Defect Analysis in Plastic Injection Molding Process

Abstract

Mold Design is the first stage in the development of plastic injection molded components. Plastic injection molded components can be produced in the desired number within a given time frame. Multi-cavity molds can help to produce the component in mass quantities in a short duration. The simplified mold is required to produce the quality component and it decides the associated costs of mold development. A review of the product development process with ingenious inputs in the design phase would help to achieve the overall objectives such as cost-effectiveness, minimum required cycle time, quality component. Generally, defects may arise in the molding process during the production of plastic injection molded components. The molding process offers a challenge during its design and development phase. The cost of the mold is high and any process which is not optimized renders heavy overheads during its development cycle and production. So mold design for the component is a very important part of the plastic injection molding process. Critical locations must be carefully designed for the proper filling of molten plastic.
Injection molding typically involves large volumes of parts. Small cost overheads per part can be compounded by large cost differences over the production process of the part. Major cost components considered in this study material and machine costs. Scraps,rejections, and regrinding of mold costs are also accounted for in the cost.