PLASTIC INJECTION MOLDING DEFECTS PREVENTION & ROOT CAUSE ANALYSIS

By FACE TO FACE PUBLIC PROGRAM

Date:

29 & 30 July 2024 (Every Session 9am to 5pm)

MON & TUE

Venue:

WYNDHAM GRAND BANGSAR, KUALA LUMPUR

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INTRODUCTION FOR PLASTIC INJECTION MOLDING DEFECTS PREVENTION & ROOT CAUSE ANALYSIS

Specifically designed for the practicing designer and molder.

This workshop focuses on prevention methods for defects and developing systematic root cause analysis skills. For solving molded-part defects and improving part quality problems.

 

COURSE OBJECTIVE

  • How to prevent defects from occurring in the first place?
  • Eighty % of plastic parts problems originate from poor design.
  • Gap analysis between DFM (Design for Manufacturing best practices) and your actual problems.
  • Root cause analysis.
  • Troubleshooting injection moulding defects in a systematic manner.
  • Implementing sustainable measures in place to prevent defects recurrence.
  • Scientific explanations on why these problems occur.

 

COURSE CONTENT

  • Plastic drying
    • Degradation
    • Drying time
    • Drying temperature
    • Types of dryers
    • Moisture measurement
    • Overdrying effect

 

  • Process optimization & scientific molding
    • Optimization of injection phase
    • Cavity balance
    • Pressure drop
    • Process window
    • Gate seal time
    • Cooling time
    • Screw speed & back pressure

 

  • Surface Defects
    • Flow lines and jetting
    • Splay (moisture or trapped air)
    • Haze, blush, and poor gloss
    • Mold mark
    • Gate blush and gate splay
    • Ink smearing
    • Incomplete molding
    • Race tracking
    • Jetting
    • Moldflow simulation errors

 

  • Burning and Contamination Problems
    • Burn marks and black specks
    • Burn streaks
    • Contamination
    • Discoloration or poor color match

 

  • Physical Problems
    • Flash
    • Short shots
    • Sink marks
    • Vacuum voids and bubbles
    • Burrs
    • Bulging
    • Overweight
    • Ejector marks

 

  • Geometry Maintenance Problems
    • Under- or over-sized dimensions
    • Poor dimensional repeatability (poor Cpk)
    • Warpage and bowing

 

  • Structural Defects
    • Cracking, crazing, and brittleness
    • Weld lines
    • Stuck parts and pin push marks
    • Long gates and plugged gates
    • Drag marks and mold damage
    • Break during assembly
    • Break after usage

 

  • Troubleshooting Procedures and Logic
    • How to effectively approach, analyze, and implement troubleshooting procedures.

 

  •  Exploring Root Causes
    • Explore the root causes of the various defects from the perspective of the plastic material as it fills, compresses, and cools within the cavity.

 

  • Part Defectives and Potential Solutions
    • How to avoid potential design-related problems?
    • How to optimize the part quality with process-related solutions?

 

  • Troubleshooting Guides (The Good, The Bad, The Efficient)
    • A comparison of the different troubleshooting guide formats, including which tend to be most effective for solving molded part problems.

 

  • Evaluating Attendees’ Molded Part Samples
    • Defective part samples brought in by the participants will be discussed in a group format.
    • An understanding by the participants of the processing conditions or a current process set-up sheet will greatly facilitate this discussion.

 

HOW TO ENQUIRY FROM US?

  1. Fill in the form below and submit to us.
  2. Initiate a conversation via live chat on the bottom left of our website by stating: “Hi, my name is [your-name], Ive already submitted the form for this training.”
  3. Well promptly reach out to you regarding the training youre interested in.

 

PLASTIC INJECTION MOLDING DEFECTS PREVENTION & ROOT CAUSE ANALYSIS

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