Basic Injection & Painting

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 Molding Defects: Flow Marks

Staggered type flow marks

This flow-mark pattern is characterized by alternating areas of glossy and cloudy plastic.

Cause
This type of flow mark is caused by unstable flow at the flow front.

Countermeasure
- Lower the setting for injection speed.
- Raise the temperature of the plastic and the die.

If this problem becomes worse, it may develop into silver streaking and care must 2
therefore be taken.
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 Molding Defects: Flow Marks

The term "flow mark" is used to describe the phenomenon where a striped pattern
is formed around the gates when plastic has flowed through the die.

In this, plastic which has been cooled by sprues and runners is further cooled in
the cavity and filling occurs at high viscosity. Consequently, plastic in contact with
the mold surface is pressurized in a semi-solidified condition and stripes
perpendicular to the flow direction are formed on the surface of the molded
product.

Uneven thickness type Record type Staggered type

3

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 Molding Defects: Color Streaks

The phenomenon of color streaking is characterized by localized changes in the color

of a molded component or by streaking.

Examples of variation from the original color

Causes
 This type of problem is principally caused by poor thermal stability of the coloring
agent. Furthermore, it occurs more easily in locations such as welds, ribs, and the
like which are likely to induce shear flow.

Countermeasures
 Switch to a coloring agent with good thermal stability.
 In terms of molding conditions, it is desirable for the plastic and die temperature
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to be high, and for the speed of flow to be low (i.e., hot-slow molding).
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Example of a streaking pattern in a molded product

Cause
 Poor distribution of coloring agent. (The quality of coloring-agent distribution can be
evaluated by using a compressing molding machine to manufacture thin sheeting.)
 Cleaning effect of plastic deposited within the molding machine (or cylinder).

Countermeasures
 Improve the quality of distribution during compounding.
 Fully clean the inside of the cylinders. (We recommend our own UMG Clean ™ for
this purpose.)
 Check the screw head, back-flow prevention rings, and other similar items for
defects.
 Change the molding machine. 5

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 Molding Defects: Short Shot or Short Mold

The term "short shot" or "short mold" is used to refer to a phenomenon where
plastic being injection molded does not reach certain portions of the inside of the
die before solidifying.

Some of the typical factors affecting this type of problem are as follows:
- Fluidity and viscosity characteristics of the plastic
- Die design (i.e., gate design, bushing construction for ribs and bosses,
the presence of venting, etc.)
- Direct carving design - Molding conditions
- Molding machine performance

Condition

Location On surfaces Ribs and bosses Corners and tips

Cause Generation of gas Material thickness and gas volume Plastic viscosity 6

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 Short Shot Checkpoints

 Insufficient plastic fluidity (i.e., viscosity is high): Checkpoints and countermeasures

 Die temperature : Increase within the range for removability
Note that as the molding cycle becomes longer as a result of this, care must be taken with regard to
cylinder residence time. * Refer to the molding condition sheet
 Screw failure : Replace the back-flow prevention ring
Note that this is applicable to situations where there is disparity in the degree of cushioning during
injection or back flow.
 Unstable supply
- Lower the temperature at the rear of the cylinder. If plastic at the hopper opening is bridging
- Increase the cooling water volume at the hopper opening : If plastic at the hopper opening is bridging
- Correct the back pressure : Insufficient or excess back pressure.
 Injection speed : Increase the injection speed.
If no change in the filling time is noticed after setting of a high injection rate, there is a possibility that
the performance of the molding machine is insufficient or that there is excessive pressure loss in the
sprues, runners, and gates; accordingly, separate evaluation and modification of the molding
machine's performance will be needed. * Refer to the molding condition sheet
 Injection output : a Raise the injection output
If the problem persists even after setting of a high pressure, it is highly probable that the same factors
as described in the above items are at work.
 Plastic temperature : Raise the temperature within the service range.
* Refer to the molding condition sheet 7
 Grade change : Switch to a grade with better fluidity. * Alternative grade search
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 Insufficient plastic fluidity (i.e., viscosity is high): Checkpoints and countermeasures
 Die temperature : Increase within the range for removability
Note that as the molding cycle becomes longer as a result of this, care must be taken with regard to
cylinder residence time. * Refer to the molding condition sheet
 Screw failure : Replace the back-flow prevention ring
Note that this is applicable to situations where there is disparity in the degree of cushioning during
injection or back flow.
 Unstable supply
- Lower the temperature at the rear of the cylinder. If plastic at the hopper opening is bridging
- Increase the cooling water volume at the hopper opening : If plastic at the hopper opening is bridging
- Correct the back pressure : Insufficient or excess back pressure.
 Injection speed : Increase the injection speed.
If no change in the filling time is noticed after setting of a high injection rate, there is a possibility that
the performance of the molding machine is insufficient or that there is excessive pressure loss in the
sprues, runners, and gates; accordingly, separate evaluation and modification of the molding
machine's performance will be needed. * Refer to the molding condition sheet
 Injection output : a Raise the injection output
If the problem persists even after setting of a high pressure, it is highly probable that the same factors
as described in the above items are at work.
 Plastic temperature : Raise the temperature within the service range.
* Refer to the molding condition sheet
 Grade change : Switch to a grade with better fluidity. * Alternative grade search

