Common Injection Molding

Defects and How to Solve them

Plastic injection molding is a complex process that requires precision,
expertise, and attention to detail. From material selection to tool
design, every aspect of the process must be carefully considered and
optimized to ensure high-quality, defect-free parts. However, even the
most well-designed processes can encounter issues, and how to solve
them?

Some injection molding defects may be very difficult to address. These

defects can arise from various factors, including the molding process,
the materials utilized, the maintenance of the equipment, or the
storage conditions of the components. Here are several injection
molding defects, causes, and solutions.

Type 1: Problems caused by Molding Process

Some injection molding processes may not be effective for the

production. The molding process is the leading cause of defects in
injection molding parts.

1. Blister

Blisters refer to raised bumps or defects on the surface of a molded

part. This problem can be caused by various factors such as issues with
the mold used to create the part, the materials used in the injection
process, and the specific injection process itself. Specifically, blisters
are caused by trapped gas near the outer layer of the part that cannot
be released through normal venting methods. These factors can all
contribute to the development of blisters on molded parts.

Causes:

- process parameters (cycle time too short or injection speed to

high);
- insufficient cooling time；
- material is not dry enough;
- mold temperature is not suitable;
- insufficient venting

Solutions:

- adjust the injection speed to reduce the amount of trapped gas

in the mold, so it can prevent the formation of blisters.
- increase the mold temperature to improve material flow and
reduce the risk of blistering.
 - adjust the venting to prevent the buildup of trapped gas so
that vents are appropriately sized, placed, and maintained.
- modify the material to adjust the moisture content, or adding
additives.
- modify the mold design to improve cooling or alter the gate
location.
- inspect the mold and machine to identify any issues that may be
contributing to blistering.

2. Flow Lines

Flow lines are patterns or lines on the surface of a plastic part that are
caused by the merging of multiple flow fronts during the injection
molding process. They can reduce the aesthetic quality of the part and
may also negatively affect its strength and performance. Flow lines
usually occur at the intersection or branching points of the plastic flow
path, where there may be unevenness or differences in the speed of
the plastic flow.
Causes:

- poor mold design;

- excessively high or low melt temperatures;
- uneven or insufficient injection speeds;
- the small size of the gate and flow channel;
- variation in the material’s cooling speed as it flows in different
directions.
Solutions:

Improving mold design and optimizing the plastic flow path to reduce
the number and size of branching and intersection points.

Increase nozzle diameter.

Adjusting injection molding process parameters, such as melt

temperature, injection speed, and pressure, to optimize plastic flow
uniformity and speed.

Optimizing the heating and cooling system of the mold to ensure

even temperature distribution on the mold surface, and avoid heat
accumulation or insufficient cooling.

Using high-quality plastic materials to avoid impurities and particles

that could affect flow performance.

Performing regular maintenance and cleaning of the mold and

injection molding equipment during production to ensure they are
operating properly and maintained in optimal condition.

3. Sink Marks

Sink marks are depressions or indentations on the surface of an

injection-molded part that is caused by variations in the cooling rate
of the plastic material. These variations can result in uneven shrinkage
and warpage of the part, leading to localized areas of surface
depression. Sink marks can occur in thick sections of the part where
the cooling rate is slower, and are more likely to occur when using
materials with high levels of filler or reinforcement.
Causes:

- mold temperature is not properly optimized (too short cooling or

holding time and pressure);
- injection pressure wrong or very low holding pressure;
- high melting or molding temperatures;
- improper structural design of the molded component.

Solutions:

- design the part with a uniform thickness to promote even

cooling and minimize differential shrinkage.
- modify the part design to eliminate areas of high-stress
concentration or wall thickness variation.
- optimize the injection molding process parameters, such as mold
temperature, injection speed, and pressure, to ensure even
cooling and minimize differential shrinkage.
- use plastic materials with lower levels of filler or reinforcement,
or use materials with special additives to improve cooling and
minimize sink marks.
 - modify the mold design to improve cooling efficiency, such as by
adding cooling channels or conformal cooling features.
- perform post-molding operations, such as annealing or stress
relief, to reduce the residual stresses that contribute to sink
marks.

