2

1
Tips for Defect-Free
Injection Molding
of TPU

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[Link] Edition: 2016 · Order-No.: COV00080632 · Printed in Germany

1. Tips for defect-free injection molding of TPU Various problems can arise when injection
molding thermoplastics – and that goes for
1.1 Defects in dimensions 4 TPU, too. We have compiled an extensive list
1.2 Demolding defects 9 of possible defects, explained their causes
and described preventive measures. To help
1.3 Color defects 16
you find them more easily, we have divided
1.4 Defects in the form of specks and dots 24 the defects into groups, such as “Defects
1.5 Unevenness defects 25 caused by warpage” and “Defects caused by
1.6 Processing defects 31 specks and dots”. Please do not hesitate to
contact us if this list does not help you solve
1.7 Warpage defects 34
your problem.
1.8 Gloss defects 35 We would be grateful for any hints, sugges-
1.9 Defects in mechanical properties 44 tions and illustrations you could submit to
make this catalogue of defects more com-
1.10 Surface defects 47
plete.

3
1.1 Defects in dimensions

Short molding
Description: Molding not completely filled, mostly at end of flow path or
thin-walled locations

Causes: Remedies:

Optimize processing parameters. Increase melt

Unsuitable processing parameters and mold temperatures. Increase injection speed.
Switch to holding pressure at a later point in time

Pressure losses too high in gating system, includ-

Reduce pressure losses in gating system. Increase
ing hot runner. Sprue, gate and runner cross-sec­
sprue, gate and runner cross-sections. Check hot
tions too small. Pressure loss in hot runner too
runner cross-sections, optimize nozzle point tor-
high. Pressure loss in shut-off nozzle system too
pedo. Work with machine nozzle open
high

Wall thickness inadequate Increase wall thickness

Flash
Description: Mold gap results in polymer melt penetration on molding

Causes: Remedies:

Permitted gap width exceeded. Locking force Check gap widths.

inadequate. Mold rigidity inadequate. Wear of Increase locking force. Increase mold rigidity.
sealing faces Rework sealing faces

Optimize processing parameters. Reduce injection

Processing parameters not optimized speed or melt temperature. Switch to holding
pressure earlier or reduce holding pressure

5
 Weight variation
Description: Significant fluctuations in molded part weight and mass

Causes: Remedies:

Check plasticating unit – in particular non-return

Wear in plasticating unit
valve – for wear

Check plasticating unit’s temperature control

Mold and melt temperature fluctuations
units and heating circuits

Drying inadequate Check drying process

Check injection molding machine’s injection and

Metering stroke or melt cushion fluctuates
metering stroke

Increase set locking force or select machine with

Locking force inadequate
higher locking force

Variations in size
Description: Required dimensions of part not achieved

Causes: Remedies:

Material too moist Check material’s dryness

Check shrinkage calculation actual

target
using details from raw material
Predicted shrinkage incorrect
manufacturer or comparable
molds

Check molding for warpage and switch to low-

Warpage due to unsuitable design of part or
warpage design. Change gate position to obtain
gate position
uniform orientation

Check temperature profile of machine and mold for

Machine and mold not in thermal equilibrium
thermal fluctuations

7
 Variations in wall thickness
(deviation between nominal and actual values)
Description: Thickness of molded part does not correspond to nominal
value or varies greatly and is not within tolerance range

Causes: Remedies:

Check mold rigidity and reinforce mold if

Mold rigidity inadequate
necessary

Shrinkage allowance inaccurate, mold dimensions Check mold dimensions, compare with raw
incorrect material manufacturer’s shrinkage data

Reduce cavity pressure by switching to holding

Cavity pressure too high or locking force too low pressure earlier or using a lower holding pressure
and increase locking force

Check mold centering device and replace if

Mold centering device defective or worn
necessary

1.2 Demolding defects

Sprue remains attached

Description: Sprue contracts and / or remains attached to sprue
bush or cold runner

Causes: Remedies:

Optimize processing parameters. Reduce cavity

Unsuitable processing parameters (point at which
pressure by switching to holding pressure earlier
switch is made from injection to holding pressure,
and using a lower holding pressure. Check cooling
level of holding pressure)
time and increase if necessary

Nozzle radius or aperture too large Reduce nozzle radius or aperture

Check components such as machine nozzle, cold

runner and gate for undercuts and polishing and
Drafts and polishing inadequate
rework in the direction of removal (demolding) if
necessary. Optimize drafts and polish if necessary

9
 Ejector marks
Description: Distinct ejector marks on molding

Causes: Remedies:

Optimize injection speed. Reduce holding pressure.

