®

V Y D Y N E M O L D I N G G U I D E
Contents
What is Nylon? . . . . . . . . . . . . . . . 3
Comparing Nylon to Other
Engineering Thermoplastics . . . . . . 5
Amorphous Polymers . . . . . . . . . 5
Semi-crystalline Polymers . . . . . 5
Using the Polymers in Parts
Fabrication . . . . . . . . . . . . . . . . . 5
Typical Characteristics
of Nylon Polymers . . . . . . . . . . . . . 7
Tool Design. . . . . . . . . . . . . . . . . . 9
Tool Design for
VYDYNE Nylon Resins . . . . . . . . 10
Tool Design Considerations . . . 10
Multi-cavity Tool Layout and
Tool Balancing . . . . . . . . . . . . . 11
Runner Design . . . . . . . . . . . . 13
Sprue Bushing
Considerations . . . . . . . . . . . . 14
Gate Design . . . . . . . . . . . . . . 15
Gate Location . . . . . . . . . . . . . 18
Vent Location . . . . . . . . . . . . . 20
Cooling and Mold Steels . . . . . 20
Draft Angles . . . . . . . . . . . . . . 22
Ejector Systems for Molding
VYDYNE Nylon Resins . . . . . . 22
Mold Cooling . . . . . . . . . . . . . . 22
Injection-molding Process . . . . 25 Screw and Molding
Equipment Guidelines . . . . . . . . 60
Drying of Plastics Materials . . . . . 26
Screw and Check Ring Design . . 61
Hopper Dryer Design
for Drying Hygroscopic Injection-molding Machine
Materials . . . . . . . . . . . . . . . . . 27 Type and Size . . . . . . . . . . . . . . . 64
Dew Point Temperature
Mold Shrinkage and
and its Importance in
Dimensional Stability . . . . . . . . . 65
Drying of Hygroscopic
Materials . . . . . . . . . . . . . . . . . 27 Mold Shrinkage Prediction . . . . . . 66
Troubleshooting Drying Post-mold Shrinkage and
of Plastics . . . . . . . . . . . . . . . . 28 Estimating Total Shrinkage . . . . . . 69
How to Dry Nylon . . . . . . . . . . . 30 Post-mold Shrinkage . . . . . . . . 69
Processing Conditions for Estimating Total Shrinkage . . . . 70
VYDYNE Nylon Resins . . . . . . . . 34
Packing and Part Density. . . . . . . 71
General Purpose
VYDYNE Resins . . . . . . . . . . . 35 Part Weight . . . . . . . . . . . . . . . 71
Heat-stabilized Flow Tabs. . . . . . . . . . . . . . . . . 71
VYDYNE Resins . . . . . . . . . . . 36
Cavity Pressure Control . . . . . . 71
Nucleated VYDYNE Resins . . . 38
Coefficient of Linear Thermal
Weather-resistant Expansion (CLTE) . . . . . . . . . . . . 72
VYDYNE Resins . . . . . . . . . . . 40
Troubleshooting Guide for
Ignition-resistant Injection Molding Nylon . . . . . . . . 73
VYDYNE Resins . . . . . . . . . . . 42
Coloring VYDYNE
Mineral/Glass-filled Nylon 66 Resins . . . . . . . . . . . . . 79
VYDYNE Resins . . . . . . . . . . . 44
Safety and Handling
Glass-filled Considerations . . . . . . . . . . . . . . 81
VYDYNE Resins . . . . . . . . . . . 46
Hydrolysis-resistant,
Glass-filled
VYDYNE Resins . . . . . . . . . . . 54
Nylon 66/6 Copolymer,
Glass-Filled VYDYNE Resins . 56
Industrial-grade
VYDYNE Nylon Resins . . . . . . 58
2
What is Nylon?
A monomer is the basic building
block of a polymer. The monomer is
reacted under the effect of heat
and/or pressure and a catalyst
monomer and links with more of
the same monomer, or with differ-
ent monomers, to form one long
chain of monomers called a poly-
mer, from the Greek “poly” meaning
many and “mer” meaning units.
Figure 1 – Basic Amide Group
Found in Nylon
O H
C N
Figure 2 – Manufacture of Nylon 6 and 66
Polyamides, otherwise known as
nylon, can be produced in a num-
ber of ways depending on the
combination of monomers used to
create the long chain. The amide
group, shown in Figure 1, is the
basic building block for most nylons
or polyamides. Polyamides can be
produced by combining and poly-
merizing two monomers, one or two
amine (or diamine) groups with one
or two carboxylic acids (or diacid)
groups, or by polymerizing a single
monomer containing both amine
and acid. The polymer structure will
determine the physical properties
of a particular polyamide.
Figure 2 illustrates how nylon 6
and 66 are produced. The basic
3
monomer used to produce nylon 6
is caprolactam, a monomer with a
ring-shaped structure containing an
amide group. These polymerize by
ring opening to form nylons which
are designated based on the num-
ber of carbon atoms in the lactam
monomer. For nylon 6, -caprolac-
tam (C6) is the main feedstock
used. For nylon 12, laurolactam
(C12) is used.
Nylons designated with dual
numbers, such as nylon 66 or nylon
612, are formed by combining
diamines and diacids to form the
polyamide polymer. These poly-
mers are formed using condensa-
tion polymerization. In the
What is Nylon? – continued Molding Guide

designation of these types of Table 1 shows a comparative Figure 3 – Dual Number Nylons and
nylons, the first number gives the chart of the properties of nylon 6 How They Are Formed

number of carbon atoms in the and nylon 66. Several noticeable

diamine, and the second number
notes the carbon atoms in the
diacid. Therefore, as shown in
Figure 3, various dual number
nylons can be made with different
combinations of diamines and
diacids. These com-
binations of diamines and diacids
produce nylons which display differ-
ent mechanical and physical prop-
erties. This introduction will
emphasize the properties of the
most commonly used polyamides,
nylon 6 and nylon 66.
Dual Number Nylons
differences between the properties
of nylon 6 and 66 can be seen. Hexamethylene Diamine
Process temperatures of nylon 66 + Adipic Acid = NYLON 66
are higher than nylon 6 because the Hexamethylene Diamine
melting point of nylon 66 is approxi- + Sebacic Acid = NYLON 610
mately 510°F (266°C) versus 460°F
Hexamethylene Diamine
(238°C) for nylon 6. Nylon 66 offers + Dodecanoic Acid = NYLON 612
higher rigidity or flexural properties
combined with excellent thermal
properties, especially Deflection
Temperature Under Load (DTUL),
allowing nylon 66 to withstand high-
er mechanical loading than nylon 6.
This guide will focus on
VYDYNE® nylon 66 resins and
how to design for their use in a
variety of end-use applications.

Table 1 – Property Comparison of Nylon 6 and Nylon 66

Property Nylon 6 Nylon 66 Nylon 6 Nylon 66 Nylon 6 Nylon 66

(Minimum Values) Unreinforced Unreinforced 35% Glass-filled 35% Glass-filled 40% Mineral-filled 40% Mineral-filled

Specific Gravity, gms/cm3 1.12-1.14 1.13-1.15 1.38-1.43 1.35-1.45 1.44-1.54 1.45-1.55

Tensile Strength, psi (MPa) 10,150 (70) 10,150 (70) 22,475 (155) 24,650 (170) 10,875 (75) 11,600 (80)
Flexural Modulus, psi (MPa) 319,000 333,500 1,087,500 1,160,000 652,500 725,000
(2,200) (2,300) (7,500) (8,000) (4,500) (7,500)
Izod Impact, ft-lbs/in ( kJ/m 2)
@ 70°F (21°C) .55 (3.0) .55 (3.0) 1.50 (8.0) 1.31 (7.0) .84 (4.5) .38 (2.0)
@ -40°F (-40°C) .38 (2.0) .28 (1.5) .94 (5.0) 1.14 (6.1) .66 (3.5) .24 (1.3)
DTUL @ 264 psi (1.80 MPa)
°F (°C) 122 (50) 140 (60) 374 (190) 455 (235) 158 (70) 194 (90)

®Registered trademark of Solutia Inc. used by The Dow Chemical Company under
license.

4
Comparing Nylon to Other
Engineering Thermoplastics
The basic difference between nylon
and many other engineering ther-
moplastics (ETPs) such as polycar-
bonate, polycarbonate/ABS blends,
and polystyrene, is that nylons are
semi-crystalline polymers, whereas
most ETPs are classified as amor-
phous polymers. The following sec-
tion explains the difference
between semi-crystalline and amor-
phous polymers, and how this dif-
ference distinguishes nylon from
other ETPs.
Figure 4 – Amorphous Polymer
Conformation vs. Semi-crystalline
Polymers
Amorphous Polymers the polymer behaves like an amor-
phous polymer in that the molecu-
Amorphous polymers consist of
lar conformations become random.
polymer molecules having no
Another factor, the degree of crys-
ordered structure. Figure 4 shows
tallinity, is not only effected by the
the structure of a typical amor-
chemical structure, but by the
phous polymer and a semi-crys-
process conditions used to manu-
talline polymer. Upon heating
facture the plastic part. The rate of
amorphous polymers, the tangled
cooling is the process variable hav-
polymer chains become active and
ing the greatest effect on the
begin moving past each other to
degree of crystallinity. The slower
disentangle themselves. This
the rate of cooling, the greater the
results in softening of the polymer
degree of crystallinity.
and ultimately creating polymer
flow. As molecular activity increas-
es, the material becomes more Using the Polymers in
fluid. After polymer flow is achieved, Parts Fabrication
the molten polymer is fabricated or In comparison to amorphous poly-
shaped into a defined plastic part. mers, highly crystalline polymers,
Upon cooling, rigidity returns to the like polyamide, have improved
polymer and molecular movement chemical resistance.
decreases. Part shrinkage for nylon is higher
than for amorphous polymers
Semi-crystalline Polymers because the molecular chains in
the crystalline regions are more
In semi-crystalline polymers,
space efficient because differences
because of their stereo-regularity,
incooling lead to differences in
ordered molecular configurations
crystallinity and, thus, differences in
are built into the chain structure.
shrinkage. Therefore, controlling
These ordered areas are crystals
process variables such as mold
that form when the polymer is
temperature and cooling time, play
cooled from its molten state. When
the polymer is heated once again,
the crystal domains remain
unchanged until the polymer reach-
es its melting point. This point is
referred to as the crystalline melting
point of the polymer. Once these
materials reach the melting point,
5
Comparing Nylon to Other Engineering Thermoplastics – continued Molding Guide

a major role in determining mold shrinkage for nylon in comparison

shrinkage for all semi-crystalline
materials such as polyamides.
In semi-crystalline polymers,
crystals will form more completely
in areas where they are the most
densely packed. A crystallized area
is rigid and strong, where an amor-
phous area is tougher and more
flexible. This results in superior
creep, heat, and stress crack
resistance, as well as increased
to amorphous polymers. However,
amorphous materials, such as ABS,
PC/ABS, and PC offer better low
temperature performance in
comparison to polyamides.
Table 2 provides a comparison of
the mechanical properties of both
crystalline and amorphous polymers.

Table 2 – Properties of Crystalline and Amorphous Polymers

Mechanical Property Crystalline Polymer Amorphous Polymer

Examples: Examples:
Polypropylene, Polycarbonate,
Polyethylene, PC Blends, ABS,
Nylon, PBT, PET Polystyrene, TPU,
SAN, PPO

Chemical Resistance Higher Lower

Shrinkage Higher Lower
Warpage Higher Lower
Tensile Strength Higher Lower
Tensile Modulus Higher Lower
Elongation Lower Higher
Creep Resistance Higher Lower
Flow Higher Lower
Maximum Exposure Temperature Higher Lower
Density Higher Lower
Source: Rosato, Donald V. and Dominick V., Injection Molding Handbook, 1995.

6
Typical Characteristics of
NylonPolymers
Nylons, like many other thermo-
plastics, have their own set of
unique characteristics. Figure 5
shows some of the key characteris-
tics of nylon.
Nylon polymers have excellent
heat resistance properties and can
be used in continuous environments
as high as 450°F (232°C).
Due to their flow characteristics,
nylons have excellent processability
for filling long flow lengths and
nominal wall thicknesses as thin as
.015 inch (.38 mm). Nylons have a
wide processing window that can
range from 480-570°F (249-299°C).
The high strength and rigidity of
nylons make them suitable for high
load-bearing applications, such as
automotive fascia brackets, engine
fan shrouds and automotive fan
pulley wheels.
Nylons exhibit excellent tough-
ness at room temperature and in
extremely cold environments, as
low as -40°F (-40°C).
Nylons have excellent abrasion
resistance, making it a choice for
applications such as gears, pulleys
and door handles.
Nylons display good chemical
resistance, and are highly resistant
to organic solvents such as
acetates, alcohols, and chemicals
such as benzene, Xylene, gasoline,
and petroleum products. Contact
with some acids, bases, halogens
and some inorganic salts, such as
mercuric chloride, ferric chloride, and
potassium dichromate can lead to a
reduction in properties.
Lastly, nylons on their own
show good ignition resistance,
which can be vastly improved with
the addition of ignition-resistant
additives with flammability ratings
of V-0 at .015 inch (.38 mm).
Designations for VYDYNE
Nylon Resins
The Dow Chemical Company,
under license from Solutia Inc., pro-
duces a number of nylons listed in
Table 3 for use in many end-use
applications. Proper material selec-
tion is a critical factor to consider in
designing or processing a part made
with VYDYNE nylon resins.

Figure 5 – Key Characteristics of Nylon

Good
Heat
Excellent Resistance
Excellent
Electrical Processability
Properties

Good High
Flame Strength
Resistance Rigidity

Good
Chemical Good
Resistance Toughness
Good
Abrasion
Resistace

7
Typical Characteristics of NylonPolymers – continued Molding Guide

Table 3 – Nomenclature for VYDYNE Nylon Resins

Product Designation Resin Type

20 Series Non-reinforced General Purpose

40 Series Impact Modified
100 and 200 Series Mineral-reinforced Resins
300 Series Ignition-resistant Resins
400 Series Glass/Impact Nylon 66
500 Series Glass Fiber-reinforced Nylon 66
600 Series Glass Fiber-reinforced Nylon 66/6 Copolymer
800 Series Industrial-based Nylon 66 Feedstocks
01 thru 7 Black Colorant Added

Material Code
Designation Additive Type

X External Lube Additive

SP Internal/External Lube Additive
N Nucleated
H Heat Stabilized
W Weather Stabilized
M (Preceding Number) Ignition Resistant
R (Preceding Number) Reinforced

8
M O L D I N G G U I D E

Tool
Design

9
Tool Design for VYDYNE
Nylon Resins
This section of the VYDYNE nylon
resins Molding Guide reviews the
area of tool design for molding
VYDYNE resins. The topics to be
covered include basic tool design
considerations, multi-cavity tool
layout and balancing, runner
design, sprue design, gate design,
venting, mold cooling and mold
steels, draft angles, prototyping,
ejector systems and pin design.
Tool Design Considerations
The basic mold design is determined
by the following considerations.
1. The size and shape of the
molded part.
2. The number of cavities in the
mold.
3. The size of the injection molding
machine, including the barrel
and clamping force capacity, in
which the tool is to be installed.
These factors are interrelated, but it
is the part size and weight that limits
the number of cavities in the mold,
and determines the machine capaci-
ty required for injection molding.
One consideration in determining
press size is the total projected
area. This determines the clamping
force needed to hold the mold
closed during the injection phase of
the injection molding cycle. This is
defined as the area of the shadow
cast by the molded part and runner
system when it is held under a light,
with the shadow falling on a plane
surface parallel to the parting line.
The clamping force is calculated
by the following equation:
F total = (A proj x F matl) + 
where
A proj = Projected area of the part
F matl = Clamping force of material
 = Thickness factor
= .1 x (A proj x F matl)
As a general rule, the value of F
mat1 is usually about 3 tons/in of
2
the molded shot. VYDYNE nylon
resins may require up to 4 tons/in2
due to their low melt viscosity.
10
Another consideration for pro-
cessing VYDYNE nylon resins is
the barrel-to-shot ratio, which
measures the rated barrel capacity
for a given material as a compared
to its rated capacity for polystyrene.
This is determined by the follow-
ing equation:
S matl = (S ps x  matl/ ps ) x 100%
where
S matl = Shot capacity of barrel
with resin to be molded
S ps = Shot capacity of barrel
with polystyrene
 matl = Density of material to
be molded
 ps = Density of polystyrene
(typically = 1.04)
For VYDYNE and VYDYNE R
nylon resins, the recommended shot
capacity should be between 40%
and 80%, with a target of 50%. For
VYDYNE ignition resistant grades,
the target range is 50% to 70%.
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Multi-cavity Tool Layout and shown in Figure 7 is optimized with Figure 8 – Poor Design of a Six-
cavity Mold
Tool Balancing the addition of cold slug wells at the
ends of each runner. These wells
Once the number of cavities has
trap cooled polymer, preventing it
been determined, the proper layout
from entering the cavity where it
must be planned to produce a bal-
could cause surface blemishes or
anced mold.
other part aesthetic problems.
The cavities must be located so
In some cases, multi-cavity molds
that the most distant cavity is close
must be laid out in straight patterns Poor (Unbalanced)
enough to the spine that the poly-
due to movable cores. Figures 8
mer melt does not lose too much
and 9 show both poor and good
heat in the filling process. The cavi-
designs for a six-cavity mold. Figure 9 – Good Design of a Six-
ties should be arranged around the
In the mold shown in Figure 8, cavity Mold
sprue so that each receives material
the two cavities nearest the sprue
at equal pressure through its gate.
would receive much more pressure
Therefore, the shortest possible
than the outlying cavities. Such
distance between cavities and
unbalanced filling makes it virtually
sprue, equal runner and gate
impossible to equalize the density
dimensions, as well as uniform cool-
and, therefore, the dimensions of
ing is required.
the parts. An optimum arrangement Good (Balanced)
Figure 6 illustrates a mold with
is seen in Figure 9 where all cavities
six cavities grouped together about
would fill at nearly the same rate and
a single center sprue. Although this
under the same pressure.
is adequate, the arrangement

Figure 6 – Six-cavity Layout – Figure 7 – Six-cavity Layout –

Adequate Cavity Arrangement Optimum Cavity Arrangement

11
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Figure 10 shows a family mold in Figure 10 – Unbalanced Family Tool

which one part is larger than the
other. In this situation, if the same Unbalanced Flow Pattern
runner size is used, the smaller
part will fill faster. Once the smaller
part is filled, it will continue to pack
out until the larger part is filled. This
results in overpacking of the smaller
part which can result in warpage,
poor dimensional stability, and high
stress buildup leading to possible Sprue
Bushing
part failure. To eliminate this prob- Small Part

lem, Figure 11 shows how to size

the runner system so that both Large Part
parts will fill at the same time and
pressure will be equalized.

