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Common problems and countermeasures of injection molding
1
Principle of injection molding

Injection molding refers to a method of injecting a heated and melted material into a mold, and then cooling and solidifying to obtain a molded product.

Generally follow the following six sequences: mold clamping, injection, pressure holding, cooling, mold opening, and product removal.

A
Schematic of injection molding machine
Countermeasure
Molding problem
  • a. Air eye refers to the phenomenon that air is trapped in the cavity and the product produces bubbles.
  • b. It is caused by the inability of gas to escape from the parting surface, ejector or exhaust hole when two melt forwards meet.
  • c. The gas eye is usually located where the melt is finally filled.
  • d. Lack of vents or undersized vents will cause air holes or other surface defects in the final filling area
  • e. If the design of the product is uneven, it is also very easy to cause gas eye phenomenon.

Possible problems caused by gas eyes : The gas trapped in the cavity cannot be exhausted in time, which may cause surface blistering, air trapping inside the product, and injection dissatisfaction.

ways to improve:

Structural design 1. Reduce thickness inconsistency and try to ensure uniform wall thickness
Mold design 1. Add an exhaust port in the final filling place
2.Redesign the gate and runner system
3. Make sure the exhaust port is large enough so that the gas has enough time and space to drain away
Process conditions 1. Reduce the last injection speed
2. Increase mold temperature
3. Optimize injection pressure and holding pressure

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