Lab 7: Injection Molding

1. Purpose
To learn processing techniques associated with injection molding.

2. Theory
In injection molding, a plastic is heated to a molten state and then forcefully
pushed through a nozzle into a heated mold, typically made of stainless steel (though the
ones used in this lab are aluminum).Error: Reference source not found The plastic enters
the mold through the sprue, then through runners which distribute the molten plastic
evenly to all cavities in the mold. The mold cavity is connected to the runners via a gate
(Figure 8.1).1 These extra pieces may be later removed, chopped up and recycled back
into the machine (called regrind). The mold is used to create the desired resulting part
shape and may consist of two or even three pieces.2
The two types of injection molding typically used are screw plunger and plunger.
In either case, the plastic, usually in the form of
pellets, is fed in through a hopper in the top of the
barrel and melted in the barrel. It is next forced into
mold through the heated barrel.Error: Reference
source not found
part In the screw plunger method, the faster of the two
methods (Figure 7.2a), a screw is used to evenly
distribute the heat to the plastic pellets, causing them
Figure 7.1: Mold showing positions to melt more quickly. The screw can also be used to mix
of part, gate, runner, and in any additives that could cause the polymer to change
sprue.Error: Reference source not color.Error: Reference source not found
found In plunger injection molding, a ram is used to
force the molten plastic into a mold through the nozzle (Figure 7.2b). At the end of either
1
Fried, J. R., “Polymer Science and Technology”, Prentice Hall PTR, Upper Saddle
River, NJ, 1995
2
IST Amatrol, “Manufacturing Processes 3. LAP1: Introduction to Injection Molding and
Operations.” Amatrol, Inc., 1999

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 process, the plastic part is removed from the mold (Figure 7.3).Error: Reference source
not found The molds must be able to withstand high temperatures and pressures “and
produce parts with close tolerances after numerous rapid operations.”Error: Reference
source not found
a b

Figure 7.2: Steps in injection molding: a) screw-plunger method b) plunger

method.Error: Reference source not found
Based on their thermal processing behavior, all polymers can be
divided into two groups: thermoplastics and thermosets.
Thermoplastics polymers are commonly used for injection
molding because they can be heat-softened to obtain a desired
Figure 8.3: Mold and
cooled molded part.Error: form. Table 7.1 below contains commonly used thermoplastics
Reference source not
found that can be used in injection molding.3 In thermoset polymers,
the individual chains are covalently linked and cannot be reformed upon heating. Unlike
thermoplastics polymers, thermosets are usually not used in injection molding because
after they are formed their cross-linked networks resist heat softening and

3
BFP, “Injection Moulding” http://www.bpf.co.uk/bpfindustry/process_plastics_injection_moulding.cfm

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reforming.Error: Reference source not found Thus, it is easier and cheaper to use
thermoplastics over thermosets in processing applications.
Table 7.1: Commonly used Thermoplastics used in Injection MoldingError: Reference source not
found
Name Abbreviation
Acrylonitrile-Butadiene-Styrene ABS
Nylon PA
Polycarbonate PC
Polypropylene PP
Polystyrene GPPS

Typical products that can be made using injection molding include: power-tool
housings, telephone handsets, safety helmets, television cabinets, washing-up bowls and
rubber ducks (Figure 7.4).Error: Reference source not found
a b

Figure 7.4: Various items that can be made using Injection molding: a) plastic containersError:
Reference source not found; b) rubber duck4.
Injection molding is used for mass consumables because it is a cheap and quick
way to mass produce products. However, there are some typical engineering problems
associated with injection molding which will now be described. Table 7.2 shows common
problems and some solutions associated with injection molding.