Figure 11 – Balanced Family Tool

Balanced
Runner
System

Note: Reducing
diameter may also
be used to
balance tool Small Part

Large Part
Balanced Flow Pattern

12
Tool Design for VYDYNE Nylon Resins – continued
Runner Design
Different runner designs can be
used when molding nylon parts.
These include full round runners,
standard trapezoidal runners, and
modified trapezoidal runners.
Full round runners, as shown in
Figure 12, are found to be the best
at holding pressures, because full
round runners offer the smallest
mold contact to their cross-section-
al area. This type of runner allows
the plastic material in the center to
remain hotter longer and move
more rapidly. Machining of full
round runners is relatively easy in
that standard-size end mills can be
used. However, while full round
runners are very efficient, machin-
ing is more expensive because the
runner must be cut into both mold
halves. For parts over 8 ounces, or
227 grams, full round runners of
.375 inch (9.53 mm) are
recommended.
Trapezoidal runners, illustrated
in Figure 13, offer a lower-cost
alternative to machining full round
runners because machining is only
Molding Guide
performed on one mold half. The Figure 12 – Full Round Runner Design
trapezoidal runner offers a higher
volume-to-surface area than full
runner systems. This runner system
should be designed with a taper of
2° to 5° per side, with the depth of
the trapezoid at least equal to its
base width.
Another runner system recom-
mended for nylon is the modified
trapezoidal runner system, shown
in Figure 14. This runner system
has the features of a standard
Figure 13 – Trapezoidal Runner Design
trapezoidal runner system, but
includes a radiused base. This
design provides ease of part ejec-
tion and is also easy to machine.
Other Runner Design Considerations
There are several other factors to
consider in designing runners for
nylon. The recommended cold run-
ner diameter range for nylon is
0.062-0.375 inch (1.6-9.5 mm). This
runner should never have a diame-
ter less than the thickest section of
Figure 14 – Modified Trapezoidal
the plastic part to be molded. The Runner Design
runner should be large enough to
minimize pressure loss, yet small
enough to not adversely affect cycle
time, and minimize scrap.
13
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Sprue Bushing Figure 15 – Sprue Bushing Design and Location

Considerations
The front end of the sprue bushing
Parts
contains a spherical depression to
fit the cylinder nozzle. Figure 15 Runner Sprue Bushing
illustrates the location of the sprue
Cold
bushing.
Slug Nozzle
The sprue bushing is a standard Well
taper to diverge from the nozzle, Sprue
facilitating release of the sprue when Length = 4 in
the mold opens. The sprue should (101.6 mm) max.
Parts
be at least .375 inch (9.53 mm) in
diameter, and .500 inch (12.7 mm)
for parts weighing more than one
pound (.45 kg). An insufficient sprue
diameter will create frictional drag
and prevent the rapid injection Figure 16 – Nozzle Bore Recommendations

speeds required by VYDYNE nylon

materials. Also, the bore of the noz-
zle must be properly matched to that
of the sprue bushing to minimize
pressure losses. It is recommended
that the bore size of the nozzle be
slightly smaller than that of the
Nozzle Nozzle Nozzle
sprue at its narrowest dimension. Bore Bore Bore
Too Small Too Large Properly
Figure 16 shows recommendations
Matched to Sprue
for the nozzle bore.
The length of the sprue should
be no longer than 4 inches (101.6
mm). If a part design requires a
longer sprue, the bushing should
be recessed deeper into the mold,
and an extended, controlled heater
tip should be installed on the barrel.
The sprue should also be pol-
ished and free of all burrs, tool
marks, and undercuts. It is good
practice to include a generous
.750 inch (19.05 mm) cold slug
well at the dead end of the sprue.

14
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Gate Design Figure 17 illustrates a suggested Figure 18 shows a suggested

Many types of gate designs can be
molded from nylon. Gates dis-
cussed in this section include:
1. Edge gates
2. Fan gates
3. Pin gates
4. Tunnel or submarine gates
edge gate design for nylon. A fan gate design, and a chisel-type
straight land is used with this gate design for ease of trimming.
design in order to facilitate part trim-
ming. To avoid excessive shear, Figure 17 – Edge Gate
a minimum of .030 inch (.762 mm)
length for the straight land is sug-
gested. Table 4 lists recommenda- Runner
tions for edge gates based on
nominal wall thickness requirements.

5. Ring gates 2. Fan Gates Part

Edge Gate

Fan gates provide reduced pres-

6. Diaphragm or disk gates
sures and clamp tonnage over other Side View

7. Sprue gates conventional gate designs, and are

8. Tab gates excellent for relatively short flow
lengths. Like edge gates, fan gates
Table 4 lists a summary of recom- Figure 18 – Fan Gate and Chisel Fan Gate
allow for a wide process window.
mended gate dimensions for two
Problems in using fan gates include
gate types.
the inability to trim off the gate
1. Edge Gates because a larger area must be Runner

Edge gates are used for multi-cavi-
ty tools and are suitable for a wide
range of nominal wall thicknesses.
One of the advantages of edge
gates is that, of all gate designs, it
provides the widest molding win-
dow due to lower shear rates.
trimmed through. Increased scrap
Fan Gate
may also be found due to the diffi- Part
culty in trimming off gates. Trimming,
however, can be an issue because
Side View
the gates are much larger, but can
be facilitated with the use of a chisel
gate or half-chisel gate.

Table 4 – Recommended Dimensions for Edge and Drop Gate Designs for Nylon Materials

Gate Type Nominal Wall Thickness Gate Thickness Gate Width Land Length
in (mm) in (mm) in (mm) in (mm)

Edge < 0.030 (0.762) to 0.030 (0.762) to 0.045 (1.14) 0.030-0.050 (0.762-1.27)
Edge 0.030-0.125 (0.762-3.18) 0.050-0.080 (1.27-2.03) 0.050-0.080 (1.27-2.03) 0.030-0.050 (0.762-1.27)
Edge 0.125-0.250 (3.18-6.35) 0.060-0.140 (1.52-3.56) 0.060-0.140 (1.52-3.56) 0.030-0.050 (0.762-1.27)

Gate Type Nominal Wall Thickness Gate Diameter Land Length

in (mm) in (mm) in (mm)

Pin 0.125 (3.18) 0.030-0.050 (0.762-1.27)0.030-0.050 (0.762-1.27)

Pin 0.125-0.250 (3.18-6.35) 0.040-0.120 (1.02-3.05) 0.030-0.050 (0.762-1.27)
Source: Multiple Industry Sources

15
Tool Design for VYDYNE Nylon Resins – continued
3. Pin Gates
Pin gates, otherwise known as pin
point gates, are used primarily in
single or multi-cavity three plate
tools. Typically, pin gates are used
in parts which have a thin nominal
wall thickness, and a large surface
area. Pin gates are also used to
minimize finishing where edge gat-
ing is undesirable and for automatic
degating. A big advantage of pin
gates is that they are self-degating,
with no need for a special degating
tool.
Figure 19 shows a pin gate
design for nylon and Table 4 (page
15) gives recommendations for
drop gate designs.
Figure 19 – Pin Gate
Runner
Sprue
Part
Drop Gate
Molding Guide
4. Tunnel or Submarine Gates The cross section of tunnel
Tunnel or submarine gates for gates is either elliptical or round in
nylon are typically used for smaller shape. A tunnel gate diameter of no
parts weighing less than 2 lbs (.91 less than .060 inch (1.63 mm)
kg) and for parts with short flow dis- should be used to insure complete
tances. Tunnel gates provide auto- filling of the cavity.
matic degating and are suitable for Figure 20 shows both good and
thin nominal wall sections. This poor tunnel gate designs for nylon.
gate is used to convey material
5. Ring Gates
below the parting line of the mold
Ring gates are commonly used in
into a cavity. An advantage of this
molding cylindrical cores, such as
gate design is the ease with which
ball point pen barrels. The material
the part is separ-ated from the run-
flows around a core and flows
ner system. A disadvantage of tun-
down evenly. Advantages of this
nel gates is a narrower processing
gate design are the elimination of
window because of the high shear
trapped air that can cause weld
rates and pressure losses associat-
lines and the reduction of the core
ed with them. With heat stabilized
pin shift phenomenon, which can
nylon materials, this thermal degra-
result in extreme variations in nomi-
dation resulting from excessive
nal wall thickness of material
shear can take the form of blue
around the core.
streaks in the finished part. Jetting
can also take place with tunnel gates
and may result inpoor surface aes-
thetics and weak weld lines.
Figure 20 – Good and Poor Tunnel Gate Design
Good Design- Poor Design-
W ide angle gate Narrow angle gate
will"pull
" onm old will breakf of
opening on part
16
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Figure 21 illustrates a ring gate. Figure 21 – Ring Gate Figure 22 – Diaphragm or Disk Gate

6. Diaphragm or Disk Gates

Diaphragm or disk gates are the
opposite of ring gates in that the
Ring Runner Sprue Part
material flows from a cylindrical Gate
Core
core to its perimeter. These gates Pin Part Runner
Diaphragm
are used mostly for single-cavity or Disk Gate
tools in fabricating single-shaped
parts, such as cylindrically shaped Ring Gate
Part

objects with small or medium-sized L core < 5 D core where:

internal diameters. These gates Side View L = Length of core
Part D = Diameter of core
improve flow around a core, and
also improve the core pin shift phe-
nomenon when molding tube- Figure 23 – Sprue Gate
shaped parts. Figure 23 shows a sprue gate
Top View
Figure 22 illustrates a diaphragm design and an equation for determin-
gate, and an equation for minimiz- ing the correct sizing for a sprue gate.
ing core pin shifting using a
8. Tab Gates
diaphragm gate.
Tab gates usually extend from the
7. Sprue Gates Side View
runner system directly into the
Sprue gates are found in large molded part, and can be the same Sprue Gate

parts made in a single-cavity tool, nominal wall thickness as the mold-

such as a business machine enclo-
sure. Typically, the gate is located
at the center of the part to allow for
even flow throughout.
A reverse taper is placed at the
end of a sprue gate to remove the
part from the mold upon ejection.
The taper also acts as a cold slug
well to capture the coldest material
coming from the end of the nozzle
of the barrel, preventing it from
entering the runner system. Vari-
ations of the reverse taper also
include ring pullers and Z-pullers.
Part
ed part. This type of gate is used
W 4 L Where:
with larger parts such as enclosures. D= D = Aver. of inlet/outlet
16
Tab gates also can be used to stop diameters to nearest
.060 in
jetting when other means are not W = Part weight (oz)
L = Sprue length (in)
available and when a restricted
gate, such as a drop gate or a tun-
nel gate, is desired. The tab gate Figure 24 – Tab Gate
design enables the area of greatest
strain near the gate to be removed
from the molded part. It is suggested
that the thickness of the tab gate be
Runner
no more than 50% of the part’s nomi-
nal wall thickness, in order to degate Tab Gate
the part without using a gate removal
Part
apparatus.
Figure 24 shows a typical tab
gate design. Side View

17
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Gate Location
The following guidelines should be
used in determining gate location
for VYDYNE nylon resins.
1. Gates should be located so the
flow of the resin goes from the
thickest to the thinnest sections
of the part.
2. Gates should be located in non-
aesthetic areas of the part.
3. Balance the flow within the mold
cavities. This will avoid over-
packing which can lead to varia-
tions in shrinkage and cause
warpage in the finished part.
4. Flow length and the pattern of
melt flow are important factors to
keep in mind. The flow ratio is
defined as:
5. Use as few gates as possible to
reduce the number of weld lines,
and alter the flow to place them
in areas where they will not
affect the structural integrity
or the aesthetics of the part.
6. Place gates in areas where the
material can flow smoothly and
uniformly through the mold cavity.
7. In molding grilles or louver-type
designs, gating should be posi-
tioned so that air trapped in the
mold can escape ahead of the
advancing melt front. Figure 25
illustrates the recommended gate
location for these design types.
Figure 25 – Gate Location for Grilles and Louvers
8. For molding around cores or
holes, Figure 26 shows both a
poor and optimal gate design to
eliminate weld lines.
9. For picture frame-type parts,
Figure 27 illustrates a spider
gate design to reduce and elimi-
nate weld lines.
10. For integral hinges, locate gat-
ing to provide a smooth, even
flow across the hinge web in
order to prevent a premature
hinge failure. An optimum loca-
tion is beyond the hinge center-
line and away from the hinge, as
shown in Figure 28.
Gate

Flow Ratio = L/D

where
L = Longest flow length
from gate
D = Average nominal wall
thickness
For VYDYNE R resins, the flow
Poor Design
ratio should be kept below 120.

