Major Plastics

Properties Acetal (POM) Copoly Acetal (POM) Homopoly Acrylic (PMMA)
Specific Gravity (g/cm³) 1.37 to 1.43 1.33 to 4.84 1.15 to 1.19
Melt Mass Flow Rate (g/10 min) 1.5 to 27 -- 0.30 to 4.6
Flexural Modulus (psi) 272000 to 428000 359000 to 458000 162000 to 500000

(ratio of stress to strain)
Flexural Modulus (MPa) 1880 to 2950 2480 to 3160 1120 to 3450

(ratio of stress to strain)
Tensile Strength (psi) 6160 to 9460 7620 to 10700 5310 to 11800
Tensile Strength (MPa) 42.5 to 65.2 52.5 to 73.5 36.6 to 81.1
Tensile Elongation (%) 1.0 to 200 3.0 to 71 0.0 to 7.3
Rockwell Hardness 80 to 117 93 to 120 44 to 102
Notched Izod Impact (ft·lb/in) 0.738 to 1.70 0.694 to 2.39 0.200 to 1.16
Notched Izod Impact (J/m) 39.4 to 90.5 37.0 to 128 10.7 to 61.9
DTUL at 66 psi (0.45 MPa) (°F)

(deflection 309 to 323 320 to 342 176 to 218
temperature under
load - HDT)
DTUL at 66 psi (0.45 MPa) (°C)
(deflection 154 to 162 160 to 172 80.0 to 103
temperature under
load - HDT)
DTUL at 264 psi (1.8 MPa) (°F)

(deflection 210 to 234 196 to 277 170 to 219
temperature under
load - HDT)
DTUL at 264 psi (1.8 MPa) (°C)
(deflection 98.9 to 112 91.0 to 136 76.5 to 104
temperature under
load - HDT)
CLTE, Flow (in/in/°F)
Coefficients of Linear Thermal 5.6E-6 to 0.14 0.000055 to 0.000067 0.000025 to 0.000061
Expansion
CLTE, Flow (cm/cm/°C)

Coefficients of Linear Thermal 0.000010 to 0.25 0.000100 to 0.00012 0.000045 to 0.00011
Expansion
Mold Shrinkage, Flow (in/in) or 0.018 to 0.023 0.019 to 0.020 0.0035 to 0.0060
(mm/mm)
Melt Mass Flow Rate (g/10 min) 1.5 to 27 -- 0.30 to 4.6
Drying Temperature (°F) 174 to 250 174 to 186 171 to 185
Drying Temperature (°C) 78.9 to 121 78.9 to 85.3 77.0 to 85.0
Drying Time (hr) 2.0 to 4.5 1.9 to 3.5 2.5 to 5.0
Suggested Max Moisture (%) 0.15 to 0.20 0.2 0.097 to 0.30
Suggested Max Regrind (%) 20 to 25 20 to 25 25
Injection Pressure (psi) 7550 to 15700 12000 to 15600 10500 to 16000
Injection Pressure (MPa) 52.0 to 108 82.7 to 108 72.4 to 110
Rear Temperature (°F) 336 to 401 372 to 391 378 to 491
Rear Temperature (°C) 169 to 205 189 to 199 192 to 255
Middle Temperature (°F) 372 to 401 371 to 388 427 to 476
Middle Temperature (°C) 189 to 205 188 to 198 220 to 247
Front Temperature (°F) 369 to 402 371 to 401 438 to 474
Front Temperature (°C) 187 to 206 188 to 205 226 to 246

Nozzle Temperature (°F) 369 to 405 400 to 405 429 to 476
Nozzle Temperature (°C) 187 to 207 205 to 207 220 to 247
Processing (Melt) Temp (°F) 373 to 412 390 to 420 435 to 475
Processing (Melt) Temp (°C) 189 to 211 199 to 216 224 to 246
Mold Temperature (°F) 120 to 204 117 to 201 140 to 171
Mold Temperature (°C) 48.9 to 95.8 47.2 to 93.9 59.9 to 77.1

Acrylic (SMMA) Acrylic, Unspecified PMMA+PVC PC PC Alloy
1.04 to 1.09 1.11 to 1.19 1.34 to 1.35 1.20E-6 to 30.0 1.14 to 1.22
0.40 to 9.1 -- 34 3.0 to 27 1.3 to 36
285000 to 493000 210000 to 500000 293000 to 372000 276000 to 386000 281000 to 362000
1960 to 3400 1450 to 3450 2020 to 2560 1900 to 2660 1940 to 2490
4000 to 9290 3800 to 10200 5740 to 6160 7610 to 10200 7150 to 9040
27.6 to 64.0 26.2 to 70.3 39.6 to 42.5 52.5 to 70.0 49.3 to 62.3
2.0 to 59 2.7 to 250 55 to 170 0.0 to 120 1.7 to 94
61 to 86 74 to 123 87 to 111 70 to 121 117 to 121
0.340 to 3.00 0.397 to 0.455 0.600 to 18.0 0.00 to 18.0 1.45 to 15.0
18.1 to 160 21.2 to 24.3 32.0 to 961 0.00 to 961 77.3 to 801
188 167 to 203 162 to 178 269 to 290 254 to 280
86.7 75.0 to 95.0 72.2 to 81.1 132 to 143 123 to 138
187 to 201 153 to 221 151 to 174 243 to 285 177 to 265
86.2 to 94.1 67.2 to 105 65.9 to 79.1 117 to 140 80.6 to 129
-- 0.000034 to 0.000059 4.2E-05 0.000029 to 0.000049 0.000035 to 0.000039
-- 0.000062 to 0.00011 7.6E-05 0.000052 to 0.000087 0.000063 to 0.000070
0.0039 to 0.0040 0.0040 to 0.0059 0.0030 to 0.0050 0.00060 to 0.16 0.0060 to 0.0061
0.40 to 9.1 -- 34 3.0 to 27 1.3 to 36
149 to 180 200 130 to 145 216 to 263 224 to 248
65.0 to 82.2 93.3 54.4 to 62.8 102 to 128 107 to 120
2.0 to 2.1 4 4 2.8 to 4.3 3.5 to 6.0
-- -- -- 0.019 to 0.020 0.0100 to 0.020
-- -- -- 20 20
15000 12500 -- 1300 to 20400 12500 to 15000
103 86.2 -- 8.96 to 140 86.2 to 103
384 to 391 -- -- 485 to 576 481 to 508
195 to 199 -- -- 252 to 302 249 to 264
395 to 420 -- 350 517 to 593 482 to 520
201 to 216 -- 177 269 to 312 250 to 271
404 to 441 -- 350 539 to 611 491 to 536
207 to 227 -- 177 282 to 321 255 to 280

380 to 440 -- -- 532 to 606 544 to 545
193 to 227 -- -- 278 to 319 284 to 285
429 to 441 393 395 to 400 540 to 586 499 to 522
221 to 227 200 202 to 204 282 to 308 259 to 272
104 to 116 200 115 175 to 215 138 to 172
40.2 to 46.5 93.3 46.1 79.7 to 102 59.0 to 77.5

