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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

1. Plastic drying

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

2. Process optimization & scientific molding

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

3. 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

4. Burning and Contamination Problems

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

5. Physical Problems

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

6. Geometry Maintenance Problems

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

7. 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

8. Troubleshooting Procedures and Logic

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

9. 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.

10. Part Defectives and Potential Solutions

• How to avoid potential design-related problems?
• How to optimize the part quality with process related solutions?

11. 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.

12. 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?

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