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Different Types of Injection Molding Processes 

Although most injection molding processes are covered by the conventional process
description above, there are several important molding variations including: 
 Co-injection(sandwich)molding
 Fusible(lost, soluble)core injection molding
 Gas-assisted injection molding
 In-mold decoration and in mold lamination
 Injection-compression molding
 Injection molding of liquid silicone rubber
 Insert and outsert molding
 Lamellar (microlayer) injection molding
 Low-pressure injection molding
 Microinjection molding
 Microcellular molding
 Multicomponent injection molding(overmolding)
 Multiple live-feed injection molding
 Powder injection molding
 Push-Pull injection molding
 Reaction injection molding
 Resin transfer molding
 Rheomolding
 Structural foam injection molding
 Structural reaction injection molding
 Thin-wall molding
 Vibration gas injection molding
 Water assisted injection molding
 Rubber injection
Stress 
The main enemy of any injection molded plastic part is stress. When a plastic resin
(which contains long strains of molecules) is melted in preparation for molding, the
molecular bonds are temporarily broken due to the heat and shear force of the
extruder, allowing the molecules to flow into the mold. Using pressure, the resin is
forced into the mold filling in every feature, crack and crevice of the mold. As the
molecules are pushed through each feature, they are forced to bend, turn and distort
to form the shape of the part. Turning hard or sharp corners exerts more stress on
the molecule than taking gentle turns with generous radii. Abrupt transitions from one
feature to another are also difficult for the molecules to fill and form to.
As the material cools and the molecular bonds re-link the resin into its rigid form,
these stresses are in effect locked into the part. Part stresses can cause warpage,
sink marks, cracking, premature failure and other problems.
While some stresses in an injection molded part are to be expected, you should
design your parts with as much consideration for stress reduction as possible. Some
ways to do this are by adding smooth transitions between features and using rounds
and fillets in possible high stress areas.

Wall Thickness
Prior to ejection from the mold, injection molded parts are cooled down from
manufacturing temperatures so that they hold their shape when ejected. During the
part cooling step of the molding process, changes in pressure, velocity and plastic
viscosity should be minimized to avoid defects. Few aspects are more crucial during
this period than wall thickness. This feature can have major effects on the cost,
production speed and quality of the final parts.
Proper Wall Thickness:
Choosing the proper wall thickness for your part can have drastic effects on the cost
and production speed of manufacturing. While there are no wall thickness
restrictions, the goal is usually to choose the thinnest wall possible. Thinner walls use
less material which reduces cost and take less time to cool, reducing cycle time.
The minimum wall thickness that can be used depends on the size and geometry of
the part, structural requirements, and flow behavior of the resin. The wall thicknesses
of an injection molded part generally range from 2mm – 4mm (0.080" – 0.160"). Thin
wall injection molding can produce walls as thin as 0.5mm (0.020"). The chart below
shows recommended wall thicknesses for common injection molding resins.

Uniform Wall Thickness:

Thick sections take longer to cool than thin ones. During the cooling process, if walls
are an inconsistent thickness, the thinner walls will cool first while the thick walls are
still solidifying. As the thick section cools, it shrinks around the already solid thinner
section. This causes warping, twisting or cracking to occur where the two sections
meet. To avoid this problem, try to design with completely uniform walls throughout
the part. When uniform walls are not possible, then the change in thickness should
be as gradual as possible. Wall thickness variations should not exceed 10% in high
mold shrinkage plastics. Thickness transitions should be made gradually, on the
order of 3 to 1. This gradual transition avoids stress concentrations and abrupt
cooling differences.
Alternatives:
If your part is so complex that you need variations on your wall thickness, look for an
alternative. You may want to use design features such as coring or using ribs. At the
very least, try not to make the transitions between thicker and thinner sections too
abrupt. Try using a gradual transition or chamfered corners to minimize the dramatic
change in

Draft
Most injection molded plastic parts include features such as outside walls and
internal ribs that are formed by opposing surfaces of tool metal inside a closed mold.
To properly release the part when the mold opens, the side walls of the mold are
tapered in the direction that the mold opens. This tapering is referred to as "draft in
the line of draw". This draft allows the part to break free of the mold as soon as the
mold opens. The amount of draft required can depend on the surface finish of the
mold. A smooth, polished tool surface will allow the part to eject with less draft than a
standard tool surface.
Consider the fabrication of the hollow plastic box seen to the right. Once the plastic
has hardened around the mold, the mold must be removed. As the plastic hardens, it
will contract slightly. By tapering the sides of the mold by an appropriate "draft angle",
the mold will be easier to remove.
The amount of draft required (in degrees) will vary with geometry and surface texture
requirements of the part. Below are several rules for using draft properly:

