JRG AUTOMOTIVE INDUSTRIES (INDIA) PVT. LTD.

IMT BAWAL

Department: QUALITY

Training Topic: MOULDING & PAINTING DEFECT AWARENESS AND IDENTIFICATION

Total Pages: 7

TRAINING CONTENTS

Injection molding overview:-

Injection Molded Part: -

Molding Defects:-

1
 JRG AUTOMOTIVE INDUSTRIES (INDIA) PVT. LTD.
IMT BAWAL

1. Short Shot- A short shot is the incomplete filling of a mold cavity which results in the
production of an incomplete part. If a part short shot, the plastic does not fill the cavity.

2. Shrinkage- Shrinkage is the contraction of the molded part as it cools after injection. Most
of the part shrinkage occurs in the mold while cooling. A small amount of shrinkage occurs
after ejection as the part continues to cool, especially for Delrin or POM.

SHRINKAGE

3. Warpage- Warpage occurs when there are variations of internal stresses in the material
caused by a variation in shrinkage. Warped parts may not be functional or visual.

4. Flow marks- Flow mark also known as flow lines, are molding defects that can occur in the
manufacturing process of injection molding. They are best described as directionally "off
tone" wavy lines or patterns.

2
 JRG AUTOMOTIVE INDUSTRIES (INDIA) PVT. LTD.
IMT BAWAL

5. Weld line or Knit line or Meld line- Weld line is the line where two flow fronts meet
when there is the inability of two or more flow fronts to "knit" together, or "weld", during
the molding process. These lines usually occur around holes or obstructions and
cause locally weak areas in the molded part.

6. Silver streaks- Silver Streaks are a phenomenon in which shining line shaped patterns
appear on the surface of the molded product. ... The cause of silver streaks is the air
or gases contained in the molding material appearing on the surface of the molded
product.

7. Black spot- Black spot or mix material defect is the commonest appearance defects
during molding production which would largely add your cost. ... 2.Mold problem
2.1.Poormold
steel makes P/L surface or cavity or kiss-off area drop off iron powder

8. Burn marks- Burn Mark can be defined as small dark brown or black discolorations on
the surface of a molded part, usually found at the end of the material flow path or in
blind pockets. Machine. Excessive Injection Speed or Pressure.

3
 JRG AUTOMOTIVE INDUSTRIES (INDIA) PVT. LTD.
IMT BAWAL

9. Sink marks- Sink marks and voids both result from localized shrinkage of the
material
at thick sections without sufficient compensation.

10. Sticking of parts- Ordinarily a molded product is removed from the mold by having
the product stick to the moving side of the mold when the mold opens, after which the
product is ejected using ejector pins. Sticking occurs when the part fails to separate
from the stationary mold or from the moving mold. In the case of the latter, the problem
could result in broken ejector pins.

11. Scratch- score or mark the surface of (something) with a sharp or pointed object.

12. Molding flash- Molding Flash occurs when a thin layer of material is forced out of the
mold cavity at the parting line or ejector pins location. This excess material remains
attached to the molded article, and normally has to be manually removed

4
 JRG AUTOMOTIVE INDUSTRIES (INDIA) PVT. LTD.
IMT BAWAL

13. Thread Mark –

14. Rib Damage -

15. Deep Cut –

16. Colour Variation –

5
 JRG AUTOMOTIVE INDUSTRIES (INDIA) PVT. LTD.
IMT BAWAL

17. Crack - Cracking can cause part failure, a short part life and be visually
unacceptable.
Cracks may not be obvious until several days or weeks after production. Hence, it is
better to recognize and remove the potential problem of cracking before production.
Moldflow Plastics Insight provides detailed shear stress results
Causes:-
High residual stresses
Cracks may occur in regions where internal shear stresses are frozen into the part.
Weld line weaknesses
Differential shrinkage
Differential orientation, packing and cooling cause differential shrinkage resulting in high internal
stress levels being frozen in.

18. Shining –

19. De-gating – De-gating is the process of removing the molded part from the gate and
runner system.

6
 JRG AUTOMOTIVE INDUSTRIES (INDIA) PVT. LTD.
IMT BAWAL

20. Pit Mark –

Prepared By: Tanuja Singh Reviewed By: Sanjeev Jha