Gate

Recommended Design

18
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Figure 26 – Gate Location for Molding Around Pins

Gate

Gate

Poor Design Recommended Design

Figure 27 – Gate Location with

Spider Design

Spider

Part

Figure 28 – Gating Recommendations for Molding Nylon Living Hinges

Hinge Hinge Gate Hinge

Gate Gate

OPTIMUM NOT AS OPTIMUM NOT RECOMMENDED

Assures good, Shear of material Uneven flow
even flow may occur from across hinge
across hinge flow across hinge

19
Tool Design for VYDYNE Nylon Resins – continued
Vent Location
The use of vents offers a number
of advantages to the molder. These
include:
1. improving weld line strength and
appearance;
2. reducing pack and hold pres-
sures in filling the part;
3. preventing gate overpacking;
and
4. reducing part weight;
In all cases, all cavities molding
VYDYNE nylon resins must be suffi-
ciently vented so that trapped air
inside the cavity is evacuated from
the tool. If no venting or insufficient
venting is used, burn marks caused
by “dieseling” of air within the cavity
will occur. Weak weld lines, as well
as incomplete or short shots might
also be found in the part as a result.
Table 5 gives suggested vent
sizes and locations for tools mold-
ing with VYDYNE nylon resins.
Other methods which also can be
used in providing proper venting
Molding Guide
Table 5 – Vent Size and Vent Location Requirements for Molding Nylon Parts
Vent Size Requirements
Width: 0.125-0.250 in (3.175-6.35 mm)
Depth: 0.0005-0.0015 in (0.127-0.0381 mm)
Length of Vent Land: 0.03-0.04 in (0.762-1.02 mm)
Vent Location Requirements
Locate vents: 1. at last section of mold or part to be filled.
2. where converging melt fronts meet to form knit
or weld lines.
3. in the area of surface projections, such as
bosses, ribs and gussets.
4. in blind spots, such as ribs.
include grinding a flat on one side Cooling and Mold Steels
of the ejector pin, as shown in
When fabricating nylon parts, mold
Figure 29. A flat of .002 inch (.051
temperature control is one of the
mm) is recommended for venting at
biggest factors to consider due to
an ejector pin. Also, a porous metal
the potential for shrinkage and
insert can be used in the area of
warpage. From a productivity
the part where converging melt
standpoint, even though cooler
fronts are found, forming gas or
mold temperatures lead to reduction
trapping air.
in cycle time, cooler tooling for mold-
ing nylon may lead to dimensional
Figure 29 – Venting Recommendations stability problems and excessive
for Ejector Pins
residual stresses. This, in turn, leads
to problems such as differential
shrinkage and part warpage.
For faster cycles in molding
nylon, the optimum is to design a
cooling system that provides uni-
form cooling of the part, minimizes
residual stresses, and reduces
shrinkage and warpage.
.002 in (.051 mm)
Flat Ground on
Ejector Pin
20
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Figure 30 illustrates guidelines stainless steel tooling. However, Table 6 – Thermal Conductivity of
Various Mold Materials and Other
for the layout of cooling channels beryllium copper molds are capable Materials
when designing tools for nylon. It is of molding some thin wall parts sig-
Mold Material Thermal
also suggested to use bubbler cool- nificantly faster. Con- Conductivity
ing for long cores as well as thin sideration must also be given to the (BTU/ft - °F hr)
core projections. Another sugges- length of the production run, where at 212°F (100°C)
tion is to use highly conductive steel materials are known to last Copper (Pure) 222
metal inserts in areas where these longer in comparison to beryllium Aluminum 100
core projections are found. copper and other metals. Brass (60-40) 70
In existing tools, other consider- To further improve mold cooling, Kirksite 62
ations include increasing the rate of it is suggested, but not required, to Beryllium Copper 62
coolant flow-through, reducing use an insulation plate at the inter- Tool Steel (P-20) 21
coolant temperature, and removing face between the mold steel and Tool Steel (H-13) 12
rust and scale buildup in cooling the injection molding machine plat- Stainless Steel 10
lines which may adversely affect en to reduce the amount of heat Water 0.39
the cooling efficiency of the tool. To transfer to the surroundings, and Air 0.14
maximize cooling rate, the cooling keep the heat transfer within the Nylon 66 0.142
fluid used, whether it be water or mold steel. Source: Multiple Industry Sources

an ethylene glycol/water mixture,

should flow turbulently. Turbulent
flow provides as much as 3 to 5 Figure 30 – Guidelines for Laying Out Cooling Channels in Nylon Tools
times more heat transfer than lami-
Cooling Lines
nar, or non-turbulent flow.
In molding integral hinges, it is
recommended to set up a separate ds
Cooling Lines
cooling line and control near the
dc
thin sections of the integral hinge.
Mold temperatures between 160-
200°F (71-93°C) may be needed in
these areas. xc

Nylons can be molded in a vari-

ety of materials, such as aluminum,
Channel Guidelines: dc = 7/16 - 9/16 (11.0 - 14.2 mm)
beryllium copper, and various steel ds = (1.0 - 2.0) dc
xc = (3.0 - 5.0) dc
materials. Selection of mold materi-
als is critical in molding nylon.
For example, Table 6 shows that
a tool made of beryllium copper
offers 3 to 4 times the heat transfer
rate in comparison to a tool steel
mold. This does not mean that
using a beryllium copper mold will
give a cycle time 4 times as fast as

21
Tool Design for VYDYNE Nylon Resins – continued
Draft Angles
Due to the high mold shrinkage
and low elongation at yield of
VYDYNE nylon resins, it is recom-
mended to use draft angles of at
least 1.5° minimum per side.
If anything less than this is
used, the side walls should be
draw-polished to a high degree
(SPE 2 finish). Knockout pins
should be carefully placed near
these areas.
Ejector Systems for Molding
VYDYNE Nylon Resins
Ejector systems should be
designed so that:
1. the diameters of the pins are as
large as the design allows.
2. as many pins should be used as
possible without interfering with
mold cooling lines.
3. pins should seat uniformly on the
molded piece to eject it smoothly
without distortion.
The total force required to eject a
part can reach up to several hun-
dred pounds due to the relatively
high mold shrinkage of VYDYNE
nylon resins. The pressure required
is also dependent on the following
factors:
1. Sidewall draft
2. Sidewall contact area
3. Sidewall polish
4. Degree of part packing
5. Mold temperature
One guideline to determine the
required number of ejector pins is
to provide 1 square inch of pin
bearing surface area for every 80
to 100 square inches of sidewall
contact. Table 7 shows the advan-
tages of using large ejector pins.
Ejector pins should be adjusted so
that the pin face is flush with the part
surface. Pins protruding into the cavi-
ty or recessing into the core can
cause localized stress concentrations
which can affect the part’s structural
integrity.
Mold Cooling
The mold must be maintained at a
consistent temperature below the
Table 7 – Guidelines for Ejector Pin Design
Pin Diameter Pin Bearing Surface
in (mm)
.125 (3.18) 1 in2 (25.4 mm2)
.250 (6.35) 1 in2 (25.4 mm2)
.375 (9.52) 1 in2 (25.4 mm2)
22
Molding Guide
heat distortion temperature of
VYDYNE resins to ensure that the
molten resin will freeze and take
the shape of the mold. The impor-
tance of uniform cooling is rarely
given the priority it deserves at the
mold building stage.
Uniform cooling is particularly
important with VYDYNE resins
because of the highly crystalline
nature of the resin. The amount
of shrinkage is related to the rate
of cooling. Non-uniform cooling will
yield differential shrinkage across
the part thus causing warpage.
For VYDYNE R reinforced nylon
resin, 220 BTU/lb is required to trans-
form pellets at 70°F (21°C) to
a molten material at 540°F (282°C).
Much of this heat must be removed
to freeze the resin sufficiently
before ejection of the part, and also
insure dimensionally stable parts.
Heat removed must equal heat
added to achieve thermal equilibrium.
Improving the heat transfer within the
mold will reduce the cooling time
needed and improve cycle times.
Number of Pins
82
20
9
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

In mold construction, the mate- Figure 31 – “V” Channel Figure 33 – Basic Fountain (Bubbler)
rial size, design, and the location of
cooling channels are all variables
affecting the efficiency of the cool-
ing system.
Heat exchanging surfaces
should be maximized and the vis-
cosity of the cooling medium, if not
water, should be minimized for PL PL

highest efficiency.
Insuring turbulent flow in the
water passages of the mold will also
maximize cooling. This type of flow
Figure 32 – Improved Fountain (Baffle) Figure 34 – Baffle Design for Large or
breaks up the natural insulating Irregularly Shaped Cores
effect of fluid layers and allows high-
er heat transfer. Often this can be
achieved by simply increasing the
velocity of fluid through the system.
PL
The most efficient cooling sys-
tems are those which operate such PL
that the inlet and outlet coolant tem-
peratures are within 10°F (-12°C) of
each other.
Water temperature in each half
of the mold should be separately
controlled and be within 30°F (-1°C)
of each other. It is especially impor-
tant to dedicate separate cooling
circuits for slides and split cores
since they are surrounded by steel
and tend to run hotter.

23
Tool Design for VYDYNE Nylon Resins – continued Molding Guide

Plugs and cores should be
channeled for coolant circulation. In
general, every core over 1.5 inch
(38.1 mm) in diameter and 1.5 inch
long should be channeled with an
inverted “V” or by installing an
internal fountain or baffle, as
shown in Figures 31-34 (page 23).
This is particularly important with
direct sprue-gated parts where
local frictional heating is intense.
Spot cooling is often necessary
on areas other than cores to insure
a uniform temperature across the
mold surface. A common trouble
spot occurs around bosses.
Because of the thicker section,
bosses often cause sink marks to
form on the opposite wall. This can
be minimized by spot cooling with
conductive insert pins, or conduc-
tive metal plugs made from alu-
minum or beryllium copper, shown
in Figure 35.
The technique of using metals of
higher heat conductivity for spot
Beryllium copper core pins are Figure 35 – Conductive Insert for
Cooling Slender Core
quite successful in this regard, but
care must be taken to insure good
contact with cooler mold steel to
obtain the highest efficiency. Figure
36 illustrates the use of beryllium
copper inserts.
Actual surface temperatures of
the mold while operating at equilib-
PL
rium with VYDYNE R resin should
never be below 160°F (71°C) to
insure proper dimensional control
and surface finish.
Figure 36 – Beryllium Copper Insert
PL
Beryllium
Insert
Boss
Sink Mark

cooling is particularly useful for

core pins. Core pin temperatures Beryllium Core Pin

have been recorded at or near the

Beryllium Insert
melt temperature. This not only lim- Boss
its cycle time, but the concentricity
of holes cannot be maintained. Sink Mark

24
M O L D I N G G U I D E

Injection-molding
Process

25
Drying of Plastics Materials

The chemical structure of a particu-
lar polymer determines whether it
will absorb moisture or water. A
number of polymers, for example
polystyrene, polyethylene, and
polypropylene, due to their non-
polar chemical structures are non-
hygroscopic, and do not absorb
moisture. Due to their more com-
plex chemistry, materials such as
polycarbonate, polycarbonate
blends, acrylonitrile butadiene
styrene (ABS) terpolymers, poly-
esters, thermoplastic
polyurethanes, and nylon are hygro-
scopic, and absorb moisture. This
moisture can be either external
(surface of the pellet), or internal
(inside the pellet) as shown in
Figure 37. The problem arises when
solidifying in the mold. This phe-
nomenon, resulting in splay marks
or silver streaks, is shown in Figure
38. In some cases, as found in
polycarbonate and nylon-based
materials, polymer degradation
occurs as the water reacts with the
polymer to reduce its physical and
mechanical properties. Another
effect results in the reversing of the
polymer forming reaction in the
polymer, leading to a phenomenon
called chain scission or depolymer-
ization. These types of conditions
can make a polymer difficult, if not
impossible, to process.
The critical factor in drying plas-
tics materials is to remove moisture
not only from the pellet’s exterior
surface, but from the pellet’s interi-
as the recipient or “sponge” to
receive the moisture from the pellet
surface. The dry air flow supplies the
transportation to remove the moist
air, which goes to the desiccant dryer
for collection and reconditioning. All
of these steps are important to prop-
erly dry plastic materials.
Figure 37 – Plastic Pellet
Showing Moisture
Absorbed Water
Moisture Droplets
(External Surface)
Plastic Pellet

polymer processing temperatures, or as well. Pellets reach a moisture Adsorbed Water

which can exceed 400°F (204°C),
boil off the water at 212°F (100°C) in
the polymer.
The effect the water has on a
molded part is that imperfections
will appear on the aesthetic surface
since the bubbles generated from
the boiling of the moisture get
trapped in the polymer, cooling and
Moisture Droplets
balance point with the surrounding (Pellet Interior)
environment. This is determined by
the resin type, the ambient relative
humidity, and time. For some
resins, like ABS, this is usually .3%
where for nylons this is typically
Figure 38 – Splay Marks
.15%. Moisture can be driven out of
the pellets under four essential con-
ditions: (1) heat, (2) air flow, (3) dry
air, and (4) time for the drying effect
to take place.
Heat drives the moisture to the
surface of the pellet. The dry air acts

26
Drying of Plastics Materials – continued Molding Guide

Hopper Dryer Design for
Drying Hygroscopic Materials
The proper sizing of a dryer hopper
is very critical and depends on:
a. mass flow of the material.
b. required drying time for actual
molding conditions.
Inside a hopper, plastic material
pellets move downward due to
gravity while air flow for drying
moves upward, assuming plug flow
conditions. The mass flow of the
resin is determined by three factors:
(1) shot size, (2) cycle time, and (3)
number of machines that the dryer
supplies. Figure 39 shows a calcu-
lation to determine mass flow.
Dew Point Temperature and
Its Importance in Drying of
Hygroscopic Materials
The delivery air to the hopper must
be dry so that it can absorb water
from the moist pellets. The drier
the air, the more effective it will be
in extracting moisture from the resin.
The term “dew point” is used to
describe the actual amount of water
in the air. The dew point tempera-
The delivery air to the hopper
must be dry. Only a dew point
meter can determine this. Some
drying units have an on-board dew
point meter, which quickly becomes
unreliable due to vibration, oxida-
tion on sensor plates, and contami-
nation from plant air (oils, dust,
etc.). After some time, an on-board
unit will continuously read -40°F
(-40°C) even though the actual dew
point is much higher. Hand-held
dew point meters are recommend-
ed because they are not exposed
to continuous use and are typically
Figure 39 – Sample Calculation for Determination of Material Mass Flow
Description of Variables
w = Part weight (lbs)
t = Cycle time (min)
Q = Machine throughput (lbs/hr)
Mf = Mass flow (lbs)
td = Drying time (hrs)
Hc = Hopper dryer capacity (lbs)
Hc1 = Required hopper
dryer capacity (lbs)
Machine #1
w1 = 2 w2 = 2.5
t1 = 75 sec = 1.25 min t2 = 45 sec = .75 min
(2)(60) lbs
Q1 = = 96 Q2 =
1.25 hr
stored in a dry, clean environment.
Sensor plates which are critical to
the function of a dew point meter
remain clean, allowing for accurate
and reliable results.
When using a hand-held unit,
some precautions must be taken
because the unit draws a sample
from the delivery air (which should
be hot and dry). The air filter must
be in place to avoid plugging or
contaminating the sensor plates.
The hand-held unit draws in a
sample at a very slow rate. Allow
10 to 15 minutes for sample
Assume:
Material = VYDYNE 21SP
Drying time = td = 4 hrs @ 170°F
Hopper Dryer
Hc = 2000 lb
Machine #2 Machine #3
w3 = 2.5
t3 = 50 sec = .833 min
(2.5)(60) lbs (2.5)(60) lbs
= 200 Q3 = = 180
.75 hr .83 hr

ture is defined as the temperature Total mass flow = Mf = Q1 + Q2 + Q3 = 96 + 200 + 180 = 476 lbs
at which moisture will just begin to Hc1 = Mf x td = 476 lbs x 4 hrs = 1904 lbs
Hc = 2000 lbs Hc > Hc1
condense at a given temperature Hopper sizing is adequate.
and pressure. It is a measure of the
actual water in the air. The higher
the dew point, the more saturated
the air will be.

27
Drying of Plastics Materials – continued Molding Guide

extraction. The operation of the
dryer needs to be considered as
well since desiccant beds do swing
or index at predetermined times;
one bed may be acceptable while
the other is faulty. Allow enough
time to measure dew point tempera-
ture to monitor all beds inside the
system (usually two to three beds).
The typical life expectancy for
replacement of desiccant beds is
two to three years. Also, inspect the
desiccant beds for contamination
by fines, dust, and chemical
byproducts of dried resins.
Desiccant beds must be properly
sealed, and clean filters must
always be in place in order to avoid
the loss of drying capacity.
A poor dew point does not
always point to bad desiccant beds.
The rate of moisture pickup from
the air intake may simply over-
whelm the capacity of the dryer
For air leaks, it is strongly recom- air is already laden with moisture
mended that hoppers operate with before contacting the resin to be
secured hopper lids and that hoses dried. It is recommended that dew
be checked for pin hole leaks point temperatures of -20 to -40°F
because these problems can draw be used to dry hygroscopic materi-
moist plant air into the dryer and als such as nylon.
create inefficient drying.
Hygroscopic materials can Troubleshooting Drying
absorb more moisture from the air of Plastics
than other plastic resins. This puts
Figure 40 gives a dryer audit check
some demands on the molder to
sheet for checking the operation of a
keep the material dry before and
desiccant dehumidifying dryer. Table
during molding. High dew point tem-
8 lists the individual items, potential
peratures above 15°F (-9°C) are not
problems, and solutions in order to
adequate to properly dry most
obtain optimum drying of materials.
hygroscopic materials because the
Figure 40 – Dryer Audit Check Sheet
A B
J
G
Outlet
D

unit. This can occur for several rea-

K
sons such as:
H H
Inlet
1. inaccurate sizing of the dryer.
I
2. an air leak in the return system. E
C F

A Process Air Filter G Regeneration Filter

B Process Air Blower
C Process Air Heater
D Rotating Tower Seal
E Regeneration Blower
F Regeneration Heater
H Desiccant Tower
I Desiccant Bed
J Material Hopper
K Diffuser Cone

