Robust Process Development and Scientific Molding 2E (eBook)

Theory and Practice
Copyright: 2017
ISBN: 9781569905876
PDF: 367 pages
$169.99 (US)

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Introduction to Scientific Processing. Properties of Polymers and Plastics That Influence Injection Molding. Polymer Rheology. Plastic Drying. Common Plastic Materials and Additives. Injection Molding and Molding Machines. Scientific Processing, Scientific Molding, and Molding Parameters. Process Development Part I:  The 6-Step Study – Exploring the Cosmetic Process. Process Development Part 2:  Exploring the Dimensional Process via the DOE. Mold Qualification Flowchart, Production Release, and Troubleshooting. Role of Mold Cooling, Venting, and Regrind in Process Development. Related Technologies and Topics. Quality Concepts. Appendices:  Materials Data Sheet. Conversion Tables for Commonly Used Process Parameters. Water Flow Tables. Part Design Checklist. Mold Design Checklist. Mold Qualification Checklist. Regrind Tables – Percentage of Regrind in Total Shot.


This book introduces the concepts of Scientific Molding and Scientific Processing for Injection Molding, geared toward developing a robust, repeatable, and reproducible (3Rs) molding process. It explains the underlying principles of polymer science: the properties that are important to injection molding and their application to molding process development. The effects of polymer morphology, thermal transitions, drying, and rheology on the injection molding process are explained in detail. The development of a robust molding process is broken down into two sections: the Cosmetic Process and the Dimensional Process. Scientific molding procedures to establish a 3R process are provided.

The concept of Design of Experiments (DOEs) for and in injection molding is explained, giving insight into the cosmetic and dimensional process windows. A plan to release qualified molds into production with troubleshooting tips is also provided. Topics that impact a robust process such as the use of regrind, mold cooling, and venting are also described.
Readers will be able to utilize the knowledge gained from the book in their day-to-day operations immediately.
This second edition includes a completely new chapter on Quality Concepts, as well as much additional material throughout, covering fountain flow, factors affecting post mold shrinkage, and factor selections for DOEs. There are also further explanations on several topics, such as in-mold rheology curves, cavity imbalances, intensification ratios, gate seal studies, holding time optimization of hot runner molds, valve gated molds, and parts with large gates. A troubleshooting guide for common molded defects is also provided.

Author Info:

Kulkarni, S.

Suhas Kulkarni is the President of FIMMTECH, a consulting firm that specializes in services related to injection molding. He earned his Masters in Plastics Engineering from the University of Massachusetts, Lowell and a Bachelors in Polymer Engineering from the University of Poona, India. He has 24+ years of experience as a process engineer. His main area of expertise is Scientific Processing for Injection Molding. Based on his experience, he has developed a custom software called Nautilus, that aids the complete process development routine to production release. He has given numerous presentations on Injection Molding related topics and written several articles.  He also teaches a plastics and molding course at the University of California, San Diego and is a contract faculty at the University of Massachusetts at Lowell.