Table 7.2: Causes and solutions of Injection MoldingError: Reference source not found
Problem Possible Causes Solutions
No polymer enters Mold is not properly Re-align mold
the mold aligned
Only sprue forms or Not all purging If the sprue is white while it is still in the
the mold is not compound has been melt state, there is purging compound in the
filling completely removed from the barrel. Remove the mold and then eject all
barrel of the purging compound from the barrel
Not enough material add more material but do not overfill barrel
available in barrel

4
Excel Step Limited (China), “PLASTIC INJECTION: PI-001”
http://www.label-pin.com/plastic-injection/plastic-injection02.htm

3
 Mold is not warm Heat mold longer
enough
Air pressure is too Increase air pressure
low
Nozzle temperature Increase nozzle temperature but only by 5oC
is too low at a time

Not enough polymer Increase the amount of polymer to the mold

is entering the mold
Mold vents may be Unclog any polymer-clogged vents and use
clogged less mold release
There is a loud Polymer may not be Examine the polymer coming out of the
popping sound when melted nozzle to make sure that there are no un-
the polymer is melted polymer beads; allow more time to
ejected from the melt the polymer
barrel Not all purging If the sprue is white while it is still in the
compound has been melt state, there is purging compound in the
removed from the barrel. Remove the mold and then eject all
barrel of the purging compound from the barrel
Part has flash on it injection pressure is This causes the mold to separate; decrease
too high injection pressure but make sure mold still
fills fully
clamp pressure is too This causes mold to separate; increase the
low clamp pressure slightly until problem is
solved
Temperature is too Reduce nozzle and barrel temperature
high slightly (only 5oC at a time)
Appearance of Weld Barrel temperature is increase the barrel temperature by 5oC
marks around a too low increments only
manufactured hole in Mold is not warm Heat mold longer
sample enough
incorrect flow rate Increase the pressure used or increase the
barrel temperature by 5oC increments only

3. Experimental Procedure
WARNING: In this laboratory experiment you MUST wear safety glasses and heat-
resistant gloves.

3.1 Making the Part

(1). Put on safety glasses and heat-resistant gloves.

(2). Observe the main parts of the injections molding machine before starting the lab

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 Barrel and Hopper for
Main switch
screw zone feeding polymer

(3). Switch on the main power followed my starting the cooling system and hydraulic
system.

Injection
molding
chamber with
sliding door

Switch for hydraulic Main control unit

system

Figure 7.5: Injection molding machine

(3). Turn the temperatures at different zones in the barrel, nozzle and mold as listed
below
Rear 160 oC
Middle 180 oC

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Front 200 oC
Nozzle 200 oC
Mold 32 oC
(4). Set the back pressure and screw speed as 0.6 MPa and 50 rpm respectively.
WARNING: You now must use EXTREME caution around the barrel and the
nozzle as they will become hot enough to leave severe burns.
(6). Do not proceed until the nozzle and the barrel have reached the set temperatures.
(7). Feed the polymer in to the hopper. Each dog bone sample requires approximately
10 grams of polymer.
(8). Start the process with manual operation mode.
(9). Apply mold release to both sides of the mold. This can be used like cooking spray
as not too much is needed and it needs to be reapplied only every third or forth time.
(10).Follow the different steps in manual operation to inject the polymer in to the
mold.
a) Filling the barrel with the resin
b) Melting it through the barrel
c) Closing the mold and injecting polymer melt in to the mold
d) Open the mold and eject the injected sample out
(11). Close the injection molding chamber door while injecting the melt in to the
mold. The machine has a safety switch that will not allow it to be run unless the door
is closed
(12). Operate the machine in semi-automatic and automatic modes by changing the
mode of operation from the main control panel.
(13). Change the polymer weight for injection to see its influence on the quality of the
product.
(28). Typical results obtained from the experiment can be seen below (Figure 7.6)
with the description of the experimental parameters below it.

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 1

Figure 7.6: Dog bones obtained in injection molding procedure: 1) not enough polymer is
injected into the mold; 2) too much polymer is injected into the mold; 3) just enough polymer
is injected into the mold.

3.2 Purging the Machine

(1). Feed the purging polymer pellets in to the hopper.
(2). Set the temperature limits at different zones on the battle from the main control
unit.
(3). Wait for the temperatures at the different zones to stabilize.
(4). Move the nozzle back from the mold by switching to manual mode of operation.
(5). Desired amount of the purging polymer will be pushed out of the barrel to clean
the barrel and nozzle
(6). Clear the polymer chips struck to the injection mold and gates
(7). Turn the barrel temperature to zero.
(8). Turn the nozzle temperature to zero.
(9). Turn off the cooling system and hydraulic systems
(10). Turn the key to the off position (counter clockwise 90o).