PC+Acrylic PC+PBT PC+PET PC+Polyester PC+PPC PC+TPU
1.15 1.18 to 1.24 1.19 to 1.22 1.19 to 1.20 1.2 1.20 to 1.22
1.5 to 15 6.2 to 26 8.0 to 35 3.0 to 22 5.6 to 30 9.2 to 21
280000 to 361000 210000 to 390000 266000 to 353000 231000 to 336000 307000 to 334000 3900 to 151000
1930 to 2490 1450 to 2690 1830 to 2440 1600 to 2310 2120 to 2300 26.9 to 1040
6000 to 9100 5480 to 8850 6420 to 8170 6460 to 9020 8680 to 10200 1640 to 6050
41.4 to 62.7 37.7 to 61.0 44.2 to 56.3 44.5 to 62.2 59.8 to 70.0 11.3 to 41.7
3.7 to 11 1.5 to 150 3.0 to 54 2.0 to 150 6.0 to 86 120 to 180
44 to 46 89 to 119 115 to 121 114 to 118 85 to 122 --
3.27 to 30.0 0.618 to 16.5 0.937 to 18.1 0.0937 to 21.0 2.25 to 11.2 1.00 to 18.0
175 to 1600 33.0 to 880 50.0 to 966 5.00 to 1120 120 to 600 53.4 to 961
215 to 253 213 to 260 238 to 278 172 to 257 298 to 300 207 to 229
102 to 123 101 to 127 115 to 137 77.9 to 125 148 to 149 97.3 to 109
209 to 216 137 to 225 189 to 251 165 to 236 257 to 288 138 to 167
98.2 to 102 58.1 to 107 87.0 to 122 73.8 to 113 125 to 142 59.0 to 75.3
5.2E-05 1.7E-6 to 1.0 0.000024 to 0.000047 0.000032 to 0.000064 0.000033 to 0.86 0.000050 to 0.000089
9.4E-05 3.0E-6 to 1.9 0.000043 to 0.000084 0.000058 to 0.00011 0.000060 to 1.5 0.000090 to 0.00016
0.0059 to 0.0071 0.0047 to 0.010 0.0049 to 0.0091 0.0050 to 0.0076 0.007 0.0078 to 0.012
1.5 to 15 6.2 to 26 8.0 to 35 3.0 to 22 5.6 to 30 9.2 to 21
180 to 182 201 to 232 207 to 244 159 to 192 248 to 250 200 to 220
82.2 to 83.2 93.8 to 111 97.0 to 118 70.8 to 88.9 120 to 121 93.3 to 105
3.5 to 4.5 2.0 to 5.1 3.0 to 8.7 4.0 to 4.1 3.0 to 3.5 0.033 to 2.0
-- 0.020 to 0.022 0.019 to 0.020 0.02 0.02 0.03
-- 5 to 25 20 -- -- 20
9000 to 10100 9430 to 15000 14900 to 15100 15000 -- 9500 to 10500
62.1 to 69.3 65.0 to 103 103 to 104 103 -- 65.5 to 72.4
418 to 421 463 to 493 477 to 506 469 to 485 545 to 570 375 to 440
215 to 216 239 to 256 247 to 264 243 to 252 285 to 299 191 to 227
464 to 465 483 to 502 486 to 514 479 to 545 563 to 590 380 to 450
240 to 241 251 to 261 252 to 268 248 to 285 295 to 310 193 to 232
485 to 486 499 to 512 488 to 522 488 to 501 581 to 610 385 to 450
252 260 to 267 253 to 272 253 to 260 305 to 321 196 to 232
484 to 485 484 to 506 491 to 515 488 to 501 563 to 600 393 to 463
251 to 252 251 to 263 255 to 268 253 to 260 295 to 316 200 to 239
440 to 487 494 to 517 513 to 520 488 to 516 581 to 610 393 to 465
227 to 253 257 to 270 267 to 271 253 to 269 305 to 321 200 to 241
120 to 180 157 to 221 175 to 177 123 to 125 210 to 230 84.9 to 95.0
48.9 to 82.2 69.3 to 105 79.2 to 80.4 50.6 to 51.8 98.9 to 110 29.4 to 35.0
PPC Nylon 11 Nylon 12 Nylon 12 Elast Nylon 46
1.2 1.03 to 1.04 0.978 to 1.23 1.01 to 1.02 1.17 to 1.19
2.0 to 3.0 -- -- 7.0 to 20 --
294000 to 341000 41800 to 200000 16000 to 334000 17600 to 47400 50800 to 490000
2030 to 2350 288 to 1380 110 to 2310 121 to 327 350 to 3380
9280 to 11300 5740 to 10000 2610 to 9090 1160 to 7040 5550 to 14600
64.0 to 78.0 39.6 to 69.0 18.0 to 62.7 8.00 to 48.6 38.3 to 101
6.0 to 120 5.0 to 58 0.40 to 210 17 to 400 0.56 to 53
85 to 127 78 to 108 79 to 115 -- 90 to 100
1.57 to 12.0 0.300 to 7.65 0.206 to 10.1 1.78 to 1.85 0.750 to 1.59
84.0 to 641 16.0 to 408 11.0 to 540 94.9 to 98.5 40.0 to 85.1
329 290 to 305 175 to 380 124 to 240 429 to 556
165 144 to 152 79.2 to 193 51.0 to 116 220 to 291
270 to 302 112 to 130 104 to 138 113 to 114 318 to 380
132 to 150 44.7 to 54.6 40.0 to 58.8 45.0 to 45.3 159 to 193
0.000033 to 0.000051 0.000047 to 0.000071 4.2E-6 to 0.00013 0.000050 to 0.00013 0.000038 to 0.000050
0.000060 to 0.000092 0.000085 to 0.00013 7.5E-6 to 0.00023 0.000090 to 0.00023 0.000068 to 0.000090
0.0075 to 0.0090 0.012 to 0.015 0.0047 to 0.019 0.0040 to 0.0085 0.0033 to 0.083
2.0 to 3.0 -- -- 7.0 to 20 --
250 to 266 175 to 176 175 to 212 179 to 230 193 to 219
121 to 130 79.4 to 80.0 79.4 to 100 81.5 to 110 89.6 to 104
3.5 3.9 to 12 3.0 to 10 3.5 to 4.1 4.0 to 12
0.02 0.1 0.020 to 0.50 0.030 to 0.10 0.050 to 0.053
-- 20 20 -- 20
-- 12400 to 12500 12400 to 12700 -- 9430 to 12700
-- 85.3 to 86.2 85.7 to 87.5 -- 65.0 to 87.5
590 to 640 390 to 480 425 to 465 356 to 410 572 to 573
310 to 338 199 to 249 218 to 241 180 to 210 300 to 301
608 to 660 410 to 480 426 to 475 374 to 428 585 to 591
320 to 349 210 to 249 219 to 246 190 to 220 307 to 310
626 to 680 430 to 480 425 to 484 383 to 437 590 to 596
330 to 360 221 to 249 218 to 251 195 to 225 310 to 313
626 to 670 430 442 to 477 383 to 428 554 to 608
330 to 354 221 228 to 247 195 to 220 290 to 320
649 to 680 493 452 to 527 390 to 455 590 to 595
343 to 360 256 233 to 275 199 to 235 310 to 313
210 to 235 125 100 to 188 68.0 to 87.8 212 to 238
98.9 to 113 51.6 to 51.7 38.0 to 86.5 20.0 to 31.0 99.8 to 114
Nylon 6 Nylon 6 Alloy Nylon 6 Elast Nylon 6/3T Nylon 6/6T
0.920 to 1.17 1.03 to 1.14 1.01 to 1.18 1.12 1.16
-- -- 6.0 to 7.0 -- --
290 to 453000 13000 to 430000 10000 to 508000 -- 421000
2.00 to 3130 89.6 to 2960 69.0 to 3500 -- 2900
2980 to 13300 3140 to 12400 870 to 12600 13000 to 13100 13100 to 14500
20.6 to 91.7 21.6 to 85.5 6.00 to 86.6 89.8 to 90.0 90.0 to 100.0
-1.0 to 74 4.0 to 64 20 to 270 7.4 to 51 8.0 to 12
101 to 123 -- 74 to 120 -- --
0.300 to 11.2 1.00 to 1.38 5.60 to 10.4 -- --
16.0 to 596 53.4 to 73.4 299 to 555 -- --
295 to 420 140 to 374 102 to 374 282 to 285 --
146 to 216 60.0 to 190 39.0 to 190 139 to 140 --
119 to 178 122 to 167 95.0 to 212 246 to 249 212
48.3 to 81.4 50.0 to 75.0 35.0 to 100 119 to 120 100

5.6E-6 to 0.00011 0.000052 to 0.000094 0.000088 to 0.000090 2.8E-05 3.9E-05
0.000010 to 0.00020 0.000093 to 0.00017 0.00016 0.000050 to 0.000051 7E-05
0.000100 to 0.044 0.0080 to 0.012 0.0030 to 0.022 0.0045 to 0.0046 0.0065
-- -- 6.0 to 7.0 -- --
173 to 180 160 176 -- --
78.5 to 82.3 71.1 80 -- --
1.9 to 5.1 5 8 -- --
0.095 to 0.20 -- 0.1 -- --
19 to 26 -- -- -- --
1000 to 16400 -- 5080 to 9430 -- --
6.89 to 113 -- 35.0 to 65.0 -- --
436 to 506 430 -- -- --
224 to 264 221 -- -- --
442 to 490 445 -- -- --
228 to 254 229 -- -- --
443 to 513 465 -- -- --
228 to 267 241 -- -- --

423 to 514 485 -- -- --
217 to 268 252 -- -- --
360 to 597 480 419 to 595 -- 617
182 to 314 249 215 to 313 -- 325
138 to 177 95 122 to 194 -- 176
58.7 to 80.3 35 50.0 to 90.0 -- 80

Nylon 6+ABS Nylon 610 Nylon 612 Nylon 66 Nylon 66 Alloy
1.06 to 1.08 1.07 to 1.17 1.01 to 1.35 0.390 to 4.11 1.13 to 1.14
6.0 to 7.0 -- -- 10 --
145000 to 315000 180000 to 315000 43500 to 409000 85300 to 510000 399000 to 451000
1000 to 2170 1240 to 2170 300 to 2820 588 to 3520 2750 to 3110
4330 to 6620 5780 to 9020 1310 to 28500 5000 to 14000 11000 to 12900
29.9 to 45.6 39.9 to 62.2 9.00 to 196 34.5 to 96.5 75.5 to 88.7
3.2 to 100 3.3 to 300 2.5 to 62 0.70 to 56 19 to 50
90 to 105 90 to 116 113 to 115 78 to 123 --
0.182 to 15.0 0.700 to 3.81 0.393 to 1.53 0.0843 to 1.32 0.892 to 1.11
9.70 to 801 37.4 to 203 21.0 to 81.6 4.50 to 70.3 47.6 to 59.4
190 to 387 318 to 356 117 to 331 348 to 465 320
87.8 to 197 159 to 180 47.2 to 166 176 to 241 160
145 to 305 134 to 156 104 to 207 137 to 217 149 to 176
62.5 to 152 56.9 to 68.7 40.0 to 97.1 58.4 to 103 65.0 to 80.0
0.000055 to 0.000056 0.000044 to 0.000067 0.000027 to 0.00010 0.000025 to 0.000076 3.6E-05
0.000100 to 0.00010 0.000079 to 0.00012 0.000049 to 0.00018 0.000046 to 0.00014 6.5E-05
0.0079 to 0.010 0.0030 to 0.020 0.0010 to 0.060 0.00015 to 0.075 0.015 to 0.017
6.0 to 7.0 -- -- 10 --
176 to 178 175 to 180 170 to 180 165 to 196 --
79.9 to 81.3 79.4 to 82.2 76.7 to 82.2 73.8 to 91.3 --
3.0 to 3.5 2.0 to 4.0 2.9 to 4.1 2.8 to 5.3 --
0.2 0.020 to 0.20 0.020 to 0.25 0.15 to 0.20 --
-- -- 25 20 to 25 --
900 1250 to 14000 14000 to 14300 12100 to 15000 --
6.21 8.62 to 96.5 96.3 to 98.7 83.7 to 104 --
490 to 491 420 to 451 440 to 550 496 to 543 --
254 to 255 216 to 233 227 to 288 258 to 284 --
508 to 509 430 to 471 445 to 525 515 to 556 --
264 to 265 221 to 244 229 to 274 268 to 291 --
473 to 527 440 to 490 440 to 515 499 to 569 --
245 to 275 227 to 254 227 to 268 259 to 299 --

473 480 to 490 450 to 555 498 to 557 --
245 249 to 255 232 to 291 259 to 292 --
446 to 505 480 to 550 470 to 513 515 to 565 --
230 to 263 249 to 288 243 to 267 268 to 296 --
131 to 158 125 to 190 157 to 176 147 to 191 --
55.0 to 70.0 51.7 to 87.8 69.4 to 79.8 63.8 to 88.1 --

Nylon 66/6 Nylon 6T Nylon 9T Nylon Copolymer Nylon, Unspecified Nylon+PP
1.10 to 1.14 -- 1.14 1.10 to 1.21 0.990 to 1.20 0.957 to 1.05
-- -- -- -- 0.52 to 6.5 1.0 to 7.5
98300 to 458000 -- 435000 294000 to 1.16E+6 43500 to 510000 126000 to 295000
678 to 3150 -- 3000 2030 to 8000 300 to 3520 869 to 2030
3340 to 12600 -- 13100 2900 to 23200 2430 to 16600 3190 to 7400
23.0 to 86.8 -- 90 20.0 to 160 16.7 to 115 22.0 to 51.0
3.0 to 52 -- 15 2.1 to 69 2.5 to 200 4.0 to 95
112 to 120 -- 118 -- 119 to 120 --
0.483 to 2.03 -- 0.375 0.993 to 2.70 0.627 to 1.62 2.00 to 15.0
25.8 to 109 -- 20 53.0 to 144 33.5 to 86.4 107 to 801
296 to 449 -- -- 122 to 410 238 to 362 140 to 284
146 to 231 -- -- 50.0 to 210 115 to 183 60.0 to 140
117 to 196 -- 275 118 to 392 124 to 388 131 to 135
47.2 to 91.1 -- 135 48.0 to 200 51.3 to 198 54.9 to 57.0

0.000038 to 0.000053 -- -- 0.000011 to 0.000056 0.000012 to 0.000071 2.2E-05
0.000068 to 0.000096 -- -- 0.000020 to 0.00010 0.000022 to 0.00013 4E-05
0.0099 to 0.016 -- 0.01 0.00040 to 0.0052 0.0013 to 0.022 0.013 to 0.021
-- -- -- -- 0.52 to 6.5 1.0 to 7.5
176 to 177 -- -- 160 to 176 174 to 180 167 to 194
80.0 to 80.4 -- -- 71.1 to 80.0 78.7 to 82.5 75.0 to 90.0
2.8 to 3.0 -- -- 5.0 to 18 3.0 to 9.1 2.9 to 3.0
0.099 to 0.20 -- -- 0.1 0.020 to 0.20 --
20 -- -- -- -- --
1160 to 7380 -- -- -- 6530 to 14200 --
8.00 to 50.9 -- -- -- 45.0 to 98.1 --
471 to 519 -- -- 410 to 500 534 to 539 380 to 391
244 to 270 -- -- 210 to 260 279 to 282 193 to 200
470 to 1110 -- -- 430 to 500 506 to 558 400 to 410
243 to 600 -- -- 221 to 260 263 to 292 204 to 210
490 to 529 -- -- 440 to 500 508 to 573 430 to 440
254 to 276 -- -- 227 to 260 264 to 301 221 to 227

