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Systematic Molding

Systematic Molding. Use right arrow to advance Slides. MOLDING: Art or Science?. Injection Molding Approaches. Traditional Molding (Art) Decoupled Molding (Science). Traditional Molding. Fill & Pack on first stage

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Systematic Molding

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  1. Systematic Molding Use right arrow to advance Slides WINWARD TECHNOLOGIES, LLC

  2. MOLDING: Art or Science? WINWARD TECHNOLOGIES, LLC

  3. Injection Molding Approaches Traditional Molding (Art) Decoupled Molding (Science) WINWARD TECHNOLOGIES, LLC

  4. Traditional Molding • Fill & Pack on first stage • Use only enough first stage pressure to pack the mold • Subject to large shot to shot variation • Shorts, flash, warp, dimensional issues WINWARD TECHNOLOGIES, LLC

  5. thin As speed increases, the plastic gets thinner and easier to push viscosity thick flow rate slow fast WINWARD TECHNOLOGIES, LLC

  6. thin High sensitivity to fill speed variation viscosity Low sensitivity to fill speed variation thick flow rate slow fast WINWARD TECHNOLOGIES, LLC

  7. Decoupled Molding A method of process control that minimizes variation in parts by: • separating the filling stage from pack & hold • Utilizing the machine controls to manage fill, pack & hold WINWARD TECHNOLOGIES, LLC

  8. Decoupled Molding • Set first stage hydraulic pressure control “high” • Allow machine to provide whatever pressure needed to deliver constant fill speed • Set first stage velocity for constant and fast fill speed WINWARD TECHNOLOGIES, LLC

  9. Decoupled Molding • Separate the filling (velocity) phase from packing phase • Transfer to pack at ~ 95% of full shot (by position) WINWARD TECHNOLOGIES, LLC

  10. Benefits of Decoupled Molding • Fast fill at constant speed • Reduce part variations due to material viscosity variations • Won’t flash • Pack consistently • Gives the most robust, repeatable process • Reduces cycle time, improves quality WINWARD TECHNOLOGIES, LLC

  11. Systematic Decoupled Molding • Philosophy of molding from the plastics point of view • Non-Newtonian • Flow rate, temperature, pressure, cooling rate • Use optimum constant flow rate • Separates fill from pack and hold • Cavity pressure controls process WINWARD TECHNOLOGIES, LLC

  12. Flow Rate Temperature Pressure Cooling Rate Total Process Control EXTERNAL VARIATION PROCESS VARIABLES Material Viscosity WINWARD TECHNOLOGIES, LLC

  13. Systematic Decoupled Molding Process Optimization • Rigorous methodology to launch a new part • Arrives at the optimum process • Drives the set-up sheet • Should be done at prototype WINWARD TECHNOLOGIES, LLC

  14. Dimensions Surface Structure Total Process Control Correlates: PART CHARACTERISTICS To: PROCESS PARAMETERS WINWARD TECHNOLOGIES, LLC

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