Injection process development

Injection process development expertise is becoming more and more important when dealing with more and more complex or demanding products. Large components are very often very critical from the visual aspect point of view as well as the dimensional point of view. Technical components are usually more critical from the dimensional point of view.

The injection specialist need to be able to develop the injection process that way, that the process remains repeatable even if some standard deviation can occur in the plastic material or in the machine itself. The injection process need to be able provide products in reasonable scrap and as quick cycle time as possible.

To be able to provide this kind of service, the specialist needs to know a lot about the material, about the tooling, about the injection process, about the quality specification as well as the customer requirements. To approach quickly and systematically he/she needs to know/use many special “scientific techniques”. Most common used are:

• Various techniques of problem solving (8D, KT, Fishbone diagram, …)
• Various techniques of systematic approach of troubleshooting (DoE, Scientific molding, …)
• Material processing differences (Semicrystaline or Amorphous materials, Materials sensitive to shear or materials needing higher shear…)
• Needs to posses a lot of experience to be able to “diagnose” the root cause of the particular defects to be able to define the needed corrective actions (part design change, tooling change, injection process change…)