Scientific Injection Molding

Scientific injection molding is a disciplined approach to establish consistent, repeatable plastic injection molding process parameters based on predictable facts and data. Focusing on part design, mold design, material selection, and measurement of plastic injection molding process parameters, EVCO Plastics systematically controls variables that would result in defective or low-quality parts.

Benefits

EVCO Plastics applies the latest scientific injection molding practices and tools, coupled with the experience of our highly trained team and innovative engineering, to ensure optimal plastic injection molding process control, repeatability and part quality.

Higher yield and lower material consumption
Higher yield and lower material consumption

Repeatability across set-ups and material lot
Better flow control

Process

Plastic injection molding process parameters controlled by scientific injection molding include:

Robust part design
Hold Pressure
Mold Temperature
Melt Temperature
Mold design and build

Cooling Time
Critical performance criteria
Filling, flow and cooling analysis and engineering
Quality planning

Integrated operation requirements
Proper material selection
Repeatable process
Part ejection and handling
Ergonomics

Data Analysis

Applying scientific injection molding practices isolates where problems may occur and gathers data to document and scientifically eliminate those problems. Strategically placed mold transducers assist and provide real-time process feedback.

Some of the process data and chart profiles include:

Fill optimization (fill optimization curve)

Fill cavity at several speeds under pure velocity control
Record fill time and peak plastic pressure at each velocity
Chart relative viscosity as a function of fill time

Pressurization and gate freeze

Fill cavity to 95-99% under controlled velocity
Set hold pressure at 50-70% of peak fill pressure
Increase hold time at constant intervals for each shot
Record and chart part weight versus time

Pressure loss study

Fill the cavity to transfer position and record peak pressure
Reduce shot size and fill cavity to post-gate position
Reduce shot size and fill cavity to pre-gate position
Repeat as necessary by reducing shot size to fill to areas of desired pressure measurement

Case Study

Thermoforming to Plastics Injection Molding

Orion Energy Systems partnered with EVCO Plastics to enhance part quality and save cost.

EVCO Plastics’ expertise in material selection and part and process engineering and design helped Orion Energy Systems find the right plastic material and plastic injection molding process parameters.