P O LY M E R S O L U T I O N S

Injection Molding Guide

Injection Molding Guide
barrel of the molding machine, they achieve a viscous fluid state
Contents: characteristic of a polymer much like low-density polyethylene.

Introduction...................................................................... 2 Theoretically, TPUs can be injection-molded; but from a practical

Materials........................................................................... 2 standpoint, many, particularly the softer grades (<70A), are not viable
Equipment Requirements................................................. 3 for practical, commercial use. Many of the softer types are nearly
amorphous; consequently, molding would require long setup times.
Mold and Part Design...................................................... 4
They could be very tacky and stick to the metal
The Molding Operation..................................................... 6
mold surfaces.
Startup Procedure............................................................ 9
Troubleshooting Guide................................................... 10 Melt viscosities suitable for molding will generally be lower than for
typical extrusion processing. Temperatures and shear forces in
the molding machine barrel will be higher than for extrusion. Some
of the harder grades will have melt temperatures approaching
Introduction 450°F/232°C. In general, 450°F/232°C is the onset of TPU thermal
LifeScience LifeSciences is a business within The Lubrizol degradation. All LifeSciences TPU grades can be injection-molded
Corporation that provides innovative polymer solutions for below this temperature; individual Technical Data Sheets should be
healthcare products. Among the chemical technologies employed consulted and the recommendations followed. Products should be
by LifeSciences are thermoplastic polyurethane elastomers (TPUs). selected from the LifeSciences molding product sheets. If a specific
LifeSciences TPUs are grouped into several families of products set of end-use physical properties is found on on the LifeSciences
with varying chemical and physical characteristics. They can be TPU Extrusion list, it is very likely that the grade can be successfully
readily converted to durable, tough, impact-resistant articles such injection-molded.
medical device housings, tubing connectors, etc., on conventional Molding conditions can be recommended by Lubrizol technical
thermoplastic injection-molding equipment. representatives.

This brochure is intended to provide general guidelines for The harder thermoplastic polyurethane TPU compounds are
equipment, procedures and molding machine conditions that will specifically designed for fast, easy injection-molding of large and
help the customer obtain the best possible performance from the the small parts. By the nature of their chemical structure, the softer
Lubrizol LifeSciences of TPU molding grades. Additional information TPU compounds, in the Shore hardness range of 70A to 90A, will
can be obtained by consulting individual product Technical Data take longer to set-up (longer cycle times). Many of the grades are
Sheets or by contacting your Lubrizol technical service or sales formulated with small amounts of additives to facilitate mold release
representative. and prevent blocking of molded parts. All TPU materials produce a
very low-viscosity melt compared to other thermoplastics such as
Materials polyethylene. Polyethylene PE is a crystalline polymer that still has
a relatively high melt viscosity when the crystalline structure “melts”
LifeSciences TPUs are available in both aromatic and aliphatic types. it. This is due to the high molecular weight (length of polymer chain)
The choice of polyol raw material during manufacture leads to the of PE. PE can have molecular weights above 1,000,000. In contrast,
families of polyester, polyether and polycarbonate grades. Separate when a harder (e.g.g. 50D) TPU melts, it goes to a low melt viscosity
literature is available describing detailed properties of the various rapidly. This is due to the relatively low molecular weight of TPU.
molding grades. All of these TPU types have common characteristics TPU will typically have molecular weights in the 100,000 to 200,000
as far as basic molding processing behavior and practices. This range. Once melted, increasing the melt temperature generally does
guide covers those general characteristics. not reduce the melt viscosity significantly.

