Problem Causes Possible Solutions

1. Sink Marks Part is under filled or has Increase shot size

excessive shrinkage in Maintain adequate cushion
thicker sections Increase cavity or hold pressure
Melt or mold temperature too high (if gate freeze off too slow)
Increase hold time
Reduce fill rate
Cool sink area faster
Open gates
Reduce wall thickness of intersecting rib or boss
Improper gate locations or design

2. Voids Part is under filled or has Incomplete mold fill (short shot)
excessive shrinkage Maintain adequate cushion
Poor venting
Improper gate location
Injection rate too high
Excessive part thickness (+ 0.25 in. or 0.64 cm)

3. Shrinkage Volume decreases as Excessive shrinkage Increase cavity pressure and hold time
plastic cools and crystal- Part oversized or not enough shrinkage Decrease cavity
lizes or part is not fully pressure
packed out due to gates Maintain adequate cushion
freezing off too soon or Increase hold time
insufficient cooling time Delay gate sealing to allow pack out (increase melt
temperature)
Mold or melt temperature too high (gates not freezing off)
Improperly balanced cavity and core temperatures
Runners or gates too small
Wall thickness variation

4. Poor Weld Line Strength The convergence of flow Increase peak cavity pressure (fill faster)
fronts past an obstacle Increase mold and melt temperatures
or merging flow fronts in Increase hold pressure and time
multi-gated molds results Change gate location
in a weak, interfacial bond

5. Flash Insufficient clamp force, Decrease peak cavity pressure (decrease fill rate and/or
mold surface is deflecting, use profile injection)
mold shutoff surfaces not Decrease melt temperature
seating properly Increase clamp force
Clean mold surfaces
Check mold surface for flatness
Check integrity of mold shutoff
Change gate location
Use larger press
 Problem Causes Possible Solutions

6. Burning Compressed air in the Decrease peak cavity pressure (decrease fill rate and/
mold degrades resin or use profile injection)
Clean vents, increase size or number of vents
Reduce melt temperature

7. Warp Non-uniform stress due Part ejected too hot (increase cycle time)
to excessive orientation Mold at high temperatures, low pressures, and moderate
and/or shrinkage fill rates
Decrease injection fill rate
Improperly balanced core and cavity temperature
Molded in stress due to low stock temperature and
cold mold
Minimize hot spots in mold
Improperly balanced multiple gates
Flow too long, insufficient gates
Change gate location

8. Brittle Parts Excessive orientation, Increase injection fill rate

degradation of resin, over Increase melt temperature
packing, contamination, or Increase mold temperature and cool time
improper design Over packing (decrease hold pressure and time)
Degraded material (excessive melt temperature or
long residence time in barrel)
Contamination from other polymers
Use of incompatible carrier resins in color concentrates or
other additives
Unintentional nucleation from pigments
Improper design; inadequate radii at corners, notches,
or threads

9. Poor Appearance Flow front slips-sticks on Increase cavity pressure

(Flow marks, low mold surface, jets, or Fill speed and/or packing time too low
gloss, rough surface, pulsates Increase melt and/or mold temperature
jetting, orange peel, Cool more slowly
etc.) Mold temperature non-uniform or too low
Insufficient lubrication (internal lubricant or on tool surface)
Excessive mold lubricant (e.g. grease bleeding out of
the mold)
Dirty mold surface (clean and/or polish)
Poor pigment dispersion
Increase venting
Improper gate location or design

General Processing Guidelines

Drying: Barrel Temperature: Mold Temperature: Pressures: Times (sec):

Generally unnecessary; Rear 390-440F, 60-120F, 15-49C Boost 500-1500 psi, Boost 2-10
however, may be required 199-227C 3.45-10.34 MPa Hold Adjust for gate
for aesthetic purposes or
with highly filled products Middle 390-450F, Cushion: Hold 50-75% of Boost freeze-off
199-232C 0.25 in., 0.64 cm Back 50-100 psi, Cooling Depends on
Melt Temperature: Front 390-460F, .34-.69 MPa part thickness
400-460F, 199-238C Screw RPM medium
204-238C to fast
 Problem Causes Possible Solutions

10. Sticking in Mold Over packing, excessive Over packing, injection pressure too high reduce
shrinkage, tool design Under packing, excessive shrinkage see solutions to
causes physical attach- Short Shot
ment to the core or cavity Improperly balanced mold temperatures (colder on
movable half)
Reduce cycle time (sticking on cores)
Increase cycle time (sticking in cavities)
Insufficient knockouts
Remove undercuts
Increase draft angles
Surface irregularities in the mold (polish cavity surfaces)
Highly polished core surface (vacuum lock), polish to a
coarser finish, apply a surface coating, or increase venting

11. Gate Blush, Melt fracture Adjust injection speed (increase or decrease)
Delamination or Modify gate geometry (e.g. gate too small, land too long)
Cracking at the Gate Add cold slug wells in runners
Increase melt and/or mold temperature

12. Black Specks or Degradation Excessive melt temperature or residence time in barrel
Discoloration Improper venting
Possible contamination
Excessive screw RPM
Excessive back-pressure
Excessive shear created by the use of a mixing screw

13. Short Shot Under filled part Increase shot size

Inadequate cushion
Increase fill speed, pack pressure, and/or injection time
Increase melt and/or mold temperature
Plugged gates, runners, or vents
Inadequate melt flow rate (use higher MFR material)
Undersized gates, runners, and vents

14. Splay Streaks on surface Volatiles created by hot spot in manifold

caused by volatiles such Excessive moisture (dry resin)
as moisture or degraded Reduce melt temperature
material

15. Gate Stringing Plastic strings on parts Increase gate size (reduce orientation)
located at the gates Decrease melt temperature, increase cooling time
formed during ejection Decrease drop tip temperature
Increase mold opening speed (break strings upon ejection)
Use valve gates

MYTEX
POLYMERS
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Polypropylene

Injection Molding Problems & Solutions