 Be sure to add draft to your 3D CAD model before creating radii

 Use at least 1 degree of draft on all "vertical" faces
 1 ½ degrees of draft is required for light texture
 2 degrees of draft works very well in most situations
 3 degrees of draft is a minimum for a shutoff (metal sliding on metal)
 3 degrees of draft is required for medium texture
Sink Marks  (^ Back to Top)

Textures 
Texturing is a process used to apply patterns to a mold surface. This process allows
flexibility in creating the final appearance of your parts. Texturing is an integral piece
in overall product development and should be considered during the design process
to achieve the desired results. Texture can be a functional component of design as
well. Imperfect parts can be camouflaged by the right texture. Is the part designed for
frequent handling? Texture can be used to hide finger prints and improve the grip for
the end user. Texture can also be used to reduce part wear from friction
A wide variety of textures are available for injection molded parts such as:
  Natural/Exotic
 Matte Finishes
 Multi-Gloss Patterns
 Fusions
 Graphics
 Leather Grains/Hides
 Woodgrain, Slate & Cobblestone
 Geometric & Linens
 Layered Textures to Create New Looks
 Images or Logos Incorporated into the Pattern

Alternative
Molding Defects Descriptions Causes
Name
Raised or layered zone on surface of Tool or material is too hot,
Blister Blistering
the Plastic part heater
Black or brown burnt areas on the
Air Burn/Gas
Burn marks plastic part located at furthest points Tool lacks venting, injectio
Burn
from gate
Color streaks Plastic material and colora
  Localized change of color
(US) starting to come through a
Contamination of the mate
Thin mica like layers formed in part
Delamination   being used for a safety cri
wall
delaminated as the materi
Excess material in thin layer Tool damage, too much in
Flash Burrs
exceeding normal part geometry also be caused by dirt and
Embedded Embedded Foreign particle (burnt material or Particles on the tool surfac
contaminates particulates other) embedded in the part too much shear heat burni
Directionally "off tone" wavy lines or Injection speeds too slow
Flow marks Flow lines
patterns injection speeds must be s
Deformed part by turbulent flow of
Jetting   Poor tool design, gate pos
material
Polymer polymer breakdown from oxidation,
  Excess water in the granu
degradation etc.
Localized depression  Holding time/pressure too
Sink marks  
(In thicker zones) can also be caused by the
Non-Fill/Short
Short shot Partial part Lack of material, injection
Mold
Splash
Circular pattern around gate caused
Splay marks Mark/Silver Moisture in the material, u
by hot gas
Streaks
 String like remain from previous shot
Stringiness Stringing Nozzle temperature too hi
transfer in new shot
Lack of holding pressure (
Empty space within part 
Voids   holding time). Also mold m
(Air pocket)
properly and part walls are
Knit Line/Meld Discolored line where two flow fronts Mold/material temperature
Weld line
Line meet don't bond)
Cooling is too short, mater
Warping Twisting Part Distorted part
temperatures (the parts bo

https://www.creativemechanisms.com/blog/what-cause-injection-molding-defects-and-how-to-fix-
them

Top-10 Injection Molding Defects And How To Fix Them

Making injection molded prototypes is both an art and a science. High
levels of technical expertise and attention to detail are required to prevent
small mistakes from costing companies big money when it comes to mass-
production of novel parts.
Preventing such a circumstance is all about highly competent design. This
article discusses some of the molding defects that can occur in a part
during injection molding, and ways to fix and avoid them. Design
shortcomings we will discuss include:
1. Flow Lines
2. Sink Marks
3. Vacuum Voids
4. Surface Delamination
5. Weld Lines
6. Short Shots
7. Warping
8. Burn Marks
9. Jetting
10. Flash
Most mistakes are caused by nescient personnel without the necessary
experience or the right tools at their disposal. Conversely, creative solutions
and ingenuity abound in personnel with the right experience and the correct
combination of hardware and software. Finding the right team of people
with relevant expertise is the most important part of the process.
Flow Lines
Description: Flow lines are streaks, patterns, or lines - commonly off-toned
in color - that show up on the prototype part as a consequence of the
physical path and cooling profile of the molten plastic as it flows into the
injection mold tooling cavity. Injection molded plastic begins its journey
through the part tooling via an entry section called a “gate.” It then flows
through the tool cavity and cools (eventually hardening into a solid).