TPUs are generally not considered to be crystalline polymers that TPU melt viscosity easily fills the most complex mold cavities under
would be represented by a product like low-density polyethylene low injection pressure. The low viscosity melt permits the material
(PE). Some of the harder TPU grades (~> 90 Shore A) could be to flow through small gates and into thin wall sections under low
considered semicrystalline. Softer grades 62A–85A can be nearly injection pressure. Low-viscosity melt combined with low injection
amorphous — they have no definite melting point, but soften pressure minimizes the possibility of producing highly stressed parts.
gradually on heating. Upon heating and shear mixing within the

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 P O LY M E R S O L U T I O N S

Equipment Requirements Clamp Capacity

A new machine having a minimum clamp force of 300 kg/cm2
Type of Machine
to 400 kg/cm2 (2 to 3 tons/square inch) of projected part area,
Although all types of machines have been successfully used, a including runners, is recommended. The area of runners in a three-
reciprocating-screw machine is preferred for molding LifeSciences plate mold should be included.
TPU compounds. A reciprocating-screw machine is capable of
producing the most uniform melt, is the most easily controlled, and is Screw and Tip
capable of the fastest cycles.
The screw and tip designs that are designated "general purpose" are
best. The compression ratio of most of the general-purpose screws
Machine Size
falls between 2:1 and 3:1; this range is the most desirable for melting
Barrel capacity and homogenizing TPU compounds.
To obtain the widest processing latitude and optimum physical
The general-purpose tip usually has a 60° included angle and a
properties, an appropriate match of shot size, (i.e., volume of cavities,
free-flow mechanism of either ball check or sliding ring type. It is
runners and sprue) to barrel capacity is very desirable.
recommended that an antibackflow valve, in good working order, be
A shot weight of 60% to 75% of barrel capacity is recommended.
used when TPU compounds are molded. The low viscosity of their
This minimizes melt residence time in the barrel, enabling processing melts makes satisfactory packing-out of the mold cavity very difficult
at higher stock temperatures with optimum melt flow while avoiding unless an antibackflow device is used.
degradation.
Nozzles
Since the optimum match of barrel capacity is not always practical A straight, open nozzle with a full internal taper tip is recommended.
due to clamp requirements or machine availability, shot sizes as A positive-shut-off, antidrool nozzle can be helpful but is not a
low as 30% to 35% may be used with the understanding that the necessity. If the particular machine or mold design requires a long
processing latitude of the material may be significantly reduced. nozzle or a nozzle extension, it should be well insulated with heater
Lower stock temperatures mean higher melt viscosity and more bands so that there are no cold spots. The harder TPU compounds,
resistance to flow. Greater injection pressures will be needed to fill because of their sharp melting point, can crystallize (set up) if a cold
the part, and molded-in stresses may result. It is likely that these spot exists. The next shot will result in cold slugs of material carried
molded-in stresses could adversely affect impact, dimensional into the cavity along with the hot melt. The longer the cycle required
stability and other properties of the finished part. by the particular part, the more troublesome this can become;
therefore, the nozzle must be well insulated with heater bands. The
When calculating optimum barrel capacity, always consider the
bands must extend as close to the tip as possible.
specific gravity of the TPU compounds versus the specific gravity of
the material for which the machine was rated. Most machines are
Molds
normally rated for kilograms (ounces), a unit of weight of general-
purpose polystyrene. Any type of mold that incorporates good thermoplastic design
principles is satisfactory for TPU compounds. Two-plate, three-plate
Example: Given that the specific gravities of TPU compounds and hot-runner molds have all been used successfully for a variety
and general purpose polystyrene are 1.20 and 1.05, respectively, of large and small parts. For hot-runner molds, as with nozzles, it
a 1.7 kg (60 oz.) barrel rated in general-purpose polystyrene will is important that heaters provide full coverage of the runner system
deliver 1.9 kg (67 oz.)* of TPU. so that cold spots do not exist; the TPU can be maintained in its
fluid melt state. The mold must also be adequately cored for cooling
because TPU normally requires a relatively cool mold [(10°C to 44°C)
*1.7 kg x 1.2 = 1.9 kg (67 oz.) (50°F to 110°F)] to produce optimum cycle. The nozzle tips within
the hot-runner mold must be well-insulated from the cold side of
1.05 the mold. Poor insulation and the quick setup characteristics of
TPU compounds (primarily the harder grades) can lead to plugged
A targeted TPU shot weight, including sprue, runners and parts, nozzles. A sheet of transite separating the hot and cold sections of
would then be 1.4 kg (50 oz.) on this machine.(1.9 kg x 75% capacity the mold is recommended.
= 1.4 kg or 50 oz.)

