Plastic Injection Molding

8 Steps to Injection Molding Process Optimization

When making decisions about process optimization, tool engineers and process engineers work together to proactively identify and correct any tooling weaknesses, following these 8 steps:

1. TOOL FUNCTIONALITY EXAMINATION 

Every aspect of the tool’s mechanical functionality is assessed to make sure everything works as designed, using the material settings provided by the supplier of the material to be molded.

2. SHORT SHOT TESTING

Dynamic pressure loss and, in a multiple-cavity tool, cavity imbalance are determined and documented using sample parts. Also, the rheology curve (or viscosity curve) is established to indicate the best fill rate and pattern.

3. GATE SEAL STUDIES

Both the pressure curve and weight of the sample parts are observed to see if the gates fully seal and at what point sealing occurs.

4. SAMPLE PARTS EVALUATION/DATA RECORDING

All defects are examined and recorded, along with recommendations for any adjustments in the process or the tool in order to correct the defects. Likewise, data is recorded with regard to melt temperature, fill time, tool temperature, coolant flow, cycle time and pressure curves.

5. QUALITY CONTROL

The sample parts go to quality control for examination and documentation of their measurements, shot-to-shot consistencies and overall quality.

6. TOOL ADJUSTMENTS

Based on information gathered during quality control, necessary tool adjustments are made, and new sample parts are made.

7. NEW SAMPLE CREATION/QUALITY CONTROL TESTING

The new sample parts are subjected to the same quality testing and more adjustments are made, if necessary.

8. PROCESS PARAMETER/PERFORMANCE RANGES VERIFICATION

The quality testing and adjustments continue until all process parameters meet their performance ranges. Once verified, the tool is ready for use and the process is deemed optimized.

By leveraging scientific molding, experienced custom injection molding engineers understand each phase of development — from tool design and mold fill analysis to process monitoring and quality control. The result? The most efficient and robust process possible for manufacturing the complex injection molded plastic parts and products you need for complex applications from medical devices,  electronic parts to automotive parts and other custom plastic parts.

Jingwei molding has more than 15 years experience in plastic injection molding and mold making. Your High Volume, Custom Plastic Parts Injection Molding Specialist.Any questions,please feel free to contact us via info@jweimolding.com or visit us at :jweimolding.com

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