Trouble Shooting For INJECTION MOULDING

TROUBLESHOOTING
FOR INJECTION
MOULDING
SUBMITTED BY : HARSH MODI

STUDY : M.SC. SEM : 3
SUBMITTED TO : PRAVEEN SIR
INJECTION MOULDING PROBLEMS
In the injection moulding process , faults can appear –

When changing to a new material
While running regular production runs
While trying out a new mould.
Cont…
The faults appearing while moulding components can be

due to one or more factors given below:
Machine related
Mould and mould design related
Op. condition related (time , temp.& pressure)
Material related
Component design related.
Cont…
Before going to the analysis to find out reasons for the

moulding faults , it must be ensure that –
the machine operating conditions are consistent
 temperature control is maintained
 moulding operation is consistent and
 a uniform cycle time is maintained.
~ HOW MANY KINDS OF DEFECTS ARE THERE?
~ HOW MANY KINDS OF DEFECTS ARE
THERE?
31
DEFECTS
1. Sink Marks
2. Streaks
3. Blistering
4. Weld Lines
5. Gloss difference
DEFECTS
6. Jetting
7. Record grooves effect
8. Dull spots near gate area
9. Incompletely filled part ( Short

shots)
10. Diesel effect

DEFECTS
11. Over sprayed parts (Flashes)
12. Stress whitening/Cracking
13. Ejector marks
14. Deformation during demolding
15. Ejection Grooves

DEFECTS
16. Flaking of surface layer
17. Cold slug
18. Filamentation
19. Dark spots
20. Plate outs

DEFECTS
21. Defects on electroplated parts

22. Broken or ragged film hinge
23. Warpage
24. Fish eye
DEFECTS
25. Hesitation
26. Over packing
27. Unbalanced flow

28. Nozzle drool
29. Nozzle freeze – off
30 Nozzle spitting
31. Screw slip
1.SINK MARKS
SINK
MARKS
Sink marks are the localized contractions or the

depressions on the surface of the moldings 14
1.SINK MARKS
SINK
MARKS
15
1.SINK MARKS
Sink
marks
Sink marks on a cylindrical core with poor

temperature control
CAUSE OF SINK MARKS
➢ Sink marks occur during the cooling process if

certain areas of the part are not cooled
sufficiently causing them to contract
➢ If these contractions are not compensated and

the outside wall is not stable enough due to
insufficient cooling depressions occur
CAUSAL FACTORS OF SI NK MARKS
➢ 1. Insufficient plastic in the mould to

compensate for shrinkage due to:
• Thick sections, bosses, ribs

• Injection pressure too low
• Unbalanced gate
• Injection speed too slow
➢ 2. Plastic too hot
➢ 3. Article ejected too hot due to insufficient

cooling
➢ 4. Gate located at thin section

POSSIBLE SOLUTIONS FOR SI NK MARKS
1. Relocate gates on or as near as possible to

thick sections
2. Increase cooling time
3. If possible change the mold design to

maintain an even wall thickness throughout
the part
POSSIBLE SOLUTIONS FOR SI NK MARKS
4. Increase injection speed & mold

temperature. Do this if the sink marks are
away from the gate or in thin walled areas
5. Dry the material

2. STREAKS
➢ Streaks are the prominent stretchy marks
on the surface of the moldings.
➢ CHARRED STREAKS
➢ MOISTURE STREAKS
➢ AIR STREAKS
➢ COLORED STREAKS
➢ GLASS FIBER STREAKS

2.CHARRED STREAKS
➢ Charred streaks due to excessive residence time in

the plasticising cylinder
2.MOISTURE STREAKS:
➢ Streaks due to excessive moisture content of the

granules
2.AIR STREAKS:
➢ Streaks near rib due to entrained and stretched air

2.COLOUR STREAKS:
➢ Colour streaks in the sub-manifold of the cold runner

2.COLOUR STREAKS:
➢ Colour streaks due to an incompatible master batch

2.GLASS FIBRE STREAKS
➢ Glass fibre Streaks (clearly visible weld line)

CAUSAL FACTORS FOR STREAKS
➢ Temperature too high or residence time too

long during pre drying
➢ Melt temperature too high
➢ Residence time in plasticizing unit too long
➢ Insufficient pre-drying of the granules

