INJECTION KNOW HOW

How Backpressure Optimization Affects Melt Preparation

Backpressure is often the least understood of the settings in an injection molding process, even though it can play a significant role in the final quality of the part. Let’s start with understanding what backpressure is and then learn how to optimize it for a given mold.
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How Important is Minimizing Residence Time in Injection Molding?

Does a focus on the concept of “minimum residence time” distract attention from areas of injection molding that have more of a direct impact on melt quality?
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Understanding Flow Fronts and Defects

Flow-front behavior and corrections are key to solving many common molding problems —what is your process’s flow trying to tell you about your part?
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Melt Preparation Part 1: Melt Temperature Optimization

A homogenous melt is required for consistent part quality, but achieving it requires balancing a number of factors, including barrel usage and temperature as well as screw speed, backpressure and residence time. Learn how to prepare your melt for molding success in this two-part series.
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How to Set Barrel Zone Temps in Injection Molding

Start by picking a target melt temperature, and double-check data sheets for the resin supplier’s recommendations. Now for the rest...
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What is Backpressure and How Should We Calculate It?

Does using an intensification ratio to calculate backpressure result in an accurate reflection of what’s happening in the barrel? Newer machine technologies have us revisiting an old project with fresh eyes.
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What to Do About Weak Weld Lines

Weld or knit lines are perhaps the most common and difficult injection molding defect to eliminate.

Are Your Sprue or Parts Sticking? Here Are Some Solutions

When a sprue or part sticks, the result of trying to unstick it is often more scratches or undercuts, making the problem worse and the fix more costly. Here’s how to set up a proper procedure for this sticky wicket.
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Understanding Intensification Ratio

A first step in taking the “art” out of molding.

Improve Quality & Productivity With Advanced Screw Design

Most molders are still running with screw designs that haven’t changed much in 30 years. But they don’t need to.

Stop Controlling Your Injection Molding Process with Machine-Only Settings

Monitor and record process outputs instead of the machine setpoints to ensure a validated process regardless of any machine deterioration, viscosity changes or other alterations.

How to Stop Flash

Flashing of a part can occur for several reasons—from variations in the process or material to tooling trouble.
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A Simpler Way to Calculate Shot Size vs. Barrel Capacity

Let’s take another look at this seemingly dull but oh-so-crucial topic.
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How to Get Rid of Bubbles in Injection Molding

First find out if they are the result of trapped gas or a vacuum void. Then follow these steps to get rid of them.
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Creating a Capable Process Using Process Capability

Know your Cp from your Cpk and how parts can meet dimensional specifications but still not be “capable.”

Molders’ Block: Dealing With Foreign Materials in a Hot-Runner System

Understanding plastic flow can help you understand how foreign materials move—or don’t move—through your hot-runner system.

How to Set Up Mold Protect on Your Injection Machine

Set the start position for mold protect where anything in the mold could be subject to damage.

Revisiting the '5 M's' of Molding

All injection molding ultimately comes down to the “Man, Mold, Machine, Material and Method.” But those key aspects can be viewed differently if you’re auditing mold changes before startup or troubleshooting changes for an already validated process.
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