Image From DieNamic.com

Causes: Flow line defects are caused by the varying speed at which the
molten plastic flows as it changes direction through the contours and bends
inside the mold tool. They also occur when the plastic flows through
sections with varying wall thickness, or when the injection speed is too low
causing the plastic to solidify at different speeds.
Remedies:
1. Increase injection speeds and pressure to the optimal level, which will
ensure the cavities are filled properly (while not allowing the molten
plastic time to start cooling in the wrong spot). The temperature of the
molten plastic or the mold itself can also be elevated to ensure the
plastic does not cool down sufficiently to cause the defect.
2. Round corners and locations where the wall thickness changes to
avoid sudden changes in direction and flow rate.
3. Locate the gate at a spot in the tool cavity with thin walls.
Sink Marks
Description: Sink marks are small craters or depressions that develop in
thicker areas of the injection molded prototype when shrinkage occurs in
the inner portions of the finished product. The effect is somewhat similar to
sinkholes in topography, but caused by shrinkage rather than erosion.

Image From PlasticTroubleshooter.com

Causes: Sink marks are often caused when the cooling time or the cooling
mechanism is insufficient for the plastic to fully cool and cure while in the
mold. They can also be caused by inadequate pressure in the cavity, or by
an excessive temperature at the gate. All else being equal, thick sections of
the injection molded part take longer to cool than thin ones and so are more
likely to be where sink marks are located.
Remedies:
1. Mold temperatures should be lowered, holding pressure increased,
and holding time prolonged to allow for more adequate cooling and
curing.
2. Reducing the thickness of the thickest wall sections will also ensure
faster cooling and help reduce the likelihood of sink marks.
Vacuum Voids
Description: Vacuum voids are pockets of air trapped within or close to the
surface of an injection molded prototype.

Causes: Vacuum voids are often caused by uneven solidification between

the surface and the inner sections of the prototype. This can be aggravated
when the holding pressure is insufficient to condense the molten plastic in
the mold (and thereby force out air that would otherwise get trapped). Voids
can also develop from a part that is cast from a mold with two halves that
are not correctly aligned.
Image from PlasticTroubleshooter.com

Remedies:
1. Locate the gate at the thickest part of the molding.
2. Switch to a less viscous plastic. This will ensure that less gas is
trapped as air is able to escape more rapidly.
3. Increase holding pressure as well as holding time.
4. Ensure that mold parts are perfectly aligned.
Surface Delamination
Description: Surface delamination is a condition where thin surface layers
appear on the part due to a contaminant material. These layers appear like
coatings and can usually be peeled off (i.e. “delaminate”).
 Image From PlasticTroubleshooter.com

Causes: Foreign materials that find their way into the molten plastic
separate from the finished product because the contaminant and the plastic
cannot bond. The fact that they cannot bond not only has an affect on the
appearance of the prototype, but also on its strength. The contaminant acts
as a localized fault trapped within the plastic. An over-dependence on mold
release agents can also cause delamination.
Remedies:
1. Pre-dry the plastic properly before molding.
2. Increase the mold temperature.
3. Smooth out the corners and sharp turns in the mold design to avoid
sudden changes in melt flow.
4. Focus more on the ejection mechanism in the mold design to reduce
or eliminate the dependence on mold release agents.
Weld Lines
Description: Weld lines are actually more like a plane than a line that
appears in a part where molten plastics meet each other as they flow from
two different parts of the mold.

Image From PlasticTroubleshooter.com

Causes: Weld lines are caused by the inadequate bonding of two or more

flow fronts when there is partial solidification of the molten plastic.
Remedies:
1. Raise the temperature of the mold or molten plastic.
2. Increase the injection speed.
 3. Adjust the design for the flow pattern to be a single source flow.
4. Switch to a less viscous plastic or one with a lower melting
temperature
Short Shot
Description: As the term implies, short shots can be described as a
situation where a molding shot falls short. This means that the molten
plastic for some reason does not fully occupy the mold cavity or cavities,
resulting in a portion where there is no plastic. The finished product
becomes deficient because it is incomplete.