CAUSAL FACTORS FOR STREAKS
➢ Wrong storage of the material
➢ Temperature at flange too low
➢ Poor venting
POSSIBLE SOLUTIONS FOR STREAKS
1. If melt temperature is above processing range

reduce cylinder temperature,Screw speed,
dynamic pressure
2. If the residence time is in critical range reduce

the cycle time.
3. If burnt marks appear near gate decrease

injection rate avoid sharp corners, edges in gate
4. Material to be sufficiently pre dried
5. Check material storage and its packaging

6. Reduce residence time in material hopper
7. Reduce injection rate
8. Round sharp edges of transitions.
9. Reduce depth of engraving
10. Provide for venting

11. Use smaller colour pigments
12. Check solubility of the used die
13. Use shorter glass fiber

3.BLISTERS
➢ Hollows created on or in the molded part
AIR BUBBLES
1. Air bubbles
(solidified while flowing around)
3.BLISTERS
➢ Air traps occur when converging flow fronts

surround and trap a bubble of air.
➢ The trapped air can cause

➢ Incomplete filling and packing,
➢ Surface blemish in the final part.
➢ Air trapped in pockets may compress, heat up
and cause burn marks.
3.BLISTERS
(hollows created on or in the molded part)
voids
2. Voids in a thick walled molded part.

3.BLISTERS / BUBBLES
Bubbles
3.Bubbles
3.BLISTERS
DELAMINATION
4.Blisters and delamination

CAUSAL FACTORS FOR BLISTERS
➢ Decompression is excessively high or fast
➢ Insufficient dynamic pressure
➢ Venting problems inside the mould
➢ Regrind use
POSSIBLE SOLUTIONS FOR BLISTERS
1. Decrease melt temperature
2. Decrease screw speed
3. Dry the material
4. Increase back pressure

POSSIBLE SOLUTIONS FOR BLISTERS
5. Increase mold temperature
6. Ensure regrind is not too coarse
7. Provide additional mold vents
8. Relocate gate
4.WELD LINE
(Witness marks of two or more melt flow fronts at their joining
zone)
WELD LINE
➢ Weld Lines are created when two or more melt flow fronts
meet possibly causing a cosmetically visible line.
➢ It can also create a weakened area in the finished

molded part especially with filled resins
CAUSAL FACTORS OF WELD LINE
➢ Low melt temperature

➢ Injection pressure too low
➢ Excessive mould lubricant on the mould
➢ Improper venting in the mould
➢ Low mould temperature
➢ Injection speed very slow
➢ Shift in mould resulting in one wall being
too thin
➢ Poor material flow properties
POSSIBLE SOLUTIONS FOR WELD LINE
1. Increase injection pressure
2. Increase injection speed
3. Increase injection hold
4. Increase melt & mold temperature

POSSIBLE SOLUTIONS FOR WELD LINE
5. Make sure part contains no sharp variation

in cross-section
6. Move gate (Move weld line to invisible

area)
5.GLOSS/GLOSS DIFFERENCES
Very glossy impression due to reflection on the polished surface

Only slightly glossy impression due to reflection on a rough

surface
➢ The gloss of a mould is the reflecting property of

its surface when exposed to incident light.
➢ When a ray of light hits the surface its direction will
change (Refraction).
➢ The smoother the surface of molding the smaller
the scattering angle of reflecting ray and rougher
the surface the larger the angle.
CAUSAL FACTORS FOR GLOSS DIFFERENCES
➢ Different cooling conditions
➢ Shrinkage differences
➢ Stretching of already cooled areas e.g. due to

warpage
➢ Molds that are textured or resins that are

filled
➢ Poor polished mold surfaces

POSSIBLE SOLUTIONS FOR GLOSS DIFFERENCES
1. Clean mold surface
2. If the part design allows increase the polish of

the molding surface
3. Increase melt temperature
4. Make sure venting is adequate