490 to 545 -- -- 445 to 500 500 to 536 450 to 460
254 to 285 -- -- 229 to 260 260 to 280 232 to 238
503 to 537 -- -- 435 to 518 507 to 620 446 to 474
262 to 281 -- -- 224 to 270 264 to 327 230 to 245
157 to 176 -- -- 45.0 to 230 100 to 300 100 to 168
69.4 to 80.0 -- -- 7.22 to 110 37.8 to 149 37.8 to 75.8

Nylon+PPE Nylon+TPE PAMXD6 PPA PBT PBT Alloy
1.08 to 1.10 1.07 to 1.13 -- 1.10 to 1.16 1.30 to 1.34 1.07 to 1.35
4.0 to 27 3 -- 20 to 310 20 to 26 --
277000 to 345000 63500 to 68100 -- 219000 to 536000 202000 to 390000 227000 to 472000
1910 to 2380 438 to 469 -- 1510 to 3700 1400 to 2690 1570 to 3260
6350 to 9950 7500 to 8420 -- 6680 to 12500 4900 to 9240 4970 to 7160
43.8 to 68.6 51.7 to 58.1 -- 46.0 to 86.3 33.8 to 63.7 34.3 to 49.4
7.0 to 100 300 to 500 -- 1.5 to 31 0.70 to 52 2.8 to 31
110 -- -- 110 to 128 86 to 120 85
0.749 to 4.98 1.60 to 16.1 -- 0.300 to 18.2 0.187 to 1.26 1.47 to 15.0
40.0 to 266 85.4 to 859 -- 16.0 to 972 10.00 to 67.5 78.5 to 801
273 to 385 -- -- 307 to 454 226 to 358 212 to 225
134 to 196 -- -- 153 to 234 108 to 181 100 to 107
239 to 390 -- -- 218 to 284 112 to 161 158 to 212
115 to 199 -- -- 103 to 140 44.5 to 71.5 70.0 to 100

0.000044 to 0.000051 -- 2.8E-05 0.000026 to 0.000053 5.0E-8 to 0.00019 0.000038 to 0.000039
0.000079 to 0.000091 -- 5.1E-05 0.000046 to 0.000095 9.0E-8 to 0.00035 0.000068 to 0.000070
0.0098 to 0.014 0.0080 to 0.012 -- 0.013 to 0.020 0.0010 to 0.48 0.0055 to 0.0057
4.0 to 27 3 -- 20 to 310 20 to 26 --
203 to 222 160 -- 175 to 275 236 to 269 203 to 212
95.0 to 106 71.1 -- 79.4 to 135 113 to 132 95.0 to 100
3.0 to 3.5 5 -- 4.0 to 6.1 3.0 to 5.1 3.5
0.0005 -- -- 0.045 to 0.15 0.020 to 0.043 --
20 -- -- -- 19 to 26 --
-- -- -- 14000 to 15000 10700 to 12600 11400
-- -- -- 96.5 to 103 74.0 to 86.8 78.4
535 430 -- 579 to 618 445 to 476 401
279 221 -- 304 to 325 229 to 246 205
540 445 -- 518 to 635 446 to 492 446
282 229 -- 270 to 335 230 to 256 230
545 465 -- 612 to 615 464 to 496 464
285 241 -- 322 to 324 240 to 258 240

550 485 -- 518 to 653 463 to 491 464
288 252 -- 270 to 345 239 to 255 240
491 to 554 480 -- 592 to 631 462 to 501 464
255 to 290 249 -- 311 to 333 239 to 260 240
149 to 177 95 -- 172 to 320 137 to 182 158
65.0 to 80.6 35 -- 78.0 to 160 58.4 to 83.3 70

PBT+ASA PBT+PET PCT PET PETG Polyester Alloy
-- 1.64 to 1.79 1.2 1.32 to 1.41 1.25 to 1.27 1.72
-- 5.0 to 43 12 -- 4.0 to 35 --
-- 501000 to 1.77E+6 326000 to 3.39E+6 226000 to 476000 300000 to 315000 1.16E+06
-- 3450 to 12200 2250 to 23400 1560 to 3280 2070 to 2170 8000
-- 0.00 to 17000 8700 to 92800 3340 to 36300 3750 to 7360 7250
-- 0.00 to 117 60.0 to 640 23.0 to 250 25.9 to 50.7 50
-- 0.0 to 5.0 5.8 to 140 2.5 to 210 4.0 to 79 --
-- 80 to 120 -- 88 to 120 106 to 117 --
-- 0.393 to 1.91 13.4 0.262 to 1.51 0.0700 to 26.8 --
-- 21.0 to 102 713 14.0 to 80.4 3.74 to 1430 --
-- 396 to 425 -- 147 to 415 153 to 158 --
-- 202 to 219 -- 63.9 to 213 67.0 to 70.1 --
-- 177 to 428 223 136 to 446 140 to 147 --
-- 80.5 to 220 106 57.8 to 230 59.9 to 64.0 --

-- 9.4E-6 to 0.0010 0.000050 to 0.000058 9.4E-6 to 0.000086 0.000038 to 0.000051 --
-- 0.000017 to 0.0018 0.000090 to 0.00010 0.000017 to 0.00015 0.000069 to 0.000092 --
-- 0.0038 to 0.012 0.006 0.0029 to 0.020 0.0035 to 0.0051 0.0055 to 0.0075
-- 5.0 to 43 12 -- 4.0 to 35 --
-- 250 to 284 163 248 to 356 149 to 161 --
-- 121 to 140 72.5 120 to 180 65.0 to 71.5 --
-- 3.0 to 5.0 4 5 4.9 to 9.0 --
-- 0.020 to 0.040 0.02 0.0030 to 0.20 0.05 0.1
-- -- -- -- -- --
-- -- -- 14500 12500 to 14100 --
-- -- -- 100 86.0 to 97.5 --
-- 480 480 474 to 493 410 to 450 --
-- 249 249 246 to 256 210 to 232 --
-- 480 to 490 505 484 to 511 472 to 473 --
-- 249 to 254 263 251 to 266 245 --
-- 490 to 500 515 495 to 527 450 to 473 --
-- 254 to 260 268 257 to 275 232 to 245 --

-- 505 to 510 515 485 to 500 473 --
-- 263 to 266 268 252 to 260 245 --
-- 509 to 515 515 493 to 545 497 to 500 --
-- 265 to 268 268 256 to 285 258 to 260 --
-- 175 to 176 125 59.0 to 145 80.0 to 104 --
-- 79.2 to 80.0 51.7 15.0 to 62.8 26.7 to 40.1 --

ABS+Nylo
Polyester, TP PTT ABS n ABS+PBT ABS+PC ABS+PVC Epoxy
0.600 to 1.04 to 1.07 to 0.898 to 1.17 to

1.18 to 1.41 1.29 to 1.43 1.01 to 2.00
26.6 1.07 1.38 28.9 1.34
0.20 to 0.20 to
-- -- 2.5 to 36 7.0 to 51 2.0 to 150 --
30 30
240000 214000 279000

98600 to 279000 to
225000 to 377000 397000 to 400000 to to to 9.96 to 1.80E+6
326000 300000
451000 394000 410000
1550 to 2600 2740 to 2760

1650 to 680 to 1480 to 1920 to 1920 to 0.0686 to 12400
3110 2250 2710 2830 2060
5.50 to 4210 to 4530 to 3050 to 4490 to

3190 to 9110 6380 to 8900 0.900 to 10100
16400 7440 7110 14000 6400
0.0379 to 29.0 to 31.2 to 21.0 to 30.9 to
22.0 to 62.8 44.0 to 61.4 0.00621 to 69.8
113 51.3 49.0 96.7 44.1
2.0 to 130 9.8 to 10 0.0 to 56 3.0 to 3.3 to 2.0 to 35 to 40 0.40 to 7.9

210 100 100
105 to 109 to
103 to 115 -- 93 to 115 90 to 110 64 to 110 109 to 118
117 120
0.462 to 1.00 to 0.562 to 0.468 to 0.600 to

0.400 to 9.40 0.500 to 0.607 0.00646 to 1.01
7.53 16.2 10.3 13.5 15.0
24.7 to 53.4 to 30.0 to 25.0 to 32.0 to
21.4 to 502 26.7 to 32.4 0.345 to 53.7
402 865 550 722 801
176 to 171 to 171 to 192 to 153 to

155 to 168 -- 119 to 470
222 215 419 268 190
79.8 to 77.4 to 77.0 to 88.7 to 67.2 to

68.5 to 75.6 -- 48.1 to 243
105 102 215 131 87.8
165 to 136 to 162 to 176 to 154 to

140 to 155 140 to 151 75.0 to 480
217 196 216 250 175
73.9 to 57.5 to 72.5 to 79.8 to 67.8 to

60.0 to 68.5 60.0 to 66.0 23.9 to 249
103 91.3 102 121 79.4
0.000017
1.0E-5 to 0.000055 4.4E-6 to
3.9E-6 to 0.00070 -- to 4.6E-05 3.2E-6 to 0.000065
0.011 to 0.011 8400
0.000057
0.000030
0.000018 0.000099 8.0E-6 to
7.0E-6 to 0.0013 -- to 8.3E-05 5.8E-6 to 0.00012
to 0.020 to 0.020 15000
0.00010
0.000055 0.00030 0.0054 to 0.0 to 0.0055 to

0.0030 to 0.0063 0.011 to 0.025 0.00010 to 0.0051
to 0.014 to 0.022 0.013 0.016 0.0060
0.20 to 0.20 to
-- -- 2.5 to 36 7.0 to 51 2.0 to 150 --
30 30
174 to 158 to 185 to 173 to

153 to 315 260
190 186 221 232 160 --
79.0 to 70.0 to 85.0 to 78.5 to

67.2 to 157 127
88.0 85.8 105 111 71.1 --
3.0 to 6.0 5 2.0 to 3.6 3.0 to 4.0 3.0 to 4.0 3.0 to 4.1 1 --
0.0100 to 0.050 to 0.020 to

-- -- -- -- --
0.15 0.35 0.043
-- -- 5 to 20 5 to 20 -- 5 to 25 25 --
11700 to 7250 to 12300 to 1150 to

-- 12500 1250 4170 to 4250
15400 9000 15200 15200
80.9 to 50.0 to 85.0 to 7.93 to
-- 86.0 to 86.2 8.62 28.7 to 29.3
106 62.1 105 105
338 to 462 to 392 to 419 to

