INJECTION KNOW HOW

Secrets of Quick Part-to-Part Changeovers

Part-to-part changeovers can be fast only with proper advance planning. Here’s what you need to know to convert from sluggish to swift in job changes.
#bestpractices

#MeetMeInChicago

Join us September 21-23 for a first-of-its-kind event that brings under one roof our annual Molding and Extrusion Conferences, together with the Amerimold Expo. 

Apply the Power of a Troubleshooting Checklist to Your Process

Pocket guides provide processors an injection molding “crib sheet,” but in a process with thousands of interactions, applying if-this/then-that logic can’t always get you to a problem’s root cause.
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The Difference Between Knit and Meld Lines--and Why It Matters

In many part designs, flow fronts will inevitably be split, but how and where they come back together is hugely important to the molded part’s finished strength.

Consider the Cushion When Seeking Shot-to-Shot Consistency

Creating and maintaining a consistent cushion is a key step in achieving shot-to-shot consistency. Learn what cushion is and how it affects part quality.
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Three Key Decisions for an Optimal Ejection System

When determining the best ejection option for a tool, molders must consider the ejector’s surface area, location and style.
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Process Monitoring or Production Monitoring—Why Not Both?

Molders looking to both monitor an injection molding process effectively and manage production can definitely do both with tools available today, but the question is how best to tackle these twin challenges.
#monitoring

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.  
#scientificmolding #processingtips #screws

The Importance of Gauging Residence-Time Distribution—Part 2

Each molecule in the molded product can have a different residence time. This variance is reflected in the Residence-Time Distribution, which you can learn how to determine below.  

Residence Time and Residence-Time Distribution—Part 1 of 2

Failing to calculate and accurately account for residence time can compromise material integrity before it’s even injected.

Injection Molding: Understand the Link Between Feed Throat Temperature & Bridging

Save time and money by properly controlling the feed-throat temperature. In some cases—but not all—it can help you solve a bridging problem.

How to Know When Your Process is Ready to Make Acceptable Parts

Focus on six key metrics to help you determine when a process is lined out and stable enough to start production. 
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Back to the (Re)Grind

Some amount of scrap—generated in startup, shutdown or defective parts—is inevitable. How can you reclaim regrind into new profitable parts?
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Fundamentals of Proper Press Shutdown

Press shutdown procedures have a significant impact on achieving smooth machine startups and restarts to improve uptime. Here’s a procedure you might want to deploy in your molding operation.
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The Cosmetic Process Window: Key to a No-Tweak, Robust Process

Establishing a process with the widest possible cosmetic window can help put your injection molding on cruise control.

Don’t Get Caught in the Flash-and-Shorts Chase

Injection molding’s most common defects can have inverse correlation, where correcting one causes the other, leading to the “chase.”

Follow These Tips to Sanitize Machine Controller Screens & Buttons

Keeping your workers safe from the coronavirus makes it extremely important to institute a sanitizing procedure on all touch surfaces of the controller, screen and operating panel. I did some research and here’s what I found.

In Search of a Universal Setup Sheet

Duplicating a process from one injection machine to another is frustrating and time-consuming. Develop a mold-specific setup sheet that works in all kinds of presses by differentiating plastic parameters from machine parameters and duplicating those plastic conditions from machine to machine, electric or hydraulic. 
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Revisiting Shot Size vs. Barrel Capacity

We’ve covered this topic before, but it’s important enough to warrant another look..
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How Can Molders Achieve Effective Process Monitoring?

You have developed a proper process; now you need to monitor that process to ensure its stability through a run.
#bestpractices #monitoring

V-to-P Ramp Time and Over-Travel

Many injection machines use ramp time to control the transition from injection pressure to hold pressure and reduce over-travel. Do you know how to set yours?

Graphing Injection Pressure: What Should Pack & Hold Curves Show?

Are you sure your press is doing what you want? Visit your controller often to ensure your machines plot the pressure vs. time graph for all your processes. Here let’s focus on pack and hold.

Understanding—and Using—Decompression to Your Advantage

Decompression—aka suckback—is a very important setting on an injection molding machine. On today’s machines, molders typically get the option to set decompression before and after screw rotation/recovery. Are they using this feature to their advantage?