6.JETTING
The prominent inhomogeneous snake like strands
on the surface of molding
JETTING
JETTING
➢ Jetting originating at the gate, spreading over

entire part. 56
6.JETTI N G
Mould filling process in frontal flow and with jetting
➢ When cross section of the molded part is

increased rapidly in conjunction with high injection
speeds
➢ Wrong position of the mold where melt fills the

cavity from top to bottom
6. JETTING
THREE EXAMPLE OF JETTING

6.JETTING
Jetting occurs when polymer melt is pushed at a high

velocity through restrictive areas, such as the nozzle,
runner, or gate, into open, thicker areas, without forming
contact with the mold wall. Jetting leads to part weakness,
surface blemishes, and a multiplicity of internal defects.
POSSIBLE SOLUTIONS FOR JETTING
1. Decrease injection speed
2. Change the melt temperature, up or down
3. Increase the gate diameter
4. Move the gate so that when the plastic first

enters the cavity it hits an obstruction such
as a rib or wall
7.RECORD GROOVES EFFECT
Very fine grooves on the surface of the moulded

part
Causes:
1. Insufficient mold & melt temperatures
2. Injection speed
7.RECORD GROOVES EFFECT
RECORD GROOVE OR ORANGE PEEL

POSSIBLE SOLUTIONS FOR RECORD GROOVES EFFECT
1. Increase mould temperature
2. Increase melt temperature.
3. Avoid small runners
4. Increase injection rate
5. Increase maximum injection pressure

8.DULL SPOTS IN GATE AREA
Dull spots in the gate area are primarily caused

by
1. Small gates
2. High injection rate.
59
8.DULL SPOTS I N GATE AREA
Melt flows into the open

cracks in the peripheral
area.
➢ High injection rates and small gate cross sections and by-
passes create strong orientations of the molecules during
injections.
➢ Since there is not enough time for the relaxation directly
behind the gate the peripheral layers are frozen while they
are still strongly oriented.
60
8.DULL SPOTS I N GATE AREA
Melt flows into the open

cracks in the peripheral
area.
➢ Such peripheral layers can be stressed with a very minimal

degree and crack under the slightest impact of high shear
stress.
➢ The hot melt inside flows towards the wall and forms
extremely fine notches.
➢ Dullness is due to widely spread reflections in this area
61
POSSIBLE SOLUTIONS FOR DULL SPOTS I N GATE AREA
2. Increase gate diameter
3. Round of transition from gate to cavity
4. Move the position of gate to unimportant

area
62
9.INCOMPLETELY FILLED PART (SHORT SHOTS)
SHORT SHOT
➢ Failure to fill the mould or cavities of the mould

completely is termed as a short shot. 68
INCOMP0LETELY
FILLED
64
➢ A short shot is the incomplete filling of a mold cavity

which results in the production of an incomplete part.
➢ The flow freezes off before all of the flow paths have
filled.
65
CAUSAL FACTORS FOR SHORT SHOTS
➢ Injected compound volume is too small (shot

volume)
➢ Poor venting
➢ Injection pressure or rate is insufficient
➢ Wrong temperature control
66
CAUSAL FACTORS FOR SHORT SHOTS
➢ Thin cross sections where in, the melt freezes

pre maturely due to unfavorable flow conditions
➢ improper balance of plastic flow in multiple

cavity moulds
➢ Insufficient gate opening
67
POSSIBLE SOLUTIONS FOR SHORT SHOTS
1. Increase injection pressure,speed
2. Increase melt and mold temperature
3. Increase nozzle temperature. Ensure that the manifold

and nozzles have reached the set temperature
4. Increase shot size
68
POSSIBLE SOLUTIONS FOR SHORT SHOTS
5 . Make sure mold is vented correctly and vents are clear.
6. Change part design.

Thin areas of the mold may not fill completely, especially
if there is a thick to thin transition, or there is a long rib
that cannot be vented very well.
If the part design allows it, change in these areas can
improve the situation
69
10.DIESEL EFFECT / BURNED MARKS
BURNED MARKS
➢ Diesel effect due to entrapped air at the end of flow path &
poor ventilation near rib.
➢ Burn Marks or Dieseling show up on the finish molded

parts as charred or dark plastic caused by trapped gas 75
and is usually accompanied by a distinctive burnt smell.
BURN MARKS
BURN MARKS 76
BURNS
77
BURNS
➢ This is purely a venting problem, the trapped gas

is compressed and gets heated to a high degree
causing the burn on the plastic.
➢ It can occur at blind holes, fillets, narrow ribs,near

places where several flow fronts meet, end of
flow paths etc.
73
POSSIBLE SOLUTIONS FOR DIESEL EFFECT
1. Alter gate position and/or increase gate size
2. Decrease injection pressure
3. Decrease injection speed
4. Decrease melt and/or mold temperature
5. Improve mold cavity venting.
Vents may become smaller over time due to

wear and they will need to be brought back
to their original depth
11.FLASHES
FLASHES
➢ Flashes are often seen near sealing faces, out of

