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For mass production of parts, plastic injection molding is a very cost-effective way but sometimes the best designs have faulted by the Injection Molding Manufacturers and their consequences show in quality defects. To troubleshoot and identify them, it is essential to be familiar with these defects. So, here we will discuss about top 5 most common quality defects in injection molding:
1. Weld lines:
A weld line refers to a mark, line, or color change that is made on the molded element caused by the meeting of two split flows of molten plastic. This happens wherever there is a mark, hole, or any other element on a piece that separates the flow of plastic into two distinct “flow fronts”. As these flow fronts come jointly on the other side of a given component, similar to a parting line mark. At the mark where the two flows reconnect there is insufficient interfusing of the plastic, maybe because limited molecules and cooling are not oriented in the same direction of the flow path.
2. Short shots:
A short shot is an unfinished component where the molten plastic does not fill up the whole mold cavity, consequential in a portion where there is no plastic. The missing point on a plastic fork is an example of a short shot. For short shots, here are many remedies and reasons. - Short shots can be happened by the use of a raw material that is too viscous and unable to flow into all sections of the mold cavity. - Short shots can be the consequence of insufficient and inappropriate expelling, ensuing in a pressure buildup that inhibits run. Consider adding more venting near the area of the mold that is having short shot concerns. - During injection, short shots may be related to the fill rate.
3. Flash:
It is a thin layer of plastic that flows outer surface of the cavity, naturally where the two halves of the injection mold get together. Along the parting line of the mold, flash can come into view on the part’s edge. Where the mold has metal meeting metal to form the boundary of the part, it can also occur at ejector pin locations and anywhere. Leftovers and flash cool are connected with the final product. Through deflashing process, injection molding must remove unwanted flash that may engage operations robots or personnel trimming the overloaded material in between cycles.
4. Burn marks:
In injection molding, the burn marks are an ordinary defect. On the part of the surface, these are discolorations that are often a red color or black color. Where the plastic material burned and overheated against the injection mold these marks are present at those places. Burn marks are most often caused by the following: undersized and excessive speed gating that does not allow proper gas venting, an extreme temperature that degrades the resin, or remaining material from an earlier cycle that overheats. The temperature, cycle time, and injection speed can be condensed to burn marks.
5. Sink marks:
On the surface of the part, a sink mark is a local depression. These marks are usually found in thicker areas because of inadequate cooling or varying cooling rates across the part whereas the element is in the mold. In the cavity or at an extreme temperature at the gate, they can also be caused by low pressure. The holding pressure can be increased, mold temperature can be lowered, or to encourage more adequate, holding time prolonged to resolve sink marks.
Final Words
These are the top 5 most common quality defects in injection molding. I hope you like this blog. If you want to know more about injection molding or injection molding manufacturers, please leave a comment in the comment section. We are always here to provide you informative blogs.
1. Weld lines:
A weld line refers to a mark, line, or color change that is made on the molded element caused by the meeting of two split flows of molten plastic. This happens wherever there is a mark, hole, or any other element on a piece that separates the flow of plastic into two distinct “flow fronts”. As these flow fronts come jointly on the other side of a given component, similar to a parting line mark. At the mark where the two flows reconnect there is insufficient interfusing of the plastic, maybe because limited molecules and cooling are not oriented in the same direction of the flow path.
2. Short shots:
A short shot is an unfinished component where the molten plastic does not fill up the whole mold cavity, consequential in a portion where there is no plastic. The missing point on a plastic fork is an example of a short shot. For short shots, here are many remedies and reasons. - Short shots can be happened by the use of a raw material that is too viscous and unable to flow into all sections of the mold cavity. - Short shots can be the consequence of insufficient and inappropriate expelling, ensuing in a pressure buildup that inhibits run. Consider adding more venting near the area of the mold that is having short shot concerns. - During injection, short shots may be related to the fill rate.
3. Flash:
It is a thin layer of plastic that flows outer surface of the cavity, naturally where the two halves of the injection mold get together. Along the parting line of the mold, flash can come into view on the part’s edge. Where the mold has metal meeting metal to form the boundary of the part, it can also occur at ejector pin locations and anywhere. Leftovers and flash cool are connected with the final product. Through deflashing process, injection molding must remove unwanted flash that may engage operations robots or personnel trimming the overloaded material in between cycles.
4. Burn marks:
In injection molding, the burn marks are an ordinary defect. On the part of the surface, these are discolorations that are often a red color or black color. Where the plastic material burned and overheated against the injection mold these marks are present at those places. Burn marks are most often caused by the following: undersized and excessive speed gating that does not allow proper gas venting, an extreme temperature that degrades the resin, or remaining material from an earlier cycle that overheats. The temperature, cycle time, and injection speed can be condensed to burn marks.
5. Sink marks:
On the surface of the part, a sink mark is a local depression. These marks are usually found in thicker areas because of inadequate cooling or varying cooling rates across the part whereas the element is in the mold. In the cavity or at an extreme temperature at the gate, they can also be caused by low pressure. The holding pressure can be increased, mold temperature can be lowered, or to encourage more adequate, holding time prolonged to resolve sink marks.
Final Words
These are the top 5 most common quality defects in injection molding. I hope you like this blog. If you want to know more about injection molding or injection molding manufacturers, please leave a comment in the comment section. We are always here to provide you informative blogs.
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