Cavity pressure too high
Switch to holding pressure earlier

Mold rigidity inadequate Improve mold rigidity

Inadequate cooling time or mold temperature

Optimize cooling / mold temperature control
locally too high

Unsuitable mold design. Excessive undercuts, Optimize mold design. Reduce undercuts,
inadequate draft optimize drafts

Inadequate mold (cavity) polishing. Ejector position Improve mold (cavity) polishing. Optimize ejector
unsuitable or ejector area too small position or enlarge ejector area

10

Noises as mold opens

Description: Opening the mold generates a considerable amount of noise

Causes: Remedies:

Check mold polishing and drafts, rework if

Drafts inadequate
necessary. Use an appropriate mold release agent

Mold centering device unsuitable or worn Improve mold centering

Reduce cavity pressure. Switch from injection to

Cavity pressure too high
holding pressure earlier. Reduce holding pressure

Mold rigidity inadequate Increase mold rigidity

Insufficient release agent Use release agent batch

11
 Part fractures during removal
Description: Part damaged during removal

Causes: Remedies:

Optimize injection speed. Reduce holding pressure.

Cavity pressure too high
Switch to holding pressure earlier

Mold rigidity inadequate Improve mold rigidity

Inadequate cooling time or mold temperature

Optimize cooling / mold temperature control
locally too high

Unsuitable mold design. Excessive undercuts, Optimize mold design. Reduce undercuts,
inadequate draft optimize drafts

Polish mold surface in direction of removal

(demolding), select appropriate coating or rough-
Inadequate mold (cavity) polishing. Ejector position
ness height. Improve position and size of ejec-
unsuitable or ejector area too small
tors (in particular, locate near corners or under
ribs / domes)

Inadequate material drying, residence time Check material drying, residence time and melt
too long temperature

12

Mold fails to open

Description: Even when applying maximum permitted opening force, injection
molding machine fails to pull two halves of mold apart

Causes: Remedies:

Reduce cavity pressure. Switch from injection to

Cavity pressure too high holding pressure earlier. Reduce holding pressure.
Increase melt temperature within permitted limits

Mold rigidity inadequate Increase mold rigidity

Slide valve control failure Check slide valve is in correct position

Tips for opening mold: Use cold water to reduce

temperature of mold to room temperature, fit
additional hydraulic rams between machine
platens to help open mold. If necessary, raise
mold temperature above glass transition tempera-
ture, pull mold apart

13
 Molded part remains in cavity
Description: Molded part jams, cores / ejectors deform or penetrate part

Causes: Remedies:

Reduce injection speed and holding pressure

Mold overloaded
and switch to holding pressure earlier

Excessive undercuts, inadequate drafts Reduce undercuts, improve drafts

Inadequate mold polishing on flanges, Polish mold surface in direction of removal

ribs or studs (demolding)

Vacuum between mold surface and molding Optimize mold venting

Premature ejection, molded part sticks or still

Increase cooling time, reduce mold temperature
too soft

Ejector pins too few in number or poorly Increase number of ejector pins or optimize their
positioned position

14

Part deformed during removal

Description: Part deformed during removal

Causes: Remedies:

Optimize injection speed. Reduce holding

Cavity pressure too high
pressure. Switch to holding pressure earlier

Mold rigidity inadequate Improve mold rigidity

Inadequate cooling time or mold temperature too

Optimize cooling / mold temperature control
high locally

Unsuitable mold design. Excessive undercuts, Optimize mold design. Reduce undercuts,
inadequate draft optimize drafts

Polish mold surface in direction of removal (de-

molding), select appropriate coating or rough-
Inadequate mold (cavity) polishing. Ejector
ness height. Improve position and size of ejec-
position unsuitable or ejector area too small
tors (in particular, locate near corners or under
ribs / domes)

15
1.3 Color defects

Darker color at weld lines

Description: Colored stripe. Darker color occurs at weld lines or near
leading / lagging flow fronts fed from neighboring melt streams

Causes: Remedies:

Pigment separation or refractive effect due to

Vary flow front speed
unsuitable flow at weld lines

Overheating of melt, resulting in color changes at

Reduce thermal melt load
weld lines

Improve venting, if necessary by relocating

weld line
Oxidation due to inadequate venting
N.B.:
Fault tends to occur on light, bright colors such
as white, blue, green and orange.