vent grooves, or down ejector pins.
➢ It appears as thin or sometimes thick sections of
plastic where it would not be on a normal part.
Equivalent in PDC?
11.FLASHES
76
11.FLASHES
➢ Flashing occurs when a thin layer of material is
forced out of the mold cavity at the parting line or
ejector pins location.
➢ This excess material remains attached to the

molded article, and normally has to be manually
removed.
77
11.FLASHES
FLASHES
78
CAUSAL FACTORS FOR FLASHES
➢ Permissible gap widths exceeded,due to

insufficient mold tightness, exceeding
production tolerances,damaged sealing faces
➢ Clamping force too high or too low
➢ Internal mould pressure too high
➢ Insufficient viscosity of melt
79
POSSIBLE SOLUTIONS FOR FLASHES
1. Increase clamp pressure
2. Check mold venting. Vents may have been ground too

deep for the material being used
3. Check sealing surfaces to ensure that they seal off

properly by “blueing” them in under clamp tonnage
80
POSSIBLE SOLUTIONS FOR FLASHES
4. Check ejector pin bore diameter to pin diameter

tolerances.
5. The tolerances may be too large allowing plastic to

flash down the opening.
6. The tolerances may be too large for the material being

used and can occur due to wear over time.
81
12.STRESS WHITENING
➢ Cracking or Crazing is caused by high internal

molded in stress or by an external force imposed
upon the part.
➢ They can also be caused by an incompatible
external chemical being applied to the finished
parts
➢ The cracks often don't appear until days or
weeks after the parts have been molded. 87
12.STRESS WHITENING
STRESS WHITENING 88
POSSIBLE SOLUTIONS FOR STRESS WHITENING
1. Decrease injection pressure
2. Dry material
3. Increase cylinder temperature
84
POSSIBLE SOLUTIONS FOR STRESS WHITENING
5. Increase nozzle temperature
6. Modify injection speed
7. If the material is partially crystalline then it may

help to reduce the mold and/or melt temperature
8. If the material is amorphous then it may help to

increase the mold and/or melt temperature
85
13.EJECTOR MARKS
DEPRESSED EJECTOR
MARKS
➢ Ejector marks are the depressions or the

elevations causing abrupt changes in the wall
thickness these may also cause punctures of the
91
surface of part.
CAUSES FOR EJECTOR MARKS
➢ Wrong dimensioning or the design of mold
➢ High temperature differences within the mould

or between mold wall and ejector
➢ Premature demoulding or high demoulding

forces
➢ Wrong fittings or ejector lengths
87
POSSIBLE SOLUTIONS FOR EJECTOR MARK S
1. Check counter bores and contact surfaces of

the ejector heads
2. Refit ejector
3. Change ejector size accordingly
88
POSSIBLE SOLUTIONS FOR EJECTOR MARK S
5. Change ejector system
6. Check draft on core
7. Reduce demoulding force if it is high, reduce

holding pressure
89
14.DEFORMATION DURING DEMOULDING
DEFORMATION
DEFORMATION ON THE MOULDED PART DUE TO FORCED DE MOULDING
➢ A residual pressure builds up inside the moulded

part which is suddenly released during de moulding.
➢ It may be impossible to demould the part. 95
POSSIBLE SOLUTIONS FOR DEFORMATION DURING DEMOULDING
1. Reduce holding pressure
2. Reduce holding pressure time
4. Check ejector dimensions
91
POSSIBLE SOLUTIONS FOR DEFORMATION DURING DEMOULDING
5. Use antifriction layer to reduce demoulding

forces
6.Adopt direction of polishing to direction of

de molding
7. Use mould release agent
92
15.EJECTION GROOVES
➢ Ejection grooves are produced during demoulding

and constitute damage to the surface of the
molded part.
➢ They mainly occur on the structured surfaces. 98
CAUSES FOR EJECTION GROOVES
These may appear due to
➢ Less draft.
➢ More surface roughness.
➢ Mold deformation due to excessive cavity

pressure.
➢ Mold is not stiff.
94
POSSIBLE SOLUTIONS FOR EJECTION GROOVES
2. Increase wall thickness
3. Increase drafts
4. Use lower surface roughness
5. Increase mould stiffness
95
16.FLAKING OF SURFACE LAYER
FLAKING
➢ Delamination occurs when single surface layers

start flaking off the molded part due to insufficient
101
bondage between adjacent layers.
POSSIBLE SOLUTIONS FOR FLAKING OF SURFACE LAYER
1. Check for material contamination.

