MOLDING ILLUSTRATION DESCRIPTION
DEFECTS
Splay It refers to the appearance of streaks,
lines, or patterns on the surface of
molded plastic parts
Flow lines Flow lines refer to the undulating
patterns frequently observed on the
slender portions of molded
components. These lines exhibit a
slight variation in color compared to
their surroundings and can occasionally
manifest as circular bands.
Weld Lines Weld lines are generally seen at places
where molten material tends to
coverage after it is separated into two
different directions in the mold. These
lines are usually not thicker than a hair.
They might not be prominent, but they
signify weak material bonding.
Flash Flash is an excess material that flows
out of the mold cavity and forms a thin,
unwanted, and typically irregular
extension around the part. This excess
material is usually a result of poor
sealing of the mold components and
can negatively affect the quality of the
final product.
CAUSE
This defect is typically
caused by the presence of
moisture or other
contaminants in the plastic
material.
Flow lines in injection
molding occur when molten
material cools at varying
rates where flow fronts meet,
especially when material
solidifies too quickly due to
insufficient injection speed
or pressure. The choice of
plastic material can also
impact the likelihood of flow
lines, with some materials
being more susceptible to
this defect.
Weld lines in injection
molding happen when the
mold or part design creates
flow obstructions, parts have
complex geometry, injection
pressure or speed is
insufficient, or certain plastic
materials with specific flow
properties are used.
These defects are caused by
factors such as inadequate
mold clamping, excessive
injection pressure,
insufficient cooling time,
worn or damaged mold
components, and poor
material selection.
RESOLUTION
Prevent splay defects by storing plastic materials in
a dry environment with sealed containers and
moisture-resistant packaging to avoid moisture
absorption. Proper pre-drying of the material
eliminates potential moisture and contaminants that
may cause splay defects. Additionally, adjust and
optimize the injection molding process parameters,
including temperature, pressure, and injection speed,
to reduce the impact of moisture or contaminants
during molding. Effective process control helps
prevent the occurrence of splay defects.
To prevent flow lines in injection molding, adjust
injection speed and pressure for even filling,
optimize mold design for smoother material flow,
and consider using less flow-prone plastic materials
for specific applications.
To prevent weld lines in injection molding, optimize
mold design, simplify part geometry, ensure proper
injection pressure and speed, and select materials
with properties less prone to weld lines.
To prevent flash defects, ensure proper mold
clamping, adjust injection parameters, optimize
cooling time, maintain tooling, select suitable
materials, and improve mold design. These measures
help ensure the production of high-quality plastic
parts without flash.