DEFECTS IN INJECTION

MOULDING
GROUP MEMBERS:
SITI HAJAR BINTI PAIMAN 2012763798
NURATIQAH BINTI MOHD SALLEH 2012850174
NUR FATIN AFIQAH BINTI ISMAIL @ AHMAD 2012815616

Defects

Definition

Physical cause

Sink mark

A sink is a dip or
depression in the
part which does not
follow the molds
surface. In clear
parts, bubbles can
be seen in thick
areas. These
bubbles can be the
precursors of shrink

Sink mark occurs during

the cooling process:
-The thermal
contraction (shrinkage)
of the plastic cannot be
compensated in that
area.
-The outside walls of
the molded part are not
stable enough, due to
insufficient strength,
the outer layer is drawn
inside by cooling
stresses.
-Low injection and
packing pressure.
-Short hold time or
cooling time.

Possible Part or
Mold Design
Processing Faulty
-Cross-section
area of gate is too
small.
-Inconsistent wall
thickness. i.e.
Thick areas
adjacent to thin
areas.

Defects

Short shot

Definition

The incomplete
filling of a mold
cavity which
results in the
production of an
incomplete part.

Physical cause

-Flow restrictions.
-Back pressure due
to unvented air
traps can cause a
short shot.
-Low melt and/or
mold temperatures
Insufficient
material entering
the cavity.
-Under packing,
low injection
pressure.

Possible Part or
Mold Design
Processing
Faulty
-Due to
channels
freezing or
inadequate
runner design.
-An undersized
machine, low
shot volume, or
inadequate ram
speed.
-Last part of the
mold to fill.

Defects

Definition

Physical cause

Flash

Excess plastic
squeezing out
perpendicular to the
part at parting line.
Found at locations
where the mold
separates, notably
the parting surface,
movable core,
vents, or venting
ejector pins.

-Improper molding
conditions, such as a
high melt
temperature (which
makes a thinner melt)
or high injection
pressure.
-If the clamp force of
the injection machine
is too weak to hold
the mold plates
together during the
molding process.
-The parting surface
does not contact
completely, due to a
deformed mold
structure.

Possible Part or
Mold Design
Processing Faulty

-An improperly
designed venting
system, a very
poor venting
system, or a
venting system
that is too deep.
-Along any parting
line.

Defects

Definition

Discoloration

Deviation from
the original
intended color of
the material as
compared to the
manufacturers
color chip.

Physical cause

Possible Part or
Mold Design
Processing
Faulty

-Contaminated
-Entire part
resin.
-Overheated resin.
-Incorrect regrind
ratio.
-Incorrect color
mixing or blending.

Defects

Definition

Physical cause

Warpage

The failure to
maintain flatness
of a plastic part
that was intended
to be flat. A
distortion of the
shape of the final
injection
molded item.

Caused by
differential
shrinkage,
that is, the
pattern, shape,
and thickness of
ribs on the part if
one area or
direction of the
article undergoes
a different degree
of shrinkage than
another
area or direction,
the part will warp.

Possible Part or
Mold Design
Processing
Faulty
-Molded in
stresses
-Differential
mold
temperatures.
-Distribution of
wall thickness,
areas with nonuniform
distribution are
included.
-Detected on
large flat parts.

Defects

Excessive
shrinkage

Definition

A characterized
by moulded
parts which
appear smaller
than the
intended
dimensions or
show warpage.

Physical cause

-Cure time too

short
-Pack pressure too
low
-Mould or stock
temperature too
high
-Insufficient
injection pressure

Possible Part or
Mold Design
Processing
Faulty
-Runners or
gates too small.
-Poor part
design, varying
wall thickness.

Defects

Definition

Physical cause

Jetting

Squiggly line in part

pointing to gate.
Looks like a worm in
the part. In this case
rough or matt lines
appear at the
surface of the
moulding starting at
the gate and
spreading over the
entire part. The lines
will appear different
in gloss and colour
and are more visible
with coloured parts.

-Undeveloped front
flow
-Excessive injection
speed
-Programme injection
(distance pressure
speed)

Possible Part or
Mold Design
Processing
Faulty
Incorrect gate
placement or
size. The gate is
positioned in
such a manner as
to aim the plastic
straight into an
open area. The
plastic launches
out into the open
like a piece of
"silly string" and
then stacks up in
squiggles.

Defects

Definition

Physical cause

Blister

Hollow Created On
Or In The Molded
Part

-Air Traps Occurs

When Converging
Flow Fronts Surround
And Trap A Bubble Of
Air.
-- Air Bubbles Will
Solidified While
Flowing Around

Possible Part or
Mold Design
Processing
Faulty
-The Surface Of
The Molded Part
-- Voids In Thick
Walled Molded
Part

Defects

Definition

Weld line

-Witness marks of
two or more melt
flow fronts at their
joining zone.

Physical cause

-Low melt
temperature
-injection pressure
low
-excessive mould
- Weld lines are
lubricant on the
created when two mould
or more melt flow -improper venting
fronts meet
in the mould
possibly causing a -low mould
cosmetically visible temperature
line.
-poor material flow
properties
-injection speed
very slow

Possible Part or
Mold Design
Processing
Faulty
- Area in the
finished molded
part especially
with filled
resins.

Defects

Definition

Physical cause

Diesel effect/
burn marks

Show up on the
finish molded parts
as charred or dark
plastic causeb by
trapped gas and
usually
accompanied by a
distinctive burnt
smell.

-Due to entrapped air

at the end of flow
path and poor
ventilation near rib.
-The trapped gas is
compressed and gets
heated to a high
degree causing the
burn on the plastic.

Possible Part or
Mold Design
Processing
Faulty
- at blind holes
-Fillets
-Narrows ribs
-Near places
where several
flow fronts meet
-End of flow
paths

Defects

Definition

Silver streak

Gaseous
components in the
plastic appear at the
molding surface and
collapse.

Physical cause

-Insufficient drying
-Inclusion of air
-Degradation
-Incompatible of
master batch

Possible Part or
Mold Design
Processing
Faulty
-Molding surface
of product

Defects

Definition

Physical cause

Color streak

The phenomenon of
color streaking is
characterized by
localized changes in
the color of a
molded component
or by streaking.

-Poor thermal
stability of coloring
agent
-Low die temperature
-High speed of flow
-Poor distribution of
coloring agent

Variation from the

original color

Possible Part or
Mold Design
Processing
Faulty
-Welds
-Ribs
-Surface of
molded part
-Part which likely
to induce shear
flow

Defects

Definition

Flow mark

A flow mark or halo

is a surface defect in
which circular
ripples or wavelets
appear near the
gate.

Physical cause

-Low melt
temperature
-Low mold
temperature
-Low injection speed
-Low injection
pressure
-Small runner stem
and gate

Possible Part or
Mold Design
Processing
Faulty
-Around the
gates when the
plastic has
flowed through
the die