Incompatible resins or colorants may have
been accidentally mixed causing this condition
to be seen
2. Dry material
3. Increase melt temperature
5. Insufficient Blending. Check melt homogeneity

and plasticizing performance 102
17.COLD SLUG
COLD SLUG NEAR THE GATE
➢ Cold slugs are formed when melt solidifies in the 98

gate or in the nozzle before the cavity is filled.
17.COLD SLUG
WELD LINE BEHIND A COLD SLUG

17.COLD SLUG
FLOW FRONT TRANSFORT THE COLD SLUG IN TO THE MOULD

CAUSES FOR COLD SLUG
The causes may be
➢ Tip of the nozzle too cold
➢ Nozzle too long or unsuitable heater band
101
CAUSES FOR COLD SLUG
Possible Solutions
1. Check nozzle design
2. Check nozzle temperature regulation system
3. Increase nozzle temperature
4. Move injection unit backwards
102
18.FILAMENTATION
Long filamentation of a cold runner gating system near the machine

nozzle
➢ Due to insufficient cooling of the gate or sprue
area, the part does not break cleanly from the gate
area.
➢ The shape may range from a short pointed cone to
a filament of several centimeters.
➢ The premature retracting can crack the layer which108
is still in fluid state in to a form of filament.
18.FILAMENTATION
Long filament near a hot runner gate
➢ Due to insufficient cooling of the gate or sprue

area, the part does not break cleanly from the gate
area.
➢ The shape may range from a short pointed cone to
a filament of several centimeters.
➢ The premature retracting can crack the layer which109
is still in fluid state in to a form of filament.
POSSIBLE SOLUTIONS FOR FILAMENTATION
1. Provide sufficient cooling time during the cycle.
2. Excessive heat in the gate area.
3. Check thermocouple in the nozzle or decrease

the temperature of the hot runner manifold and
nozzle.
105
POSSIBLE SOLUTIONS FOR FILAMENTATION
4. Increase cooling at the gate area.
5. Ensure that you have controllable turbulent flow

in the gate area.
6. Reduce melt temperature.
7. Increase holding pressure time
106
19.DARK SPOTS
➢ Dark spots are similar to burn marks or brown

streaks but generally not as dark or severe.
➢ It may cause the part to be a darker shade than the
virgin pellets and is often found nearest the gate
area, however it can also appear as dark streaks
throughout the part. 112
19.DARK SPOTS
Severe black specks 113

19.DARK SPOTS
Poor screw flights design ,dead spots lead to black specks
109
CAUSES FOR DARK SPOTS
Causes: Tool Wear, thermal damage, dirt
Possible Solutions
1. Check hopper and feed zone for contamination.
2. Decrease back pressure.
3. Decrease melt temperature.
4. Decrease nozzle temperature.
110
CAUSES FOR DARK SPOTS
Causes: Tool Wear, thermal damage, dirt
Possible Solutions
• Move mold to smaller shot-size press.
• Provide additional vents in mold.
• Purge heating cylinder.
• Shorten overall cycle.
111
20.PLATE OUT
ROUGH SURFACE DUE TO PLATE OUT IN THE MOULD
➢ Plate out is a surface defect on the mold surface e.g on

inserts which eventually causes production of defective
parts.
➢ It usually occurs in materials such as
POM,PP,PETABS,PC,PSU,PE Materials with additives such
as flame retardants, lubricants and colorants are also 117
subject to plate out
20.PLATE OUT
PLATE OUT NEAR THE GATE
➢ Plate out is a surface defect on the mold surface e.g on

inserts which eventually causes production of defective
parts.
➢ It usually occurs in materials such as
POM,PP,PETABS,PC,PSU,PE Materials with additives such
as flame retardants, lubricants and colorants are also 118
subject to plate out
CAUSES FOR PLATE OUT
➢ Wrong or excessive use of lubricants
➢ In compatibility of colorant ,lubricant and base

material.
➢ Drying times too long.
➢ High material stress, such as excessive melt

temperatures, shear stress, shear rates.
114
POSSIBLE SOLUTIONS FOR PLATE OUT
1. Use suitable lubricant
2. Check metering of lubricant.
3. Use antifriction layers for moving mould