16

Homogeneous discoloration
Description: Uniform deviation from basic color, especially with light colors

Causes: Remedies:

Melt temperature too high Check melt temperature and reduce if necessary

Inadequate utilization of plasticating unit capacity,

Use smaller plasticating unit
resulting in excessive residence time

Master batch unsuitable Use suitable master batch

Production stoppage without reduction in

Comply with instructions for production stoppage
temperature

17
 Partial color change
Description: Partial change in color

Causes: Remedies:

Material not adequately homogenized Increase back pressure, reduce screw speed

Injection and screw speeds too high Reduce injection and screw speeds

Gate too narrow Widen gate

Shorten residence time by selecting smaller

Residence time too long
plasticating unit

18

Rings
Description: Rings, bloom effect, matte rings running concentrically to gate

Causes: Remedies:

Melt flow stagnates in mold, melt temperature Try to achieve even melt flow, increase melt
too low temperature

Mold temperature too low Increase mold temperature

Inadequate injection speed Increase injection speed

19
 Black (overheating) marks
Description: Streaks and stains from burning, periodic discoloration,
dark spots. Brown to black discoloration of molding, at different locations
and irregular distances

Causes: Remedies:

Optimize mold venting, in particular near flow lines

and at end of flow path. Correct flow front (wall
Entrapped, compressed air in injection mold,
thickness, gate position or flow promoters). Check
resulting in burns
venting channels. Reduce clamping force. Evacuate
mold

20

Black discoloration
Description: Diesel effect. Concentrated black coloring at points where
flows merge, e.g. on flanges or studs or in corners at end of flow paths

Causes: Remedies:

Unfavorable cross-section changes / bends or Check / rework parts and sealing faces affected.

defective sealing faces, resulting in dead spots Eliminate dead spots. Check weep holes for needle
where material burns. Dead spots at sealing faces, valve system. Check sealing faces. Check direction
cross-section changes or bends in hot runne changes and transition cone

Check screw, non-return valve and cylinder for

wear

Screw, non-return valve or cylinder wear N.B.:

In addition to optical degradation of the molded
part, this fault can also damage the mold through
corrosion.

21
 Stress-whitening
Description: Lighter color in places, with velvety molding surface

Causes: Remedies:

Overstretching of polymer matrix. Demolding Reduce mechanical stress during demolding.

causes excessive mechanical stress. Ejector pins Position ejector pins near corners, domes and ribs
poorly positioned and drafts inadequate (in general at stress-whitened lines)

Excessive service load Adapt service loads to material values

Reduce cavity pressure. Increase mold rigidity

Cavity pressure too high. Mold rigidity inadequate N.B.:

Fault mostly occurs with thermoplastics
containing rubber.

22

Cloudy appearance
Description: Gray streaks. Molding surface has dark, cloudy appearance

Causes: Remedies:

Clean plasticating unit.

Plasticating unit dirty
Reduce screw speed

Replace entire unit or

individual (worn) com­-
Wear effects on plasticating unit
ponents. Use a plasticating unit with an abrasion-
and corrosion-resistant coating

23
1.4 Defects in the form of specks and dots

Black or brown dots

Description: Specks, either spherical with irregular contours or flaky
with sharp, linear contours, occurring sporadically

Causes: Remedies:

Clean plasticating unit mechanically. Comply

Boundary layers that have formed on screw / 
with procedures for production stoppages.
cylinder surface damaged / flaking off
Check plasticating unit for wear

Check cleanness of granules. Store granules in

a dust-free location. Clean soiled moldings prior
Soiling of granules or regranulated scrap to regranulation. Do not regranulate moist or
thermally damaged moldings. Check drying and
conveyor system for soiling

24

1.5 Unevenness defects

Pockets
Description: Highly localized round or elongated solid swellings – horizontal or vertical
– on molded part, not necessarily discernible on both sides

Causes: Remedies:

Unmelted material or air intake during metering,

Use appropriate screw
screw cut too deeply

Unmelted material or air intake during metering,

Select metering stroke between 1 and 3 D
metering stroke greater than 3D (D = diameter)