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 Die design: Checkpoints and countermeasures

 Uneven thickness (if both thin and thick walled sections are present within the
same cavity)
Standardize the wall thickness in each cavity. Note that this can result in sink
marks on the top of ribs and bosses, and therefore, special care must be taken in
this regard.

 Rib and boss design (if constantly occurring in specific ribs and bosses)
Use shaped-section bushings and ensure smooth extraction of gas from the
extremities of dead-end sections.

 Hesitance (if flow patterns and gate layouts are defective) a

Modify the gate design (i.e., method, dimensions, locations, and quantity)

 Defective cooling design (if the distribution of die temperatures is non-uniform)

Review the adjustment of temperature (i.e., the cooling design) and the
performance of the die's temperature regulator.

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 Molding Defects: Flash (fins or spew)

The terms "flash", "fins", and "spew" are used to refer to excess molding material that penetrates into mold
gaps (i.e., between parting faces, slide push-out faces, and inserts, etc.) in a molten state.

Normal Flash

Molding machine Causes

- Insufficient mold clamping pressure in the molding machine.
- Aging of the die.
Countermeasures
- If there is insufficient clamping pressure, estimate the correct pressure using
the following equation and choose an appropriate molding machine.
Die clamping pressure = Projected surface area x die-internal effective injection
pressure / 1,000 kg
In the case of ABS, a rough value for 400 kg/cm2 can be used in this calculation for
the die-internal effective injection pressure 10

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Die Causes
- Insufficient mold clamping pressure.
- Insufficient precision at the die's mating faces
- The molded product is arranged in a cantilever-type setup as a result of die design.
Countermeasures
- Switch to a suitable molding machine.
- If the problem is related to mating faces, a joint examination must be carried out with
the die machining company.

Material Causes
- Plastic has low viscosity.

Countermeasures
- If the problem is related to the plastic's viscosity, either lower the temperature of the
plastic or switch to a grade with higher flowability.

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 Molding Defects: Delamination
The term "delamination" is used to refer to a condition where a thin micaceous layer develops on the
molded product and then becomes separated. In severe cases, this will extend over the entire molding and
give the impression that its skin is peeling away.

Layer peeling caused by fracture (right) as a result of PS inclusion

Although peeling may be identified immediately after molding, it is usually detected as a result of cracking
of the product. 12

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Cause 1
 Inclusion of a plastic which has poor compatibility with ABS (i.e., PP or PS, etc.)
Countermeasure
 Carry out cleaning.
- Inside the cylinder
- Inside the hopper
- Inside the air feed lines
- Inside the dryer

Cause 2
 When the die and plastic temperatures are extremely low, the difference in
temperatures between the outer walls and the fluid layer results in the development
of a thin hard coating which then peels

Countermeasure
 Standardize the resin temperatures.
- Raise the temperature of the resin
- Raise the temperature of the die

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 Molding Defects: Silver Streaks

Gaseous components in the plastic appear at the molding surface and collapse.
Click on any of the following photographs for the corresponding causes and countermeasures.

