middle of the part as the molten plastic cools. The
problem is material shrinkage during the cooling phase. Voids are a cosmetic defect if the part is transparent
and can be a structural defect if the void is large.
Eliminate voids by using proper cavity pressurization in the packing phase.

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W
Warpage
Warpage is a part defect caused by a non-uniform change of internal stresses.
Weld Line
A weld line is a weakness or visible flaw created when two or more flow paths meet during the filling process.
If the two flow fronts have cooled before meeting they don't interdiffuse well and can cause a weakness in the
molded part. A line, notch and /or color change can appear.
Move weld lines to areas where strength is of less importance and visual appearance is less obvious. You can
move weld lines by changing:
Polymer injection location.

Wall thickness.
Wire-Sweep Index
A value that represents the force created by the flow of plastic past the wires of an integrated circuit. The wire
sweep index (also known as sweep index) is the sum of viscosity times velocity at each grid point in the model,
with the result averaged by the number of grid points.
If the wire sweep index is high in regions of the model containing wires, then it indicates a possible location for
wire breakage. Since viscosity is dependent on temperature, shear rate, and the rate of cure, a sweep index
may be reduced by changes to these variables.

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X
Y
Z
Zero Screw Position
The zero screw position is the furthest forward position possible for the screw. This is when the end of the
screw is in contact with the barrel or hits machine 'stops'.

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Moldflow

See also Crystalline Polymers, Semi-crystalline Polymers

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See also Bubbler

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See Shot size.

See also Compressibility Model.

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Boundary Representation Solid

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See also Baffle.

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See also: gate.

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See Non-Return Valve.

Closed Loop Controller

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See also Free Edges

IGES composite curves are:

Composite Curve (IGES Type 102)

Boundary Entity (IGES Type 141)

Curve on a Parametric Surface (IGES Type 142)

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See also Amorphous Polymers

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Line - a straight curve defined by two end points.

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Mold open time.

Design of Experiments (DOE)

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Dominant Flow Path

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caught in the mold.

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Three-node triangular elements, used to represent surfaces.

Four-node tetrahedral elements, used to represent solids.

The properties of the element are assumed to be homogeneous.

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Feasible Molding Window

In the illustration below:

1. Random fibers are found at the entrance.

2. Flow-aligned fibers are found in the converging flow area.

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3. Transversely aligned fibers are found in the diverging flow area.

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Flow Leaders and Deflectors

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See also Manifold edge and Non-manifold edge

Free-form Curves and Surfaces

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Intersecting Mesh Elements

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See also Free Edge and Non-Manifold Edge.

Mesh - Surface (Fusion)

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A surface mesh can include Midplane areas.

Mesh - Volume (3D)

See also Overlapping Mesh Elements