4. Weld Lines

Weld lines, also known as knit lines, are areas of an injection-molded

part where two or more molten plastic flow fronts converge, resulting
in a visible line or seam on the surface of the part. These lines can
occur when the molten plastic flow fronts cool and solidify at different
rates, creating a visible seam or weakened area. Weld lines can occur
in areas of the part where the plastic flow fronts meet, such as in the
center of a part or at the intersection of multiple flow paths.
Causes:

- uneven wall thickness. (plastic material is reinforced with fillers or

fibers that interfere with the flow of the molten plastic)
- a too-low or too-high temperature of molten material.
- inserts, holes, and multi-gate features on fabricated parts.

Solutions：

- optimize the plastic flow path and minimize the occurrence of

weld lines.
- modifying the part design to eliminate areas of high-stress
concentration or areas where the flow fronts converge.
- adjusting the injection molding process parameters, such as melt
temperature, injection speed, and pressure, to optimize the
plastic flow and minimize the occurrence of weld lines.
- using plastic materials with lower viscosity or using materials
with special additives that improve plastic flow and minimize the
occurrence of weld lines.
- improve the cooling efficiency, such as by adding cooling
channels or conformal cooling features.
- performing post-molding operations, such as annealing or stress
relief, to reduce the residual stresses that contribute to the
formation of weld lines.

5. Burn Marks

Burn marks are discolorations or black or brown spots on the surface

of an injection-molded part caused by excessive heat during the
molding process. These marks can negatively affect the aesthetic
quality of the part and may also weaken the material, reducing its
strength and performance.
Causes:

- the plastic material is exposed to excessively high temperatures

or prolonged heat exposure, leading to thermal degradation and
the release of gases that cause discoloration or burning.
- insufficient ventilation in the mold leads to trapped air pockets
that can become superheated and cause burn marks.
- slowly removing the air in the cavity;
- the melting temperature is too high;
- tast screw or excessive injection speeds are too high.
- the runner system’s design is improper.
Solutions：

- adjusting mold temperature within the recommended range for

the specific plastic material being used.
- adjust injection speed and pressure, to prevent excessive heat
buildup and minimize the occurrence of burn marks.
- improving the mold ventilation system to ensure proper airflow
and reduce the risk of trapped air pockets that can cause burn
marks.
- using plastic materials that are more heat-resistant or adding
special additives that improve heat resistance and reduce the risk
of burn marks.
- cleaning and maintaining the mold regularly.

Type 2: Problems caused by wrong mold storage or

materials used

In addition to issues that may arise during the molding process,

defects in injection-molded parts can also be attributed to factors
related to the plastic resin used, or the way in which it was handled
prior to production. These types of defects can range from relatively
minor cosmetic imperfections to more serious issues that compromise
the structural integrity of the part and potentially pose safety risks in
certain applications.

6. Discoloration

The discoloration is a common defect in injection-molded parts and

refers to any variation in color or appearance that deviates from the
desired specification. It can occur due to a variety of reasons, including
contamination, degradation of the plastic material, overheating, and
improper processing.

Contamination can occur when foreign particles, such as dust, oil, or

grease, come into contact with the plastic material during processing.
These particles can affect the color and appearance of the final part,
resulting in discoloration. Degradation of the plastic material can
occur due to exposure to high temperatures, moisture, or ultraviolet
light, which can cause the material to break down and change color.
Overheating can occur when the mold temperature is too high or the
injection speed and pressure are not optimized.

Causes:

- the plastic material to overheat and change color

- using the wrong processing parameters
- failing to properly dry the plastic material

Solutions:

- using high-quality plastic materials that are less prone to

discoloration and degradation.
 - ensuring proper handling and storage of the plastic material to
prevent contamination and degradation.
- maintaining the mold and equipment to prevent contamination
and overheating.
- optimizing the injection molding process parameters, such as
mold temperature, injection speed, and pressure, to ensure
proper processing and prevent overheating.
- using colorants and additives that are compatible with the plastic
material to achieve the desired color and appearance.
- conducting regular inspections and quality checks to identify and
address any discoloration issues.
- use a purging compound to eliminate excess colorant.
- ensure even mixing of the masterbatch.