elements.
4. Check compatibility of base material with

additives/colorants/lubricant.
115
POSSIBLE SOLUTIONS FOR PLATE OUT
5. Check mixing ratio.
6. Reduce temperature
7. Ensure sufficient venting.
8. Eliminate moisture
116
21.DEFECTS ON ELECTROPLATED PARTS
PIMPLES AND BLISTERS ON A MOULDED PART
➢ Defects on electroplated parts (pimples,blisters,insufficient

layer adherence).
➢ Almost all defects on injection molded parts are also
visible on electroplated parts.
➢ These defects look more prominent than on part with1o2u2t
plating.
21.DEFECTS ON ELECTROPLATED PARTS
BLISTERING DUE TO DRAWN –IN AIR (COMPONENT

WITH AND WITHOUT ELECTROLITIC LAYER)
➢ Defects on electroplated parts (pimples,blisters,insufficient

layer adherence).
➢ Almost all defects on injection molded parts are also
visible on electroplated parts.
➢ These defects look more prominent than on part with1o2u3t
plating.
POSSIBLE SOLUTIONS DEFECTS ON ELECTROPLATED PARTS
2. Increase mould wall temperature when

using amorphous materials.
119
POSSIBLE SOLUTIONS DEFECTS ON ELECTROPLATED PARTS
4. Avoid wall thickness variations.
5. Avoid deformation during transportations
6. Avoid internal stresses.
7. Do not use releasing agent.
120
22.BROKEN/ RAGGED FILM HINGE
STRESS WHITENING ON A FILM HINGE
➢ Film hinges are moving and permanent joints.
➢ Their function is based on the elastic properties of

the material. 126
22.BROKEN/ RAGGED FILM HINGE
STREE
WHITENING
STRESS WHITENING ON A FILM HINGE
➢ The failure of film hinges is mainly caused by

overly stressed plastic.
➢ The film hinge may break partially or
completely.
➢ Over stressing can also result in whitening.
127
POSSIBLE SOLUTIONS FOR B R OK E N / RAGGED FILM HINGE
If the film not filled
2. Increase injection rate.
3. Increase mold wall temperature.
4. Increase wall thickness of film hinge.
5. Use easier flow material
6. Move position of gating away from hinge.

123
If too much force required to operate hinge.
1. Reduce mold wall thickness
2. Use material of low modulus of elasticity
3. Check hinge design
124
If breaks immediately or after few uses.
1. Remove weld line from film hinge area.
2. Reduce mold wall temperature.
3. Use material of higher viscosity
4. Ensure parallel flow of flow front
125
23.WARPAGE
MOULDED PART WITH WARPAGE ON THE EDGE
➢ Warpage is the deviation of the mould part from its

required shape.
➢ Warping, Part Distortion is shown up as parts being

bowed, warped, bent or twisted beyond the normal
specification outlined on the drawing
126
23.WARPAGE
WARPAGE
WARPAGE IN THE FLANGE AREA

➢ Warpage is the deviation of the mould part from its
required shape.
➢ Warping, Part Distortion is shown up as parts being

bowed, warped, bent or twisted beyond the normal
specification outlined on the drawing
127
23.WARPAGE
Variation in mould temperature will cause

component to warp 128
23.WARPAGE
Warped component
129
23. WARPAGE
➢ Distortion of the part caused by non-uniform shrinkage of

the plastic.
130
23.WARPAGE
➢ Typical warpage in most radiator end tanks.
131
CAUSAL FACTORS FOR WARPAGE
➢ Article ejected too hot.
➢ Variation in section thickness or contours of the

screw.
➢ Excessive area discharged or packed into the area

around the gate.
➢ Non-uniform mould temperature due to improper

positioning if the cooling channels in the mould.
➢ Excessive feed.
132
CAUSAL FACTORS FOR WARPAGE
➢ Injection pressure too high.
➢ Insufficient cooling time.
➢ Poorly designed or operated cooling system.
➢ Unbalanced gates on articles with more than one

gate.
➢ Holding time is more.
133
POSSIBLE SOLUTIONS FOR WARPAGE
1. Adjust melt Temperature (increase to relieve molded-

in stress, decrease to avoid over packing). stress,
decrease to avoid over packing). stress, decrease to
avoid over packing).
2. Check gates for proper location and adequate size.
3. Check mold knockout mechanism for proper design

and operation.
4. Equalize / balance mold temperature of both halves.
134
POSSIBLE SOLUTIONS FOR WARPAGE
5. Increase injection-hold.
6. Increase mold cooling time.
7. Relocate gates on or as near as possible to thick

sections.
8. Try increasing or decreasing injection pressure.
135
24. FISH EYES
➢ Fish eyes are a surface defect that results from

un melted material being pushed with the melt
stream into the cavity and appearing on the surface
of a molded part.
24. FISH EYES
Remedies for Fish eyes
1. Reduce regrind material

