When producing injection molding products, we often encounter various challenges. Below, the Yize Mould team has carefully compiled solutions to four common problems for your reference.
Bubbles appearing during injection molding product formation primarily stem from the following points, with corresponding solutions as follows:
Vacuum Bubbles Caused by Uneven Wall Thickness:
Optimize gate and runner design; gate height is recommended to be 50%-60% of product wall thickness.
Ensure sufficient additional injection material until the gate is fully sealed.
Extend injection time slightly beyond gate sealing time.
Reduce injection speed while increasing injection pressure.
Select materials with higher melt viscosity.
Bubbles Induced by Volatile Gases:
Enhance pre-drying processes.
Lower resin temperature to prevent gas formation.
Bubbles Due to Poor Flowability:
Increase resin and mold temperatures.
Accelerate injection speed.
Main runner sticking is another common problem in injection molding, with causes and solutions including:
Insufficient cooling time results in the main runner not fully solidifying.
Increase the draft angle of the main runner.
Adjust the fit between the main runner bushing and nozzle to prevent leakage.
Improve the surface roughness of the main runner and add cooling wells.
Raise the nozzle temperature.
Slow production in injection molding may stem from the following factors, with corresponding countermeasures:
High plastic and mold temperatures prolong cooling times.
Shorten melt time, reduce back pressure, and optimize cooling in the feed section.
Adjust oil and electrical circuits to speed up machine actions.
Design molds that facilitate ejection and enable fully automatic operation.
Avoid excessive wall thickness to reduce cooling time.
Address nozzle drooling by using self-locking nozzles or lowering temperatures.
Enhance barrel heat supply by selecting machines with larger plasticizing capacities or strengthening preheating.
Incomplete formation of injection molding products is mainly attributed to insufficient material and improper injection pressure and speed, with specific analyses and countermeasures as follows:
Injection Molding Machine Factors:
Choose machines with larger plasticizing and heating powers.
Address screw and barrel wear issues to ensure adequate filling volume.
Repair heating systems to ensure barrel temperature.
Fix injection cylinder seal components to guarantee injection pressure.
Adjust nozzle orifice size and centrality to reduce resistance.
Injection Molding Mold Factors:
Increase mold temperature to improve material flow.
Balance cavity distribution, increase wall thickness, or set auxiliary runners.
Properly set runner sizes, using arcuate transitions to reduce pressure loss.
Improve mold ventilation by utilizing screw gaps or parting lines, and add vent channels or holes if necessary.
Yize Mould, as a group enterprise deeply involved in precision mold design, manufacturing, and injection molding product production, is committed to providing customers with one-stop solutions from product design to after-sales service. Our products are widely used in automotive connectors, medical device injection molding parts, medical consumables, PFA fluoropolymer tube fittings, and other fields. Welcome to contact us at [email protected] to create a better future together.