7. Delamination

Delamination is a defect that occurs when the layers of an injection-

molded part separate or peel apart from each other, resulting in a
weakened or structurally compromised part.

Causes:

- improper processing, such as using the wrong processing

parameters or failing to properly dry the plastic material, can
result in delamination
- contamination: such as the presence of foreign particles or
moisture, can also cause delamination by preventing the plastic
material from adhering properly to the mold surface
- material incompatibility: such as using different types of plastic
materials that are not compatible with each other, can also cause
delamination
- design issues: such as having thin or uneven walls or sharp
angles, can cause stress concentrations that lead to
delamination.
Solutions:

- ensuring proper handling and storage of the plastic material to

prevent contamination and degradation.
- properly drying the plastic material before processing to remove
any moisture.
- optimizing the injection molding process parameters, such as
mold temperature, injection speed, and pressure, to ensure
proper processing.
- using plastic materials that are compatible with each other and
the mold surface.

Designing the part with adequate wall thickness, smooth surfaces, and
rounded edges to reduce stress concentrations.

Conducting regular inspections and quality checks to identify and

address any delamination issues.

Type 3: Problems caused by Poor Mold Maintenance or

Poor Mold Design

Flaws in injection molding can significantly impact mold design.

Neglecting to maintain the mold appropriately can also act as a
trigger for molding defects. As these defects manifest in the final
stages, rectifying them can be an arduous and expensive task.

8. Flash

Flash is a common defect in injection-molded parts and refers to

excess material that extends beyond the intended parting line or mold
cavity. It can occur due to several reasons, including improper mold
design, poor mold maintenance, excessive injection pressure or speed,
and material shrinkage.

Causes:

- improper mold design or poor mold maintenance can cause

flash by allowing the plastic material to escape from the mold
cavity through gaps or spaces in the mold.
- excessive injection pressure or speed can also cause flash by
forcing the plastic material beyond the intended mold cavity.
- material shrinkage can also contribute to flash by causing the
plastic material to contract and pull away from the mold surface,
leaving excess material behind.
Solutions:

- optimizing the mold design and maintaining the mold to ensure

proper sealing and prevent material escape.
- reducing injection pressure and speed to prevent excessive
material flow.
- using plastic materials with lower shrinkage rates reduces the
likelihood of excess material being left behind.
- conducting regular inspections and quality checks to identify and
address any flash issues.
- using automation or robots to trim excess material and ensure
consistent quality.

9. Short Shot

A short shot is a defect that occurs when the injection-molded part is

incomplete, resulting in missing or underdeveloped sections of the
part. It can occur due to several reasons, including insufficient
material, improper mold design, processing parameters, or material
properties.
Causes:

- insufficient material can cause short shots by not providing

enough plastic material to fill the mold cavity completely.
- improper mold design, such as inadequate venting or gating, can
also cause short shots by restricting the flow of plastic material
into the mold cavity.
- improper processing parameters, such as low injection pressure,
short injection time, or inadequate cooling time, can also cause
short shots by not allowing the plastic material to flow and
solidify properly.
- material properties, such as high viscosity or low melt flow index,
can also contribute to short shots by making it difficult for the
plastic material to flow into all areas of the mold cavity.

Solutions:

- optimizing the mold design to ensure adequate venting and

gating for proper material flow.
- adjusting the processing parameters, such as increasing injection
pressure, prolonging injection time, or increasing cooling time, to
provide sufficient material flow and solidification.
- using plastic materials with appropriate properties, such as low
viscosity or high melt flow index, to facilitate material flow into
all areas of the mold cavity.
- conducting regular inspections and quality checks to identify and
address any short-shot issues.

Conclusion

Injection molding is a common manufacturing process used to

produce plastic parts. However, this process can result in various
defects, such as blisters, sink marks, weld lines, burn marks,
discoloration, delamination, flash, and short shot. These defects can be
caused by factors such as material properties, mold design, processing
parameters, or maintenance. To minimize or eliminate these defects,
solutions such as adjusting processing parameters, optimizing mold
design, using appropriate materials, and conducting regular
inspections and maintenance can be employed.