Custom Injection Molding: The Best Solution for Troubleshooting
Custom Injection Molding
Details
Details:
Model
Material
Brand
Origin
Application
Booling-Injection-3
P20, 718, S136, 2738 etc
Booling
China
Automotive parts, industrial parts, medical parts, household
Custom injection molding technology involves stages such as plastic melting, preform manufacturing, pressure holding, cooling, and solidification. This is a process that requires manufacturers to precisely control and provide timely feedback and best troubleshooting solution for any issues that arise during the process.
Advantages of Custom Injection Molding：
- Higher Precision
- Lower Cost
- Fast Production Rate
- Wide Material Choice
- Environment Protection
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Custom injection molding is a plastic processing method widely used in various fields such as automotive parts manufacturing, electronic appliances, medical devices, and daily necessities. This plastic injection molding method mainly involves injecting molten plastic into an injection mold, cooling it, and solidifying it to obtain the desired customized plastic parts.
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The Finished Product is Not Satisfactory
-Reason
- Insufficient injection volume, inadequate plasticizing ability, and insufficient excess material
- Custom injection molded products have thin walls, complex shapes, and large areas
- Insufficient diversion channels or small gates
- The amount of adhesive in the mold cavity exceeds the injection molding machine’s injection volume
- The flow state of the melt adhesive flowing into the multi-cavity mold cannot be properly balanced
- The temperature of the custom injection molding mold is too low, and the plastic cools too quickly
- The flow resistance of the mold pouring system is high, the feeding port position is improper, the cross-section is small the form is poor, and the process is long and tortuous
- When customizing injection molding, the raw materials may contain more moisture, volatile substances, or inflation in the melt
- Low nozzle temperature, low barrel temperature, causing blockage, or nozzle aperture too small
- Air cannot be discharged from the mold cavity in a timely and sufficient manner
- The material “bridges” in the hopper, causing insufficient feeding amount
- The injection time is set too short
- The holding time is set too short
- Plastic has poor fluidity, resulting in excessive flash and overflow
When customizing injection molding, excessive use of release agents and moisture in the mold cavity
-Solution
- Correct the unbalanced flow state in custom injection molding
- Add custom injection molding channels or enlarge gate sizes
- Use larger custom injection molding machines or reduce the number of mold cavities in the production mold
- Plastic custom injection molding should be dried before molding to ensure the mixing ratio and reduce impurities
- Correct the parameter values of temperature settings to prevent material overflow
- Increase the temperature of the material barrel and nozzle to ensure sufficient plasticization, and replace the large aperture nozzle
- Check the cooling system of the water transport ring and eliminate the phenomenon of “bridging”
- Increase injection pressure and speed parameter values
- Increase the setting value of the injection time parameter
- Improve or modify the pouring system of customized injection molds, including the position, section, form, and process of the feeding port
- Increase the setting value of the holding time parameter
- Adjust the mold temperature and cooling time
- Reasonably control the dosage of the release agent to prevent excessive moisture
- Reduce the injection volume of custom injection molding to ensure a fixed amount of material enters and enhance the plasticizing ability
- Increase the number and size of exhaust ducts
- Strive to reduce the complexity of custom injection molded products
Poor Welding
-Reason
- The gate system form of custom injection molding equipment is inappropriate, with small gates, small diversion channels, long processes, high flow resistance, and rapid temperature drop of the material
- The material temperature is too low or the mold temperature is too low
- The plastic chosen by manufacturers for custom injection molding has poor flowability, with the addition of cold materials and fast cooling speed
- There is moisture or lubricant in the custom injection molding mold, and there is too much inflation of the melted material and too much release agent
- Injection pressure is too low or injection speed is slow
- Poor shape of the product, uneven wall thickness, causing the melted material to converge at the thin wall
- Improper mold cooling system or poor exhaust
- Improper mixing of incompatible materials, oils, or release agents into plastics
-Solution
- Improve the gating system by increasing the gating or diversion channels, reducing process and flow resistance, and maintaining the temperature range of the material
- Increase the temperature of the melt glue cylinder and mold
- For materials with poor fluidity, prevent the addition of cold materials to accelerate cooling and affect the flow rate
- Check the exhaust holes of custom injection molding, dry the inner wall of the mold, or use plastics, additives, etc. according to the process technology standards
- Increase the injection pressure and speed settings
- Improve the shape of custom injection molded products or increase the injection molding cycle time
- Check the condition of the cooling system and exhaust vents
- Check for contamination of the mold material, clean the mold wall, and apply the appropriate release agent to crack the product
Product Pifeng
-Reason
- The projected area of the product exceeds the maximum product area allowed by the injection machine
- Incorrect mold installation or unidirectional force
- Injection molding machine templates are not parallel or the rod deformation is uneven
- Poor parallelism of the mold or obstruction at the mold edge
- Poor sealing of the mold parting surface, deviation of the mold cavity and core, or excessive clearance between sliding parts
- Plastic has too much fluidity and the amount of material added is too large
- The mold cavity material temperature of custom injection molding molds is high, and the mold temperature is too high
- Excessive injection pressure and fast injection speed
- Unstable or uneven clamping force
-Solution
- Choose a larger custom injection molding machine or select a suitable area of product mold
- Check the installation of customized injection molds and secure them tightly
- Check if the template and tie rod are parallel and correct to eliminate deformation
- Clean or polish the mold edges and check the parallelism of the mold
- Check whether the mold parting surface is clean and free of debris, correct the offset or gap, or replace the parts
- Proper control of feeding amount
- Control the temperature of the heating glue cylinder and the mold temperature
- Reduce the setting of injection pressure and speed parameter values
- Adjust the locking force parameters or correct the symmetry on both sides of the mold
Custom injection molding, due to its high degree of automation, has the characteristics of a short molding cycle and high production efficiency, which is suitable for the production of large quantities of precision parts and can well meet market demand. Modern injection molding technology has become a mature plastic molding technology with significant advantages.
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