Injection Molding Troubleshooting Guide

Problem Source(s) Cause(s) Problem Source(s) Cause(s) Problem Source(s) Cause(s)

Machine Excessive residence time in barrel Mold (cont.) Improper runners or gates Machine Injection speed too low

Bubbles
(cont.)
Hang-up of molten material in injection barrel or runner system Mold temperature too low Inadequate injection cushion
Contamination of injection barrel Material Excessive moisture Injection hold time too short

Delamination
Black Specks or Streaks

Degradation due to malfunctioning heater bands or thermocouples Operator Inconsistent cycle Barrel temperature too low
Defective nozzle shutoff mechanism Machine Excessive injection speed or pressure Mold Mold temperature too low
Inefficient injection conditions Excessive back pressure Sharp gate and runner corners
Cracked injection cylinder or pitted screw Screw speed too high Excessive mold release
Oil leaking into the injection unit Improper compression ratio of screw Material Contaminated regrind
Mold Sprue bushing nicked, rough, or not seating Faulty temperature controllers Foreign materials and/or additives
Burned material caused by improper venting Nozzle too hot Excessive moisture

Burn Marks
Contamination caused by grease or lubricants Excessive barrel temperatures Machine Excessive shot size ratio
Mold too small for machine size Nozzle diameter too small Excessive residence time
Material Contamination of raw material Mold Improper venting (size or lacation) Barrel temperature too high

Discoloration
Wrong material used for particular mold Vents plugged or peened shut Nozzle temperature too high
Operator Inconsistent process cycle Improper gating (size or location) Excessive cycle time
Machine Injection screw rotation (RPM) too high Material Excessive regrind use Improper screw design
Screw back pressure too low Flow too soft Mold Mold temperature improper
Injection speed too high Excessive lubricant Inefficient cooling
Cycle time too short Operator Inconsistent cycles Inadequate venting
Blisters

Mold Mold temperature too low Machine Barrel temperature too low Material Contaminated material
Improper gate location Back pressure too low Operator Inconsistent cycles

Clear Spots
Insufficient venting Screw speed too low Machine Excessive injection pressure
Material Use of regrind that is too coarse Improper compression ratio of screw Excessive residence time
Use of highly volatile materials Faulty temperature controllers Barrel temperature too high
Excessive moisture Material Excessive regrind use Excessive cycle time
Machine Injection fill speed too fast Operator Inconsistent cycles Inadequate clamp pressure
Melt temperature too high or too low Machine Barrel temperature too low Mold Improper parting line seal
Blush

Contamination Cloudy Appearance

Flash
Injection pressure too low Back pressure too low Inadequate mold supports
Nozzle diameter too small Screw speed too low Inadequate venting
Nozzle temperature too low Excessive wear between barrel and screw Sprue bushing too long
Machine Clamp opens too quickly Mold Uneven packing Improper stackup dimensions
Ejector system not level or parallel Dull finish on mold surface Material Improper flow rate
Cooling time too short Poor mold temperature control Excessive mold lubricant
Bowing

Parts not packed properly Material Excessive moisture Operator Improper cycling
Mold Temperature too low Operator Inconsistent cycles Machine Inadequate injection pressure

Flow Lines
Inconsistent mold temperature Machine Oil leaks and grease drips Inadequate residence time
Improper gate location Mold Excessive lubrication Barrel temperature too low
Operator Parts mishandled after ejection Material Improper regrind usage Nozzle temperature too low
Machine Improper injection screw design Excessive moisture Operator Inconsistent cycles
Cycle time too short Operator Poor housekeeping Machine Inadequate injection pressure
Excessive packing Machine Molded in stresses Inadequate residence time
Excessive back pressure, screw RPM, or injection speed Cooling cycle too short Barrel temperature too low
Brittleness

Nozzle too hot Mold Excessive lubrication Nozzle temperature too low

Cracking
Injection pressure too low Insufficient draft allowance Excessive feed cushion
Mold Gate and/or runner restrictions Improper injection Ram speed too slow
Condensation Material Improper regrind usage Nozzle bore too small

Gloss (Low)
Material Resin too cold Excessive moisture Inadequate cycle time
Excessive moisture in resin Operator Inconsistent cycles Mold Mold temperature too low
Resin is degraded Machine Molded in stresses Gates or runners too small
Machine Injection temperature too high Cycle time too short Improper gate location
Injection pressure too low Inadequate injection speed and/or time Inadequate venting
Injection forward time too low Injection barrel temperature too high Inadequate polishing of molding surfaces
Crazing
Bubbles

Insufficient material feed Mold Excessive gate size Contaminated molding surfaces
Improper injection temperature profile Mold temperature too low Material Improper flow rate
Excessive injection speed Contaminated mold surfaces Inadequate lubrication
Insufficient back pressure Improper ejection Moisture in resin
Mold Improper venting Material Contaminated material Operator Inconsistent cycles
Section thickness too great Excessive moisture