How to avoid common injection molding problems

- Aug 28, 2020-

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Create accurate mold.


Creating custom molds for plastic parts is a highly skilled task.Crucially, the die is well suited to solve manufacturability and tool problems that can lead to component defects such as blowhole, voidage, warping, shrinkage, wrinkling and defects, as well as defects within the component structure.

Traditionally, this process has relied on the skills and experience of the tool administrator.As a result, the die has to be tested repeatedly before it is perfected.The delay of this process increases the time and cost of injection molding.

Tooling and prototyping software reduce the risk associated with mold development.Tool manufacturers can now digitally simulate molds and printing processes, so they can be sure that molds are ready for use before they are created.This, in turn, reduces the production process, enabling manufacturers to deliver components to customers in less time.


Avoid burn marks. 



Avoiding burn marks is discoloration on the surface of components.In addition to the aesthetic issues associated with marking, burns can cause plastic to degrade.Burn marks can be caused by overheating air trapped in the molding machine, or by a build-up of resin in the mold.

To avoid burn marks, manufacturers can slow down the rate at which the resin is injected.This reduces the chance that the air will get trapped.Alternatively, the manufacturer could introduce vents or degassing systems to remove residual air.The final option is to lower the temperature to which the plastic is heated.


Avoid wavy lines that on components. 


Wavy lines that appear on components are usually the result of resin cooling too quickly in the molding machine or the gate (the opening that allows molten plastic to be injected into the mold cavity) needing to be repositioned.

This problem can usually be solved by increasing the speed and pressure of liquid plastic injection molds.This will help the plastic fill the mold in a more uniform manner, which will lead to more consistent cooling throughout the mold.However, in severe cases, the mold needs to be redesigned to change the gate position to abruptly stop the molten plastic from changing direction.By working with a skilled manufacturer, you will be able to avoid these problems and obtain consistently high quality parts.


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