Cause

Insufficient drying Inclusion of air Degradation

Illustration Illustration Illustration

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 Molding Defects: Stringiness

The term "stringiness" is used to refer to a phenomenon where string-line sections of plastic which are
formed upon opening of the die adhere to the inside of the die and are transferred to the product during the
next shot, resulting in string-line unevenness on the surface of the molded component.

Thin plastic string formed at the tip of a sprue Plastic string after transfer to the molded
component

Cause
 This problem is principally caused by high nozzle temperatures.

Countermeasures
 Lower the nozzle temperature; alternatively, make combined use of pull-back and cylinder
repetition.
 Strings can be forced to break by increasing the speed of die opening, however, care
must be taken as this can result in reduced die service lives for certain die designs (i.e., slides, etc.).
 Use a string-prevent ring (commercially available). 15

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 Molding Defects: Weld Lines

The term "weld line" is used to describe the narrow V-shaped line that occurs at the point where two different
flow fronts meet.

This phenomenon is guaranteed to occur whenever using inserts, lattices, or multi-point gates, and there is
no theoretical means for its elimination; accordingly, its effect must be minimized or the resulting marks must
be moved from a decorative face to a side face. To the untrained eye, a weld line may seem to be a crack. In
terms of product specifications, the presence of weld lines in areas of stress concentrations may lead to
strength problems, and therefore, countermeasures should be implemented in advance.

Weld lines disappear when the angle of meeting is 120deg. or more. 16

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Cause
Weld line factors
 Shape of molded component
- Holes (i.e., lattices, round holes, square holes)
- Differences in material thickness (or uneven thickness)

 Plastic
- Fluidity (or viscosity) Die
- Die temperature
- Gates (number and location)
- Gas vents (method and location)
- Cooling ducts (and die temperature distribution)

 Molding machine
- Performance (precision and response)
- Injection and plasticization

Countermeasures
 Shaping conditions used to minimize weld lines
- Plastic temperature a High
- Die temperature a High
- Injection speed a Low
*Although weld lines will become less obvious when the speed is increased
(i.e., the depth is minimized), there is a tendency for their length to increase.
- Holding pressure a High
* Marks are made less noticeable using the compression effect of the weld's V-notch.
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Verification
Die temperature which is most effective in minimizing weld lines

Normal molding High-speed heat and cool molding

Die temperature: 40deg.C Die temperature: 100deg.C
Weld section (central) Weld section (central)
Width: Approximately 10 mm Not visible with the naked eye
Depth: Approximately 120 mm

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 Painting Defects : Cracks
As with pin holes, these fine cracks on the painted surface are caused by solvent attack, and this phenomenon is
often seen in acrylic painting. These cracks generally occur near gates and at edges in particular.

We recommend our special painting grades for use in painted products

Example: Acrylic paint

Cause
Solvent in the paint attacks sections of the substrate material where levels of residual strain are high, thus
causing chemical stress.

Countermeasures
- Selection of a less aggressive solvent
- Modification of the paint and solvent mixture ratios
- Annealing (at between 60deg.C and 70deg.C for 20 to 60 minutes)
- Raising of the cylinder temperature and die temperature.
- Lowering of the injection and dwell pressures, and raising of the injection speed
* Generally speaking, the addition of retarder is not a good means of treating chemical cracks. 19

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 Painting Defects : Sinking
Solvent in the paint penetrates the component near the gates, at areas of varying thickness, or near welds;
consequently, luster becomes uneven and fine cracks develop.

We recommend our special painting grades for use in painted products.

Normal surface Sinking

Example : Metallic acrylic paint

Cause
 This problem often occurs at areas close to gates with molding defects such as gate flash, flow marks, or
jetting; furthermore, these factors are difficult to eliminate even by annealing.

Countermeasures
- Selection of a less aggressive thinner
- Slight increase of the paint's viscosity
- Raising of the cylinder temperature and die temperature.
- Lowering of the injection pressure and raising of the injection speed 20
- Modification of the gate type (i.e., switching to the use of tab gates)
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 Painting Defects : Poor Adhesion
One of a number of phenomena where paint peels from the surface of the component, poor adhesion is
generally identified during paint-film property testing.

We recommend our special painting grades for use in painted products.