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Mold and Part Design Secondary runners should be perpendicular to the main runner,
and the runner junction should be vapor-honed to remove burrs and
Sprue Bushing sharp edges, and contain a cold slug well at every turn of direction.
A sprue bushing with a standard 2½° included angle, Figure 2 shows a properly sized runner system.
approximately 42mm taper per meter (0.5 in. taper per foot)
should be used. The entrance diameter of the bushing should Figure 2 Proper Runner Sizing.
always be slightly larger than the nozzle exit orifice. To promote a
balanced pressure to the runners and cavities, the exit diameter Correct Undesirable
of the sprue bushing should be larger than the diameter of the
main runner. Z-pin-type pullers are preferred for easy removal of
the sprue.

Runners
Sprue Larger Secondary Runners
In a two-plate mold, full-round runners are preferred because they than Main Smaller than
Runner Main Runner
provide the highest volume-to-surface ratio, the least pressure drop
and are the easiest to eject from the mold. Depending on the part
size and weight, typical full-round runner diameters are 0.6 cm to 1.0
cm (0.25 in. to 0.4 in.). Because of excessive flow restriction, small
diameter runners, less than 0.6 cm (0.25 in.) diameter, should be
avoided. Excessively large-diameter runners offer little advantage
and contribute to longer cycle times and greater material usage. No Cold Unbalanced
Cold Slug Well Slug Wells Flow Length to
If a three-plate mold is being used, full-round runners are still Cavities
preferred, but trapezoidal runners can be used.

Figure 1 shows typical relative dimensions of a trapezoidal cross- In addition to proper runner sizing, the layout of the mold is also an
section runner. The flow through a trapezoidal runner is equivalent important consideration. A runner system should be designed to give
to that of the largest circular runner whose cross-section can be balanced flow to all gates, ideally designed so that the melt reaches all
inscribed within the trapezoid. of the gates simultaneously.

TPU compounds have been molded successfully in hot-runner systems.

Figure 1 Relative Dimensions of a Trapezoidal Runner In many cases, hot-runner mold design and temperature control have
for Use in a Three-Plate Mold. become the most complex part of the molding process. Hot-runner
molds have usually been designed originally for plastics other than TPU.
In general, those created for PVC would offer the best characteristics for
success with TPU.
W
L Cold Slug Wells
During injection, the initial surge of material is generally cool since it
2
/3W has remained dormant in the nozzle while the previous shot was being
ejected from the mold. To prevent this cold material from entering the
cavity and causing a visual defect, cold slug wells or runoffs should be
incorporated into the runner system before material is allowed to enter
¾W the cavities. Properly sized runner systems designed for balanced flow
which incorporate cold slug wells are shown in Figure 3.

To maintain pressure and balanced flow during injection into a

multiple cavity or multigated mold, the secondary runners should be
slightly smaller in cross section than the main runner.

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 P O LY M E R S O L U T I O N S

Figure 3 Runner Systems with Balanced-Flow Tab gates are strongly recommended for the softer TPU grades.
Cavity Layouts and Cold Slug Wells. They eliminate the distortion in the gate area that commonly occurs
with very flexible materials. The use of pinpoint gates and tunnel
gates should be restricted to very small parts of a few ounces or less
in weight where the flow length from the gate is less than two inches.
The land length for gates should always be as short as possible. A
good rule of thumb for determining the proper land length is that it
should be no greater than one-half the gate thickness.