352 448 to 485 363 --
478 500 491 518
170 to 239 to 200 to 215 to
178 231 to 252 184 --
248 260 255 270
398 to 463 to 430 to 443 to

343 448 to 485 373 --
466 514 491 526
203 to 240 to 221 to 228 to
173 231 to 252
241 268 255 275 189 --
379 to 464 to 460 to 461 to

334 448 to 485 378 --
491 509 491 539
193 to 240 to 238 to 239 to
168 231 to 252 192 --
255 265 255 282
371 to 490 to 446 to 479 to
334 -- 375 --
501 491 509 552
188 to 254 to 230 to 248 to
168 -- 191 --
260 255 265 289
414 to 481 to 459 to 478 to

488 to 546 475 410 303
475 509 483 551
212 to 249 to 237 to 248 to
253 to 286 246 210 150 to 151
246 265 250 288
121 to 139 to 105 to 138 to

71.6 to 126 220 90 --
168 176 185 178
49.2 to 59.3 to 40.6 to 58.9 to
22.0 to 52.0 104 32.2 --
75.4 80.0 85.0 81.1
Vinyl Ester CPE ECTFE EPE EVA HDPE
1.02 to 1.24 1.16 1.67 to 1.68 0.910 to 0.962 0.926 to 0.960 0.932 to 0.971
-- -- -- 0.85 to 1.2 0.15 to 21 0.020 to 9.0
480000 to 520000 -- 239000 to 245000 -- 276 to 14700 87000 to 218000
3310 to 3590 -- 1650 to 1690 -- 1.90 to 101 600 to 1500
9070 to 13300 1400 to 3250 4270 to 7890 1030 to 8410 174 to 4640 12.0 to 33900
62.6 to 91.7 9.65 to 22.4 29.5 to 54.4 7.10 to 58.0 1.20 to 32.0 0.0827 to 234
2.8 to 8.0 290 to 800 4.0 to 260 540 to 730 8.0 to 910 1.0 to 1000
-- -- 90 to 94 -- 38 to 40 50 to 65
-- 3.67 2.03 to 3.88 -- -- 0.281 to 7.77
-- 196 108 to 207 -- -- 15.0 to 415
245 -- 192 to 194 -- 98.6 to 113 148 to 184
118 -- 88.8 to 90.1 -- 37.0 to 45.0 64.6 to 84.3
203 to 302 163 149 to 170 -- 73.4 to 95.0 102 to 159
95.0 to 150 72.5 64.8 to 76.9 -- 23.0 to 35.0 39.1 to 70.6

0.000017 to 0.000065 -- 0.000056 to 0.000057 -- 8.9E-05 0.000051 to 0.00012
0.000031 to 0.00012 -- 0.0001 -- 0.00016 0.000093 to 0.00022
0.083 to 0.085 -- 0.023 to 0.025 -- 0.012 to 0.022 0.0077 to 0.030
-- -- -- 0.85 to 1.2 0.15 to 21 0.020 to 9.0
-- -- -- -- 140 to 141 174 to 176
-- -- -- -- 60.0 to 60.6 78.8 to 79.8
-- -- -- -- 7.9 to 8.0 2.0 to 3.0
-- -- -- -- -- 0.050 to 0.30
-- -- 15 -- -- 10 to 100
-- -- 1200 to 1500 -- 1310 to 10000 12400 to 20000
-- -- 8.27 to 10.3 -- 9.00 to 68.9 85.4 to 138
-- -- 399 to 450 -- 250 to 254 383 to 452
-- -- 204 to 232 -- 121 to 123 195 to 234
-- -- 441 to 470 -- 300 to 302 417 to 473
-- -- 227 to 243 -- 149 to 150 214 to 245
-- -- 469 to 500 -- 350 to 351 371 to 477
-- -- 243 to 260 -- 177 189 to 247

-- -- 469 to 490 -- 350 to 352 390 to 479
-- -- 243 to 254 -- 177 to 178 199 to 248
-- -- 517 to 520 428 to 520 208 to 446 356 to 478
-- -- 269 to 271 220 to 271 97.5 to 230 180 to 248
330 -- 89.6 to 250 -- 68.0 to 356 50.0 to 115
166 -- 32.0 to 121 -- 20.0 to 180 10.0 to 45.8

HDPE Copolymer HDPE, HMW HDPE, MMW HMWPE LDPE
0.945 to 0.957 0.943 to 0.960 0.946 to 0.962 0.96 0.891 to 0.953
0.050 to 1.0 0.027 to 11 0.028 to 2.8 -- 0.12 to 58
100000 to 200000 119000 to 222000 115000 to 189000 145000 to 235000 13300 to 52400
690 to 1380 819 to 1530 793 to 1300 1000 to 1620 91.8 to 361
1800 to 5190 3070 to 5390 2600 to 8040 3980 to 4060 300 to 5010
12.4 to 35.8 21.2 to 37.2 17.9 to 55.4 27.4 to 28.0 2.07 to 34.5
7.0 to 810 6.6 to 800 10 to 870 10 to 69 3.0 to 710
-- 49 41 to 52 51 to 55 40 to 93
0.480 to 4.12 7.21 to 10.3 16.9 to 19.7 3.03 to 3.63 7.82 to 8.63
25.6 to 220 385 to 548 900 to 1050 162 to 194 417 to 460
140 to 165 156 to 173 158 176 99.8 to 203
59.7 to 74.0 68.9 to 78.1 70.0 to 70.1 79.9 to 80.0 37.7 to 95.0
100 171 to 172 166 111 104 to 110
38 77.0 to 77.8 74.4 44 40.2 to 43.2

0.000070 to 0.000071 0.000066 to 0.00010 0.000066 to 0.000100 0.000070 to 0.00035 0.000100 to 0.00013
0.00013 0.00012 to 0.00018 0.00012 to 0.00018 0.00013 to 0.00062 0.00018 to 0.00023
0.025 0.025 to 0.030 -- 0.018 0.015 to 0.030
0.050 to 1.0 0.027 to 11 0.028 to 2.8 -- 0.12 to 58
-- -- -- -- 175 to 180
-- -- -- -- 79.3 to 82.2
-- -- -- -- 2.0 to 3.1
-- -- -- -- --
30 to 40 25 -- -- 100
14200 19600 to 20000 -- 14200 925 to 15000
98 135 to 138 -- 98.1 6.37 to 103
448 to 450 385 -- 410 324 to 402
231 to 232 196 -- 210 162 to 205
467 to 470 420 -- 473 349 to 401
242 to 243 216 -- 245 176 to 205
472 to 475 440 -- 518 349 to 401
245 to 246 227 -- 270 176 to 205

472 to 475 430 -- 518 350 to 426
245 to 246 221 -- 270 177 to 219
401 to 438 425 -- -- 327 to 432
205 to 225 218 -- -- 164 to 222
54.5 to 99.5 50 -- 89.6 59.0 to 110
12.5 to 37.5 10 -- 32 15.0 to 43.5

LDPE+LLDPE LLDPE LMDPE MDPE mPE PE Copolymer
0.918 to 0.925 0.915 to 0.946 0.933 to 0.940 0.929 to 0.953 -- 0.929 to 0.966
0.30 to 35 0.20 to 4.1 0.60 to 8.0 0.040 to 6.4 0.93 to 3.6 0.080 to 6.1
-- 16000 to 123000 70200 to 118000 82400 to 120000 -- 2610 to 190000
-- 110 to 846 484 to 812 568 to 831 -- 18.0 to 1310
2170 to 4560 470 to 6720 2010 to 3630 1880 to 4760 830 to 7250 933 to 3830
15.0 to 31.4 3.24 to 46.4 13.8 to 25.1 13.0 to 32.8 5.72 to 50.0 6.43 to 26.4
530 to 960 1.0 to 900 11 to 1000 4.0 to 900 460 to 740 6.0 to 30
-- -- -- -- -- --
-- 0.900 to 34.4 0.937 to 4.29 0.281 to 34.1 -- --
-- 48.0 to 1840 50.0 to 229 15.0 to 1820 -- --
-- 112 to 148 126 to 163 116 to 148 -- --
-- 44.4 to 64.4 52.0 to 72.8 46.8 to 64.5 -- --
-- 93.2 to 167 104 99.1 to 108 -- --
-- 34.0 to 75.0 40.0 to 40.1 37.3 to 42.0 -- --

-- 0.000047 to 0.00011 3.6E-05 0.000056 to 0.00016 -- 0.00010 to 0.00011
-- 0.000084 to 0.00020 6.4E-05 0.00010 to 0.00028 -- 0.00018 to 0.00020
-- 0.015 to 0.020 -- -- -- 0.012 to 0.016
0.30 to 35 0.20 to 4.1 0.60 to 8.0 0.040 to 6.4 0.93 to 3.6 0.080 to 6.1
-- 110 to 194 -- -- -- --
-- 43.3 to 90.0 -- -- -- --
-- 1.5 to 3.0 -- -- -- --
-- 0.05 -- -- -- --
-- -- -- -- -- --
-- 900 to 10200 -- -- -- --
-- 6.21 to 70.0 -- -- -- --
-- 349 to 351 365 to 392 329 -- --
-- 176 to 177 185 to 200 165 -- --
-- 373 to 375 365 to 392 329 -- --
-- 190 to 191 185 to 200 165 -- --
-- 364 to 400 365 to 392 329 -- --
-- 185 to 204 185 to 200 165 -- --

-- 400 to 403 -- -- -- --
-- 204 to 206 -- -- -- --
-- 356 to 464 462 to 491 401 to 446 -- --
-- 180 to 240 239 to 255 205 to 230 -- --
-- 63.5 to 95.0 77 -- -- --
-- 17.5 to 35.0 25 -- -- --
PE, Unspecified UHMWPE ULDPE VLDPE XLPE PAI
0.899 to 0.965 0.918 to 0.958 0.904 to 0.912 0.884 to 0.914 0.912 to 0.945 1.34 to 1.59
0.10 to 5.3 0.10 to 0.69 0.95 to 4.1 0.090 to 3.1 0.32 to 2.2 --
11600 to 223000 64000 to 152000 -- 4300 to 22000 1400 to 105000 599000 to 757000
80.0 to 1540 441 to 1050 -- 29.6 to 152 9.65 to 724 4130 to 5220
1150 to 4100 2470 to 5920 522 to 6680 500 to 7550 2150 to 3190 9990 to 27800
7.91 to 28.3 17.0 to 40.8 3.60 to 46.1 3.45 to 52.1 14.8 to 22.0 68.9 to 192
0.70 to 770 10 to 360 490 to 760 490 to 930 190 to 510 0.80 to 15
113 50 to 66 -- -- -- 69 to 120
0.500 to 10.7 14.9 to 15.6 -- -- -- 0.500 to 4.30
26.7 to 571 797 to 835 -- -- -- 26.7 to 230
73.0 to 158 149 to 204 -- -- 151 --
22.8 to 70.0 65.0 to 95.6 -- -- 66 --
73.0 to 121 108 to 119 -- -- -- 532 to 534
22.8 to 49.2 42.0 to 48.2 -- -- -- 278 to 279

