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Steps to Optimizing the Injection Molding Process

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The complexities of engineering an injection molded plastic component or part for a complex application must translate to mold ability. If a molder is inexperienced in tool design and process optimization, there’s a good chance they won’t be familiar with methodologies essential for creating a highly efficient production process such as scientific plastic injection molding and, more specifically Design of Experiments (DOE) within scientific molding.

Let's take a look at the key steps that tool and process engineers take to ensure consistent and repeatable manufacturability of flawless molded parts.

1. PRODUCT DESIGN Determining product objectives such as function, aesthetics, assembly, etc., and the requirements for accomplishing the objectives. A team of engineers specially trained in advanced methodologies such as Design for Manufacturability (DfM) is assembled to identify and possibly improve upon solutions to meet the particular project requirements — including the selection of materials for the final complex injection molded part and the tool.

2. TOOL DESIGN Like product design, a thoughtful approach to tooling proves valuable. In addition to choosing the appropriate material for tool construction — hardened steel, prehardened steel, or aluminum — designing for proper gate location, draft, etc., is necessary to prevent costly project missteps.

3. MANUFACTURING Production is the obvious goal of the step-by-step injection molding process. Achieving successful outcomes brings together the product and tool designs with resins that deliver to project needs (such as strength, heat tolerances, sterility, etc.) and moldability requirements including tight tolerances, uniform wall thickness, heating, cooling, and consistent repeatable cycling.

WHY DOES THE PROCESS MATTER? Why are scientific molding and DOE important to your injection molding project? Simply put, they take the injection molding process to a much higher level of precision, helping to lower costs in the long run by allowing for identification and correction of tooling problems prior to production.

STEPS TO PROCESS OPTIMIZATION

1. TOOL FUNCTIONALITY EXAMINATION Every aspect of the tool's mechanical functionality is assessed to make sure everything works as designed, using the material settings provided by the supplier of the material to be molded.

2. SHORT SHOT TESTING Dynamic pressure loss and, in a multiple-cavity tool, cavity imbalance are determined and documented using sample parts. Also, the rheology curve (or viscosity curve) is established to indicate the best fill rate and pattern.

3. GATE SEAL STUDIES Both the pressure curve and weight of the sample parts are observed to see if the gates fully seal and at what point sealing occurs.

4. SAMPLE PARTS EVALUATION/DATA RECORDING All defects are examined and recorded, along with recommendations for any adjustments in the process or the tool in order to correct the defects. Likewise, data is recorded with regard to melt temperature, fill time, tool temperature, coolant flow, cycle time and pressure curves.

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