28
Drying of Plastics Materials – continued
Table 8 – Dryer Audit Troubleshooting Check List
Dryer Issue Potential Problem
Drying Check operating
Temperature temperature of dryer.
Check delivery
hose length.
Air Drying Check if air is dry.
Air Delivery Check whether
sufficient air is being
used to dry the material.
Other Dryer Issues Check for mechanical
and electrical problems
within the dryer system.
29
Molding Guide
Possible Solutions
Use local temperature gauge at hopper inlet
to monitor dryer temperature.
Long hose length can change setup temperature
by 10°F. Set hose length so that there is minimal or no
change in inlet temperature from set temperature.
Use a dew point meter, preferably a hand-held unit, to
check if dew point is in -20 to -40°F (-29 to -40°C) range.
Avoid dependence on on-board dew point units.
Ensure that air filters are mounted in place or
are unplugged.
Check regeneration of desiccant beds.
Check desiccant beds for any contamination from
dust, fines, and certain chemical byproducts of the
dried materials.
Check if proper hopper capacity is being used. (See
Figure 39 on page 27 for calculation of hopper capacity.)
Check for leaks in hoses or in other areas of the
delivery system.
Ensure that hopper lids are secured and unit is
sealed from plant air.
Check air flow capacity of the drying unit.
Inspect for dirty or blocked filters (fines & pellets).
Check for plugged diffuser cone in hopper.
Inspect delivery lines for kinks or twists, both
external and internal to the desiccant.
Check if proper hopper capacity is being used. (See
Figure 39 on page 27 for calculation of hopper capacity.)
Check for faulty timers for swinging desiccant beds.
Check internal hose connections for possible
disconnection.
Check for faulty level switches at the top of the hopper.
Note: Hoppers must always be full to ensure proper
residence time.
Check whether material flow is too fast through the
hopper due to excessive or unplanned part production.
Insulate hopper and hoses to improve drying efficiency.
Drying of Plastics Materials – continued Molding Guide

How to Dry Nylon
Nylon materials, because they are
hygroscopic, require drying before
being molded into parts. Figure 41
shows how nylons can rapidly pick
up moisture at different levels of
relative humidity.
The reasons for drying nylon
include eliminating part surface
problems and molding problems.
These can be seen physically dur-
ing processing and include:
1. Splay marks
2. Blisters
3. Drool and stringing of material
from the nozzle
4. Part flashing
5. Inconsistent part packing and
short shots
6. Part sticking in the mold cavity
Other problems seen during pro-
cessing include:
1. Material degradation
2. Reduction and toughness lead-
ing to part embrittlement
3. Inconsistent part size and
dimensions
In order to properly dry nylon,
drying times are typically between
160-170°F (71-77°C) for a period
of one to three hours. Increasing
the time or temperature will result
in color change and material
degradation, thus reducing the
material properties. For “wet”
material, it is recommended to
dry at a reduced temperature of
140-160°F (60-71°C) for a longer
period of time. It is also recommend-
ed to keep the temperature above
the glass transition temperature of
130°F (54°C) to minimize color
change and material degradation.
The time to dry depends upon how
wet the material is. Figure 42 shows
drying time versus the resin color at
several drying temperatures.
Overdrying of nylon materials
can also cause a number of prob-
lems in processability and part per-
formance. These include:
1. Stiffer flow of material
2. Underpacked parts
3. Brittle “as -molded” parts
Figure 43 illustrates the effect of
overdrying on several VYDYNE
nylon resins in terms of failure rate
and moisture content. Figures 44-
46 show drying curves for VYDYNE
21SP general purpose nylon resin.

Figure 41 – Effect of Relative Humidity and Exposure Time Figure 42 – Nylon 66 Resin Color vs. Hot Air Oven Drying
to Humid Air of Water Absorption for Nylon 66 Temperature

1.2 Material: General Purpose Nylon 6 /6 Oven Temp.

100% RH 19 225°F
noitprosbA retaW % tW

1.0 18
17
75% RH 16 200°F
0.8
15
roloC niseR

14 175°F
0.6 13
50% RH
12 150°F
0.4 11
10
2 9 160°F (71°C) max. Recommended
0.
8 D y g T mp.
2 12
r in e
0 4 6 8 10 7
6
Exposure Time to umid Air @ 72°F (22°C), ours
H H
0 2 4 6 8
Tm
i e, Hours

30
Drying of Plastics Materials – continued Molding Guide

Figure 43 – Effect of Overdrying on Several VYDYNE Resins Figure 44 – VYDYNE 21SPF Resin Drying Curve

8
0.9
Tem er ture t
e oi t
p a a 160°F (71°C)
Over Drying Nylon Causes Brittle 0.8
D w P n +35°F (+1.7°C)
7 0.7

erutsioM %
0.6

6 0.5
Failure Rate, %

0.4

5 0.3

0.2

0.1
4
0

0 1 2 3 4 7 8 12 16 20 24 29

Time, Hours
3
VYDYNE M340
2

1
VYDYNE 21SPF
Figure 45 – VYDYNE 21SPF Resin Drying Curve

Temperature °F ( °C)
0 0.9

Dew Point - °F (- °C)

160 71
0 0.1 0.2 0.3 0.4 0.5 0.8
45 43

0.7
Moisture Content, %
erutsioM %

0.6

0.5

0.4

0.3

0.2

0.1

0 1 2 3 4 5 6 7 8 12 16 20 24

T im e , H ours

31
Drying of Plastics Materials – continued Molding Guide

Moisture can act as a plasticizer Figure 47 – Recommended Moisture Levels for Molding Nylon Resins
for nylon materials and improve
toughness of nylon injection-mold-
ed parts. Figure 47 illustrates the Moisture Excessive
Too Low Optimum
optimum moisture levels for mold- Level Moisture

ing nylon. It is recommended to dry Loss Optimum Foaming at

nylon to a level indicated by the of Impact Molding & Nozzle
Properties
shaded area of the graph marked (Embrittlement Zone) (Unmoldable Zone)
(Molding
“molding zone” to avoid molding dif- Zone)
ficulties and defects, and to obtain
optimum physical properties.
Desiccant dryers are found to be
optimum for drying nylon materials.
Figure 48 provides a schematic
drawing of a typical dessicant dryer
configuration. Desiccant dryers can .05 .10 .15 .20 .25 .30 .35 .40
control air temperature and provide
dry air to circulate through the Moisture Level (%)
material. Heated hopper dryers are
not recommended because they
only heat the surrounding air and,
Table 9 – Nylon Regrind Drying Guidelines
unlike desiccant dryers, do not sup-
Time in Open Container Drying Time @ 150-160°F (66-71°C)
ply dried air. These drying systems
can cause ambient air moisture lev- 0-2 Hours 0-4 Hours
els to increase, and can actually 2-4 Hours 4-6 Hours
cause nylon to absorb additional 4-24 Hours 6-24 Hours
moisture instead of being dried. 1-5 Days 24-36 Hours
>5 Days 48-72+ Hours

32
Drying of Plastics Materials – continued Molding Guide

Regrind nylon pellets are han- Figure 48 – Schematic of Typical Desiccant Dryer Configuration
dled differently than virgin materi-
als. The particle size of regrind, as Heated e umidi ied Air
, D h f

seen in Figure 49, is larger than Heater

Temperature
that of virgin material. If material Controller
handling is closed loop, virgin dry- Moisture Moisture-laden
ing parameters are adequate.
Out Air Return

However, if regrind is stored and not

immediately reprocessed, longer Regenerating
Desiccant
drying times are necessary. It is
Blower
recommended to lock and cover all
drums or containers while the Air n
I

material is not being used. If

regrind is stored in boxes or gay- On-stream
lords at the machine, keep the con- Desiccants
tainer covered at all times. Clearly Regeneration Hopper
Manifold Return Air Heater
mark all boxes or gaylords of
regrind materials by type, resin, Blower
and production run number. Avoid
storage in open containers. Table 9
lists recommended guidelines for Figure 49 – Comparison of Regrind Sizes vs. Standard Virgin Pellets
drying regrind materials.
In handling parts to be reground,
it is recommended to regrind parts
and reuse material immediately. .125 in
ave. ???
Regrind runners and sprues within
three hours after molding and store
in an airtight container. A maximum
.060 - .075 Dia.
of 25% regrind is recommended to
avoid loss of mechanical properties
and is the maximum allowed by
Underwriters Laboratories. Uniform Shape Irregular Shape
(Virgin Pellets) (Regrind Pellets)

33
Processing Conditions for
VYDYNE Nylon Resins
VYDYNE nylon resins can be mold- Table #10. Guidelines for Molding VYDYNE Nylon Resins
ed on standard injection molding
equipment, but do need drying
because they are hygroscopic
(water absorbing) materials.
The next few pages will review
process conditions for a number of
VYDYNE nylon resins, including
general purpose, heat-stabilized,
nucleated, weather-resistant, igni-
tion-resistant, mineral-filled, miner-
al/glass-filled, glass-filled,
hydrolysis-resistant, nylon 66/6
copolymer and industrial resins.
VYDYNE Grades- 25W, 25WSP, 41, 45
General Purpose, Heat Stabilized 47H, 20NSP, 24NSPF, 22H
Nucleated, Weather Resistant 22HSP, 21X, 21SPF
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 520-560º F (271-293ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 50 and 150 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
100 and 200ºF (38-93ºC). Temperatures on the high end are
recommended as the molding cycle allows assisting in mold filling and
improving molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the
barrel. General purpose crystal polystryene, natural polyethylene, or
clear acrylic regrind is recommended.
9. Typical Process Conditions
(See Table #11 for typical process conditions.)
34
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

General Purpose applications, the molding cycle can

VYDYNE Resins be reduced because parts may be
removed from the cavity at higher
VYDYNE 21X and 21SPF Resins temperatures. In difficult molds
VYDYNE 21X and 21SP resins are where parts have a tendency to
general-purpose nylon 66 resins stick in the cavity, VYDYNE 21SPF
available in natural (off-white) and in resin can reduce or eliminate the
black, and are principally used in need for mold release sprays. It is
the injection molding process. recommended to check critical part
VYDYNE 21X resin is externally dimensions against specifications
lubricated for improved machine before implementing shorter molding
feed and mold release. This formu- cycles on a routine production basis.
lation is designed to provide easy
release of parts from molds using
standard molding conditions.
VYDYNE 21SPF resin is internal-
ly and externally lubricated for
improved machine feed and excep-
tional mold release. VYDYNE
21SPF resin is intended for use in
productivity applications. In many

Table 11 – Typical Injection Molding Conditions – VYDYNE Nylon 21X, 21SPF

Resins

English Units SI Units

Melt Temperature, °F (°C) 520-560 (271-293)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 480-520 (249-271)
Center Zone 530-550 (277-288)
Front Zone 540-560 (282-293)
Nozzle 530-550 (277-288)
Mold Surface Temperature, °F (°C) 100-200 (38-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 50-125
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0-4.0

35
Processing Conditions for VYDYNE Nylon Resins – continued
Table #12. Guidelines for Molding VYDYNE Nylon Resins
Heat-stabilized
VYDYNE Resins
VYDYNE 22H and 22HSP Resins
VYDYNE 22H and 22HSP resins
are heat-stabilized nylon 66 resins
available in natural (off-white) and
in black, and are principally used
in injection molding.
VYDYNE 22H resin is externally
lubricated and designed to provide
easy release of parts from molds
using standard molding conditions.
Molding Guide
VYDYNE Grades- 25W, 25WSP, 41, 45
General Purpose, Heat Stabilized 47H, 20NSP, 24NSPF, 22H
Nucleated, Weather Resistant 22HSP, 21X, 21SPF
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 520-560º F (271-293ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 50 and 150 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
100 and 200ºF (38-93ºC). Temperatures on the high end are
recommended as the molding cycle allows assisting in mold filling and
improving molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the
barrel. General purpose crystal polystryene, natural polyethylene, or
clear acrylic regrind is recommended.
9. Typical Process Conditions
(See Table #13 for typical process conditions.)
36
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

VYDYNE 22HSP resin is internal-

ly and externally lubricated for im-
proved machine feed and excep-
tional mold release. VYDYNE
22HSP resin is intended for use in
high productivity applications. In
many applications, the molding
cycle can be reduced because
parts may be removed from the
cavity at higher temperatures. In dif-
ficult molds, VYDYNE 22HSP resin
can reduce or eliminate the need
for mold release sprays. It is recom-
mended to routinely check critical
part dimensions against specifica-
tions before implementing shorter
molding cycles.

Table 13 – Typical Injection Molding Conditions – VYDYNE Nylon 22H, 22HSP

Resins

English Units SI Units

Melt Temperature, °F (°C) 520-560 (271-293)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 480-520 (249-271)
Center Zone 530-550 (277-288)
Front Zone 540-560 (282-293)
Nozzle 530-550 (277-288)
Mold Surface Temperature, °F (°C) 100-200 (38-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 50-125
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0-4.0

37
Processing Conditions for VYDYNE Nylon Resins – continued
Table #14. Guidelines for Molding VYDYNE Nylon Resins
Nucleated VYDYNE Resins
VYDYNE 20NSP and 24NSPF Resins
VYDYNE 20NSP and 24NSPF
resins are nucleated nylon 66
resins available in natural (off-
white) and in black (20NSP-02).
They are designed to crystallize
rapidly when cooled from the
molten state. This rapid crystalliza-
tion can result in reduced cycle
times and increased productivity
through faster part set-up when
compared to standard general pur-
pose nylon 66 resins. The crystalline
structure resulting from nucleation
will alter part properties yielding
increased modulus or rigidity,
increased tensile strength, reduced
elongation, reduced impact strength,
and mold shrinkage compared to
standard general purpose nylon 66.
Molding Guide
VYDYNE Grades- 25W, 25WSP, 41, 45
General Purpose, Heat Stabilized 47H, 20NSP, 24NSPF, 22H
Nucleated, Weather Resistant 22HSP, 21X, 21SPF
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 520-560º F (271-293ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 50 and 150 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
100 and 200ºF (38-93ºC). Temperatures on the high end are
recommended as the molding cycle allows assisting in mold filling and
improving molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the
barrel. General purpose crystal polystryene, natural polyethylene, or
clear acrylic regrind is recommended.
9. Typical Process Conditions
(See Table #15 for typical process conditions.)
38
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

VYDYNE 20NSP and 24NSPF

resins have an internal lubricant for
improved machine feed and mold
release. This formulation is
designed to provide easy release of
parts from molds using standard
molding conditions.
The rapid crystallization of
VYDYNE 20NSP and 24NSPF
resins may allow part ejection at
higher temperatures compared to
general purpose nylon 66. This will
reduce the mold closed time and
thereby decrease the molding cycle.
Critical factors unique to each appli-
cation, such as mold/part design,
tolerances, etc., may negate these
cycle time benefits. It is recom-
mended to check critical part
dimensions against specifications
before implementing shorter molding
cycles on a routine basis.
Table 15 – Typical Injection Molding Conditions – VYDYNE Nylon 20NSP, 24NSPF
Resins

English Units SI Units

Melt Temperature, °F (°C) 520-560 (271-293)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 480-520 (249-271)
Center Zone 530-550 (277-288)
Front Zone 540-560 (282-293)
Nozzle 530-550 (277-288)
Mold Surface Temperature, °F (°C) 100-200 (38-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 50-125
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0-4.0

39
Processing Conditions for VYDYNE Nylon Resins – continued
Table #16. Guidelines for Molding VYDYNE Nylon Resins
Weather-resistant
VYDYNE Resins
VYDYNE 25W, 25WSP, and 45 Resins
VYDYNE 25W, 25WSP, and 45
resins are black, weather-resistant,
injection molding-grade nylon 66
resins. They have been developed
to meet U.S. Military Specification
MIL-M-20693B, ASTM Specification
D 4066 PA 0181, and are rated
UL94-V2 at thicknesses down to
0.031 inch (0.787 mm).
Molding Guide
VYDYNE Grades- 25W, 25WSP, 41, 45
General Purpose, Heat Stabilized 47H, 20NSP, 24NSPF, 22H
Nucleated, Weather Resistant 22HSP, 21X, 21SPF
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 520-560º F (271-293ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 50 and 150 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
100 and 200ºF (38-93ºC). Temperatures on the high end are
recommended as the molding cycle allows assisting in mold filling and
improving molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the
barrel. General purpose crystal polystryene, natural polyethylene, or
clear acrylic regrind is recommended.
9. Typical Process Conditions
(See Table #17 for typical process conditions.)
40
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

VYDYNE 25W resin is externally mold sprays. It is recommended to

lubricated for improved machine check critical dimensions against
feed and mold release. This formu- specifications before implementing
lation is designed to provide easy shorter molding cycles on a routine
release of parts from molds using production basis.
standard molding conditions. VYDYNE 45 resin is a moderate-
VYDYNE 25WSP resin is inter- impact, injection molding nylon
nally and externally lubricated for 66 resin. This resin is externally
improved machine feed and excep- lubricated for machine feed and
tional mold release. VYDYNE exceptional mold release, and
25WSP resin is intended for use in weatherable additives for improved
high productivity applications. In weatherability.
many applications, the molding
cycle can be reduced because
molded parts may be removed
from the cavity at higher tempera-
tures. In difficult molds where parts
have a tendency to stick in the cav-
ity, VYDYNE 25WSP resin can
reduce or eliminate the need for