Unmelted material or air intake during metering,

Increase back pressure
back pressure inadequate

Unmelted material or air intake during metering,

Increase melt temperature
melt temperature too low

Unmelted material or air intake during metering,

Reduce screw speed
screw speed too high

25
 Delamination
Description: Delamination. Surface layer detaches or flakes off.
Can occur over extensive areas of molding or just near sprues

Causes: Remedies:

Excessive shear stress. Gate too narrow. Reduce shear stress. Widen gates. Reduce
Injection speed too high injection speed

Clean plasticating unit. Check material in hopper

Contamination by incompatible resins and ma­terial supply system for contamination by
other materials

Color batch unsuitable Use appropriate color batch

26

Sink marks, localized

Description: Localized, pronounced depression in surface, mostly opposite
ribs, at thick-walled locations, cores, weld lines, throats, hot runner nozzles
or end of flow paths

Causes: Remedies:

Compensate for volume contraction by adapting

wall thickness-rib ratio to material, increasing
holding pressure and holding pressure time, and
No compensation for volume contraction during
making nozzle aperture and sprue cross-section
cooling phase
larger. Reduce melt and mold temperatures (may
result in formation of voids). Check melt cushion.
If necessary, laminate sink marks

27
 Dog’s bone effect, extensive sink marks
Description: Extensive contraction of molding away from mold surface
except at edges

Causes: Remedies:

Change flow front or

Glass fibers standing up at end of flow path or at
move weld line to
weld lines
non-critical area

Switch from injection to

holding pressure later Smin
Holding pressure not sufficiently effective and increase both holding Smax
pressure and holding
pressure time

28

Notches along weld line

Description: Pronounced weld line, notch along weld line which
can be seen or felt

Causes: Remedies:

Improve mold venting, especially at end of flow

Inadequate mold venting
path

Improve flow properties by increasing melt and

mold temperatures. Increase injection speed.
Increase wall thickness or, if necessary, move
gates to shorten flow paths
Inadequate plastic flow properties. Insufficient
injection speed. Wall thickness inadequate / flow
N.B.:
paths too long
Fault mostly occurs with high-viscosity or quick-
setting thermoplastics. For thermoplastics with a
low pro­-­cessing temperature (e. g. PS), weld line
can be laminated using the Promold® process.

29
 Grooves
Description: Record grooves, stick-slip effect.
In sprue area: Fine, concentric grooves around gate.
In thin-walled areas: Grooves parallel to flow front

Causes: Remedies:

Melt flow in mold pulsates due to excessive

Try to obtain quick, uniform melt flow
cooling of melt front.

Injection speed too low Increase injection speed

Melt temperature too low Increase melt temperature

Mold temperature too low Increase mold temperature

Wall thickness too low Increase wall thickness

30

1.6 Processing defects

Unusual odor
Description: Pronounced odors, either typical or atypical of material

Causes: Remedies:

Thermal damage to material. Excessive residence Reduce melt’s exposure to heat. Reduce
time in cylinder or hot runner. Melt temperature residence time in cylinder or hot runner.
too high Lower melt temperature

31
 Melt cushion fluctuates
Description: Melt cushion varies greatly, sometimes approaching zero
Injection
Metering

Screw stroke (mm)

Melt cushion of
10 cycles
Holding pressure

Causes: Remedies: Time (s)

Check non-return valve and replace with a new

Non-return valve defective or worn
one if necessary

Hydraulics faulty Check hydraulics are working properly

Check cylinder barrel for wear and if necessary

Uneven metering
fit bush or use new plasticating unit

32

Cycle too long

Description: Actual cycle time exceeds scheduled cycle time

Causes: Remedies:

Cut metering time. Increase screw speed to maxi-

mum peripheral velocity of 0.25 m / s. Use larger
Metering time too long
plasticating unit. Check plasticating unit for wear.
Use more efficient screw

Cut cooling time. Reduce mold temperature within

Cooling time too long permitted limits. Improve cooling, targeting critical
areas

Handling time too long Improve handling system

33
1.7 Warpage defects

Warpage, general
Description: Moldings not as shown in drawing, distorted or
do not fit together accurately

Causes: Remedies:

Optimize design of molding. Improve glass fiber

Unsuitable design of part. Unsuitable glass fiber
orientation by optimizing gate. Optimize wall thick-
orientation. Unsuitable wall thickness distribution
ness distribution

Switch from injection pressure to holding pressure

later and increase holding pressure. Check non-
return valve and replace if necessary
Holding pressure not sufficiently effective.
Non-return valve worn N.B.:
Possible causes of defect, associated remedies
and their interdependencies are too complex to
go into here.

