Sink. Warp.
Flash. Voids.
Defect prevention.
Injection molding defects reference. Sink marks, warpage, flash, voids, weld lines, short shots. Prevention through DFM and process control.
Key principles.
Wall thickness
Thick sections cool slowly, surface depresses. Uniform walls prevent.
Differential cooling
Uneven cooling causes warping. Symmetric design + proper cooling.
Mold gap
Material squeezes between mold halves. Adjust clamping pressure.
Trapped gas
Gas trapped in part. Adjust venting, gating, hold pressure.
Material flow
Two flow fronts meeting. Cosmetically visible. Adjust gating.
Insufficient fill
Material doesn't fill cavity. Adjust pressure, temperature, gating.
FAQ
Sink mark prevention?
Uniform wall thickness. Avoid bosses thicker than 60% of base wall. Increase hold pressure.
Warpage causes?
Differential cooling, residual stress. Symmetric design + cooling channels solve.
Flash sources?
Worn mold, insufficient clamping force, contamination at parting line.
Weld line management?
Move gates to avoid weld lines on cosmetic surfaces. Increase melt temperature for stronger weld.
Short shot remedies?
Increase pressure, temperature, hold time. Check vents for trapped gas. Verify gate adequate.
When defects unavoidable?
Material/geometry combinations may have inherent issues. Mold flow analysis identifies before tooling.
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