0.000068 to 0.000096 0.000082 to 0.00020 -- -- -- 0.000014 to 0.000020
0.00012 to 0.00017 0.00015 to 0.00036 -- -- -- 0.000025 to 0.000036
0.020 to 0.030 0.0060 to 0.030 -- 0.01 -- 0.0014 to 0.0073
0.10 to 5.3 0.10 to 0.69 0.95 to 4.1 0.090 to 3.1 0.32 to 2.2 --
180 -- -- -- -- 350
82.1 to 82.2 -- -- -- -- 177
4 -- -- -- -- 3
-- -- -- -- -- 0.05
-- -- -- -- -- --
-- -- -- -- -- --
-- -- -- -- -- --
440 555 -- 356 -- 580
227 291 -- 180 -- 304
440 550 -- 356 -- --
227 288 -- 180 -- --
440 540 -- 356 -- --
227 282 -- 180 -- --

-- 560 -- -- -- 700
-- 293 -- -- -- 371
448 to 450 545 -- 416 to 450 -- --
231 to 232 285 -- 213 to 232 -- --
113 to 114 113 -- 77 -- 405
44.7 to 45.4 44.7 -- 25 -- 207

PI, TP COC PAO Polyolefin, Unspecified PP Alloy PP Copoly
1.31 to 1.37 1.02 0.858 to 0.871 0.854 to 1.14 0.897 to 0.899 0.835 to 0.970
0.0 to 12 10 to 36 0.40 to 18 0.040 to 20 4.1 to 5.6 0.20 to 36
393000 to 1.31E+6 348000 to 464000 -- 2030 to 315000 52700 to 80000 124000 to 240000
2710 to 9000 2400 to 3200 -- 14.0 to 2170 364 to 552 857 to 1650
9820 to 22600 6660 to 9140 49.3 to 339 290 to 21900 24700 to 34700 1750 to 4380
67.7 to 156 45.9 to 63.0 0.340 to 2.33 2.00 to 151 170 to 239 12.1 to 30.2
1.5 to 19 1.1 to 3.6 400 2.0 to 800 63 to 140 1.7 to 23
95 to 129 -- -- 20 to 120 66 64 to 106
0.00 to 1.43 0.468 to 0.478 -- 0.131 to 15.3 1.19 to 9.74 0.184 to 9.74
0.00 to 76.1 25.0 to 25.5 -- 7.00 to 818 63.7 to 520 9.80 to 520
482 to 506 167 to 304 -- 133 to 233 167 to 284 156 to 251
250 to 263 75.0 to 151 -- 56.3 to 111 75.0 to 140 69.2 to 122
434 to 493 140 to 275 -- 113 to 256 158 to 316 108 to 202
224 to 256 60.0 to 135 -- 45.1 to 124 70.0 to 158 42.4 to 94.6
0.0 to 0.000029 -- -- 0.000026 to 0.00011 -- -0.0012 to 0.00021
0.0 to 0.000052 -- -- 0.000048 to 0.00020 -- -0.0022 to 0.00039
0.0089 to 0.011 0.006 -- 0.0042 to 0.015 0.036 to 0.071 0.012 to 0.019
0.0 to 12 10 to 36 0.40 to 18 0.040 to 20 4.1 to 5.6 0.20 to 36
347 to 348 -- -- 164 to 167 -- 165 to 196
175 -- -- 73.5 to 74.8 -- 73.7 to 91.0
5.0 to 5.1 -- -- 1.4 to 1.5 -- 1.0 to 3.0
0.02 -- -- 0.05 -- 0.050 to 0.20
-- -- -- 20 -- 19 to 100
23800 to 24000 11600 -- 770 to 1110 -- 800 to 12500
164 to 165 80 -- 5.31 to 7.63 -- 5.52 to 86.3
698 to 725 401 to 509 -- 395 to 427 -- 372 to 431
370 to 385 205 to 265 -- 202 to 219 -- 189 to 222
721 to 748 419 to 536 -- 400 to 437 -- 405 to 442
383 to 398 215 to 280 -- 204 to 225 -- 207 to 228
738 to 761 437 to 554 -- 400 to 447 -- 374 to 451
392 to 405 225 to 290 -- 204 to 231 -- 190 to 233

730 to 761 455 to 554 -- 410 to 441 -- 410 to 460
388 to 405 235 to 290 -- 210 to 227 -- 210 to 238
739 to 766 428 to 563 -- 208 to 433 -- 409 to 476
393 to 408 220 to 295 -- 97.5 to 223 -- 209 to 247
325 to 326 131 to 284 -- 85.0 to 105 -- 66.1 to 129
163 to 164 55.0 to 140 -- 29.4 to 40.7 -- 19.0 to 53.8

PP Homopoly PP Impact Copoly PP Random Copoly PP, High Crystal PP, HMS
0.899 to 0.948 0.898 to 0.910 0.890 to 0.919 0.900 to 0.914 0.895 to 0.912
0.27 to 49 0.20 to 38 0.20 to 36 0.80 to 37 0.070 to 3.1
160000 to 319000 4350 to 467000 101000 to 203000 183000 to 314000 127000 to 279000
1100 to 2200 30.0 to 3220 699 to 1400 1260 to 2160 879 to 1930
4240 to 5660 2660 to 4210 2390 to 4790 2510 to 6120 3780 to 5800
29.3 to 39.0 18.4 to 29.0 16.5 to 33.0 17.3 to 42.2 26.0 to 40.0
1.0 to 26 2.0 to 24 5.0 to 27 3.6 to 25 6.0 to 18
90 to 111 64 to 101 79 to 101 85 to 115 80 to 94
0.100 to 0.898 0.0468 to 37.5 0.187 to 1.85 0.300 to 1.64 0.500 to 13.2
5.34 to 47.9 2.50 to 2000 10.00 to 98.8 16.0 to 87.6 26.7 to 704
180 to 261 164 to 242 148 to 213 210 to 277 186 to 232
82.0 to 127 73.6 to 117 64.3 to 101 98.8 to 136 85.5 to 111
123 to 233 114 to 138 117 to 194 125 to 133 124 to 230
50.6 to 112 45.5 to 58.6 47.4 to 90.0 51.6 to 56.2 51.0 to 110
0.000016 to 0.00061 0.000033 to 0.000072 0.000054 to 0.000083 -- --
0.000029 to 0.0011 0.000060 to 0.00013 0.000097 to 0.00015 -- --
0.012 to 0.018 0.013 to 0.017 0.013 to 0.018 0.013 to 0.016 0.0095
0.27 to 49 0.20 to 38 0.20 to 36 0.80 to 37 0.070 to 3.1
167 to 185 166 to 212 -- 194 --
75.0 to 85.1 74.5 to 100 -- 90 --
1.0 to 3.0 1.0 to 4.0 -- 2 --
0.2 0.05 -- -- --
20 to 30 -- -- -- --
950 to 15000 640 to 24900 1000 to 11400 8530 to 25700 --
6.55 to 103 4.41 to 172 6.89 to 78.5 58.8 to 178 --
349 to 488 341 to 430 350 to 430 354 to 374 --
176 to 253 172 to 221 177 to 221 179 to 190 --
383 to 488 373 to 460 400 to 450 382 to 429 --
195 to 253 189 to 238 204 to 232 194 to 220 --
383 to 491 412 to 498 417 to 470 410 to 464 --
195 to 255 211 to 259 214 to 243 210 to 240 --

370 to 475 401 to 474 410 to 473 392 to 455 --
188 to 246 205 to 246 210 to 245 200 to 235 --
413 to 480 325 to 483 399 to 482 423 to 464 220 to 240
211 to 249 163 to 250 204 to 250 217 to 240 104 to 116
35.0 to 140 90.0 to 120 74.8 to 105 99.5 to 144 --
1.67 to 60.0 32.2 to 48.9 23.8 to 40.4 37.5 to 62.2 --

PS (EPS) PS (GPPS) PS (HIPS) PS (IRPS)
PP, Unspecified PP+EPDM
Polystyrene Polystyrene Polystyrene Polystyrene
0.790 to 1.13 0.935 to 0.986 0.0155 to 0.514 1.03 to 1.05 1.03 to 1.06 1.06 to 1.18
0.10 to 24 -- -- 0.20 to 20 0.50 to 14 7.6 to 10
95100 to 314000 -- -- 312000 to 508000 182000 to 363000 240000 to 338000
656 to 2160 -- -- 2150 to 3500 1250 to 2500 1650 to 2330
1400 to 5350 435 to 3480 -- 2710 to 8100 2180 to 5080 1720 to 4300
9.67 to 36.9 3.00 to 24.0 -- 18.7 to 55.9 15.0 to 35.0 11.8 to 29.6
0.57 to 560 390 to 1200 -- 1.0 to 21 0.80 to 67 1.0 to 41
80 to 106 -- -- 58 to 122 40 to 113 55 to 75
0.127 to 2.17 -- -- 0.0900 to 0.526 0.367 to 7.71 1.38 to 2.42
6.78 to 116 -- -- 4.81 to 28.1 19.6 to 411 73.4 to 129
158 to 280 -- -- 165 to 212 167 to 208 160 to 198
70.0 to 138 -- -- 74.0 to 100 75.0 to 97.8 71.0 to 92.0
110 to 151 -- -- 159 to 208 157 to 194 156 to 191
43.2 to 66.1 -- -- 70.5 to 98.0 69.2 to 90.1 68.9 to 88.3

0.000017 to 0.000089 -- 3.5E-05 0.000039 to 0.000050 5.8E-8 to 0.00010 0.000042 to 0.000047
0.000030 to 0.00016 -- 6.3E-05 0.000070 to 0.000090 1.0E-7 to 0.00019 0.000075 to 0.000085
0.000060 to 0.041 -- -- 0.0036 to 0.0060 0.0044 to 0.0060 0.0040 to 0.0055
0.10 to 24 -- -- 0.20 to 20 0.50 to 14 7.6 to 10
158 to 186 176 -- 140 to 181 140 to 181 158
70.0 to 85.5 80.0 to 80.1 -- 60.0 to 82.5 60.0 to 82.9 69.8 to 70.0
1.8 to 3.1 3 -- 1.5 to 3.1 1.5 to 2.0 2
0.017 to 0.20 -- -- 0.02 0.1 --
20 -- -- 20 to 30 20 to 30 25
6920 to 13000 -- -- 4350 to 22500 4100 to 22500 11000
47.7 to 90.0 -- -- 30.0 to 155 28.3 to 155 75.8
104 to 478 390 to 734 -- 320 to 456 336 to 456 380
40.0 to 248 199 to 390 -- 160 to 236 169 to 235 193
104 to 478 390 to 734 -- 381 to 455 374 to 454 420
40.0 to 248 199 to 390 -- 194 to 235 190 to 235 216
104 to 478 390 to 734 -- 402 to 456 392 to 450 440
40.0 to 248 199 to 390 -- 206 to 235 200 to 232 227