34

1.8 Gloss defects

Frosting
Description: Rough, matt part surface

Causes: Remedies:

Injection speed inadequate Increase injection speed

Increase mold temperature. Equip mold with

thermal insulation. Use more efficient temperature-
control unit
Mold temperature too low
N.B.:
Only affects glass-fiber-reinforced thermoplastics.
Very evident on amorphous thermoplastics, less
so on semi-crystalline thermoplastics

35
 Gloss level not achieved on polished surface
Description: Molding fails to achieve required gloss level either over
entire surface or in a specific area

Causes: Remedies:

Mold polishing inadequate or worn Improve mold polishing

Inadequate injection speed, possibly due to Increase injection speed, if necessary by

poor venting improving venting

Fluctuating mold temperature due to insufficient

Check mold for uniform temperature
cooling

Inadequate material drying Check drying process

Increase holding pressure and holding pressure

Holding pressure not sufficiently effective
time. If necessary, widen gates

36

Gloss differential on molded part surface

Description: Different gloss levels, either over entire molded
part or at various locations

Causes: Remedies:

Inadequate injection speed Increase injection speed

Mold surface worn or corroded Rework mold surface

Service temperature control system and repair

Fluctuating mold temperatures. Fault in heating /  leak if necessary. Improve temperature control with
cooling circuit, e.g. leak, heating / cooling channel additional heating / cooling channels, by increasing
blocked, temperature control unit not working heating / cooling medium throughput or by chang-
ing this medium (water instead of oil)

37
 Localized, shiny, finger-like hollows
Description: Shiny hollows, often near sprues, at cores or close
to hot runner elements, often assumed to be bonding spots

Causes: Remedies:

Premature ejection Extend cycle time

Increase holding pressure, extend holding pressure

Inadequate holding pressure and holding time, check melt cushion. Check nozzle aperture,
pressure time sprue cross-section and gate cross-section and
widen if necessary

Premature switch to holding pressure Switch to holding pressure later

Lower mold temperature on a localized basis

using additional cooling channels or separate
temperature control
Localized excessive mold temperature
N.B.:
See also “Matt surface defects”

38

Dull spots
Description: Matt halo, dull spot. Uniform, well-defined velvety area

Causes: Remedies:

Speed differences between flow fronts (if several Even out speed differences by balancing gating
injection points) system (if several injection points)

Round off or polish changes in wall thickness

and transitions in gate / mold or adjust flow front
Tearing of already solidified outer skin at sharp speed
bends or sudden changes in wall thickness
N.B.:
See also “Flaking”

39
 Matt surface defects at hot runner elements
Description: Rough, cracked surface, creating a matt effect
close to hot runner elements or at hot cores

Causes: Remedies:

Premature ejection Extend cooling time

Improve thermal separation of hot runner, reduce

Mold temperature too high at hot runner
mold temperature

Core temperature too high Ensure adequate cooling of core

40

Matt appearance not achieved on textured surface

Description: Required matt appearance not achieved on surface
of molding

Causes: Remedies:

Injection speed and mold temperature too low Increase injection speed and mold temperature

Switch to holding pressure later and increase

Holding pressure not sufficiently effective
holding pressure

Surface texture inadequate or worn Rework mold surface

41
 Damage to grain on molded part
Description: Cracked, rough surface with scoring in direction of
removal (demolding), mostly at same location

Causes: Remedies:

Inadequate drafts Make drafts larger

Mold surface damaged Rework mold surface

Reduce cavity pressure. Switch from injection to

holding pressure earlier. Reduce holding pressure.
Cavity pressure too high
Optimize injection speed. Increase melt
temperature within permitted limits

Increase mold rigidity

Inadequate mold rigidity N.B.:

Scoring can often only be identified using
optical aids.

42

White patches
Description: Whitish, rough, flaky patches or whitish round or
oval patches resembling mildew

Causes: Remedies:

Material too moist Check dryer / drying process

Melt temperature too high, residence time in Check melt temperature, melt residence time
cylinder and hot runner too long and screw speed and reduce if necessary

43
1.9 Defects in mechanical properties

Weld line strength insufficient

Description: Part failure near weld line

Causes: Remedies:

Insufficient mold venting Improve mold venting

Improve flow properties. Increase injection speed.