Causes: Short shots can be caused by a number of things. Incorrect

calibration of the shot or plasticizing capacities can result in the plastic
material being inadequate to fill the cavities. If the plastic is too viscous, it
may solidify before fully occupying all the cavities and result in a short shot.
Inadequate degassing or gas venting techniques can also result in short
shots because air is trapped and has no way to escape; plastic material
cannot occupy the space that air or gas is already occupying.
Remedies:
1. Select a less viscous plastic with higher flowability. This plastic will fill
the hardest-to-reach cavities.
2. Increase mold or melt temperature so as to increase flowability.
3. Account for gas generation by designing the mold so that gas is not
trapped within the mold and is properly vented.
4. Increase the material feed in the molding machine or switch to a
machine that has a higher material feed in the event that the
maximum material feed has been reached. 
Warping
Description: Warping (or warpage) is the deformation that occurs when
there is uneven shrinkage in the different parts of the molded component.
The result is a twisted, uneven, or bent shape where one was not intended.
Causes: Warping is usually caused by non-uniform cooling of the mold
material. Different cooling rates in different parts of the mold cause the
plastic to cool differently and thus create internal stresses. These stresses,
when released, lead to warping.
Remedies:
1. Ensure that the cooling time is sufficiently long and that it is slow
enough to avoid the development of residual stresses being locked
into the part.
2. Design the mold with uniform wall thickness and so that the plastic
flows in a single direction.
3. Select plastic materials that are less likely to shrink and deform.
Semi-crystalline materials are generally more prone to warping.
Burn Marks
Description: Burn marks are discolorations, usually rust colored, that
appear on the surface of the injection molded prototypes.

Image From ParallelDesign.com

Causes: Burn marks are caused either by the degradation of the plastic

material due to excessive heating or by injection speeds that are too fast.
Burn marks can also be caused by the overheating of trapped air, which
etches the surface of the molded part.
Remedies:
1. Reduce injection speeds.
2. Optimize gas venting and degassing.
3. Reduce mold and melt temperatures.
Jetting
Description: Jetting refers to a situation where molten plastic fails to stick
to the mold surface due to the speed of injection. Being fluid, the molten
plastic solidifies in a state that shows the wavy folds of the jet stream on the
surface of the injection molded part.
 Image From ParallelDesign.com

Causes: Jetting occurs mostly when the melt temperature is too low and
the viscosity of the molten plastic becomes too high, thereby increasing the
resistance of its flow through the mold. When the plastic comes in contact
with the mold walls, it is rapidly cooled and the viscosity is increased. The
material that flows through behind that viscous plastic pushes the viscous
plastic further, leaving scrape marks on the surface of the finished product.
Remedies:
1. Increase mold and melt temperatures.
2. Increase the size of the gate so that the injection speed becomes
slower.
3. Optimize gate design to ensure adequate contact between the molten
plastic and the mold.
Flash
Description: Flash is a molding defect that occurs when some molten
plastic escapes from the mold cavity. Typical routes for escape are through
the parting line or ejector pin locations. This extrusion cools and remains
attached to the finished product.

Image From Paulsontraining.com

Causes: Flash can occur when the mold is not clamped together with
enough force (a force strong enough to withstand the opposing forces
generated by the molten plastic flowing through the mold), which allows the
plastic to seep through. The use of molds that have exceeded their lifespan
will be worn out and contribute to the possibility of flash. Additionally,
excessive injection pressure may force the plastic out through the route of
least resistance.
Remedies:
1. Increase the clamp pressure to ensure that the mold parts remain
shut during shots.
 2. Ensure that the mold is properly maintained and cleaned (or replaced
when it has reached the end of its useful lifespan).
3. Adopt optimal molding conditions like injection speed, injection
pressure, mold temperature, and proper gas venting.
A large number of the defects mentioned above can be prevented in the
design process by incorporating proper tooling design into the iterative
process. Using moldflow software like Solidworks plastics will help you
identify ideal gate locations, anticipate air pockets, flow or weld lines, and
vacuum voids. Most importantly, it will help you design solutions to these
problems ahead of time, so that when it comes to production you do not
have to worry about the defects costing you money.
Read more about our process at Creative Mechanisms, and how we can
help you avoid defects in the injection molding process!