365 to 475 400 to 752 -- 417 to 457 418 to 445 440
185 to 246 204 to 400 -- 214 to 236 214 to 229 227
373 to 448 400 to 409 -- 417 to 457 425 to 457 419 to 482
190 to 231 204 to 209 -- 214 to 236 218 to 236 215 to 250
84.2 to 152 103 to 106 -- 86.0 to 140 94.5 to 142 122 to 140
29.0 to 66.5 39.3 to 40.9 -- 30.0 to 60.2 34.7 to 61.1 50.0 to 60.0
PS (MIPS) PS (Specialty) PS Alloy PS+PE PS+SPS SPS
Polystyrene Polystyrene Polystyrene Polystyrene Polystyrene Polystyrene
1.04 1.02 to 1.16 1.03 to 1.27 0.0199 to 1.02 1.03 to 1.15 1.01 to 1.44
2.0 to 14 5.7 to 10 2 4.0 to 5.0 -- --
308000 to 403000 218000 to 366000 220000 to 500000 145000 to 210000 290000 to 406000 363000 to 1.23E+6
2120 to 2780 1500 to 2530 1520 to 3450 1000 to 1450 2000 to 2800 2500 to 8500
2860 to 5910 2030 to 8210 2470 to 11600 38.0 to 3190 4350 to 7250 5080 to 16700
19.7 to 40.8 14.0 to 56.6 17.0 to 80.0 0.262 to 22.0 30.0 to 50.0 35.0 to 115
1.2 to 50 2.0 to 41 2.0 to 50 3.0 to 100 15 to 45 1.9 to 20
45 to 119 55 to 56 -- -- 50 60 to 75
0.799 to 1.61 0.281 to 3.55 0.506 to 4.00 -- -- --
42.7 to 86.1 15.0 to 190 27.0 to 214 -- -- --
185 to 226 192 to 194 170 to 205 -- 199 to 239 230 to 511
85.0 to 108 88.9 to 90.0 76.7 to 96.0 -- 93.0 to 115 110 to 266
164 to 197 160 to 189 155 to 175 154 176 to 212 203 to 455
73.5 to 91.5 71.0 to 87.0 68.3 to 79.4 68 80.0 to 100 95.0 to 235
0.000028 to 0.00013 -- 6E-05 -- 4.4E-05 0.000014 to 0.000051
0.000050 to 0.00024 -- 0.00011 -- 8E-05 0.000025 to 0.000092
0.0039 to 0.0061 0.0045 to 0.0061 0.0030 to 0.010 0.0045 0.0050 to 0.0070 0.0030 to 0.020
2.0 to 14 5.7 to 10 2 4.0 to 5.0 -- --
140 to 167 158 to 167 180 -- 158 to 176 176
60.0 to 75.0 70.0 to 75.2 82.2 -- 70.0 to 80.0 80
1.5 1.5 to 2.0 2 -- 3.0 to 4.0 3.0 to 3.5
-- -- -- -- -- --
-- -- -- -- -- --
15200 12500 12500 -- -- --
105 86.2 86.0 to 86.4 -- -- --
356 to 392 338 to 435 430 -- 464 to 500 518
180 to 200 170 to 224 221 -- 240 to 260 270
383 to 410 383 to 384 430 -- 482 to 518 536
195 to 210 195 to 196 221 -- 250 to 270 280
401 to 437 406 to 410 430 -- 500 to 518 554
205 to 225 208 to 210 221 -- 260 to 270 290

392 to 428 392 to 393 -- -- 500 to 518 554
200 to 220 200 -- -- 260 to 270 290
419 to 451 426 to 428 445 -- 518 to 572 572 to 590
215 to 233 219 to 220 229 -- 270 to 300 300 to 310
95.0 to 140 113 to 122 125 to 126 -- 122 to 149 158 to 307
35.0 to 60.0 45.0 to 50.2 51.8 to 52.0 -- 50.0 to 65.0 70.0 to 153
PUR, PUR-
PAS PES PPSU PSU Unspecified Capro/MDI
Polysulfone Polysulfone Polysulfone Polysulfone Polyurethane Polyuretha
(PUR) ne (PUR)
1.37 1.36 to 1.37 1.28 to 1.37 1.23 to 1.24 0.907 to 1.45 1.13
-- 12 to 30 11 to 30 3.8 to 17 3.0 to 20 --
398000 to 400000 325000 to 452000 333000 to 405000 368000 to 407000 5500 to 390000 --
2740 to 2760 2240 to 3120 2300 to 2790 2540 to 2810 37.9 to 2690 --
8500 to 13000 8020 to 13100 10100 to 11000 7090 to 11800 11.0 to 9010 3600 to 7200
58.6 to 89.6 55.3 to 90.2 69.6 to 75.9 48.9 to 81.2 0.0758 to 62.1 24.8 to 49.6
6.5 to 10 3.5 to 50 6.9 to 90 3.7 to 77 2.0 to 54 310 to 530
120 120 80 to 120 119 to 120 111 --
1.20 to 1.60 0.500 to 1.75 12.7 to 13.0 0.800 to 1.72 0.01000 to 1.61 --
64.1 to 85.4 26.7 to 93.4 678 to 694 42.7 to 91.8 0.534 to 85.9 --
405 405 to 418 417 351 to 358 120 to 221 --
207 207 to 214 214 177 to 181 48.9 to 105 --
400 382 to 401 360 to 406 338 to 349 129 to 197 --
204 194 to 205 182 to 208 170 to 176 53.7 to 91.9 --

3.1E-05 0.000026 to 0.000033 0.000030 to 0.000032 0.000030 to 0.000031 0.000055 to 0.00010 --
5.6E-05 0.000047 to 0.000059 0.000055 to 0.000057 0.000054 to 0.000056
0.000100 to 0.00018 --
0.0060 to 0.010 0.0059 to 0.014 0.0050 to 0.0071 0.0058 to 0.010 0.00010 to 0.013 --
-- 12 to 30 11 to 30 3.8 to 17 3.0 to 20 --
300 274 to 351 300 to 301 274 to 300 150 to 225 --
149 134 to 177 149 to 150 134 to 149

65.6 to 107 --
6 2.5 to 6.0 2.5 to 4.1 3.0 to 4.0 3.0 to 5.0 --
0.04 0.020 to 0.050 -- 0.020 to 0.10 0.02 --
20 20 -- 20 -- --
17400 to 17500 1160 to 17600 15000 1160 to 17500 12500 --
120 to 121 8.00 to 121 103 8.00 to 121

86.2 --
699 to 700 599 to 700 685 597 to 632 -- --
371 315 to 371 363 314 to 334

-- --
700 653 to 700 695 614 to 632 338 --
371 345 to 371 368 324 to 334

170 --
700 653 to 700 705 630 to 638 -- --
371 345 to 371 374 332 to 336

-- --
-- 653 to 680 695 620 to 653 392 --
-- 345 to 360 368 327 to 345

200 --
-- 670 to 690 706 to 710 664 to 691 68.0 to 459 --
-- 354 to 366 375 to 377 351 to 366

20.0 to 237 --
299 to 300 274 to 313 274 to 303 250 to 303 86.0 to 215 --
148 to 149 134 to 156 135 to 150 121 to 150

30.0 to 101 --
PUR-
PUR- PUR- PUR- PUR- PUR- PUR-
Est/eth,M PUR-Ester
Est/eth,TDI Ester/MDI Ester/TDI Eth,aliphat Ether Ether/MDI
DI Polyurethane
Polyuretha Polyuretha Polyuretha Polyuretha Polyureth Polyuretha
Polyureth (PUR)
ne (PUR) ne (PUR) ne (PUR) ne (PUR) ane (PUR) ne (PUR)
ane (PUR)
1.04 to 1.21 1.15 to 1.23 1.22 to 1.23 1.20 to 1.25 1.16 to 1.27 1.02 to 1.07 1.11 to 1.23 0.998 to 1.13
-- -- -- -- -- -- -- --
-- -- 366000 to 446000 -- -- 100000 -- --
-- -- 2520 to 3080 -- -- 689 -- --
250 to 3400 2470 to 8600 5630 to 13600 1790 to 7640 5200 to 9000 3000 to 6750 569 to 6700 142 to 7600
1.72 to 23.4 17.0 to 59.3 38.8 to 93.6 12.3 to 52.6 35.9 to 62.1 20.7 to 46.5 3.92 to 46.2 0.979 to 52.4
75 to 630 220 to 890 6.8 to 650 390 to 700 280 to 710 180 to 850 500 to 750 190 to 580
-- -- -- -- -- -- -- --
-- -- 0.795 to 1.84 -- -- 14 -- --
-- -- 42.4 to 98.2 -- -- 747 -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- 127 to 191 -- -- -- -- --
-- -- 52.8 to 88.2 -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
0.0019 to 0.00510.010 to 0.016 0.009 0.010 to 0.013 0.011 to 0.016 0.013 to 0.020 0.009 0.0010 to 0.020
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- -- -- -- -- -- -- --
-- 228 140 212 to 257 220 to 235 -- -- 122 to 248
-- 109 60 100 to 125 104 to 113 -- -- 50.0 to 120

PUR-Ether/TDI PUR-MDI PUR-TDI
Polyurethane Polyurethane Polyurethan CPVC PVC Alloy PVC Elastomer
(PUR) (PUR) e (PUR)
1.03 to 1.21 0.239 to 1.22 1.01 to 1.21 1.46 to 1.52 1.15 to 1.29 1.08 to 1.31
-- -- -- 5.0 to 21 28 3.6 to 30
81000 to 116000 15000 to 309000 -- 306000 to 420000 273000 to 352000 190000
558 to 800 103 to 2130 -- 2110 to 2890 1880 to 2420 1310
2000 to 9000 560 to 7500 924 to 3580 6430 to 8140 1220 to 6410 230 to 3050
13.8 to 62.1 3.86 to 51.7 6.37 to 24.7 44.4 to 56.2 8.38 to 44.2 1.59 to 21.0
180 to 570 7.0 to 21 130 to 710 3.0 to 6.2 15 to 420 300 to 500
-- -- -- 112 to 118 110 --
1.10 to 20.0 0.9 -- 1.49 to 5.60 0.630 to 14.1 19
58.7 to 1070 48 -- 79.3 to 299 33.6 to 752 1010
365 158 to 221 -- 221 to 230 181 to 201 135
185 70.0 to 105 -- 105 to 110 82.8 to 93.9 57.2
135 -- -- 184 to 230 161 to 190 --
57.2 -- 84.4 to 110 71.7 to 87.8 --

0.000050 to 0.00010 0.000040 to 0.000056 -- 0.000032 to 0.000040 0.000036 to 0.000050 --
0.000058 to 0.000073 0.000064 to 0.000090 --
0.000090 to 0.00018 0.000072 to 0.00010 --
0.012 to 0.020 0.0040 to 0.0080 0.00050 to 0.014 0.0059 to 0.0060 0.0035 to 0.0050 0.017 to 0.018
-- -- -- 5.0 to 21 28 3.6 to 30
-- -- -- -- 155 178
-- 68.3 81.1
-- -- --
-- -- -- -- 2 2.5
-- -- -- -- -- --
-- -- -- -- -- 20
-- -- -- -- -- 12400
-- -- 85.5
-- -- --
-- -- -- -- 290 311 to 375
-- 143 155 to 191