Inadequate plastic flow properties. Injection
Increase melt and mold temperatures. Increase
speed too low. Wall thickness inadequate / flow
wall thickness or relocate gates if necessary to
paths too long
shorten flow paths

44

Defective integral hinges

Description: Integral hinges tear or break under stress

Causes: Remedies:

Incorrect material selection, e.g. amorphous

Use a suitable semi-crystalline thermoplastic
thermoplastics

Change weld line and comply with design

Weld line in unsuitable position in integral hinge
guidelines for integral hinges

45
 Mechanical problems with part
Description: Molding not up to mechanical requirements

Causes: Remedies:

Check dimensioning meets mechanical require-

ments. Check molded parts’ internal stress levels
Excessive mechanical stress (if necessary, increase mold and melt tempera-
tures, reduce cavity pressure). Check plastics’
resistance to media

Material degradation due to incorrect drying or Check melt temperature, residence time and
overexposure to heat drying process

Locate weld line outside area where main stress

Weld line in unsuitable position
occurs

Poor demolding behavior at domes and screw Avoid damaging part during removal (demolding),
connections improve removal behavior by polishing mold

46

1.10 Surface defects

Flaking
Description: Cold displacement. Surface looks flaky with
alternating shiny and matt areas, mostly near sprues

Causes: Remedies:

Inject in stages – slow to fast. Reduce mold

Displacement of already cooled material
temperature. Provide gates with radii and polish

47
 Jetting
Description: Jetting. Melt which has entered cavity first is visible on
part surface (mostly S-shaped). Fault occurs near sprues or at throats

Causes: Remedies:

Unsuitable gate or throat with result that no

Change gate. Select gate position with deflector
frontal flow is produced. Gate position has no
surfaces. Make gate cross-section larger.
deflector surface.
Improve design of changes in diameter
Gate cross-section or throat too small

Give preference to injection in stages – slow

Injection speed too high
to fast.

48

Extensive silver streaks

Description: Extensive elongated penicillate streaks

Causes: Remedies:

Use larger plasticating unit to reduce metering

stroke (‹3D). If plasticating unit cannot be changed,
increase feed section temperature, reduce screw
Plasticating unit’s metering stroke too high
speed, increase cycle time and if necessary in-
crease size of melt cushion, if possible by 1-2 D,
as an additional remedial measure

Optimize plasticating conditions. Increase back

pressure within permitted limits. Shorten screw
retraction. Let machine nozzle contact hot runner
mold
Air intake during metering
N.B.:
Fault sometimes occurs in association with
blistering.

49
 Buckling line
Description: Depending on angle of light, clearly discernible line
or shimmering area on part, often at weld lines, ribs, sudden changes
in wall thickness or slide valves

Causes: Remedies:

Spring-loaded gate valves Improve gate valve support / mold rigidity

Change position of weld line, if necessary also

Glass fibers standing up at weld lines
using sprue position and number of gates

Sudden changes in rigidity at ribs or sudden Avoid sudden changes in wall thickness and
changes in wall thickness provide gradual transitions

50

Large bubbles
Description: Hollow bubbles filled with air in wall

Causes: Remedies:

Check granule conveying system

for air intake. Increase back
Air intake during metering
pressure within permitted limits.
Shorten screw retraction

If screw stroke exceeds 3D, use plasticating unit

Capacity utilization of plasticating unit too high
one size larger

51
 Linear surface damage
Description: Scoring, scratches. Scoring or scratches on part
surface running in direction of removal (demolding), also visible as
matt stripes on high-gloss surface

Causes: Remedies:

Check mold’s surface texture and rework if

Mold’s surface texture damaged
necessary, polish in direction of removal

Spring-loaded gate valves Optimize slide valves

Reduce cavity pressure. Switch from injection

to holding pressure earlier. Reduce holding
Excessive cavity pressure
pressure. Optimize injection speed. Increase melt
temperature within permitted limits

Reinforce mold
Inadequate mold rigidity
N.B.:
See also “Noises as mold opens”

52

Streaks open towards flow direction

Description: Moisture streaks. U-shaped, elongated, tufted streaks,
open towards flow direction; in a less pronounced version in the form
of small lines

