The process known as Injection Molding Process is a technology used on the mass production of components. The technology can use almost any material to create parts by molding them under high temperatures and then leaving the part to cool down before it is ready. It is an innovative, effective, and profitable process for the industry, but it is not completely flawless. Sometimes, parts can be damaged or defect, resulting in what is called a scrap. Scraps can be difficult to predict, and sometimes only identifiable on the final product, which could be an expensive effort, and can result in large amounts of waste.
There are several causes of defect that can be traced back to four main sources. The first one being the machines utilized in the production. The Injection Molding Process is delicate and precise, therefore temperatures regulated too high or too low, the wrong pressure and speed on the injection fill or even insufficient or excessive material feed can all cause defect on the final product. When executed unproperly, the process may end up with a series of different defects and scraps from black spots and foggy appearance on the final product to broken, burnt and brittle parts, the Injection Mold Machinery can be the main source of scrap.
The materials used in the process can also be the cause of scraps. They should not be too volatile, excessively moist or contaminated with foreign materials in order to successfully produce a part. Inappropriate or excessive use of the materials may cause the machine to overflow or even to contaminate the final product.
Scraps can also come from the molds utilized in production. It is of extreme importance to maintain the perfect temperature, and to care and preserve the mold to avoid scraps. For example, inadequate temperature can cause bubbles, blisters and warpage of the final product. The cooling process of individual parts is also essential to avoid defects. When not left to cool for the proper amount of time in the mold or done inadequately, parts can end up decolorated or with a cloudy appearance.
This also ties in with the last main source of defect: the operator. When it comes to operating and maintaining the machines, poor management and other human mistakes can also end up in contamination, burn marks, crackling and flow lines, also referred to as folds, which makes the part not properly reflect the surface of the tool.
Defect products are more of a problem than it may seem. Besides the time consumed and budget that can be lost due to a defect part, it can leave behind a massive carbon footprint that all companies should aspire to reduce. Though difficult to predict, scraps int Injection Mold can certainly be avoided. Constant maintenance and a thorough check of the materials and machinery are essential. Research and understanding of cause and effect is also advised to reduce the percentage of scrap in each cycle. There is a lot that can be done, but being aware of the problem is the first step.
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