In multigated cavities, the gate location and number of gates are

very important in relation to the appearance and performance of
the molded part. Since gate areas are almost always more highly
stressed due to orientation, gates should be located in noncritical
sections of the part. Gating in thick sections of the part and allowing
the material to flow to the thinner sections keep sink marks to a
minimum. When gating into a thick section, the flow should be
directed toward a cavity wall or deflector pin to break up the melt
entering the cavity and to prevent a condition called “worming.”
Gates
Worming is a random pattern of weld lines opposite the gate caused
TPU compounds have been molded satisfactorily through awide by the rapid cooling of the injection melt. If the design of the part
variety of gate designs including fan, lab, edge, submarine and requires a split in the flow front coming from the gate, a weld line
sprue. In general, the gates should have a generous cross-sectional will usually result when the flow fronts meet. Care should be taken
area to allow the material to flow freely with a minimum of pressure in designing parts to keep the number of gates to a minimum to
loss. The gates should be vapor-honed with all rough edges and minimize weld lines. Multiple weld lines could detract from the
sharp corners removed. Figure 4 illustrates several acceptable gate surface appearance and may affect performance.
designs with rounded corners for minimum restriction.
Mold Shrinkage
Figure 4 Gate Designs. Mold design, part design and operating conditions all affect the mold
shrinkage value of any thermoplastic material. In cases where very
close tolerance must be maintained, it is suggested that a prototype
Fan tool be made before building the production tool. Where standard
Gate or coarse tolerances are all that is required,the standard mold
Submarine shrinkage allowance for the particular TPU compounds should be
Gate
used. It should be noted that post annealing or exposing parts to a
point over temperature will increase the mold shrinkage from what is
normally expected. This data is presented in Technical Data Sheets
of Lubrizol LifeSciences TPU molding compounds.
Pin
Gate Ejection of the Part
TPU compounds release easily from properly prepared mold surfaces.
Highly polished, chrome-plated surfaces should be avoided except
Tab Gate for simple flat parts. However, for high-clarity parts, a glossy surface
is required. Because most parts are more complex, a vapor-honed
matte surface is recommended to provide the easiest, most troublefree
Ring release. An electrical discharge machining (EDM) surface can also
Gate
provide a suitable, easy release. Ejector pins should have as large a
surface area as possible, especially those located at thick part sections
where the interior may still be very soft at the time of ejection.

Stripper plates and air ejection systems may also be used with TPU
compounds.

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Vents thermoplastic materials (e.g.g. nylon), LifeSciences TPU compounds
are hygroscopic (absorb water from the atmosphere). Although
Because of the low viscosity of the melt, normal vent depths of .05
TPU is dry when packaged, storage time and conditions and
mm (.002 inches) and greater will allow TPU compounds to flash.
transportation will allow moisture to enter. The amount and rate of
Therefore, vents should be cut only after initial trials on the new tool
absorption will depend on the type of urethane as well as the type
have indicated necessary locations. A vent channel 6.4 mm to 12.7
of storage container, temperature and humidity of the air to which
mm (.25 in. to .50 in.) wide by .03 mm (.001 inch) deep is usually
it is exposed. Excessive moisture can also cause splay, voids and
sufficient. See Figure 5.
parts sticking to the mold. Even if the part appearance is not being
affected, a severe reduction of the service life of the part can be
Figure 5 Mold Venting. result.
Mold Vent
When moisture reacts with the TPU, the result is shorter polymer
Dimensions: Vent
chains (lower molecular weight). Even though physical properties
A - 0.001 to 0.002 at the time of molding may be satisfactory, the reduced molecular
B - 0.100 to 0.150 C weight may be the equivalent to years of use. For optimum
C - 0.500 typical A A appearance and part longevity, TPUs must be dry when molded.
D - 0.400 minimum For a small volume of material, an oven dryer is satisfactory. The TPU
compounds should be spread in the trays one-inch deep and dried
for two hours at 105°C (220°F).
D A Plastic Part
Feed Run When larger volumes of material make oven drying impractical,
Vent a dehumidifying hopper dryer is recommended. A -40°C (-40°F)
maximum inlet air dewpoint is recommended. A 0.02% or less
Mold
Cavity moisture content should be obtained before the material is molded.
B
Polyurethanes are hygroscopic and will absorb moisture when the
containers are opened to the atmosphere.

