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https://www.avient.com/sites/default/files/2022-06/Maxxam FR Injection Molding Processing Guide.pdf
Standard grades in the portfolio conform to UL 94 V-2, V-0 and 5VA performance
ratings, and many offer elevated Relative Thermal Index (RTI) ratings.
Drying non-halogenated materials is suggested.
2 hours @ 100 (38)
Moisture Range
(%)
Not required
Vents should be placed at the intersection of each 90° bend in the runner
system off of the cold slug well and vented to atmosphere
PROBLEM CAUSE SOLUTION
Black Specks
Contamination
• Purge barrel with general purpose PP
• Verify correct nozzle is being used
• Pull screw for cleaning
Degraded/overheated
material
• Decrease melt temperature
• Decrease back pressure
• Decrease injection speed
• Use appropriately sized barrel
Brittleness
Degraded/overheated material
• Decrease melt temperature
• Decrease back pressure
• Decrease injection speed
• Use appropriately sized barrel
Gate location and/or size
• Relocate gate to nonstress area
• Increase gate size to allow higher flow rate and
lower molded-in stress
Burning
Process related
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Decrease injection rate
Mold design
• Clean, widen and increase number of vents
• Increase gate size to reduce shear
Fibers/Minerals on
Surface or Uneven
Surface Appearance
Melt temperature too low
• Increase melt temperature
• Increase mold temperature
• Increase injection speed
Insufficient packing
• Increase hold pressure and time
• Increase shot size
Flash
Injection pressure
too high
• Decrease injection pressure
• Increase clamp pressure
• Decrease injection rate
• Increase transfer position
Excess material volume
• Adjust transfer position
• Decrease pack pressure
• Decrease shot size
• Decrease injection rate
Melt and/or mold too hot
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Decrease screw speed
Loose clamp
• Reset mold height
• Increase clamp tonnage
Troubleshooting Recommendations
PROBLEM CAUSE SOLUTION
Incomplete Fill
Melt and/or mold too cold
• Increase nozzle and barrel temperatures
• Increase mold temperature
• Increase injection rate
Mold design
• Enlarge or widen vents and increase number
of vents
• Check that vents are unplugged
• Check that gates are unplugged
• Enlarge gates and/or runners
• Perform short shots to determine fill pattern
and verify proper vent location
• Increase wall thickness to move gas trap to
parting line
Shot size
• Adjust transfer position to 98% full
• Increase shot size
Nozzle Drool Nozzle temperature too hot
• Decrease nozzle temperature
• Decrease back pressure
• Increase screw decompression
Shrink
Too much shrink
• Increase cooling time
• Decrease mold temperature
Too little shrink
• Decrease cooling time
• Increase mold temperature
Sink Marks
Part geometry too thick
• Reduce wall thickness
• Reduce rib thickness
Melt too hot
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
Insufficient material
volume
• Adjust transfer position
• Increase shot size
• Increase injection rate
• Increase packing pressure
Troubleshooting Recommendations (continued)
PROBLEM CAUSE SOLUTION
Sticking in Mold
Overfilled cavity
• Decrease injection rate and pressure
• Decrease hold pressure
• Adjust transfer position
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Decrease cooling time
Mold design
• Increase draft angle
• Polish cores in direction of ejection
Part is too hot
• Decrease nozzle and barrel temperatures
• Decrease mold temperature
• Increase cooling time
Warp
Process related
• Increase cooling time
• Increase melt temperature
• Increase pack pressure
• Increase pack time
• Decrease mold temperature
Mold design • Inspect for non-uniform mold cooling
Part design • Inspect for non-uniform wall thickness
Temperature control unit
incorrect temperature
• Check settings
• Inspect thermocouple
Weld Lines
Melt front temperatures
are too low
• Increase pack and hold pressure
• Increase melt temperature
• Increase injection rate
• Increase mold temperature
Mold design
• Increase gate size
• Perform short shots to determine fill pattern
and verify proper vent location
• Add vents and/or false ejector pin
• Move gate location
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