Injection Moulding

Moulding machine

2
Basics of Injection
Moulding
Hopper
Clamping unit

Screw & Barrel

Nozzle

3
Clamping pressure

Calculated by multiplying the projected area of the cavity

(cavities), including runner system by the maximum internal
pressure (hold pressure).

4
Clamping pressure

POM 3 - 4 T/inch2

PA 3 - 5 T/inch2

LCP 4 - 6 T/inch2

PETP 4 - 6 T/inch2

PC 3 - 5 T/inch2

PMMA 2 - 4 T/inch2

PP 1 - 4 T/inch2

PE 1 - 4 T/inch2

ABS 3 - 4 T/inch2

PS 2 - 3 T/inch2
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Drying Principles

Non-hygroscopic Polymers :
e.g. P/S, P/E, P/P, POM
Drying require only to remove surface moisture.
Hygroscopic Polymers :
e.g. P.A., P/C, PBTP, PETP, PET-G
Use Dehumidified air drier or Vacuum oven

6
Polycondensation

- Water

+ Water

Hydrolytic degradation - High temperature

in the presence of water, result in the break- up of the
molecular chain

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Polycarbonate

Water content & lowering of molecular weight:

30
Lowering of molecular
weight (%)

20

10
Moulding temp.300 c

0
0 0.05 0.1 0.15 0.2 0.25
Water content of pellet (wt%)

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30% GR PET

Influence of Moisture on impact strength

9
Drying time &
temperatures
Material Moisture level o Time (Hrs)
Temp ( C)
PA 0.2 80 2–4
PBTP 0.04 120 3–4
PETP 0.02 130 3–4
P/C 0.02 120 4–6
POM 0.2 80 1–2
LCP 0.01 135 2–4
PPS 0.04 150 4–6
ABS 0.1 80 2–4

10
Polycarbonate

10000 Moulding temp. & lowering of molecular

weight:
Lowering of mol. wt. (Mv)

Residence tim e
35 min
1000
20 min

5 min

100
350 340 320 300 280
Moulding temp (deg.C)

11
Hold-up-time
Toughened Nylon 6.6

12
Temperature profile

13
Injection and Hold
Pressure

Injection pressure - Dynamic filling phase (under velocity

control), moves the screw and push the material into
the mould, (around 95% of the part volume).
“Hold” pressure - Quasi-static feeding phase (under
pressure control), packing the part to compensate for
the change in volume from a “liquid” to a “solid”.
“V-P” switch point - In crystalline material, use distance
rather than with pressure, as would typically be done
for an amorphous material.

14
Hold pressure time Vs
part weight and shrinkage
Delrin* 500

15
Hold-on-time

POM
8 secs/mm

PA
5 secs/mm

GR-PA
3 secs/mm

MR-PA
3 secs/mm

PBT
4 secs/mm

GR-PBT
3 secs/mm

PET
4 secs/mm

LCP
0.5 secs/mm

TEEE
4-8 secs/mm

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Influence of Tool
Temperature

Tool at 400C Tool at 900C

Outer layer insufficiently Optimum structure
crystallised

17
Shrinkage behaviour

18
Gate Positions

19
Gate Size and Design

20
Effect of Gate diameter
on the quality
Nylon 6.6

21
Runner Size and Design

22
Venting design

23
Moulding tolerances

24
Regrind

25
Moulding cycle-Time
For crystalline materials. (With amorphous materials, the
main differences are shorter hold on time, but much longer
cooling time.)

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A Polymer for Every Application