Example: Poor adhesion as identified in a cross cut test

Cause
Although this phenomenon readily occurs when contaminants such as grease or mold release agent are
present on the surface of the molded component, it is also affected by matching of the substrate and paint
(i.e., solubility and wetting, etc.) and by the condition of the paint itself (i.e., thinner, viscosity, film thickness).

Countermeasures
- Degreasing of the molded component's surfaces (using n-hexane, IPA, etc.)
- Switching to paint with lower cohesive power (cohesive power < adhesive power a no peeling)
- Thickening of the paint film 21
- Increasing of the injection speed ( increase orientation and raise thinner attack )
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 Painting Defects : Pinholes
Often seen in urethane painting, this phenomenon is characterized by the appearance of small holes on the painted surface,
and it is also known as "cratering."

We recommend our special painting grades for use in painted products.

Example: Urethane paint

Cause 1
 Inclusion of air
Pinholes can be caused when air bubbles trapped in the paint film expand during drying and break
through the surface. Furthermore, this phenomenon is not dependent on the substrate, and it occurs
often in high-temperature, high-humidity environments; with thick application of paint; when there is
insufficient setting time; and when the speed of thinner evaporation during drying is high.

Countermeasures
- Modification of the painting environment
- Lengthening of the setting time
- Reduction of the paint's viscosity
- Slowing of the thinner evaporation speed

Cause 2
 Residual strain
When the plastic substrate contains residual stress, the material is attacked by the paint's solvent and fine cracking
occurs. The solvent penetrates into these cracks, and when this then evaporates during the drying process, the resulting
vapor bursts through the surface of the painted film.

Countermeasures
- Selection of a less aggressive solvent
- Modification of the paint and solvent mixture ratios
- Annealing of the unpainted component (at between 60deg.C and 70deg.C for 20 to 60 minutes) 22
- Raising of the cylinder temperature and die temperature
- Lowering of the injection pressure and raising of the injection speed Created by Iwan Muhdi
 Painting Defects : Crawling
With indentations of 1 mm or more in diameter occurring on the painted surface, this phenomenon results in
the substrate becoming visible.

We recommend our special painting grades for use in painted products.

Example: Urethane paint

Cause
 This problem occurs when a contaminant with lower surface tension (i.e., lower wetting) than the paint
adheres to the surface of the molded component.
- Mold release agent (i.e., silicon oil)
- Machinery grease
- Dust or other contaminants attracted by static electricity

Countermeasures
- Regulation of the painting environment to eliminate the causative agents
- Degreasing of the molded component's surfaces (using n-hexane, IPA, etc.) 23

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 Molding Defects: Sink Marks (or shrink marks)
Sink marks or shrink marks are hollows or indentations that occur on the outer surfaces of molded components.

Whether or not sink marks are treated as a problem depends on the required quality of appearance.
For example, this would not be acceptable for external molding components which must be highly attractive in nature. It is
often the case that the decision on whether or not to treat this phenomenon as a defect depends on product quality issues.

Sink mark behavior depends on the volumetric shrinkage of the plastic (i.e., the isothermal PVT characteristic) and the
chronological history of all locations within the injection molding process is important. In specific terms, this phenomenon occurs
during the transition from the molten condition upon injection to the solid condition upon dwelling and cooling.

Molten plastic that has been injected into the die begins to cool and solidify from the die surface. As the plastic continues to cool
and harden from the outside (i.e., during dwell and cooling), certain injection settings such as the dwell pressure and time make it
impossible to compensate for changes in volume of the plastic (i.e., volumetric shrinkage) resulting from the PVT characteristic.
In these cases, the plastic at the surface of the die can be drawn towards the inside of the molding when volumetric shrinkage
occurs in the molten plastic still present at the interior, and this results in the cosmetic defect referred to as sink marks.