Table 17 – Typical Injection Molding Conditions – VYDYNE Nylon 25W, 25WSP,

41, 45, 47H, 47H-07 Resins

English Units SI Units

Melt Temperature, °F (°C) 520-560 (271-293)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 480-520 (249-271)
Center Zone 530-550 (277-288)
Front Zone 540-560 (282-293)
Nozzle 530-550 (277-288)
Mold Surface Temperature, °F (°C) 100-200 (38-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 50-125
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0-4.0

41
Processing Conditions for VYDYNE Nylon Resins – continued
Table #18. Guidelines for Molding VYDYNE Nylon Resins
Ignition-resistant
VYDYNE Resins
VYDYNE M340, M344, and
M346 Resins
VYDYNE M340 Resin
VYDYNE M340 resin is an unrein-
forced injection molding-grade
nylon 66 resin containing ignition-
resistant additives. Lubricated for
machine feed and easy mold
release, this product is available
only in rust red. VYDYNE M340
resin is modified with halogenated
and other ignition-resistant addi-
tives to provide users with a prod-
uct that meets Underwriters
Laboratory (UL) 94, V-0 flammabili-
ty classification down to a thick-
ness of 0.015 inch (0.381 mm) and
UL94, 5VA down to 0.060 inch (1.5
mm) thickness.
Mold shrinkage of VYDYNE
M340 resin is essentially equivalent
to that of general purpose nylon 66
resins, which are commonly used in
many electrical/electronic compo-
nents and other parts requiring a
UL94, V-2 flammability rating.
Therefore, existing tooling for UL94,
V-2 nylon parts can usually be used
to produce UL94, V-0 or UL94, 5VA
parts from VYDYNE M340 resin,
eliminating the delay and costs
involved in retooling.
Molding Guide
VYDYNE Grades- M340
Ignition Resistant M344
M346
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended maximum safe melt temperatures are 520ºF (271ºC).
Temperatures in excess of 520ºF (271ºC) can result in potentially
hazardous ignition-resistant additive decomposition and corrosion. If
corrosive wear occurs despite following recommended molding procedures,
the processor may need to consider contacting equipment suppliers for
information on metal treatments, coatings, and/or alloys that may be used
to minimize corrosion of molds, screws,barrels, and check rings/valves.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 50 to 70% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
70 and 200ºF (21-93ºC). Temperatures on the high end are recommended
as the molding cycle allows, assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
Tooling should be designed to minimize and eliminate dead pockets in which
gases can be trapped while the mold is being filled. Adequate venting should
be included to release trapped gasses.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
9. Typical Process Conditions
(See Table #19 for typical process conditions.)
42
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

VYDYNE M344 Resin
VYDYNE M344 resin is an unrein-
forced injection molding grade nylon
66 resin containing ignition-resistant
additives. Lubricated for machine
feed and easy mold release, this
product is available in off-white or
black (R344-01). VYDYNE M344
resin is modified with halogenated
and other ignition-resistant additives
to provide users with a product
which meets Underwriters
Laboratory (UL) 94, V-0 flammability
classification down to a thickness of
0.017 inch (0.432 mm) and UL94,
5VA down to 0.080 inch (2.03 mm)
thickness.
Mold shrinkage of VYDYNE
M344 resin is essentially equivalent
to that of general purpose nylon 66
resins, which are commonly used in
many electrical/electronic compo-
nents and other parts requiring a
UL94, V-2 flammability rating.
Therefore, existing tooling for UL94,
V-2 nylon parts can usually be used
to produce UL94, V-0 or UL94, 5VA
parts from VYDYNE M344 resin,
eliminating the delay and costs
involved in retooling.
VYDYNE M346 Resin
VYDYNE M346 resin is an unrein-
forced injection molding grade
nylon 66 resin containing ignition-
resistant additives. Lubricated for
machine feed and easy mold
release, this product is available
only in rust red. VYDYNE M346
resin is modified with halogenated
and other ignition-resistant addi-
tives to provide users with a prod-
uct which meets Underwriters
Laboratory (UL) 94, V-0 flammabil-
ity classification down to a thick-
ness of 0.015 inch (0.381 mm)
and UL94, 5VA down to 0.120 inch
(3.05 mm) thickness.
Mold shrinkage of VYDYNE
M346 resin is essentially equivalent
to that of general purpose nylon 66
resins, which are commonly used in
many electrical/electronic compo-
nents and other parts requiring a
UL94, V-2 flammability rating.
Therefore, existing tooling for UL94,
V-2 nylon parts can usually be used
to produce UL94, V-0 or UL94, 5VA
parts from VYDYNE M346 resin,
eliminating the delay and costs
involved in retooling.

Table 19 – Typical Injection Molding Conditions – VYDYNE Nylon M340, M344

and M346 Resins

English Units SI Units

Melt Temperature, °F (°C) 490-510 (241-260)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 460-500 (238-260)
Center Zone 480-520 (249-271)
Front Zone 480-520 (249-271)
Nozzle 470-490 (243-254)
Mold Surface Temperature, °F (°C) 70-200 (21-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0 - 4.0

43
Processing Conditions for VYDYNE Nylon Resins – continued
Table #20. Guidelines for Molding VYDYNE Nylon Resins
Mineral/Glass-filled
VYDYNE Resins
VYDYNE R400G Resin
VYDYNE R400G resin is a mineral
and glass-reinforced nylon 66 resin
available in natural (off white) and
black (R400G-01). VYDYNE
R400G resin utilizes a unique min-
eral and glass-reinforced polyamide
system.
As compared to unreinforced
nylon 66, VYDYNE R400G resin
offers increased stiffness and mod-
ulus, as well as increased deflec-
tion temperature under load. It min-
imizes warpage and can be
molded much flatter than similarly
reinforced nylons. In many cases,
Molding Guide
VYDYNE Grades- R400G
Mineral/Glass Filled R861H-04
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 530-570º F (277-299ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
150 and 200ºF (66-93ºC). Temperatures on the high end are recommended
as the molding cycle allows assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
10. Typical Process Conditions
(See Table #21 for typical process conditions.)
44
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

VYDYNE R400G resin can elimi-

nate post-mold shrink fixturing
common with glass-reinforced
nylons. The mineral/glass-rein-
forcement system also minimizes
the tendency to develop sink
marks over heavy sections such as
molded-in bosses and ribs.
VYDYNE R400G resin can often
permit boss and rib design, or wall
section changes which cannot be
tolerated in many other thermo-
plastic materials.

Table 21 – Typical Injection Molding Conditions – VYDYNE Nylon R400G Resin

English Units SI Units

Melt Temperature, °F (°C) 520-550 (271-288)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 500-530 (260-277)
Center Zone 510-540 (266-282)
Front Zone 510-540 (266-282)
Nozzle 500-530 (260-277)
Mold Surface Temperature, °F (°C) 150-200 (66-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0 - 4.0

45
Processing Conditions for VYDYNE Nylon Resins – continued
Table #22. Guidelines for Molding VYDYNE Nylon Resins
Glass-filled VYDYNE Resins
VYDYNE R513H Resins
VYDYNE R513H resins are 13%
glass fiber-reinforced nylon 66
resins available in natural (off-
white) and black (R513-01 and
R513H-01). They are injection
molding-grade resins that are
lubricated for machine feed, flow
and mold release.
VYDYNE R513H resins have
tensile strength and modulus prop-
erties just below aluminum and
zinc and can replace these metals
in numerous applications due to an
excellent balance of properties.
VYDYNE R513H is a heat-
stabilized resin, formulated to mini-
mize the oxidative and thermal
Molding Guide
VYDYNE Grades- R513H R533 R8533
Hydrolysis Resistant, Glass Filled R525H R533H R8533H
R530H R543H R8540
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 530-570º F (277-299ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
150 and 200ºF (66-93ºC). Temperatures on the high end are recommended
as the molding cycle allows assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
10. Typical Process Conditions
(See Table #23 for typical process conditions.)
46
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

degradation of the nylon polymer

when exposed to elevated tempera-
tures for extended periods of time.
VYDYNE R513H resin provides
improved retention of physical prop-
erties under exposure to long-term
heat. The continuous operating use
is 275°F (135°C) with short-term
peak temperatures as high as
475°F (246°C).

Table 23 – Typical Injection Molding Conditions – VYDYNE Nylon R513H Resins

English Units SI Units

Melt Temperature, °F (°C) 530-570 (275-300)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 518-536 (270-280)
Center Zone 545-572 (285-300)
Front Zone 545-572 (285-300)
Nozzle 545-572 (285-300)
Mold Surface Temperature, °F (°C) 150-200 (66-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0 - 4.0

47
Processing Conditions for VYDYNE Nylon Resins – continued
VYDYNE R533 and R533H Resins
VYDYNE R533 and R533H resins
are 33% glass fiber-reinforced
nylon 66 resins available in natural
(off-white) and black (R533-01,
R533H-01). They are injection
molding-grade resins that are
lubricated for machine feed, flow
and mold release.
VYDYNE R533 and R533H
resins have tensile strength and
modulus properties just below alu-
minum and zinc and can replace
these metals in numerous applica-
tions due to an excellent balance
of properties.
VYDYNE R533H is a heat-
stabilized resin, formulated to
minimize the oxidative and thermal
degradation of the nylon polymer
when exposed to elevated temper-
atures for extended periods of
time. VYDYNE R533H resin pro-
vides improved retention of physi-
cal properties under exposure to
long-term heat. The continuous
operating use is 275°F (135°C)
with short-term peak temperatures
as high as 475°F (246°C).
Molding Guide
Table #24. Guidelines for Molding VYDYNE Nylon Resins
VYDYNE Grades-
Hydrolysis Resistant, Glass Filled R513H R533 R8533
R525H R533H R8533H
R530H R543H R8540
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 530-570º F (277-299ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
150 and 200ºF (66-93ºC). Temperatures on the high end are recommended
as the molding cycle allows assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
10. Typical Process Conditions
(See Table #25 for typical process conditions.)
48
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

Table 25 – Typical Injection Molding Conditions – VYDYNE Nylon R533, R533H

Resins

English Units SI Units

Melt Temperature, °F (°C) 530-570 (275-300)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 518-536 (270-280)
Center Zone 545-572 (285-300)
Front Zone 545-572 (285-300)
Nozzle 545-572 (285-300)
Mold Surface Temperature, °F (°C) 150-200 (66-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0 - 4.0

49
Processing Conditions for VYDYNE Nylon Resins – continued
VYDYNE R543H Resins
VYDYNE R543H resins are 43%
glass fiber-reinforced nylon 66
resins available in natural (off-
white) and black (R543-01,
R543H-01). They are injection
molding-grade resins that are
lubricated for machine feed, flow
and mold release.
VYDYNE R543H resins have
tensile strength and modulus prop-
erties just below aluminum and zinc
and can replace these metals in
numerous applications due to an
excellent balance of properties.
VYDYNE R543H is a heat-
stabilized resin, formulated to mini-
mize the oxidative and thermal
degradation of the nylon polymer
when exposed to elevated tempera-
tures for extended periods of time.
VYDYNE R533H resin provides
improved retention of physical prop-
erties under exposure to long-term
heat. The continuous operating use
is 275°F (135°C) with short-term
peak temperatures as high as
475°F (246°C).
Molding Guide
Table #26. Guidelines for Molding VYDYNE Nylon Resins
VYDYNE Grades-
Hydrolysis Resistant, Glass Filled R513H R533 R8533
R525H R533H R8533H
R530H R543H R8540
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 530-570º F (277-299ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
150 and 200ºF (66-93ºC). Temperatures on the high end are recommended
as the molding cycle allows assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
10. Typical Process Conditions
(See Table #27 for typical process conditions.)
50
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

Table 27 – Typical Injection Molding Conditions – VYDYNE Nylon R543H Resins

English Units SI Units

Melt Temperature, °F (°C) 530-570 (275-300)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 518-536 (270-280)
Center Zone 545-572 (285-300)
Front Zone 545-572 (285-300)
Nozzle 545-572 (285-300)
Mold Surface Temperature, °F (°C) 150-200 (66-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6-6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0-4.0

51
Processing Conditions for VYDYNE Nylon Resins – continued
VYDYNE R413H-07 Resin
VYDYNE R413H-07 resin is a 13%
glass fiber-reinforced, impact-modi-
fied nylon 66 resin. It is an injection
molding -grade resin that is lubricated
for machine feed, flow and mold
release.
VYDYNE R413H-07 resin has
tensile strength and modulus
properties just below aluminum and
zinc and can replace these metals
in numerous applications due to
an excellent balance of properties.
VYDYNE R413H-07 is a heat-
stabilized resin, formulated to mini-
mize the oxidative and thermal
degradation of the nylon polymer
when exposed to elevated tempera-
tures for extended periods of time.
VYDYNE R413H-07 resin provides
improved retention of physical prop-
erties under exposure to long-term
heat. The continuous operating use
is 275°F (135°C) with short-term
peak temperatures as high as
475°F (246°C).
Molding Guide
Table #28. Guidelines for Molding VYDYNE Nylon Resins
VYDYNE Grades- R413H-07
Impact Resistant, Glass Filled
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 520-570º F (271-299ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
105 and 195ºF (41-91ºC). Temperatures on the high end are recommended
as the molding cycle allows assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
10. Typical Process Conditions
(See Table #29 for typical process conditions.)
52
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

Table 29 – Typical Injection Molding Conditions – VYDYNE Nylon R413H-07 Resin

English Units SI Units

Melt Temperature, °F (°C) 520-570 (275-300)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 510-536 (270-280)
Center Zone 535-572 (279-300)
Front Zone 535-572 (279-300)
Nozzle 535-572 (279-300)
Mold Surface Temperature, °F (°C) 105-195 (41-91)
Injection Pressure, psi (MPa) 6,000-15,000 (40-105)
Holding Pressure, psi (MPa) 6,000-15,000 (40-105)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0 - 4.0

53
Processing Conditions for VYDYNE Nylon Resins – continued
Table #30. Guidelines for Molding VYDYNE Nylon Resins
Hydrolysis-resistant,
Glass-filled VYDYNE Resins
VYDYNE R525H and R530H, Resins
VYDYNE R525H and R530, and
resins are hydrolysis-resistant, glass
fiber-reinforced nylon 66 resins.
VYDYNE R525H is available in nat-
ural color, and VYDYNE R525H and
R530 resins are available in black
(R525H, R530H). They are injection
molding-grade resins that are lubri-
cated for machine feed, flow and
mold release. VYDYNE R525H is
25% glass-filled, R530H is 30%
glass-filled nylon 66 resin.
Molding Guide
VYDYNE Grades-
Hydrolysis Resistant, Glass Filled R513H R533 R8533
R525H R533H R8533H
R530H R543H R8540
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 530-570º F (277-299ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
150 and 200ºF (66-93ºC). Temperatures on the high end are recommended
as the molding cycle allows assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
10. Typical Process Conditions
(See Table #31 for typical process conditions.)
54
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

VYDYNE R525H, R530H, and

R538H-02 resins are specifically
designed to maximize retention of
physical properties when exposed
to anti-freeze solutions at tempera-
tures in excess of 220°F (104°C)
VYDYNE R525H, R530H, and
R538H resins are heat-stabilized
grades, formulated to minimize the
oxidative and thermal degradation of
the nylon polymer when exposed to
elevated temperatures for extended
periods of time. VYDYNE R525H,
R530H, and R538H resins provide
improved retention of physical prop-
erties under exposure to long-term
heat. The continuous operating use is
275°F (135°C) with short-term peak
temperatures as high as 475°F
(246°C).

Table31 – Typical Injection Molding Conditions – VYDYNE Nylon R525H,

R525H and R530H Resins

English Units SI Units

Melt Temperature, °F (°C) 530-570 (277-299)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 518-536 (270-280)
Center Zone 545-572 (285-300)
Front Zone 545-572 (285-300)
Nozzle 545-572 (285-300)
Mold Surface Temperature, °F (°C) 150-200 (66-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6-6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0-4.0

55
Processing Conditions for VYDYNE Nylon Resins – continued
Table #32. Guidelines for Molding VYDYNE Nylon Resins
Nylon 66/6 Copolymer,
Glass-filled VYDYNE Resins
VYDYNE R633, R633H-01, and
R633H-05 Resins
VYDYNE R633, R633H-01, and
R633H-05 resins are 33% glass
fiber-reinforced nylon 66/6 copoly-
mer resins available in natural (off-
white), and black (R633-01,
R633H-01, and R633H-05). They
are injection molding-grade resins
that are lubricated for machine feed,
flow and mold release. VYDYNE
R633H-05 resin is used for automo-
tive interior components.
Molding Guide
VYDYNE Grades- R633 R633H-05
Nylon 66/6 Copolymer Glass Filled R633H-01
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 520-560º F (271-293ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
150-200ºF (66-93ºC). Temperatures on the high end are recommended
as the molding cycle allows assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
10. Typical Process Conditions
(See Table #33 for typical process conditions.)
56
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

VYDYNE R633, R633H-01, and

R633H-05 resins are developed to
provide a balance of improved
processability while maintaining the
elevated temperature properties of a
standard nylon 66 glass-filled grade.
VYDYNE R633H-01 and
R633H-05 resins are heat-stabi-
lized, formulated to minimize the
oxidative and thermal degradation
of the nylon polymer when exposed
to elevated temperatures for
extended periods of time. VYDYNE
R633, R633H-01, and R633H-05
resins provide improved retention of
physical properties under exposure
to long-term heat. The continuous
operating use is 275°F (135°C) with
short-term peak temperatures as
high as 475°F (246°C).

