Key principles.
Wall thickness
Thick sections cool slowly, surface depresses. Uniform walls prevent.
Differential cooling
Uneven cooling causes warping. Symmetric design + proper cooling.
Mold gap
Material squeezes between mold halves. Adjust clamping pressure.
Trapped gas
Gas trapped in part. Adjust venting, gating, hold pressure.
Material flow
Two flow fronts meeting. Cosmetically visible. Adjust gating.
Insufficient fill
Material doesn't fill cavity. Adjust pressure, temperature, gating.
FAQ
Uniform wall thickness. Avoid bosses thicker than 60% of base wall. Increase hold pressure.
Differential cooling, residual stress. Symmetric design + cooling channels solve.
Worn mold, insufficient clamping force, contamination at parting line.
Move gates to avoid weld lines on cosmetic surfaces. Increase melt temperature for stronger weld.
Increase pressure, temperature, hold time. Check vents for trapped gas. Verify gate adequate.
Material/geometry combinations may have inherent issues. Mold flow analysis identifies before tooling.
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