Alternatively, when the outer layer of the molded component has sufficient strength to resist the pull of volumetric shrinkage,
voids will be generated at the interior, and in certain cases, this will not be manifested as an appearance-related problem.
Furthermore, if latent causes exist in the shape of the product (i.e., bosses, ribs, thick sections, uneven thickness, etc.) or in the
construction of the die (i.e., cooling duct design, die material, cooling agent, etc.), it will be impossible to eliminate sink mark
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problems unless advance countermeasures are implemented at the product design and die design stages.
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 Localized sink marks (effect of rear surface shape and flow tips)

FACTOR CAUSE COUNTERMEASURE

Removal of material,
Material thickness Thick or uneven (thin) standardizing thickness,
thickening
Product
Addition of gates, modification of
Gate position and method Inadequate (design restrictions)
method

Resin temperature High (or low) Reduce (or increase)

Die temperature High (or low) Reduce (or increase)
Injection speed High (or low) Reduce (or increase)
VP switching Fast Slower position
Dwelling pressure Low Increase
Molding conditions / Dwelling time Short Lengthen
Molding machine
performance Back pressure Low (measurement disparity) Increase
Screw speed Temperature increase due to rotation Reduce
Insufficient, disparity Increase (excess is unacceptable)
Amount of cushioning
Mechanical back-flow Replace with normal component
Measurement Insufficient Increase
Die clamping pressure Insufficient (presence of flash) Increase
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 FACTOR CAUSE COUNTERMEASURE

Nozzle holes Small cross section Increase

Sprues Small cross section Increase
Runners Small cross section Increase
Gates Small cross section Increase
Die Insufficient (temperature disparity) Increase, standardize
Cooling circuit Unsuitable method (i.e., efficiency) Change method
Small flow volume / high pressure loss Improve efficiency
Usage of material with good thermal
Die material Insufficient cooling ability
conductivity

 Sink marks on entire molded component

FACTOR CAUSE COUNTERMEASURE

Material thickness Thick or uneven (thin) Use suitable thickness

Product
Addition of gates, modification of
Gate position and method Inadequate (design restrictions)
method

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 FACTOR CAUSE COUNTERMEASURE

Resin temperature High (or low) Reduce (or increase)

Die temperature High (or low) Reduce (or increase)
Injection speed High (or low) Reduce (or increase)
VP switching Fast Slower position
Dwelling pressure Low Increase
Molding conditions / Dwelling time Short Lengthen
Molding machine
performance Back pressure Low (measurement disparity) Increase
Screw speed Temperature increase due to rotation Reduce
Insufficient, disparity Increase (excess is unacceptable)
Amount of cushioning
Mechanical back-flow Replace with normal component
Measurement Insufficient Increase
Die clamping pressure Insufficient (presence of flash) Increase
Nozzle holes Small cross section Increase
Sprues Small cross section Increase
Runners Small cross section Increase
Gates Small cross section Increase
Die Insufficient (temperature disparity) Increase, standardize
Cooling circuit Unsuitable method (i.e., efficiency) Change method
Small flow volume / high pressure loss Improve efficiency
Usage of material with good thermal
Die material Insufficient cooling ability
conductivity

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 Molding Defects: Warping or Twisting
"Warping" is a term used to describe the deformation which occurs when there are differences in the degree
of shrinkage at different locations within the molded component.

Factors influencing warping are as follows

 Differences in shrinkage and cooling time as dependent on the differences in both surface contraction and
component thickness which result from differences in die temperature distribution.
 Residual stress resulting from molecular orientation. In fiber-reinforced materials, there are large
differences in the degree of shrinkage in the flow direction and the perpendicular direction, and for this
reason, special consideration must be given to gate design (i.e., quantity and location) at the die design
stage.

For example, if the degrees (or rates) of shrinkage at the various points in a molded component are
theoretically identical, this will simply lead to the generation of small, similar-looking cavities, and
regardless of the size of the material's shrinkage rate, there will be no occurrence of warping.
Nevertheless, a complex mix of the above-mentioned factors will exist during actual molding, and after
release of die clamping pressure and removal, the internal strain will try to fall to the minimum level (i.e., to
reduce energy to the minimum), thus resulting in the occurrence of molded-component warping.
Furthermore, consideration must also be given to insufficient cooling of the molded component and to28
deformation as a result of defective push-out mechanisms when dies are being designed.
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  Warping and Twisting Checkpoints

Causes
Molded component shape

 Distribution of wall thickness Areas with non-uniform distribution are included.

 Insufficient structural stiffness The structural stiffness of ribs and the like is insufficient. Ribs can actually
contribute to warping, and therefore, a detailed examination of thickness and
height factors must be undertaken.