Table 33 – Typical Injection Molding Conditions – VYDYNE Nylon R633, R633H-

01, and R633H-05 Resins

English Units SI Units

Melt Temperature, °F (°C) 530-570 (275-300)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 518-536 (270-280)
Center Zone 545-572 (285-300)
Front Zone 545-572 (285-300)
Nozzle 545-572 (285-300)
Mold Surface Temperature, °F (°C) 150-200 (66-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6-6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0-4.0

57
Processing Conditions for VYDYNE Nylon Resins – continued
Table #34. Guidelines for Molding VYDYNE Nylon Resins
Industrial-grade
VYDYNE Nylon Resins
VYDYNE R861H-04 Mineral/
Glass-Filled Resin
VYDYNE R861H-04 resin is a
mineral and glass-reinforced,
industrial-grade nylon 66 resin
available in black. VYDYNE
R861H-04 resin utilizes a unique
mineral and glass-reinforced
polyamide system.
Molding Guide
VYDYNE Grades-
Mineral/Glass Filled
R400G
R861H-04
Process Variable Suggested Guidelines for Molding.
1. Material Drying
A dehumidified air (desiccant bed)-type dryer is recommended
with a maximum air temperature of 160º F (71ºC) and a residence
time of 1-3 hours.
2. Melt Temperature
Recommended melt temperatures are 530-570º F (277-299ºC). The
melt temperature must be measured from an air shot using a
hand-held pyrometer, since in addition to the barrel heaters, screw
back pressure and screw rotation add additional heat to the melt.
3. Barrel-to-shot Ratio
A barrel-to-shot ratio of 40 to 80% of the machine's rated capacity
in polystyrene is recommended. A lower barrel-to-shot ratio results
in excess residence time and polymer degradation causing
permanent embrittlement of the molded part. A higher barrel-to-shot
ratio makes it more difficult for the molding machine to deliver a
uniform melt or achieve high fill speeds.
4. Injection Rates and Screw Speed
Injection rates should be as fast as possible without causing
excessive shear to the material, resulting in material degradation.
The use of back pressure should be minimized between 25 and 150 psi.
(1.72-10.34 bar) to yield a consistent melt and/or adequate mixing
of color concentrates. Screw rotation speed should be controlled
at the miminum required to maintain the molding cycle, with the
optimum range between 60 and 120 psi.
5. Mold Temperature
Mold surface temperatures should be controlled in a range between
150 and 200ºF (66-93ºC). Temperatures on the high end are recommended
as the molding cycle allows assisting in mold filling and improving
molded part performance.
6. Use of Regrind
Regrind must be dried before use.
The suggested procedure is to grind and reuse the reground material
immediately after molding.
Regrind ratios of 25% or less have shown no significent property loss
when properly molded. However, acceptable levels for each application
should be determined by actual performance of the finished parts.
7. Molding Equipment & Tooling
Standard screw-type injection molding machines with a general
purpose injection screw design are recommended.
8. Start-up and Shutdown Procedures
To facilitate machine start-up after extended shutdown, the cylinder
and any hot runner blocks or manifold should be purged of nylon prior
to shutdown with a material that flows at a lower process temperature.
Do not shut down a machine with nylon resin remaining in the barrel.
General purpose crystal polystryene, natural polyethylene, or clear
acrylic regrind is recommended.
10. Typical Process Conditions
(See Table #35 for typical process conditions.)
58
Processing Conditions for VYDYNE Nylon Resins – continued Molding Guide

Table 35 – Typical Injection Molding Conditions – VYDYNE Nylon R861H-04 Resin

English Units SI Units

Melt Temperature, °F (°C) 520-550 (271-288)

Recommended Machine Settings

Barrel Settings, °F (°C)
Rear Zone 500-530 (260-277)
Center Zone 510-540 (266-282)
Front Zone 510-540 (266-282)
Nozzle 500-530 (260-277)
Mold Surface Temperature, °F (°C) 150-200 (66-93)
Injection Pressure, psi (MPa) 8,000-20,000 (55-138)
Holding Pressure, psi (MPa) 8,000-20,000 (55-138)
Screw Back Pressure, psi (MPa) Low: 25-150 (0.17-1.03)
Screw Speed, rpm Low: 60-120
Injection Time, sec Fast: 1-2.5
Cushion, in (mm) .0625-.250 (1.6 - 6.4)

Clamp Pressure
Tons/in2 Projected Area (U.S.) 2.0 - 4.0

59
M O L D I N G G U I D E

Screw
and
Molding
Equipment
Guidelines
Screw and Check Ring Design

A. Screw Compression Ratios B. Screw Designs A conventional flighted screw

Compression ratio of the screw is
an important consideration in
selecting the correct screw design
for a given plastic material. The
compression ratio is defined as:
C.R. = Df/Dm
Table 37 lists recommended screw
design profiles for general purpose
resins. Figure 50 shows recom-
mendations for screw depth and
compression ratios.
with an advancing spiral barrier
(ASB)1 is generally recommended
for processing both filled and
unfilled nylon. The ASB is required
to provide improved melt homo-
geneity and a more uniform melt

where Table 36 – Screw Compression Ratios for Nylon and Other Materials
Df = Depth of the screw flights in Material Compression Ratio
the feed section
Nylon 3.5 to 4.0
Dm = Depth of the screw flights in ABS 2.5 to 3.5
the metering section Polypropylene 3.0 to 3.8
Table 39 lists the compression PC/ABS Blends 2.8 to 3.5
ratios for nylon and several other Polycarbonate 2.5 to 3.0
injection- grade plastic materials. Low Density Polyethylene 3.0 to 4.0
This table should be used only as a High Density Polyethylene 2.8 to 3.5
guideline. The compression ratio High Impact Polystyrene 2.8 to 3.5
will be influenced by the type of General Purpose Polystyrene 2.8 to 3.5
screw design and the effective SAN 2.5 to 2.8
screw flighted length. This com- Source: Glycon, Inc.

pression ratio should not be used

as the only factor in determining Table 37 – Recommendations for Screw Depth and Compression Ratios for
Nylon Screw Designs
the screw’s performance. Other fac-
tors such as bulk density, percent Screw Feed Meter Compression
Diameter Depth (Df ) Depth (Dm) Ratio
of regrind, processing conditions,
percent of shot, screw rpm, color 30 mm .236 .067 3.52:1
letdown ratio, and melt index will 1.50 in .300 .085 3.53:1
effect the compression ratio. As a 40 mm .300 .085 3.53:1
general rule of thumb, the transition 1.75 in .330 .095 3.47:1
section should be at least three 50 mm .350 .097 3.61:1
diameters in length. 2.0 in .350 .097 3.61:1
55 mm .390 .110 3.55:1
2.25 in .400 .115 3.48:1
60 mm .420 .120 3.50:1
2.50 in .435 .125 3.48:1
70 mm .470 .130 3.62:1
2.75 in .470 .130 3.62:1
3.00 in .480 .135 3.56:1
80 mm .500 .140 3.57:1
1
Trademark of Glycon, Inc.
90 mm .530 .150 3.53:1
Source: Glycon, Inc.

61
Screw and Check Ring Design – continued Molding Guide

temperature. For processes that Figure 50 – Recommendations for Screw Depth and Compression Ratios for
require a higher recovery rate, it is Nylon Screw Designs

generally recommended that an

Flighted Length 18 to 23 L/D
energy transfer (E.T.)1 screw design
Feed – 8 L/D Transition – 6 to 11 L/D Meter
be used. To minimize the effects of
4 L/D
wear, the screw materials for 60 Hf ASB 3D Hm
mm diameter and under are typical-

D
ly a D-2 or CPM-9V tool steel.
Screws over 60 mm diameter are
Source: Glycon, Inc.
typically 4140, 4340, and Nitralloy-
135M. These screws have flights
that are hardfaced with Colmonoy Figure 51 – Most Common Check Ring Valve – Sliding Ring Type
56 or 88. For additional wear protec-
tion, various other surface treatments Ring in back position

such as nitriding and carbide coating during injection

can be used.
For filled material, the screw rpm
should be as slow as possible to
plasticize the material. High screw
rpm will cause the glass fibers to
break, thus reducing the physical
properties. It is also recommended
that the injection speed be set as Ring in forward position

low as possible without sacrificing during screw rotation

part appearance. Schematic of Ring to Show Forward and Back Motions

C. Check Ring Designs

Most check ring designs can be
used with nylon materials. The
most common is the sliding ring
type, shown in Figure 51.

Melt Flow Pattern

Source: Rosato, Donald V. and Dominick V., Injection Molding Handbook, 1995.

62
Screw and Check Ring Design – continued Molding Guide

Figure 52 – Three - piece “Slider” Ring Valve

Source: Glycon, Inc.

Another type of check ring rec- improved by carbide facing the

ommended for use with glass-filled
nylon resins is a three-piece “slid-
er” ring valve. The non-return valve
should be designed to minimize the
ring shut-off time. The flow pas-
sages through the non-return valve
should be streamlined and be free
of areas where material can be
caught. The material of the non-
return valve should be constructed
out of CPM-9V or an M4 tool steel.
Additional wear resistance can be
front seat of the valve body and
ring. To ensure good nozzle tem-
perature control, the heater bands
and thermocouple should be locat-
ed as far forward as possible on
the nozzle without making contact
with the sprue bushing or platen,
shown in Figure 52.

63
Injection-molding Machine
Type and Size
VYDYNE and VYDYNE R nylon
resins are designed to be
processed on standard commercial
screw injection molding machines.
Selection of the proper size and
type of injection molding machine,
however, is the first step toward
obtaining quality parts.
An injection molding machine is
essentially a heated pump. It has
provisions for heating a thermoplas-
tic to a point where it will flow under
pressure, moving the melted materi-
al into a mold, and cooling the melt
to a point where it solidifies and can
be removed from the mold.
In processing VYDYNE and
VYDYNE R resins, the first concern
is the time period in which the mate-
rial first sees elevated temperatures
above the melting point in the barrel
of the injection molding machine.
This residence time, especially for
nylon resins, is extremely important
in determining the final properties of
the molded part.
The rated polystyrene capacity
of the barrel, in ounces, should be
used in determining the proper
press size. The calculation for this
is shown under the Tool Design
Considerations section of this guide
(page 10). Generally, the shot
weight, consisting of the total
weight of the part, runner, and
sprue, in ounces of VYDYNE and
VYDYNE R resins should fall within
40 to 80% of the polystyrene
capacity of the barrel.
A shot size much less than 40%
will have an extended barrel resi-
dence time. This exposes the poly-
amide matrix to heat, pressure, and
screw shear beyond its limits of
endurance. Thus, degradation of
the polymer will commence, result-
ing in molecular changes in the
resin and the formation of brittle
parts. Extremely long residence
times can result in poor quality
molded parts due to splay, foamy
structure and brittleness.
Natural-colored VYDYNE R
resin turns a gray-blue color when
overheated. This serves as a safety
device and is indicative of condi-
tions which could degrade the resin.
The Troubleshooting Section of this
guide (page 73) provides informa-
tion to resolve degradation issues.
Residence times that are too
short due to shot size beyond 80%
of the capacity of the barrel, risk
insufficient plasticizing of the resin.
64
Since 80 to 85% of the thermal
energy in the melt comes from the
screw shearing, short residence
times will result in non-homoge-
neous melts, unmelted pellets and
slugs and short shots. Also, when
these conditions are observed, a
common tendency is to increase
barrel settings in an attempt to add
energy to the system. This may
result in local overheating and
degradation of the polymer that is
in contact with the barrel walls.
Additional problems associated
with insufficient hydraulic capacity
may be experienced in addition to
the shot size. Selection of press
size, so that the total shot size falls
within the 40 to 80% range of the
barrel capacity, insures that mini-
mal problems associated with resi-
dence times are encountered.
M O L D I N G G U I D E

Mold
Shrinkage
and
Dimensional
Stability
Mold Shrinkage Prediction
High mold shrinkage is a character-
istic of VYDYNE and VYDYNE R
resins due to their nylon base poly-
mers. As a crystalline polymer,
nylon shrinks more than amorphous
plastics because of the structural
rearrangements that occur with
heating and cooling. Among the
large number of factors that influ-
ence these effects, the common
denominator is temperature.
As nylon is heated, its volume
increases until it eventually reaches
the amorphous state. The resin
remains in the expanded state until
it is injected into the mold. During
the subsequent cooling process, it
shrinks away from the mold cavity
walls. Part of this shrinkage is the
volumetric thermal contraction com-
mon to all materials. Much of the
shrinkage, however, results from the
crystalline response to the cooling
process. The molecules rearrange
themselves to form a more dense,
stable ordered configuration.
The rate of cooling is the control-
ling factor. Often the molecular
rearrangement is arrested or frozen
before it can be completed. Fast
cooling results in the retention of a
more amorphous structure, while
slow cooling results in greater crys-
tallinity and, subsequently, lower
overall volume.
It is desirable, therefore, to have
as much shrinkage occur as possi-
ble during molding. The high mold
temperatures recommended for
VYDYNE and VYDYNE R resins
are designed to accomplish this.
However, if a mold is run at a very
hot temperature, the mold steel
thermal expansion should also be
taken into consideration.
The following equations can be
used to determine shrinkage and
cavity sizing for predicting shrinkage.
A. Shrinkage Calculation:
S = (Dcav - L p)/Dcav
where
Dcav = Cavity dimensions
Lp = Part length
B. Cavity Dimensions:
Dcav = Lpf /1-S r
where
Lpf = Finished part length
Sr = Shrinkage rate
66
The following are process parame-
ters that will have an impact on mold
shrinkage.
1. Increasing packing pressure can
reduce shrinkage.
2. Minimizing pressure drop
through by using larger gates
and larger runners can also
reduce shrinkage.
3. Warmer molds and warmer melt
temperatures will also reduce
pressure drop, but may or may
not increase shrinkage. Higher
temperatures, however, do cause
increased shrinkage. Usually, the
higher effective pressure will
override the increased shrinkage
effects caused by the higher tem-
perature. It is usually more effec-
tive to keep temperatures cooler
and to fill as fast as possible in
order to keep pressure drop to a
minimum. This also serves to
reduce viscosity, provided the
shear rate is not high enough to
cause material degradation.
Table 38 lists shrinkage rates for
several VYDYNE and VYDYNE R
resins. Table 39 (page 68) gives a
comparison of shrinkage rates for
VYDYNE nylon resins and a num-
ber of other Dow resins.
Mold Shrinkage Prediction – continued Molding Guide

Table 38 – Mold Shrinkage Data for VYDYNE Nylon Resins

Shrinkage in/in, (mm/mm)

Transverse Direction Longitudinal Direction

Thickness,
Material Type in (mm) Lower Limit Upper Limit Lower Limit Upper Limit

VYDYNE 21SPF General Purpose 0.125 (3.2) 0.019 (0.019) 0.022 (0.022) 0.019 (0.019) 0.022 (0.022)
Nylon 66 0.100 (2.5) 0.016 (0.016) 0.016 (0.016) 0.016 (0.016) 0.017 (0.017)
0.060 (1.5) 0.013 (0.013) 0.013 (0.013) 0.012 (0.012) 0.012 (0.012)

VYDYNE R513 13% Glass-filled 0.125 (3.2) 0.011 (0.011) 0.015 (0.015) 0.007 (0.007) 0.008 (0.008)
Nylon 66 0.100 (2.5) 0.011 (0.011) 0.014 (0.014) 0.006 (0.006) 0.007 (0.007)
0.060 (1.5) 0.011 (0.011) 0.015 (0.015) 0.005 (0.005) 0.006 (0.006)

VYDYNE R633 33% Glass-filled 0.125 (3.2) 0.007 (0.007) 0.011 (0.011) 0.002 (0.002) 0.002 (0.002)
Nylon 66/6 0.100 (2.5) 0.006 (0.006) 0.010 (0.010) 0.001 (0.001) 0.002 (0.002)
Copolymer 0.060 (1.5) 0.006 (0.006) 0.010 (0.010) 0.001 (0.001) 0.002 (0.002)