-- -- --
-- -- -- -- 300 335 to 375
-- 149 168 to 191

-- -- --
-- -- -- -- 310 335 to 375
-- 154 168 to 191

-- -- --
-- -- -- -- 330 347
-- 166 175
-- -- --
-- 92.5 to 110 95.0 to 111 398 to 399 399 to 405 300 to 380
203 to 204 204 to 207 149 to 193

-- 33.6 to 43.3 35.0 to 43.9
142 to 228 160 to 161 -- -- -- 75.0 to 109
-- -- 23.9 to 42.5
61.1 to 109 70.8 to 71.6 --
PVC Homopolymer PVC, Flexible PVC, Rigid PVC, Semi-Rigid PVC, Unspecified PVC+NBR
0.360 to 1.40 1.14 to 1.45 0.767 to 1.47 1.29 to 1.58 0.530 to 1.85 1.18 to 1.33
-- 0.42 to 130 1.4 to 41 19 to 87 6.2 to 42 0.46 to 42
-- 42000 to 450000 320000 to 460000 55000 to 278000 280000 to 425000 --
-- 290 to 3100 2210 to 3170 379 to 1920 1930 to 2930 --
-- 110 to 4930 5450 to 7880 2170 to 4540 220 to 23800 422 to 2580
-- 0.758 to 34.0 37.6 to 54.3 15.0 to 31.3 1.52 to 164 2.91 to 17.8
-- 240 to 450 2.6 to 66 190 to 300 210 to 450 350 to 470
-- 115 89 to 116 -- 106 to 116 --
-- 2.00 to 37.1 0.300 to 20.0 0.500 to 1.50 0.401 to 22.2 --
-- 107 to 1980 16.0 to 1070 26.7 to 80.1 21.4 to 1180 --
-- 117 to 149 147 to 174 106 to 111 201 to 220 --
-- 47.0 to 65.0 64.0 to 79.1 41.1 to 43.9 94.1 to 105 --
-- 153 to 182 137 to 168 97.0 to 97.1 143 to 206 --
-- 67.0 to 83.2 58.1 to 75.4 36.1 to 36.2 61.4 to 96.7 --

-- 3.3E-05 0.000029 to 0.000041 0.000040 to 0.000042 0.000038 to 0.000048 --
-- 6E-05 0.000052 to 0.000074 0.000073 to 0.000075 0.000068 to 0.000087 --
-- 0.0095 to 0.021 0.0035 to 0.0036 0.011 0.0035 to 0.0041 --
-- 0.42 to 130 1.4 to 41 19 to 87 6.2 to 42 0.46 to 42
-- -- 150 -- -- --
-- -- 65.6 -- -- --
-- -- 3 -- -- --
-- -- -- -- -- --
-- -- 50 -- 30 --
-- -- 16000 -- -- --
-- -- 110 -- -- --
-- 280 to 290 324 to 325 -- 328 to 338 290
-- 138 to 143 162 to 163 -- 165 to 170 143
-- 300 to 310 359 to 360 -- 337 to 338 300
-- 149 to 154 182 -- 170 149
-- 310 to 320 369 to 370 -- 338 to 347 310
-- 154 to 160 187 to 188 -- 170 to 175 154

-- 320 to 340 365 -- 356 310
-- 160 to 171 185 -- 180 154
-- 329 to 392 367 to 403 370 to 381 319 to 370 388 to 390
-- 165 to 200 186 to 206 188 to 194 159 to 188 198 to 199
-- 75.0 to 85.0 89.6 to 90.0 -- 104 --
-- 23.9 to 29.4 32.0 to 32.2 -- 40 --

PVC+PUR PVDC
1.16 to 1.26 --
-- --
-- --
-- --
1430 to 2740 1740 to 14500
9.83 to 18.9 12.0 to 99.8
390 to 600 42 to 470
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
-- --
315 to 350 --
157 to 177 --
-- --
-- --
Major Plastic Properties D:\Engineering\Engineering 1\plastic de
Polyamide (PA - Nylon)

Properties General Nylon PA 6 Polyamide (PA - Nylon)
PA 66
Capron 8202
Zytel (Dupont)
Grade (Manufacturers) Ultramid (BASF)
Miramid (BASF)
Morphology
Causes of Molded-Part Variation -material- Warpage due to material use, 27 pages.pdf
Semi crystalline Semi crystalline Semi crystalline
Linear Mold Shrinkage

inches/inch or mm/mm 0.005–0.015 0.008–0.015
% Shrinkage
0.5-1.5 0.8-1.5
Applications
Typical Butt Weld Tensile

Strength Retention Values 91
in % (source LNP)
72 pages,2003NMW_Design_with_Plastics.pdf
Page 34 of 72
1.14
Density (g/cm3) 1.13
g/cm3
Water Absorbtion (mg) 40 / 76
Elongation % 150% at break 60% at break
Maximum Operating
Temperature
Thermal Expansion in/in./- 4.5 in/in/°F x 10-5

Fx105 (8.1 mm/mm/°C x 10-5)
Hardness
Moulding Temperature 530 °F
Maximum Temperature 210°F - 99°C
Minimum Temperature 94°F -70°C

Max usage temperature
Max Continous usage

temperature
Melting Point
612 pages, Book, Handbook of Plastics Technologies110.pdf, page 34 of 612
420°F - 216°C 230°C–280°C 260°C–290°C
Tensile Strength 5,800 psi
Wear Resistance High High High
HDT
(Heat Deflection 65°C in 1.82 MPA = 264 82.2°C, 180°F in 264 PSI,
Temperature - DTUL) PSI
Note : 1.82 MPA = 264 PSI)
Glass Transition 167°F (75°C) 167°F (75°C)

Temerature (GTT)
Brittle Temperature -112°F, -80°C
Hardness
Annealing Temperature
Special Applications
Fatigue Properties
dimensional
stability
Creep
Stiffness
Water resistance
Effect of Moisture
Moisture / water More More than PA66 Less than PA6

Absobtion 0.6% - 1.2% 0.6% - 1.2% 0.6% - 1.2%
Mold Shrinkage High High High
Toughness
Ductility
Chemical Resistance
Vapor permeability
Machinaibility Excellent Excellent
Cost high high high
Thermal Stability
0 30 29 26
41 11 12 15
22
\Engineering 1\plastic design\Injection moulding\101_plastic_injection_molding_engineering_manufacturing-2, 3 pages.pdf
Nylon 66 Nylon 66 PA With 30% Glass Fiber Poly Acteal (POM)

10% reinforcement 30% reinforcement
Delrin Homo (Dupont)

Celcon copoly (Ticona)
Semi crystalline Semi crystalline Semi crystalline Semi crystalline
0.003–0.005 0.020–0.025
0.3-0.5 2-2.5
89 60
1.42
13
200°
5.8 in/in/°F x 10-5

(10.4 mm/mm/°C x 10-5)
180°F 80°C
-40°F -40°C
190°C–215°C (Homo)
175°C–220°C (Co)
General - 320°F 160°C
8,800 psi
High High
485°F 490°F 136°C in 264 PSI,
Gear,
to resist wear & tear
Good
Good
Better than Nylon
Better than Nylon
Better than Nylon
Less Effect than Nylon
Copoly 0.2%
Homo 0.25%
high high
37 37 39 21
4 4 2 20
-2, 3 pages.pdf
Poly Propylene (PP) 40% talc filled PP 40% CaCO2 filled PP Poly Propylene (PP)
Unfilled 20% Glass fiber
Semi crystalline Semi crystalline Semi crystalline Semi crystalline
0.010–0.025 0.008–0.015 0.007–0.014
1.0–2.5 0.8–1.5 0.7–1.4
86 47
0.905 g/cm3
10-60% at break
3.8 X I0-5
(mm/mnrK)
5 in/in/°F x 10-5
(9 mm/mm/°C x 10-5)
76 ShoreD
275°F 135°C
32°F 0°C
100 - 110°C
160-175°C / 320-347°F
70°C
(atactic) −20°C
(isotactic) 100°C
0°F, -18°C
72 Shore D
100°C
Food Processing Food Processing Food Processing Food Processing

Very very less in all
plastics
<0.1%
generally
less than PE
Good
Excellent
19 38 38 39
22 3 3 2
Styrene-Acrylonitrile Styrene-Acrylonitrile
Poly Propylene (PP) Copolymers (SAN) Copolymers (SAN) Poly Carbonate (PC)
40% Glass fiber Unfilled
No Reinforcement 30% Glass fiber
Lexan (GE)
Semi crystalline Amorphous Amorphous Amorphous
0.002-0.006 0.005–0.007
0.5–0.7
34 80 40 99
1.19
110% at break
290°
3.75
3.9 in/in/°F x 10-5
(7 mm/mm/°C x 10-5)
135°C (service)
-100 °C (service)
115 - 125°C
125°C
200°C–270°C 280°C–320°C
Low
100-105°C 129°C in 1.82 MPA = 264

PSI
302°F (150°C)
-215°F, -137°C
Food Processing
0.1 - 0.3%
39 36 40 23
2 5 1 18
Poly Carbonate (PC) Poly Carbonate (PC) Poly Sulphone (PSU) Poly Sulphone (PSU)
10% Glass fiber 30% Glass fiber No Reinforcement 30% Glass fiber
Udel (Solvay)
Amorphous Amorphous Amorphous Amorphous
0.002–0.005 0.001–0.002 0.007
0.2–0.5 0.1–0.2
CD's Polysulfone is used in applications requiring good high-temperature resistance such as

coffee carafes, piping, sterilizing equipment, and microwave oven cookware.377 The good
hydrolytic stability of polysulfone is important in these applications. Polysulfone is also
used in electrical applications for connectors, switches, and circuit boards and in reverse
osmosis applications as a membrane support
86 62 100 62
1.24
50
325°
3.1
150-180 °C
-50 °C (working)
350°C–380°C
barrel temp. 310 to

400°C, mold temp
100 to 170°C
70 Mpa
Low Low
174°C in 1.82 MPA =

264 PSI
185°C
0.23%
37 36 26 40
4 5 15 1
Poly Urathane (PU) ABS LDPE HDPE Polystyrene (PS)
Amorphous Amorphous Semi crystalline Semi crystalline Amorphous
0.010-0.020 0.003–0.008 0.007-0.009 0.015 - 0.040 0.004–0.007
0.3–0.8 1.5-4.0 0.4–0.7
rollers or wheels, exterior body parts, drive belts,

and hydraulic sealsPolyurethanes can be used in film applications such as textile laminates
for clothing and protective coatings for hospital beds. They are also used in tubing
a nd hose in both unreinforced a nd reinforced forms becaus e of their low-temperature
properties and toughness.
0.910 to 0.925 0.926 to 0.940 1.05