Causes: Remedies:

Check drying process (drying temperature and

Residual moisture content of pellets too high time and hourly throughput). Check dryer for soiled
filters. Check drive motor’s direction of rotation

53
 Streaks due to overheating, needle-like streaks
Description: Silver streaks. Elongated silvery streaks

Causes: Remedies:

Reduce thermal stress on melt, lower melt

Overheating of melt, melt temperature too high
temperature

Reduce thermal stress on melt, select smaller

Overheating of melt, melt residence time too long
screw diameter

Overheating of melt, screw speed too high Reduce thermal stress on melt, lower screw speed

Overheating of melt, nozzle and runners too Reduce thermal stress on melt, widen nozzle
narrow and runners

Reduce thermal stress on melt, comply with

instructions for production stoppage
Overheating of melt, production stoppage without
reduction in temperature
N.B.:
Fault often similar to moisture streaks.

54

Tear drops
Description: Air-filled hook. Lines in shape of hook / tear drop caused
by trapped air

Causes: Remedies:

Reduce injection speed in critical area. Improve

Air rolled over and trapped in injection mold, e.g.
mold venting close to flow lines and near depres-
from engravings, grooves or depressions
sions, flanges or engravings. Evacuate mold

55
 Cold slug
Description: Cold-flow mark. Well-defined, irregular matte area.
Cold melt particles entrapped in surface of molding

Causes: Remedies:

Ejector claw on cold runner rod missing or too Provide or optimize ejector claw so that cold
small to absorb cold slug slug is absorbed

Increase screw retraction, optimize thermal

Melt leaking from machine nozzle or hot runner
separation in hot runner

Make nozzle aperture larger, install band heater

Nozzle aperture and heating inadequate with higher capacity, check thermocouple and
controller

56

Small bubbles
Description: Entrapped air similar to voids but greater in
number and with much smaller diameters

Causes: Remedies:

Material too moist Check drying process

Select appropriate vented screw or replace

vented screw with normal one and pre-dry
material
Unsuitable vented screw
N.B.:
Fault often coincides with silver streaks.

57
 Craters
Description: Pinholes, pimples. Depressions the size of pinpricks

Causes: Remedies:

Material degradation Reduce melt temperature and residence time

Pigment has detrimental effect (use of incom­

Use compatible pigments or different type of
patible pigments for in-plant coloring, often
carbon black
wrong type of carbon black)

Proportion of carbon black too high Reduce proportion of carbon black

58

Gray dots
Description: Metal specks. Gray foreign particles which may appear
shiny, depending on angle of light

Causes: Remedies:

Check plasticating unit for screw, cylinder or

Plasticating unit worn
non-return valve wear

Check pipes, containers and feed hoppers for

abrasion. Make such pipes, containers and
Foreign bodies due to feed pipe, container and
hoppers from stainless steel – aluminum and
feed hopper abrasion
tinplate are unsuitable. Avoid bends as far as
possible, otherwise design with large radii

Check granulators regularly for abrasion / damage

Granulator for producing reclaim worn
and repair when necessary

59
 Microscopic cracks
Description: Fine, microscopic cracks in molded part, often just
on surface of outer fibers under tensile stress

Causes: Remedies:

Optimize processing parameters with regard

to stress levels. Increase mold and melt tempera-
Stress levels too high in molded part
tures. Design molding to reduce long-term outer
fiber strain

Check media compatibility. Check release and

anti-corrosion agents to see if they cause stress
cracking. Check molded parts for chemical
Contact with inappropriate media
resistance to cleaning / degreasing agents.
Check resistance to media used and reduce
load if necessary

60

Voids
Description: Vacuole, bubble. Round or elongated bubbles (hollow
vacuums), generally only discernible on transparent or translucent parts

Causes: Remedies:

Increase holding pressure, extend holding

No compensation for volume contraction during
pressure time, check melt cushion. Check nozzle
cooling phase. Holding pressure not sufficiently
aperture, sprue cross-section and gate cross-
effective
section and make larger if necessary

Inject in thick-walled area. Revise wall thicknesses

to avoid excessive changes in thickness
No compensation for volume contraction during
cooling phase. Unsuitable injection position or
N.B.:
part design
Comply with design guidelines for injection
molded parts

61
Notes

62

63
Notes

64

65