Die

 Cooling circuit Die temperature distribution is non-uniform, the cooling circuit is too long (i.e., large
temperature difference between in and out points), control is inadequate, or the cooling
method is not suitable.

 Die material Low thermal conductivity (i.e., low cooling efficiency)

 Gate and runner Non-uniform distribution of pressure in the dwelling process due to an insufficient
number of gates or poor positioning

 Push-out mechanism Poor push-out balance or excessive ejection load with respect to the pin surface area

Insufficient polishing in the core extraction direction, inadequate extraction angle 29

 Parting
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Molding machine and accessories

 Insufficient die clamping force Inability to setup suitable clamping conditions (i.e., pressure and time)

 Die temperature regulator Flow volume of cooling agent is insufficient (i.e., Reynolds number is not large enough
for turbulent flow), insufficient performance in terms of die thermal capacity.

Molding conditions

 Resin temperature Pressure transmissibility drops when the viscosity is high; consequently, uniformity in
the degree of shrinkage is not possible in the dwelling process.

 Die temperature When excessively low, the viscosity increases and the pressure transmissibility drops;
consequently, uniformity in the degree of shrinkage is not possible in the dwelling
process. Crystallization (or solidification) takes place before directional or stress
relaxation can take place, and anisotropical residual stress remain.

 Injection pressure Either too high or low (i.e., flow length in excess of the plastic's flow characteristic)

 Dwelling pressure Either too high or low (Over-packing in the vicinity of the gates, or back-flow as a result
of poor gate sealing)

 Dwelling time Either too long or short (Over-packing in the vicinity of the gates, or back-flow as a
result of poor gate sealing)

 Cooling time Too short (dependence of material strength on temperature)

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JENIS NG : Flow Mark
SETTING / MOLDING MACHINE MOLD / MATERIAL
 Resin temp is low and viscosity is too high  Mold temp is low
 Injection speed is low  Mold cooling is unsuitable
 Nozzle is small  Slug pool is small
 Injection holding pressure time is too short  Gate is large
 Injection holding pressure is poor  Resin flow is poor
 Poor cushion amount for material
 Cold flow mark occur die to pressure of cold slugs
 Nozzle temp is low

JENIS NG : Silver Streaks

SETTING / MOLDING MACHINE MOLD / MATERIAL
 Poor injection cavity and plasticizing capacity  Melt temp is low
 Resin dissolved due to overheating  Gas purging is poor
 Resin temp is low and melting is poor  Gate position is inferior
 Resin is partially cracked due to residual melt in  Poor cavity design ( Rapid change of
barrel thickness. etc )
 Injection speed is too high  Gate, Runner or sprue is too small
 Air intake clogged  Slug pool is small
 Back Pressure is small  Moisture or lubricant adhered to mold
 Interior of the barrel is dirty surface
 Screw speed is too high  Moisture or volatile matter included in
materials

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JENIS NG : Hose ( Poor Luster )
SETTING / MOLDING MACHINE MOLD / MATERIAL
 Uneven melting of resin or resin is partially over  Mold temp is high or low
headed  Gate, runner and sprue are small
 Nozzle is cold  Slug pool is small
 Nozzle hole is small  Water or oil adhered to mold surface
 Injection speed is to high or too low  Gas purging is poor
 Resin is dissolved due to over heating  Excessive utilization of mold release agent
 Other matter mixed in material  Moisture and volatile matter include in
materials
 volatile mater in lubricant

JENIS NG : Weld Lines

SETTING / MOLDING MACHINE MOLD / MATERIAL
 Resin temp is low and fluidity is poor  Distance between gate and weld section is
 Injection pressure is low long
 Injection speed is low  Mold temp is low
 Nozzle is cold  Gate position and number are unsuitable
 Back pressure is low  Gate and runner are too small
 Gas purging is poor
 Flow is poor

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JENIS NG : Bubbles
SETTING / MOLDING MACHINE MOLD / MATERIAL
 Injection pressure is low  Gas purging is poor
 Holding pressure is low  Interior cavity design ( Radical thickness
 Holding time is short change )
 Injection speed is too high or too low  Gate position is unsuitable
 Resin temp is low or viscosity is too high  Gate, runner or sprue are too small
 Resin temp is high and gas is produced  Cooling time is too long
 Air intake ( screw speed is to high )  Mold temp is low
 Air intake
 Resin shrinkage percentage is large