VYDYNE R860 40% Industrial- 0.125 (3.2) 0.009 (0.009) 0.014 (0.014) 0.005 (0.005) 0.006 (0.006)
grade, Glass 0.100 (2.5) 0.008 (0.008) 0.012 (0.012) 0.004 (0.004) 0.005 (0.005)
Fiber/Mineral- 0.060 (1.5) 0.008 (0.008) 0.011 (0.011) 0.003 (0.003) 0.004 (0.004)
filled Nylon 66

VYDYNE R220 40% Mineral- 0.125 (3.2) 0.010 (0.010) 0.010 (0.010) 0.011 (0.011) 0.011 (0.011)
filled, Heat- 0.100 (2.5) 0.008 (0.008) 0.009 (0.009) 0.011 (0.011) 0.011 (0.011)
stabilized 0.060 (1.5) 0.008 (0.008) 0.008 (0.008) 0.009 (0.009) 0.010 (0.010)
Nylon 66

VYDYNE R400G 40% Glass Fiber/ 0.125 (3.2) 0.009 (0.009) 0.014 (0.014) 0.005 (0.005) 0.006 (0.006)
Mineral-filled 0.100 (2.5) 0.008 (0.008) 0.012 (0.012) 0.004 (0.004) 0.005 (0.005)
Nylon 66 0.060 (1.5) 0.008 (0.008) 0.011 (0.011) 0.003 (0.003) 0.004 (0.004)

VYDYNE R525H 25% Glass-filled 0.078 (2.0) 0.013 (0.013) 0.013 (0.013) 0.004 (0.004) 0.004 (0.004)
Nylon 66, Heat-
stabilized

VYDYNE R530H 30% Glass-filled 0.078 (2.0) 0.008 (0.008) 0.008 (0.008) 0.001 (0.001) 0.001 (0.001)
Nylon 66, Heat-
stabilized

VYDYNE R533H 33% Glass-filled 0.078 (2.0) 0.009 (0.009) 0.009 (0.009) 0.003 (0.003) 0.003 (0.003)
Nylon 66, Heat-
stabilized

67
Mold Shrinkage Prediction – continued Molding Guide

Table 39 – Mold Shrinkage for VYDYNE Nylon Resins and for Other Dow Engineering Thermoplastics

Shrinkage (Longitudinal Direction)

Material Type in/in mm/mm

VYDYNE M344 Nylon Nylon .010-.015 .015-.020
VYDYNE R525H Nylon Nylon .004-.007 .003-.006
VYDYNE R530 Nylon Nylon .003-.006 .003-.005
VYDYNE 24NSP Nylon Nylon .014-.018 .008-.012
VYDYNE R400G Nylon Nylon .008-.014 .008-.014
VYDYNE 4111-07 Nylon Nylon .018-.022 .018-.020
CALIBRE™ 401-11 PC Polycarbonate .005-.007 .005-.007
PULSE™ 2000 PC/ABS PC/ABS Blend .004-.006 .004-.006
MAGNUM™ 357HP ABS ABS .004-.006 .004-.006
QUESTRA™ WA202 SPS Syndiotactic Polystyrene .003-.004 .003-.004
INSPIRE™ C703-35U PP Polypropylene .014-.016 .014-.016
TYRIL™ 880 SAN Styrene Acrylonitrile .004-.005 .004-.005
STYRON™ 478 HIPS High Impact Polystyrene .003-.007 .003-.007
Test Method: ASTM D955-@.125 in. (3.2 mm)

68
Post-mold Shrinkage and
Estimating Total Shrinkage
Post-mold Shrinkage Figure 53 – Post-mold Shrinkage in Hot and Cold Molds

Post-mold shrinkage occurs Total

Cavity Dimensions Shrinkage
because parts rarely reach maxi- = M o ld
mum density in the mold. Post- Shrinkage
– Annealing
mold shrinkage can be accelerated Hot Mold
Shrinkage
by exposure to temperatures above Post-mold M o ld
Shrinkage Shrinkage
the glass transition temperature (Tg
Post-mold Shrinkage
Final Part Dimensions
= 140°F [60°C]) of the resin. This M o ld
occurs most frequently in paint Shrinkage
bake ovens.
Cold Mold
The amount of post-mold
shrinkage is dependent on how
much primary shrinkage has
occurred in the mold. The total Figure 54 – Shrinkage Characteristics of VYDYNE R Resins
shrinkage can be thought of as a
.022
constant, increments of which are
.021
dependent on the thermal environ-
.020
ment encountered. Other factors
mm/mm dna ni/ni ,egaknirhS

.019
such as bake oven temperatures
.018 200°F Mold
and time exposure will have slight
.017 After 300°F Oven
effects. Figure 53 illustrates an
.016 After 300°F Oven
example of post-mold shrinkage in 150°F
.015
Mo ld Mold
a hot and cold mold. t of
.014 Ou
Figure 54 illustrates shrinkage of .013
old
VYDYNE R resins both out of mold ofM
Out
.012

at 150°F (66°C) and 200°F (93°C) .011

mold temperatures, and after expo- .010

sure at 300°F (149°C) in an oven.

.10 .12 .13 .14 .15 .16 .17 .18 .19 .20 .21 .22 .23 .24

Part Thickness, in

69
Post-mold Shrinkage and Estimating Total Shrinkage – continued Molding Guide

Estimating Total Shrinkage Failure to consider the post-mold

shrinkage can result in parts being
Total shrinkage will be the sum of
under-sized. While the mold is in the
mold shrinkage arising from post-
design stage, it is strongly recom-
mold annealing. It is absolutely
mended that the molder, end-user of
necessary to determine what post-
the part, and the mold designer work
molding operations will be carried
closely as a team to prevent prob-
out on the part before a shrinkage
lems with final part dimensions.
factor is selected for cavity sizing.
Gauges may be machined or
Operations such as paint oven
built for a specific stage of the
temperature and length of expo-
process. Parts to be tested should
sure, must first be identified before
be exposed to the appropriate bake
estimating post-mold shrinkage.
temperatures, cooled, and then
This number is then added to the
gauged for dimensions.
mold shrinkage estimate from nomi-
nal wall thickness considerations to
obtain the total shrinkage factor for
machining the cavity.
The total shrinkage can be
determined as follows:

Stotal = Spost-mold - Smolded-in

where
Stotal = Total mold shrinkage
Spost-mold = Post-mold shrinkage
Smolded-in = Molded-in shrinkage

70
Packing and Part Density

The degree of packing of VYDYNE Flow Tabs Cavity Pressure Control

and VYDYNE R resin parts during
A flow tab is made, as shown in A much more sophisticated
molding also controls dimensions to
Figure 55, by machining a 0.035- method, cavity pressure control
a degree. This is because the part
inch (.889 mm) by 0.25-inch (6.35 involves the use of a pressure
will strive to reach an optimum den-
mm) groove in a harmless location transducer which is installed in the
sity through shrinkage. If this densi-
of a runner. It is marked off in about cavity, usually in an ejector pin. The
ty is achieved through volumetric
0.125-inch (3.2 mm) increments to pressure transducer measures the
packing, the total shrinkage experi-
show the amount of flow into a cav- cavity pressure during injection and
enced will be less than that of
ity. The tab should be very well controls shot-to-shot pressure with-
unpacked parts.
vented to insure consistent filling. in a very narrow range. There are
In practice, this is usually not a
Its use entails simply visually many of these type of cavity pres-
concern if the degree of packing is
inspecting the tab from time to time sure controllers available and many
more or less constant. Generous
to determine whether machine con- can be connected to an off-line com-
gate, runner and sprue design will
ditions have changed from specifi- puter monitoring system.
insure proper packing. It is recom-
cation. Large variations in the flow
mended to use a feed cushion of
tab will usually be accompanied by
0.125 - 0.250 inch (3.2-6.35 mm) to
changes in dimensions.
insure proper part packing.
Cavity pressure is more difficult to
control than temperatures, but a Figure 55 – Flow Tabs
number of techniques are available
to monitor the consistency of part
density. These include part weight,
flow tabs and cavity pressure control.
Each of these will be briefly reviewed. Part Part

Part Weight
Runner Flow Tab
Once acceptable parts are (.035-inch deep x .25-inch wide)
obtained, part weight is recorded. (.889 mm) (6.35mm)
Large deviations of approximately 1 23 4 56 7 8 9 10 11 12 13 1415 16 Vent
3% from the ideal part weight will
probably result in problems, if
dimensions are critical. Part weight Part Part
may drift slowly due to normal
machine fluctuations, but can be
brought back into proper range by
a simple adjustment of pressure. If
changes occur sporadically with no
defined pattern, the molding
machine should be inspected and
repairs made accordingly.

71
Coefficient of Linear Thermal
Expansion (CLTE)
The thermal expansion of a materi- Table 40 – Coefficient of Linear Thermal Expansion Data for Selected
Thermoplastics Thermal Conductivity (x 10-5)
al is usually associated with an
increase in atomic vibrational ener- Material in/in/°F mm/mm/°C
gy when the temperature is VYDYNE 21SPF 4.5 8.1
increased, resulting in a volume VYDYNE M344 4.1 7.4
change. The coefficient of linear
thermal expansion of any material VYDYNE R400G 1.6 2.9
is the material’s change in length, VYDYNE R533H 1.3 2.6
per unit change in temperature. Polycarbonate 3.8 6.8
The following formula is used to Polycarbonate/ABS 4.1 7.4
calculate the coefficient of linear ABS 5.0 9.0
thermal expansion: High Impact Polystyrene 3.7 6.7
Polypropylene 3.3 5.9
 = LT Glass Filled Syndiotactic Polystyrene 1.2 2.2
where Styrene Acrylonitrile (SAN) 3.0 5.4
 = Elongation due to temperature Polyethylene 5.9 10.6
 = Coefficient of linear thermal Source: Multiple Industry Sources
expansion (CLTE)
L = Length subjected to the Figure 56 – Coefficient of Linear Thermal Expansion vs.
expansion Temperature (ASTM D 696), VYDYNE R220 Resin
T =Temperature change Temperature, °C
(Thigh - Tlow)
Coefficient of Linear Thermal Expansion

0 20 40 60 80 100 120 140 160

6.0 x 10-5 10.8 x 10-5
In general, plastics have a signif-
5.0 x 10-5 9.0 x 10-5
icantly higher coefficient of linear
4.0 x 10-5 7.2 x 10-5
thermal expansion than metals.
m°C
in°F

m
in

3.0 x 10-5 5.4 x 10-5

Also, the CLTE of a material will
increase with temperature. 2.0 x 10-5 3.6 x 10-5

Table 40 lists data for CLTE for a 1.0 x 10-5 1.8 x 10-5

number of different polymer materials,

0 40 80 120 160 200 240 280 320
and Figure 56 provides data for CLTE Temperature, °F
as a function of temperature for sever-
al VYDYNE resins.

72
Troubleshooting Guide for
Injection Molding Nylon
Table 41 provides troubleshooting
guidelines for injection molding
nylon parts. The guide lists the prob-
lem, the cause of the molding prob-
lem, and the process and tooling
solutions for resolving the particular
molding problem. Any one or combi-
nation of these solutions can be
used to identify and solve molding
issues when molding nylon parts.

Table 41 – Nylon Injection Molding Troubleshooting Guide

Problem Process Solution Tooling Solution Material Solution

Black Purge or clean dirty barrel Check for grease or oil in mold. Material may be setting up
Streaking and/or nozzle. too quickly.
Check for cracked barrel lining. Reduce temperature settings Dry material if moisture volatiles are
in hot runner manifold. trapped at the wide line of the part.
Clean overhead area Change mold slide grease to higher Correct overdrying to improve flow
around hopper. temperature grade of lubrication. and fill of part.
Check if hopper throat water is Check for contamination
turned on. in manifold.
Clean overhead area around hopper.
Check if hopper is covered sufficiently.
Move mold to a machine with a
smaller injection cylinder to reduce
material residence time.
Check for material contamination.

Burn Marks Reduce injection velocity or speed.
Reduce barrel temperature
settings.
Reduce injection pressure.
Reduce back pressure.
Check for insufficient vent size or Change material grade or shift to
blocked vents. material with higher melt flow rates.
Check centering of mold core and Correct overdrying to increase
adjust if shifted. resin flow.
Change gate location.
Increase gate size to reduce shear.
Check nozzle, sprue bushing,
runners, and gates for burrs and
sharp corners in flow path.

Color Fading Reduce melt temperature. Change color system to higher

temperature types.
Move mold to a machine with a Reduce level of fines in regrind.
smaller injection cylinder to reduce
material residence time.
Reduce cycle time. Change to part painting or drying
for heat stable nylons.

73
Troubleshooting Guide for Injection Molding Nylon – continued
Table 41 – Nylon Injection Molding Troubleshooting Guide – continued
Problem Process Solution
Material Purge barrel.
Discoloration
Reduce melt temperature.
Move mold to a machine with a
smaller injection cylinder to
reduce material residence time.
Reduce rear heat zones.
Reduce back pressure.
Reduce injection velocity or speed.
Splay or Silver Reduce melt temperature.
Streaking Reduce nozzle temperature.
Change nozzle length to shorter
nozzle.
Check nozzle for burr or partial
blockage in flow path
Reduce injection velocity or speed.
Increase gate size or add more
gates to part.
Move mold to a machine with a
smaller injection cylinder to reduce
material residence time.
Increase back pressure.
Check for source of water near hopper.
Reduce screw decompress or suck back.
Reduce injection velocity or speed.
Check cylinder, screw, and/or check
ring for wear.
Increase nozzle orifice diameter.
Check barrel/nozzle heater bands
for hot spots.
Brittleness Reduce melt temperature by
lowering temperature settings,
reducing back pressure, or
reducing screw speed or velocity.
Move mold to a machine with a
smaller barrel, so shot weight is
equal to 40 to 80% of barrel’s
polystyrene capacity.
Steepen barrel temperature profile
from rear zone to front zone.
Reduce injection speed or velocity
to reduce shear.
Molding Guide
Tooling Solution
Reduce temperature settings in
hot runner manifold.
Check for contamination and
purge if necessary.
Check for water leak in mold.
Increase size of sprues, runners,
gates, and/or vents.
Reduce mold temperature.
Add radii on all fillets and corners.
74
Material Solution
Visually check material in hopper
and newly opened containers for
off-color contamination source.
Dry material before use.
Install fresh desiccant bed in dryer.
Check operation of desiccant bed
in dryer.
Check for dryer hose leaks.
Reduce regrind level or ensure
regrind is dry.
Check material for outside
contamination.
Reduce amount of regrind.
If resin is too wet, dry material
before use.
If resin is too dry, reduce drying
and reduce stock temperatures
and pressures.
Visually check resin pellets for
contamination, over-sized pellets,
and excessive level of fines.
Moisture-condition parts before
shipping.
Use higher impact grade of material.
Check part relative viscosity.
Troubleshooting Guide for Injection Molding Nylon – continued Molding Guide

Table 41 – Nylon Injection Molding Troubleshooting Guide – continued

Problem Process Solution Tooling Solution Material Solution

Delamination Increase melt temperature. Increase mold temperature. Dry material.

Reduce or increase injection rate. Visually check for contamination.

Purge barrel of machine. Check color concentrate carrier

resin for compatibility.

Increase back pressure.

Increase screw speed.

Flashing Reduce injection and/or hold Align or adjust mold. Convert to material with lower melt
pressure. flow rate.
Reduce hold time. Visually examine mold for Check resin for excessive moisture
contamination on mating surfaces. levels.
Increase clamp force. Check mold alignment. Convert to nucleated resin,
if possible.
Move mold to a larger tonnage Reduce mold temperature.
machine.
Reduce injection time. Improve mold venting.
Reduce material feed setting.
Reduce melt temperature.
Make gate open times consistent.
Check for out-of-control melt pyrometer.
Reduce injection speed.
Check platen alignment.

Nozzle Drool Reduce nozzle temperature. Dry material.

Reduce melt temperature by
lowering temperature settings,
back pressure, or screw rpms.
Increase decompress or suck-back time.
Decrease nozzle orifice diameter.
Use reverse taper nozzle.
Utilize melt decompression/
suck-back function.
Use beryllium copper nozzle.
Visually check to ensure nozzle is
flush against sprue bushing.
Visually check nozzle and sprue
bushing for burrs or cracks.
Reduce cycle time.

75
Troubleshooting Guide for Injection Molding Nylon – continued Molding Guide

Table 41 – Nylon Injection Molding Troubleshooting Guide – continued

Problem Process Solution Tooling Solution Material Solution

Nozzle Increase nozzle temperature. Increase mold temperature.

