Scientific Molding

Stage Decoupling

Process is divided into the filling, packing, holding and cooling stages, which are optimized one at a time. The first step is to determine the viscosity of the material at different speeds to find the most stable injection rate. Once the fill is established, the packing pressure and the cooling time are adjusted to achieve the desired part weight and dimensions.

Data Validation

Recording the cavity pressure and the melt temperature for every shot provides a history of the production run that can be used for quality audits. This documentation is required in many regulated industries where every part must be traceable to a specific set of processing conditions. Control systems use this real-time data to identify and segregate parts that fall outside of the validated process window.

Skill Requirement

Implementing this method requires a high level of training and a deep understanding of polymer science. Operators must be able to interpret the data from the machine and make logical adjustments based on the results of the experiments. The success of the method depends on the willingness of the organization to invest in the necessary equipment and the training of their staff.