Injection Molding Guide Injection Molding: Part Design Injection Molding: Mold Design

Injection Molding Guide Injection Molding: Part Design Injection Molding: Mold Design

AUTOMOTIVE SOLUTIONS IMPROVE ADVANCED DRIVER ASSISTANCE SYSTEM DESIGN WITH THERMALLY CONDUCTIVE FORMULATIONS Thermal management is an important consideration in the design of Advanced Driver Assistance Systems (ADAS). Could your housing design be improved to allow for better overall system performance? Injection-moldable Therma-Tech™ enables you to design a housing with the required thermal conductivity at a lighter weight than aluminum.

Avient’s proprietary metering systems are designed specifically to complement its liquid formulations. HELPING YOU WITH LIQUID COLOR There are many important technical factors to consider when implementing new technologies into new or existing injection molding and extrusion processes. Dosing systems Proprietary dosing systems designed specifically for optimized metering of Avient advanced ColorMatrix liquid technologies.

Avient’s proprietary metering systems are designed specifically to complement its liquid formulations. HELPING YOU WITH LIQUID COLOR There are many important technical factors to consider when implementing new technologies into new or existing injection molding and extrusion processes. Dosing systems Proprietary dosing systems designed specifically for optimized metering of Avient advanced ColorMatrix liquid technologies.

Fiber reinforced polymer composites are exceptional alternatives to traditional materials such as wood, ceramic, and metal, enabling designers to create lighter weight structural components for increased lifetime performance, and improved fuel efficiency. Thermoplastic chemistry enables CFRTP composites to be incorporated into high volume manufacturing processes such as compression and injection molding as well as into structures with dissimilar materials via overmolding, adhesive bonding, and thermal lamination. KEY CHARACTERISTICS • Lightweight • High strength & stiffness • Excellent fatigue & impact resistance • Exceptional strength-to-weight ratio • Strong adhesive properties • Chemical and corrosion resistance • Reduced NVH compared to metals • Rapid cycle times • Low VOCs VALUE SOLUTION • Replaces metal without sacrificing strength • Reduced vehicle weight improves fuel economy, reduces energy consumption • Selective reinforcement adds strength in high stress areas • Easily integrated & streamlined manufacturing process • Easy bonding to various materials • Increases structure & puncture resistance • Can be used in injection and compression overmolding operations • Enables thin-walling and material reduction by adding reinforcement to traditional materials • Able to be re-formed, reused, recycled USES & APPLICATIONS • Interior structural reinforcement such as walls, load floors, headliners, door panels, storage, storage lids, and trim pieces • External body panels • Front end and door module reinforcement • Service access cover reinforcement • Interior hatch covers GORDON COMPOSITES™ & GLASFORMS™ THERMOSET COMPOSITES Gordon Composites™ and Glasforms™ thermoset composites are made with proprietary resin/ fiber reinforcement technologies.

With lightweighting benefits and design freedom, this high-end composite was shown in mold filling and FEA analysis to maintain the reliability and strength of metal. Avient’s team also provided hands-on design recommendations to minimize knit line concerns and address structural requirements. An injection molded solution, Complēt offered Bettcher Industries faster, single-step production with repeatable quality that enabled them to drive down overall production costs.

OnColor™ SC Super Concentrate Technologies Optimize Color Usage and Expand Sustainability PRODUCT DESCRIPTION OnColor™ SC Super Concentrate color technologies feature substantially greater active pigment loadings than traditionally designed color masterbatches. Increase Sustainability Using More Recycled Content OnColor SC Super Concentrates give you the flexibility to incorporate higher levels of post- consumer regrind (PCR) than with traditional color masterbatches to help meet sustainability initiatives and recycled content requirements without adversely affecting the performance or aesthetic of your designs. Improve color usage efficiency with increased pigment density • Drop-in solution compatible with your current process • Incorporate higher loadings of PCR while maintaining color design aesthetic TARGET MARKET AND APPLICATIONS Compatible with: • PE, PP or PET multi-layer containers • Extrusion blow molding • Injection molding (caps and closures) PRODUCT BULLETIN NO SURPRISES PLEDGESM At Avient, we are committed to helping you grow your business with safe and environmentally sound solutions.

Environmental Stress Cracking Resistance (ESCR) Design Guide Processing & Design Guides Processing & Design Guides

TEMPERATURE Material Rear Center Front Nozzle Melt Mold Nylon 6,6 540–570 530–560 530–560 540–570 540–570 200–300 (90–150) Nylon 6,6 30% SS 540–570 530–560 530–560 540–570 540–570 200–300 (90–150) PBT 510–410 (265–280) 490–540 (255–280) 480–530 480–530 480–530 150–250 (65–120) PC 14% NiCF 540–570 540–570 530–560 530–560 530–560 150–250 (65–120) ABS 470–520 460–520 460–520 460–530 (240–275) 460–530 (240–275) 100–200 (40–90) PP 440–480 (225–250) 440–480 (225–250) 430–470 (220–245) 420–460 (215–240) 420–460 (215–240) 125–175 (50–80) DRYING Material Temperature °F (°C) Time Minimum Moisture Maximum Moisture Nylon 6,6 14% NiCF 180 (80) 4–5 hours 0.05% 0.20% Nylon 6,6 30% SS 180 (80) 4–5 hours 0.05% 0.20% PBT 14% NiCF 250 (120) 6-8 hours 0.02% 0.03% PC 14% NiCF 250 (120) 3–4 hours 0.02% 0.02% ABS 14% NiCF 200 (90) 2–4 hours 0.05% 0.10% PP 14% NiCF 180 (80) 2–4 hours 0.20% 0.30% Equipment • Feed throats smaller than 2.5" may cause bridging due to pellet size - Larger feed throats will be more advantageous with long fiber EMI shielding resins • General purpose metering screw is recommended - Mixing/barrier screws are not recommended • L/D ratio - 18:1–20:1 (40% feed, 40% transition, 20% metering) • Low compression ratio - 2:1–3:1 • Deep flights recommended - Metering zone 3.5 mm - Feed zone 7.5 mm • Check ring - Three-piece, free-flowing check ring • General purpose nozzle (large nozzle tips are recommended) - Minimum orifice diameter of 7/32" - Tapered nozzles are not recommended for long fiber EMI shielding resins • Clamp tonnage: - 2.5–5 tons/in2 Gates • Large, free-flow gating recommended - 0.25" x 0.125" land length - 0.5" gate depth Runners • Full round gate design • No sharp corners • Minimum of 0.25" diameter • Hot runners can be used PROCESSING Screw Speed Slower screw speeds are recommended to protect fiber length Back Pressure Lower back pressure is recommended to protect fiber length Pack Pressure 60–80% of max injection pressure Hold Pressure 40–60% of max injection pressure Cool Time 10–30 seconds (depends on part geometry and dimensional stability) PROCESS CONSIDERATIONS Recommended – retain fiber length (maximize conductivity) • Low shear process • Low screw speed and screw RPM • Slow Injection speed • Fill to 99–100% on first stage of injection - Reduces potential nesting of fibers at gate location - Improves mechanical performance near gate location - Promotes ideal fiber orientation Resin Rich Surface • Achieved when using a hot mold temperature and longer cure times ≥ Max mold temperature recommendation • Improved surface aesthetic • Reduced surface conductivity • Could reduce attenuation performance in an assembly Fiber Rich Surface • Achieved when using a cold mold temperature and shorter cure times ≤ Minimum mold temperature recommendation • Improved surface aesthetic • Reduced surface conductivity • Could improve attenuation performance in an assembly www.avient.com Copyright © 2020, Avient Corporation.