Contact material suppliers to get the recommended
levels of regrind to use.
2. Optimize melt temperature
3. Modify screw design

Contact material suppliers to get the right screw
design information to avoid improper melt mix or
overheating that leads to material degradation.
25. HESITATION
➢ Hesitation occurs when flow slows down in ribs

and in thin section of parts.
Remedies for Hesitation
1.It is useful to have thin ribs/bosses as the last

point to fill
2.Increase the wall thickness where the hesitation

occurred, to reduce the resistance to flow.
3. Use a less viscous material
4. Inject more quickly
5. Increase the melt temp

26. OVERPACKING
➢ Over packing is when extra material is compressed
in one flow path while other flow paths are still
filling.
26. OVERPACKING
Remedies for Over packing
1. Thicken or thin parts of the model to act as flow

leaders or deflectors.
2. Move the injection location to a position that will

define similar length flow paths.
3. Divide the cavity into imaginary sections, and

use one injection location for each section.
4. Remove unnecessary gates.

27. UNBALANCED FLOW
➢ Unbalanced flow is plastic completely filling
some flow paths in the mold before other flow
paths have filled.
➢ REMEDY:By altering the thickness of regions
within the part, flow can be fastened or
delayed in certain directions to help balance
flows.
28. NOZZLE DROOL
28. NOZZLE DROOL
29. NOZZLE FREEZE - OFF
29. NOZZLE FREEZE - OFF
30 . NOZZLE SPITTING
31. SCREW SLIP

Trouble Shooting For INJECTION MOULDING

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Trouble Shooting For INJECTION MOULDING

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TROUBLESHOOTING

SUBMITTED BY : HARSH MODI

In the injection moulding process , faults can appear –

The faults appearing while moulding components can be

Before going to the analysis to find out reasons for the

7. Record grooves effect

8. Dull spots near gate area

9. Incompletely filled part ( Short

10. Diesel effect

11. Over sprayed parts (Flashes)

12. Stress whitening/Cracking

13. Ejector marks

14. Deformation during demolding

15. Ejection Grooves

16. Flaking of surface layer

17. Cold slug

19. Dark spots

20. Plate outs

21. Defects on electroplated parts

26. Over packing

27. Unbalanced flow

Sink marks are the localized contractions or the

Sink marks on a cylindrical core with poor

➢ Sink marks occur during the cooling process if

➢ If these contractions are not compensated and

➢ 1. Insufficient plastic in the mould to

• Thick sections, bosses, ribs

➢ 2. Plastic too hot

➢ 3. Article ejected too hot due to insufficient

➢ 4. Gate located at thin section

1. Relocate gates on or as near as possible to

2. Increase cooling time

3. If possible change the mold design to

4. Increase injection speed & mold

5. Dry the material

➢ GLASS FIBER STREAKS

➢ Charred streaks due to excessive residence time in

➢ Streaks due to excessive moisture content of the

➢ Streaks near rib due to entrained and stretched air

➢ Colour streaks in the sub-manifold of the cold runner

➢ Colour streaks due to an incompatible master batch

➢ Glass fibre Streaks (clearly visible weld line)

➢ Temperature too high or residence time too

➢ Melt temperature too high

➢ Residence time in plasticizing unit too long

➢ Insufficient pre-drying of the granules

➢ Wrong storage of the material

➢ Temperature at flange too low

1. If melt temperature is above processing range

2. If the residence time is in critical range reduce

3. If burnt marks appear near gate decrease

4. Material to be sufficiently pre dried

5. Check material storage and its packaging

6. Reduce residence time in material hopper

7. Reduce injection rate

8. Round sharp edges of transitions.

9. Reduce depth of engraving

10. Provide for venting

11. Use smaller colour pigments

12. Check solubility of the used die

13. Use shorter glass fiber

➢ Hollows created on or in the molded part

➢ Air traps occur when converging flow fronts