Purging
The barrel should be thoroughly purged before and after molding
The Molding Operation TPU. Since TPU compounds purge readily from the machine, the
use of purging compounds may not be necessary. When needed,
Processing Parameters suitable purging materials are reground polystyrene, general-
Successful processing of LifeSciences TPU compounds by injection purpose ABS, and acrylic molding compounds and even PE.
molding is very dependent upon a wide range of variables such as Purging should be done immediately after the production run while
machine size, shot size, screw geometry and mold design. Due to the material is still molten. If the machine is allowed to cool to room
these factors, exact machine conditions for optimum processing temperature, purging can be more difficult because the cold material
have to be determined by the processor for the system chosen. will stick tenaciously to the screw and, on reheating, will be difficult
The sections that follow will outline the conditions the molder to remove. Slowing cooling TPU in a barrel can also crystallize within
should strive to achieve. The best processing latitude and ultimate the barrel by an annealing process.
properties in the molded part will then be realized. Finally, startup
and shutdown procedures are summarized in the Processing Guide Mold Temperature
section. This section and the Troubleshooting Guide section should Molds should be provided with good temperature control to obtain
be readily available to setup personnel and machine operators. optimum appearance and production rates. The set temperature
depends on the particular design, operation and the TPU grade
Dryers being used. Polyether-type polyurethane materials tend to release
TPU compounds are fully reacted thermoplastic polyurethane better and set up faster when parts are cooled at a relatively slow
materials and will not react when exposed to atmospheric moisture. rate. Thin-walled parts [less than 3mm (.118 in.)] require higher
However, as with all polyurethane compounds and many other temperatures; thicker-walled parts require lower mold temperatures.

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 P O LY M E R S O L U T I O N S

be conducted with adequate ventilation to dissipate hot vapors.

Precautions should be taken to avoid being struck by hot melt. The
needle should be jabbed into the molten plastic successively four to
five times in different locations before the actual reading is taken.

Occasional wiping of the needle probe with some mold release

agent will help prevent “freezing” of plastic on the probe during the
initial portion of the reading. If material “freezes” to the probe on
the first insertion, it acts as an insulator on the probe’s surface and
erroneously low values for stock temperature will be obtained.

If gassing or bubbling of the hot plastic is observed during the

airshot, it generally indicates a higher-than-recommended stock
temperature is being achieved and/or excessive moisture is present.
Stock temperature and moisture content should be rechecked. The
molten plastic rope should appear smooth and reasonably glossy if
the stock temperature is near optimum.

Heater Band Settings

To achieve a given stock temperature, heater band settings depend
greatly on machine size, screw design and other settings such as
backpressure and screw RPM. Large machines typically yield stock
temperatures higher than the heater band settings.

For the initial trial of TPU, an ascending barrel temperature profile

shots and will not cause any degradation from overheating. Care from rear to front zones is recommended. These settings should be
should be taken so that there are no cold spots in the nozzle area. adjusted to achieve an airshot, stock temperature 5°C to 10°C (9°F
The full length of the nozzle should be covered with heater bands to 18°F) less than the final desired temperature (more heat will be
as close to the tip as possible. Inadequate coverage by the heater generated once the machine is cycling continuously). Since heat is
bands can produce cold spots and allow some of the material to set being generated by the screw within the material, it is quite normal
up between shots. The result will be that the parts will contain lumps for the middle and front barrel temperature zones to override the
of material that were carried into the cavity by the melt stream. setpoint. As long as the machine is cycling regularly, these setpoints
do not need adjustments. Carefully monitor stock temperature
Stock Temperature during initial startup and after any condition changes.
The stock temperature can be controlled by a proper combination
of the heater band settings, screw backpressure and screw Nozzle Temperature
RPM. To develop ultimate physical properties, it is important that The nozzle should be controlled to the same temperature as
recommendations for stock temperature be followed. that of the melt. This will prevent material from setting up between
shots and will not cause any degradation from overheating. Care
To measure stock temperature, use an accurately calibrated needle-
should be taken so that there are no cold spots in the nozzle area.
probe pyrometer. When making a temperature measurement with
The full length of the nozzle should be covered with heater bands
a needle pyrometer, the molten material should be injected directly
as close to the tip as possible. Inadequate coverage by the heater
from the nozzle onto a piece of heavy cardboard or some other
bands can produce cold spots and allow some of the material to set
insulating material that will not absorb heat from the plastic. The
up between shots. The result will be that the parts will contain lumps
injection pressure, injection speed and backpressure are normally at
of material that were carried into the cavity by the
a lower setting for taking these airshots than when at normal cycle;
melt stream.
therefore, a stock temperature of approximately 5°C to 10°C (9°F
to 18°F) lower than the recommended range is a good objective
when starting. As with any thermoplastic resin, airshots should

