Scientific Molding Pocket Guide

Scientific Molding Pocket Guide

THIRD EDITION

Injection Molding Reference Guide

Materials, Design, Process Optimization, Troubleshooting and Other Practical Information from the Experts at Routsis Training

Plastics is a sophisticated and diverse discipline. To excel, you need a good grasp of a wide range of concepts and data.

That's what this Injection Molding Reference Guide is all about. Designed as both a starting point for entry-level personnel and a refresher reference for experienced professionals, this guide is packed with practical information built on Routsis's 30-plus years of plastics training and consulting success. ? The science of plastics processing ? Materials and properties ? Part and mold design basics ? Process optimization ? Scientific troubleshooting While we hope you find this information useful, it should not be considered a substitute for continuous training. Techniques and technologies are advancing rapidly throughout the industry, which is why top-performing professionals turn to Routsis to keep enhancing their skills.

We invite you to further explore the topics covered in this guide through the comprehensive array of online training programs we provide at .

275 Donohue Rd., Suite 1 Dracut, MA 01826

phone: (978) 957-0700 FAX: (978) 957-1860

email: info@

DISCLAIMER

This reference guide contains general recommendations intended solely for informational use within the plastics injection molding industry. It is not intended to serve as engineering advice.

The information contained herein is based on published information, knowledge, research, and experience which are presumed to be accurate and complete to the best of our ability.

All information is based on averaged data of commonly available grades of plastics and current industry practices at the time of this printing. Therefore it is the user's responsibility to review and confirm all design, calculations and processing decisions.

You should always design and process using the recommendations that are provided by your raw material supplier, resin distributer, machine and equipment supplier(s).

Each material, machine, and process has its own set of influencing factors and therefore may, or may not; comply with the information provided in this guide. A. Routsis Associates, Inc., will not accept responsibility or liability for use of the information contained within this guide.

Contents

1

Understanding Plastics

1.1 General Classification of Polymers

1

1.1.1 Thermoplastics vs. Thermosets

1

1.1.2 Amorphous vs. Semi-Crystalline

1

1.2 Hygroscopic vs. Non-Hygroscopic

2

1.3 Understanding Variability in Plastics Processing

2

1.4 Understanding Viscosity

3

1.4.1 Capillary Rheometry

3

1.4.2 Melt Flow Index

4

1.4.3 Spiral Flow Test

4

1.4.4 In-Mold Rheology

5

2

Plastic Materials Overview

2.1 Table of Plastic Material Properties

6

2.2 General Information About Common Materials

8

2.2.1 ABS (Acrylonitrile Butadiene Styrene)

8

2.2.2 Acetal or POM (Polyoxymethylene)

8

2.2.3 Acrylic or PMMA (Polymethyl Methacrylate)

8

2.2.4 CPVC (Chlorinated Polyvinylchloride)

9

2.2.5 HDPE (High Density Polyethylene)

9

2.2.6 HIPS (High Impact Polystyrene)

9

2.2.7 Ionomer

10

2.2.8 LDPE (Low Density Polyethylene)

10

2.2.9 LLDPE (Linear Low Density Polyethylene)

10

2.2.10 PA-11 (Nylon-11)

11

2.2.11 PA-12 (Nylon-12)

11

2.2.12 PA-4/6 (Nylon-4/6)

11

2.2.13 PA-6 (Nylon-6)

12

2.2.14 PA-6/10 (Nylon-6/10)

12

2.2.15 PA-6/12 (Nylon-6/12)

12

2.2.16 PA-6/6 (Nylon-6/6)

13

2.2.17 PAEK (Polyaryletherketone)

13

2.2.18 PBT (Polybutylene Terephthalate)

13

2.2.19 PC (Polycarbonate)

14

Table of Contents

i

2.2.20 PC/ABS (PC/ABS Alloy)

14

2.2.21 PC/PET (PC/PET Alloy)

14

2.2.22 PEEK (Polyetheretherketone)

15

2.2.23 PEI (Polyetherimide)

15

2.2.24 PES (Polyethersulfone)

15

2.2.25 PET (Polyethylene Terepthalate)

16

2.2.26 PETG (Polyethylene Terepthalate Glycol)

16

2.2.27 PP (Polypropylene)

16

2.2.28 PPO (Polyphenylene Oxide)

17

2.2.29 PS (Polystyrene)

17

2.2.30 PVC (Polyvinylchloride)

17

2.2.31 SAN (Styrene Acrylonitrile)

18

2.2.32 TPC-ET (Thermoplastic Copolyester Elastomers)

18

2.2.33 TPE (Thermoplastic Elastomer)

18

2.2.34 TPO (Thermoplastic Polyolefin)

19

2.2.35 PPS (Polyphenylene Sulfide)

19

2.2.36 PSU (Polysulfone)

19

2.2.37 PUR (Polyurethane)

20

3

Properties, Additives & Preparation

3.1 Common Fillers and Fibers

21

3.2 Heat Resistance

24

3.3 Hardness

25

3.4 Burn Characteristics

26

3.5 Feed Zone Temperature Study

26

4

Establishing a Scientific Molding Process

4.1 1st Stage Filling

27

4.2 1st Stage to 2nd Stage Transfer

27

4.3 2nd Stage Pack

27

4.4 Screw Delay or Decompression before Recovery

28

4.5 Screw Recovery

28

4.6 Screw Decompression after Recovery

28

4.7 Cooling

28

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