Freeze-off Increase barrel heater band
watt density.
Relocate heater bands forward
on nozzle.
Check for burned out heater band.
Reduce cycle time.
Increase nozzle orifice diameter.
Visually examine nozzle for
contaminated orifice.
Utilize reverse taper nozzle.
Utilize sprue break or nozzle tip insulator.

Short Shots Check for proper cushion. Increase mold temperature. Use material with higher melt
flow rate.
Increase feed setting. Open gates and/or widen runners. If resin is too dry, reduce drying.
Check for worn/damaged Check mold for proper runner and If wet resin causes screw slippage,
check ring. gate balancing. dry the resin.
Increase injection speed or Nominal wall thickness of part
velocity. too thin – increase nominal wall
thickness of part, if possible.
Increase injection pressure. Improve or clean vents.
Increase melt temperature. Optimize and improve gate locations.
Check heater bands and Increase nozzle orifice.
pyrometers.
Visually check for bridging in
hopper throat and use throat
cooling if needed.
Check machine hydraulic system.
Move mold to a machine with
a larger barrel size.

Sinks Increase hold time.
Increase hold pressure.
Reduce melt temperature.
Increase cure time.
Increase injection speed.
Increase cushion (feed setting).
Repair leaking check valve.
Relocate gates near heavy Change to material with higher melt
thickness sections. flow rate.
Increase gate size.
Reduce mold temperature.
Open runners, nozzle, and/or sprue.

76
Troubleshooting Guide for Injection Molding Nylon – continued
Table 41 – Nylon Injection Molding Troubleshooting Guide – continued
Problem Process Solution
Sticking in Reduce injection pressure.
Mold Cavity Reduce hold time.
Reduce injection time.
Increase cooling time.
Reduce melt temperature.
Sticking in Reduce injection pressure.
Sprue
Reduce hold time.
Reduce injection time.
Increase nozzle temperature.
Use reverse taper nylon nozzle.
Increase/decrease cooling time.
Voids Check for proper cushion.
Inspect for faulty check ring.
Increase injection pressure
and/or time.
Increase hold pressure
and/or time.
Reduce injection speed or velocity
if melt flows around pins, ribs,
corners, etc.
Increase/decrease melt temperature.
Warpage Increase cure time.
Increase/decrease melt
temperature.
Increase/decrease hold time.
Increase/decrease injection
speed or velocity.
Molding Guide
Tooling Solution Material Solution
Check for undercuts. Reduce regrind level.
Check for adequate draft angles. Convert to material with improved
mold release.
Increase mold temperature.
Align seating of nozzle to sprue Reduce regrind level.
bushing.
Reduce or smooth burrs or nicks Convert to material with improved
in sprue bushing. mold release.
Reduce secondary mold
temperature.
Increase sprue bushing taper.
Provide more effective sprue puller.
Check that nozzle orifice is smaller
than sprue bushing opening.
Increase runner and/or gate size. Convert to faster set-up resin grade.
Add vents or increase vent size.
Increase/decrease mold temperature.
Check for uniformity of Convert to nucleated resin grade
ejector system. for reduced shrinkage.
Reduce mold temperature on Reduce drying if material is too dry.
concave side of warped part –
increase it on convex side of part.
Recommended temperature Evaluate mineral/glass-filled in place
differential of 30°F [17°C] of standard glass-filled grade.
between halves and between points
on a given half.
Slow mold opening action.
Too abrupt changes from thin to thick
sections. Redesign, if possible.
Open gates, runners, sprue and nozzle.
Change location of gates.
Check for broken or short ejector pin.
77
Troubleshooting Guide for Injection Molding Nylon – continued Molding Guide

Table 41 – Nylon Injection Molding Troubleshooting Guide – continued

Problem Process Solution Tooling Solution Material Solution

Weld Lines Increase injection pressure.
Increase injection speed.
Increase melt temperature.
Check mold temperature.
Improve venting in weld area.
Change location of gates to
change flow pattern.
Increase nominal wall thickness.
Check for core pin-shift phenomena
causing unbalanced wall thickness.
Convert to non-nucleated resin
material.
Convert to resin with lower
glass content.
Dry material if moisture or volatiles
are entrapped at the weld.
Reduce drying if material is too dry.

Excessive Increase cooling time Open sprue, runners, and gates. Convert to nucleated resin grade
Shrinkage (except with increase in part size). for reduced shrinkage.
(small parts) Increase packing pressures Reduce mold temperature. Put ejected parts (too hot) into
(injection and hold). cold water.
Increase cushion.
Increase injection time.
Increase injection rate.
Decrease/increase melt temperature
to either cool more quickly or
increase packing.
Increase nozzle orifice.
Inspect for worn or broken check ring.

Screw Check machine for worn screw or Check for wet material, excessive
Slippage barrel, faulty check valve, blockage at fines, and faulty pellet cut/bulk
bottom of feed hopper, or empty hopper. density.

Increase/decrease barrel feed zone

temperature.
Reduce back pressure.
Check for 0.29 inch (7.4 mm) minimum
feed screw zone depth regardless
of screw diameter.

78
Coloring VYDYNE Nylon 66 Resins
Parts in a broad range of colors
can be produced with most
VYDYNE nylon resins by standard
coloring techniques, such as dry
color, solid color concentrates, or
liquid color systems. Table 42
(page 80) lists a description, advan-
tage and disadvantage of each of
these three methods.
For VYDYNE resins that are
recognized by Underwriters
Laboratory (UL), maintenance of
UL ratings can only be accom-
plished by using liquid color sys-
tems for VYDYNE nylon resins or
by the addition of approved solid
color concentrates.
Dry color, usually in powder form,
is the most inexpensive means to
color VYDYNE nylon resins, and is
used when a small quantity of parts
is needed. Special care is neces-
sary to produce consistent quality
colored parts. If proper handling is
not used, excessive dusting and
inadequate dispersion can result.
Machine clean-out can also be difficult
and time consuming.
Solid color concentrates may also
be used to produce integrally colored
parts. Specific color concentrates
recognized by UL are available for
use with VYDYNE nylon resins.
Definition of approved concentrates
and UL yellow card regulations on
their use are available from The Dow
Chemical Company.
To maintain existing UL molded
part ratings, concentrations up to
2% by weight may be used, except
for black, which is limited to 1.54%.
Use of these approved concen-
trates in amounts greater than 2%
(1.54% for black) and use of any
other concentrate or colorant,
requires special submission to UL
for molded part testing in order to
maintain/establish molded part UL
ratings. For molded parts that do
not require UL ratings, the level of
color concentrate to be used should
be determined in each application.
Economics and the effect of the
color concentrate on physical prop-
erties need to be considered.
For VYDYNE resins that contain
ignition-resistant or heat stabilizer
additives, the use of some colors is
limited because of interactions
between the colorant system and
the additives. For colorable ignition-
resistant resins, obtainable shades
are limited due to the interaction.
For heat-stabilized resins, colorant
systems containing inorganic red,
orange, pink and yellow colorants
can interact with the heat stabilizer
additives causing adverse effects
on the resulting color and a loss in
heat stabilization. Therefore, it is
not recommended to color with
these colorant systems unless the
colorants are first tested and
shown to be acceptable for color-
ing and heat stability.
79
Coloring VYDYNE Nylon 66 Resins – continued
Table 42 – Color Concentrate Types Used for Nylon
Type of
Color
Concentrate Description
Dry Color Pigment supplier develops
blends of pigments formulated
to provide a color match.
Pigments are developed with a
specified amount of natural resin
to obtain a desired color.
Solid Color High loading of pigments are
Concentrates predispersed in a resin carrier.
Concentrates are formulated to
give a specified color match when natural resin.
blended with a predetermined
amount of natural resin.
Let-down ratio used to
determine solid color to
natural resin mix (e.g., 50:1,
50 parts natural resin,
1 part color concentrate).
Liquid Color High loading of pigments are
Systems predisposed in a liquid carrier.
Let-down ratios of 100:1
are typical.
Metering takes place
at the machine throat or
at the nozzle.
Molding Guide
Advantages
Lower cost in comparison
to pre-colored resin and
color concentrates.
Natural resin can be used in
bulk as base for coloring.
Lower cost than pre-coloring.
Can store bulk quantities of
Can quickly and efficiently
change colors in process
operation.
Efficient, low cost method.
Blending operation of resin
and color eliminated.
Improved dispersion of
coloring media due to use
of liquid carrier.
80
Disadvantages
Blending operation needed
to mix materials.
Molder responsible for
final color.
Material handling of dry colors can
create housekeeping issues such as
contamination of equipment and
work area.
Cleaning of residual dry color
pigment systems from blending
equipment and mold machine
hoppers.
Molder responsible for final color.
Blending operation added at the
machine.
Mixing nozzles may need to be
added to improve mixing in
some cases.
Cleaning of equipment can be
difficult.
Molder responsible for final color.
Compatibility of liquid carrier
and natural color resin an issue.
Safety and Handling Considerations
Material Safety Data (MSD) sheets
for VYDYNE nylon resins are avail-
able from Dow Automotive, a busi-
ness unit of The Dow Chemical
Company and its subsidiaries. MSD
sheets are provided to help cus-
tomers satisfy their own handling,
safety, and disposal needs, and
those that may be required by
locally applicable health and safety
regulations, such as OSHA
(U.S.A.), MAK (Germany), or
WHMIS (Canada). MSD sheets are
updated regularly, therefore, please
request and review the most cur-
rent MSD sheet before handling or
using any product.
The following comments are
general and apply only to
VYDYNE nylon resins as supplied.
Various additives and processing
aids used in fabrication, and other
materials used in finishing steps,
have their own safe use profile and
must be investigated separately.
Hazards and Handling Precautions
These resins may contain glass
fibers as a reinforcing component.
VYDYNE nylon resins have a
very low degree of toxicity and
under normal conditions of use
should pose no unusual problems
from ingestion, eye, or skin contact.
However, caution is advised when
handling, storing, using, or dispos-
ing of these resins and good
housekeeping and controlling of
dusts are necessary for safe han-
dling of product. Workers should be
protected from the possibility of
contact with molten resin during
fabrication.
Handling and fabrication of plastic
resins can result in the generation of
vapors and dusts including small
particles of glass fibers. Dusts result-
ing from sawing, filing and sanding of
plastic parts in post-molding opera-
tions may cause irritation to eyes
and the upper respiratory tract. In
dusty atmospheres, use an
approved dust respirator.
Pellets or beads may present a
slipping hazard. Slight itching and
irritation may result from skin con-
tact. Repeated exposure to parti-
cles generated by grinding glass
fiber-reinforced materials may
result in implantation of particles in
the skin.
Good general ventilation of the
polymer processing area is recom-
mended.
In addition, to accelerate cooling
of large polymer masses, purge
patties should be quenched in
water. If quenching is not possible,
purge patties should be removed
from the general working area to a
well ventilated area to cool.
Processing may release fumes
which may include polymer frag-
ments and other decomposition
products. Fumes can be irritating.
At temperatures exceeding melt
81
Safety and Handling Considerations – continued
temperature, polymer fragments
can occur. Good general ventilation
should be sufficient for most condi-
tions. Local exhaust ventilation may
be necessary for some operations.
Use safety glasses. If there is a
potential for exposure to particles
which could cause mechanical
injury to the eye, wear chemical
goggles. If vapor exposure causes
eye discomfort, use a full-face res-
pirator. No other precautions other
than clean body-covering clothing
should be needed for handling
VYDYNE nylon resins. Use gloves
with insulation for thermal protection,
when needed.
Combustibility
Although VYDYNE nylon resins
may contain ignition-resistant
chemical additives, they will burn
and, once ignited, may burn rapidly
under the right conditions of heat
and oxygen supply. Do not permit
dust to accumulate. Dust layers can
be ignited by spontaneous combus-
tion or other ignition sources. When
suspended in air, dust can pose an
explosion hazard. Dense black
smoke is produced when product
burns. Toxic fumes are released in
fire situations.
Firefighters should wear positive-
pressure, self-contained breathing
apparatus and full protective equip-
ment. Water or water fog are the
preferred extinguishing media.
Foam, alcohol-resistant foam, car-
bon dioxide, or dry chemicals may
also be used. Soak thoroughly with
water to cool and prevent re-ignition.
Molding Guide
Disposal
DO NOT DUMP INTO ANY SEW-
ERS, ON THE GROUND, OR INTO
ANY BODY OF WATER. For
unused or uncontaminated material,
the preferred options include send-
ing to a licensed recycler, reclaimer,
incinerator, or other thermal destruc-
tion device. For used or contaminat-
ed material, the disposal options
remain the same although additional
evaluation is required (see, for
example, in the U.S.A., 40 CFR,
Part 261, “Identification and Listing
of Hazardous Waste”). All disposal
methods must be in compliance with
federal, state, provincial and local
laws and regulations.
As a service to its customers,
Dow can provide lists of companies
which recycle, reprocess, or man-
age chemicals or plastics, and com-
panies that manage used drums.
Contact the nearest Dow Customer
Service Center for further details.
Environment
Generally speaking, in the environ-
ment, lost pellets are not a problem
except under unusual circum-
stances such as when they enter
82
 Safety and Handling Considerations – continued Molding Guide

the marine environment. They are quality. To help ensure that Dow
inert and benign in terms of their products are not used in ways for
physical environmental impact, but which they were not intended or
if ingested by waterfowl or aquatic tested, Dow personnel will assist
life, they may mechanically cause customers in dealing with ecological
adverse effects. Spills should be mini- and product safety considerations.
mized and they should be cleaned up Your Dow sales representative can
when they happen. Plastics should arrange the proper contacts. Dow
not be discarded into the ocean or any literature, including MSD sheets,
other body of water. should be consulted prior to the use
of Dow products. These are avail-
Product Stewardship
able from the nearest Dow
The Dow Chemical Company has a Customer Service Center.
fundamental concern for all who
make, distribute, and use its prod-
ucts, and for the environment in
which we live. This concern is the
basis of our product stewardship
philosophy, by which we assess the
health and environmental informa-
tion on our products and then take
appropriate steps to protect
employee and public health and the
environment. Our product steward-
ship program rests with every individ-
ual involved with Dow products from
initial concept and research to the
manufacture, sale, distribution and
disposal of each product.

Customer Notice
Dow encourages its customers and
potential users of Dow products to
review their applications for such
products from the standpoint of
human health and environmental

83
 The Dow Chemical Company
1-800-635-4332
FAX: 1-517-832-1465
Outside North America, call 1-517-832-1556

Dow will not knowingly sell or sample any products into any commercial or developmental application which is intended for:
a. long- term contact with internal body fluids or internal body tissues. (Long term is a use which exceeds 72 continuous hours [except 30 days for PEL-
LETHANE* polyurethane elastomers]);
b. use in cardiac prosthetic devices regardless of the length of time involved (cardiac prosthetic devices include, but are not limited to, pacemaker leads and
devices, artificial hearts, heart valves, intra-aortic balloons and control systems and ventricular bypass assisted devices);
c. use as a critical component in medical devices that support or sustain human life; or
d. use specifically by pregnant women or in applications designed specifically to promote or interfere with human reproduction.
In addition, for Dow Engineering Plastics products, new business opportunities require a business assessment prior to sale or sampling Dow products.
Authorized distributors and resellers will adhere to the Engineering Plastics Business medical policy.
The Engineering Plastics business does not endorse or claim suitability of its products for specific medical applications. It is the responsibility of the med-
ical device or pharmaceutical manufacturer to determine that the Dow product is safe, lawful and technically suitable for the intended use. DOW MAKES
NO WARRANTIES, EXPRESS OR IMPLIED, CONCERNING THE SUITABILITY OF ANY DOW PRODUCT FOR USE IN MEDICAL APPLICATIONS. This
policy applies to all Engineering Plastics products including the following resins: CALIBRE™ Polycarbonate, CALIBRE MegaRad™ Polycarbonate,
DOW PolyPropylene RESiNS™, ISOPLAST™ Engineering Thermoplastic Polyurethane, MAGNUM™ ABS, PELLETHANE™ Thermoplastic
Polyurethane Elastomer, PREVAIL™ Thermoplastic resin, PULSE™ Engineering resin, QUESTRA™ Crystalline Polymer, TYRIL™ SAN and VYDYNE®
Nylon resin.
NOTICE: No freedom from any patent owned by Seller or others is to be inferred. Because use conditions and applicable laws may differ from one location
to another and may change with time, Customer is responsible for determining whether products and the information in this document are appropriate for
Customer’s use and for ensuring that Customer’s workplace and disposal practices are in compliance with applicable laws and other governmental enact-
ments. Seller assumes no obligation or liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.
Published July 2001

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®Registered trademark of Solutia Inc. used by The Dow Chemical Company under license. Form No. 301- 29950095-800
Printed in U.S.A. Dow Automotive is a business unit of The Dow Chemical Company and its subsidiaries. 100-HMC / DVS 2001