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Injection Speed Injection and Holding Pressures
A slow-to-moderate injection speed should be used at the start of Scientific Molding or Decoupled Molding techniques based on a two
the molding run and increased to the point where the part fills and stage volumetric part filling process are used most often for TPU
no signs of weld lines or sinks exist. If the injection speed is too fast, molding. However in some circumstances filling and packing the part
completely on the first stage filling process is used.
excessive frictional heat buildup can result in velocity burning as the
material flows through restrictions or over sharp edges. The amount of first-stage injection pressure (booster pressure) is
required to fill the mold cavity will depend on the stock temperature,
This frictional heat can result in surface appearance problems, or even
injection speed, mold temperature and mold design. Generally,
degradation of the material. Injection speeds for airshots should be
velocities/pressures in the range of 50% to 75% maximum available
relatively slow since there is very little resistance to the material flow.
offer the best consistency and processing latitude. It is advisable
A good rule of thumb for the injection speed is to use a time of two to start with lower pressures and increase to the desired pressure
seconds per inch of ram travel. to avoid flashing the mold. The position for the first-stage injection
velocity/pressure should be set to switch to the second stage
Screw Backpressure holding pressure just as the part is reaching full. This should coincide
with the moment that the screw completes its relatively fast-forward
The proper value for screw backpressure will vary from machine to
travel, leaving a 0.3 cm to 0.6 cm (0.125 in. to 0.25 in.) cushion.
machine, but generally the backpressure should be in the low end of
the 0.3 MPa to 0.7 MPa (50 psi to 100 psi) range. Low- compression The second-stage injection pressure (holding pressure) should be
ratio screws could require backpressures to 1.4 MPa (200 psi). just enough to maintain a full part as the part cools and shrinks in the
cavity. This pressure is typically one-half to two-thirds of the first-
Screw RPM stage injection pressure. Parts having thicker sections usually require
For a screw of recommended geometry, a rotating speed of 40 RPM greater holding pressure.
to 50 RPM should be satisfactory; higher speeds to 75 RPM have
been successful in some applications. Large machines generally Overpacking the part with excessive holding pressure or time on
require less RPM at optimum conditions. Due to increased diameter, the first-stage injection pressure can increase molded-in stress. This
a larger screw has a greater circumferential velocity than a smaller can be detrimental to properties. Generally, sink marks opposite the
screw at a given RPM. The greater velocity promotes more shear gate indicate that more injection pressure/time is needed. Once it is
heating of the molding compound. apparent that gates are frozen off, hold pressure can be reduced to
save on energy consumption.

A small cushion must be maintained ahead of the screw to

compensate for part shrinkage as it cools under holding pressure,
thus preventing sink marks. Ideally, the screw should only reach full
forward position when material movement has ceased.

Cooling Time
Except for parts with very thick sections, over 9.5 mm (3/8 in.),
the time required to retract the screw after the holding pressure
is released is generally sufficient for cooling harder (~>90A) TPU
compounds. The mold can be opened immediately after the screw
stops. In general, the harder the compound, the faster the setup
time. The cooling time required for a 85 Shore A TPU compound, for
example, may be two to three times as long as that required for a 65
Shore D TPU compound.