JENIS NG : Burn Marks

SETTING / MOLDING MACHINE MOLD / MATERIAL
 Resin flow is inhibited or setters is one portion of  Grease or oil present
barrel, and is dissolved  Resin is dissolved due to frictional heat at
 Poor nozzle installation the gate
 Burning due to adiabatic compression with  Poor gas purging
material wear in barrel or air  Excessive lubrication
 Poor cooling at hopper installation section  Volatile matter is included
 Barrel temp is high  Filler with poor thermal stability is used
 Injection pressure is high
 Injection speed is fast
 Long holding time in barrel
 Screw speed is too high
 Back pressure is too high
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JENIS NG : Crazing, Cracking
SETTING / MOLDING MACHINE MOLD / MATERIAL
 Injection pressure is high  Gate is too wide
 Resin temp is low and viscosity is too high  Mold temp is low
 Holding time is long  Core creates vacuum at release
 Holding pressure is high  Poor cavity design ( inside stress is
 Product push out speed is high generated avoid concentration )
 Mold opening speed at beginning is high  Unsuitable Annealing
 Product draft is small
 Mold cavity: core polishing is poor

JENIS NG : Warp
SETTING / MOLDING MACHINE MOLD / MATERIAL
 Injection Pressure is high  Poor releasing
 Holding pressure is high  Unsuitable ejection
 Holding time is long  Uneven or insufficient cooling
 Poor Resin Melting  Gate is large
 Resin temp is low  Mold temp is high
 Injection speed is low  Uneven thickness
 Cooling time is short  Under cutting
 Utilize correcting tool for wrap after releasing  Unsuitable annealing

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JENIS NG : Cracking
SETTING / MOLDING MACHINE MOLD / MATERIAL
 Injection pressure is high  Resin adheres to the mold due too poor
 Resin temp is low and viscosity is too high cooling
 Holding pressure is high  Mold temp is low
 Holding time is long  Gate is too wide
 Excessive charging  Poor gas purging
 Cooling time is short  Poor gate balance
 Nozzle diameter is large than sprue hole
 Sphere al radius of nozzle tip is large than
sprue bushing
 Sprue diameter and taper are unsuitable

JENIS NG : Unfilled ( Short Shot )

SETTING / MOLDING MACHINE MOLD / MATERIAL
 Poor injection capacity ( volume and plasticizing  Gate balance is poor
ability )  Gate, runner and sprue are small
 Material supply quantity insufficient  Mold temp is low
 Injection pressure is low  Cold slug appear
 Resin temp is low  Mold cavity is to thin
 Injection speed is low  Gas purging is inadequate
 Nozzle resistance is large ( diameter is small or  Insert ribs or other element to improve flow
nozzle is long )  Poor flow of materials
 Screw charging is poor  Improver lubricating treatment
 Nozzle is cold
 Back flow prevention ring is broken
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Created by Iwan Muhdi

JENIS NG : Flashes
SETTING / MOLDING MACHINE MOLD / MATERIAL
 Injection pressure is too high  Poor mold parallelism
 Clamping force is small  Parting lines die not matched
 Excessive injection quantity  Preserve of foreign material between mold
 Resin temp is to high halves
 Injection holding pressure time is long  Projection area is too large
 Injection speed is to high  Decrease the mold temp
 Wear of the mold half parting surface
 Resin viscosity during mold is to low

JENIS NG : Sink Mark

SETTING / MOLDING MACHINE MOLD / MATERIAL
 Injection pressure is low  Mold temp is too high
 Injection holding pressure time is large short  Mold temp is not even
 Injection speed is low  Gate is too small
 Charging quantity is insufficient  Runner and sprue are thin
 Resin temp is to high  Cavity thickness is uneven
 Nozzle resistance is large  Unsuitable ejector pin shape
 Mold opening is too early  Resin flow is too fluid
 Nozzle is cold  Shrinkage rate is large
 Back Flow prevention ring is broken or worn

36

Created by Iwan Muhdi