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Startup Procedure
Thoroughly clean the injection unit by either dismantling and
Colorants mechanical cleaning or by an approved purge.
LifeSciences TPUs may be colored by adding dry inorganic
Set temperature controllers and reduce injection pressure settings,
pigments or color concentrates. The chemistry of the carrier resin
back pressure setting and screw RPM to the lower end of their
to the type of TPU being used in the process may need to be the
operating ranges.
same. Since most TPUs commercially molded are polyester grades,
off-the-shelf color concentrates may usually be based on a polyester After temperature zones have stabilized, introduce the TPU pellets
TPU rather than a polyether type. Having a specialty concentrate into the machine.
made could be required.
Take air-shot stock temperatures and make adjustments to
Unless there is a protocol requiring that concentrates match the temperature settings and screw RPM to approach the desired stock
identity of the resin being molded, making a special concentrate with temperature. Observe the appearance of the molten plastic very
the same grade being used is not necessary for successful coloring. carefully at this stage. A smooth, glossy surface is indicative of a
It is best if the TPU concentrate has been made from a softer TPU good homogeneous melt, while a bumpy rope and/or matte surface
than that being molded. In cases where the TPU indicate nonhomogeneity and low melt temperature. A smoking or
being molded is a hard grade (e.g.g. ~50D or higher), making a color frothy melt suggests that the stock temperature is too high or has
concentrate can result in a masterbatch that can be difficult to melt excessive moisture. Another evidence of good melt temperature
in the machine. is the ability to draw down the hot rope into a thin monofilament. A
brittle break indicates a low melt temperature. Backpressure should
Summary be set to achieve adequate mixing and optimum melt temperature.
In summary, to develop the ultimate physical and appearance
Start molding ports in the semiautomatic mode of operation while
properties for LifeSciences TPU thermoplastic polyurethane
adjusting screw travel (feed) injection pressures and injection speed
compounds, the material should be at the maximum allowable stock
to obtain a full part.
temperature in a fully dried state. It should be injected at a moderate
speed, packed at the minimum pressure required to fill out the mold Consult the Troubleshooting Guide for correcting any defects in the
details and allowed to relax during the cooling stage. molded part.

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Troubleshooting Guide
Here are some typical molding problems and several possible causes for each.

Molding Problems Possible Causes

• Shot too small

• Holding pressure too low
• Holding lime too shod
• Gates too small or in wrong location
Sink Marks or Dimples • Injection speed too fast
• Stock temperature too high
• Mold temperature too high
• Cooling time too short
• Sprues, runners or gates too small

• Insufficient material
• Injection pressure too low
• Injection speed too slow
Short Shots • Cylinder temperature too low
• Mold temperature too low
• Insufficient venting
• Sprues, runners or gates too small

• Material not dried properly

• Melt too hot
Splay
• Injection too fast
• Gates too small

• Barrel temperature profile wrong. Too cold in the rear and middle zones
Unfluxed Granules in Part • Cold spots in the nozzle or nozzle adopter
• Cold spots in the hot runner

• Melt too hot

Foamy Appearance in Part
• Excessive moisture

• Melt too hot

Swelling or Ballooning • Excessive moisture
of Thick Sections • Cooling time too short
• Mold temperature too high

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 P O LY M E R S O L U T I O N S

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The information contained herein is believed to be reliable, but no representations, guarantees or warranties of any kind are made as to its accuracy, suitability for particular applications or the results to be obtained. The information often is based on laboratory work with small-scale equipment and
does not necessarily indicate end-product performance or reproducibility. Formulations presented may not have been tested for stability and should be used only as a suggested starting point. Because of the variations in methods, conditions and equipment used commercially in processing these
materials, no warranties or guarantees are made as to the suitability of the products for the applications disclosed. Full-scale testing and end-product performance are the responsibility of the user. Lubrizol Advanced Materials, Inc., shall not be liable for and the customer assumes all risk and liability
for any use or handling of any material beyond Lubrizol Advanced Materials, Inc.’s direct control. The SELLER MAKES NO WARRANTIES, EXPRESS OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE. Nothing contained herein is to be considered as permission, recommendation nor as an inducement to practice any patented invention without permission of the patent owner. Lubrizol Advanced Materials, Inc., is a wholly owned subsidiary of The Lubrizol Corporation.

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