1.12-1.24 1.05
g/cm3 g/cm3 g/cm3
3.2 600 900
200° 160° 180°
5 in/in/°F x 10-5
(9 mm/mm/°C x 10- 9.2 8.5
5
)
440°F 440°F 500°F
108°C (Service) 176°F 80°C 248°F 120°C 93°C
-60°C 58°F -50°C -148°F -100°C

60 - 75°C 70 - 80°C 60 - 70°C
151°C 220°C–260°C 180°C–280°C 205°C–280°C 190°C
5000 psi 4,300 psi 2600-10200 psi
88°C, 193°F in 1.82 43°C in 1.82 MPA = 74°C in 1.82 MPA = 93°C in 1.82 MPA =
MPA = 264 PSI 264 PSI 264 PSI 264 PSI
219°F (104°C) 75-80°C also cited 219°F (104°C)
-60°F, -51°C -85 to -35°C -100 to -70°C 200°F, 93°C
Excellent X-ray
Foam Products
resistance
<0.1% <0.1%
0.27% Very Low Very Low <0.1%
High High
High High
Excellent Excellent
Low Low
Excellent Fair
medium medium medium low
32 28 21 20 25
9 13 20 21 16
PPE PPS PPS PPS PMMA
No Reinforcement 10% Glass fiber 40% Glass fiber
Amorphous Semi crystalline Semi crystalline Semi crystalline Amorphous
0.004–0.008 0.002-0.008
0.4–0.8 0.2-0.8
83 38 20
1.185
5% at break
6.3 10~5 mm/mm-K

3.8 in/in/°F x 10-5
(6.8 mm/mm/°C x
10-5)
210°C–270°C
92°C in 1.82 MPA =

264 PSI
250°F, 121°C
0.02% 0.20%
Excellent
medium
39 39 40 40 30
2 2 1 1 11
PBT + 40% Glass
PBT Fiber Teflon (PTFE) Polyamide-imide Polyimide (PI)
(Polyester) (PAI)
(Polyester)
Torlon (Solvay) Kapton (Dupont)
Semi crystalline Semi crystalline Semi crystalline Both Both
0.02 < 0.007 0.033-0.053
3.3 - 5.3 %
The first application of polyimides was for wire enamel.262 Applications for polyimides
hydraulic bushings and seals, mechanical
include bearings for appliances and aircraft, seals, and gaskets. Film versions are used
parts for electronics, a nd eng ine components, laminating r esin for s pacecraft, a decora tive finish for kitchen equipment, a nd a s
wire enamel in flexible wiring and electric motor insulation. Printed circuit boards are also fabricated
with polyimides
1.3 1.6 2.16 1.42
150% at break
6 in/in/°F x 10-5
(10.8 mm/mm/°C x 1.89 (10~5 mm/mm-K) 9.9(IO"5 mm/mm-K)
10-5)
Mold 230°C
Melt 355°C
300 °F (149 °C)
Up to 500 °C (Service)
(Service)
-10 °C (Service)
70°C -250°C to +250°C
220°C–260°C
75-90 Mpa
54°C in 1.82 MPA = 232°C in 1.82 MPA = 280°C

264 PSI 264 PSI
266°F (130°C) 270°C-285°C 482°F (250°C)
Should be done
replacements for
Machining metal and
glass
0.08% <0.01 %
Good
Excellent
Medium Medium
Excellent -
exceptional
32 36 30 35 32
9 5 11 6 9
PVC PET PEEK PEEK 30% GF
Amorphous Semi crystalline Semi crystalline Semi crystalline
1.42 1.32 1.5
158°F 70°C
-13°F -25°C
176°F 80°C 334°C 334°C
6,500 psi
160°C 315°C
176°F (80°C) 143°C 143°C

0.50% 0.10%
Medium
34 41 36 36
7 0 5 5
Extreme Poly Propylene (PP) Nylon (PA) Teflon (PTFE) Polystyrene (PS) PVC
Moisture Absorption Low High -- -- --
Machinability -- -- High -- --
Glass Transition Temp. -- -- -- Low Low
Coefficient of Friciton -- Low -- --
Abrasion Resistance -- -- -- -- --
Chemical Resistance -- -- High -- --

Polyetherimide (PEI) Polyethersulfone (PES) UHMWPE
-- -- --
-- -- --
High High --
Low
-- --
(Next to PTFE)
-- -- High
-- -- --
Amorphous (PC, PS, PVC…)
Amorphous vs. Semicryastalline Thermoplastics
page 11 of 72
• Low mold shrinkage

• Limited chemical resistance
• Light transmission (many)
• High coefficient of friction
• Toughness or brittle ?
• Stiff or flexible ?
• Other properties ?
Semi-crystalline (PE, PP…)

• Higher mold shrinkage
• Good chemical resistance
• Opaque or translucent
• Low coefficient of friction
• Toughness (most) ?
• Stiff or flexible ?
• Other properties ?
Relationships between Polymer Properties and Morphology
Property Crystalline Amorphous

Light transmission Less High
Solvent resistance High Low
Lubricity High Low
Dimensional stability High Low
Mold shrinkage High Low
Resistance to dynamic fatigue High Low
Facility to form high strength fibers High None
Thermal expansion coefficient High Low
Melting temperature Sharp Absent
Dependence of properties on temperature High Low
Engineering Thermoplastics, Overview, 22 pages.pdf

Page 4/22
Property Crystalline Crystalline Amorphous Liquid Crystalline
Specific Gravity Higher Lower Higher
Tensile Strength Higher Lower Highest
Tensile Modulus Higher Lower Highest
Ductility, Elongation Lower Higher Lowest
Resistance to Creep Higher Lower High
Max. Usage Temp. Higher Lower High
Shrinkage and Warpage Higher Lower Lowest
Flow Higher Lower Highest
Chemical Resistance Lower Higher Highest
Plastics-Design, 84 pages.pdf
14/84
Molten amorphous polymer - Shrinkage due to thermal contraction only

Molten semi-crystalline polymer (amorphous in the melt state) - Shrinkage due to thermal contraction and re-crystallization
Moldcooling
page 38 of 72
Ultimate strength measures the highest stress value during the tensile test.
Higher mold temperature

Increases
Crystallinity (crystalline resins)
Shrinkage (all resins)
Heat distortion temperature (crystalline resins)
Decreases
Molded in stresses
(all resins)
Impact strength
(crystalline resins)
Homopolymer polypropylene is stronger and stiffer than copolymer.

Copolymer polypropylene is a bit softer, but it is tougher and more durable than
homopolymer polypropylene. Copolymer polypropylene tends to have better
stress crack resistance and low temperature toughness than homopolymer.
The copolymers have generally similar properties, but the homopolymer

may have slightly better mechanical properties, and higher melting point, but
poorer thermal stability and poorer alkali resistance.
Ultraviolet light may cause degradation in Plastics, which can be reduced by the addition
of carbon black.
Nylon has a very sharp melting point and low melt viscosity, which is advantageous in injection molding but causes difficulty in
and blow
molding.
Polyamide-imides can be used from cryogenic temperatures to nearly 260°C.

PAI should be annealed after molding at gradually increased temperatures
The most common method of processing HDPE is blow molding
Polyimides are used in high-performance applications as replacements for metal and

glass.
One weakness of polypropylene is its low-temperature brittleness
behavior, with the polymer becoming brittle near 0°C
molecular weight distribution (MWD)
Polyurethanes are available as both thermosets and thermoplastics.
In SAN The polymers generally contain

between 20 to 30 percent acrylonitrile.333 The acrylonitrile content of the polymer influences
the final properties with tensile strength, elongation, and heat distortion temperature
increasing as the amount of acrylonitrile in the copolymer increases.
Toughness - ability to withstand both plastic and elastic deformation

Stiffness - resistance of a material to elastic deformation or deflection
Hardness - the ability of material to resist scratching, abrasion, indentation & penetration
• Acrylonitrile - Butadiene - Styrene (ABS)
• Polyvinyl Chloride (PVC)
• Polyethylene Terepthalate Glycol (PETG)
• Cellulose Acetate Butyrate (CAB)
Amorphous Engineering Thermoplastics

• Polycarbonate (PC)
• Polyphenylene Oxide (Modified PPO)
• Polyphenylene Ether (Modified PPE)
• Thermoplastic Urethane (TPU)
Amorphous High Performance Thermoplastics

• Polysulfone (PSU)
• Polyetherimide (PEI)
• Polyethersulfone (PES)
• Polyarylsulfone (PAS)
Semi-Crystalline Commodity Thermoplastics

• Polyethylene (PE)
– High Density Polyethylene (HDPE)
– Low Density Polyethylene (LDPE)
• Polypropylene (PP)
• Polymethylpentene (PMP)
Semi-Crystalline Engineering Thermoplastics

• Polyamide (PA - Nylon)
• Acetal (POM)
• Polyethylene Terepthalate (PET)
• Polybutylene Terepthalate (PBT)
• Ultra High Molecular Weight Polyethylene (UHMW-PE)
Semi-Crystalline High Performance Thermoplastics

• Polyvinylidene Fluoride (PVDF)
• Polytetra Fluoroethylene (PTFE)
• Ethylene-chlorotrifluoroethylene (ECTFE)
• Fluorinated Ethylene Propylene (FEP)
• Polychlorotrifluoroethylene (PCTFE)
Thermosets :
• Phenol Formaldehyde,
• Urea Formaldehyde,
• Melamine Formaldehyde,
• Unsaturated Polyester Resin
• Poly Bismaleimides etc.,
Some important terms
Tg - Glass transition temperature
Tm - sharp melting transition
TC – Crystallization temperature
cryogenic temperatures to nearly 260°C.
MD - Machine direction - Drawing in the longitudinal machine direction (MD)
TD - Transverse direction - Drawing in the transverse direction (TD)
MWD - molecular weight distribution
IUPAC – International union of Pure and Applied Chemistry
LCP – Liquid Crystal Polymer
RTI – Relative Temperature Index
RTM – Resin Transfer Moulding
RIM – Reaction Injection Moulding
RRIM – Rainforced Reaction Injection Moulding
DTUL – Deflection Temperature Under Load
HDT – Heat Distortion Temperature
CLTE – Coefficient of Linear Thermal Expansion
BMC – Bulk Molding Compound
SMC – Sheet Molding Compound
LPMC – Low Pressure Molding Compound
Plastic Memory
Each time a plastic is reheated it will attempt to return to its original flat shape unless it has been over heated or damaged. Th
a plastic memory
PF
PHB
PHV
PI
PMMA
PMP
POM
PP
PPE
PPMI
PPO
PPS
PPSU
PPT
PS
PSF
PSO
PTFE
PTMT
PU
PVAc
PVAl
PVB
PVC
PVCA
PVDC
PVDF
PVF
PVF2
PVFM
PVK
PVOH
PVT
SAN
SHIPS
SMC
TPX
UF
Plastic name A / S Brand Name Company / Make / Manufacturer
Polyetherimides (PEI) A Ultem General Electric
Polytrimethylene Terephthalate (PTT) -- Corterra Shell Chemicals
Polyamide (PA) S Zytel Dupont
Polyacetal (POM) S Delrin Dupont
Polycarbonate (PC) A Lexan General Electric
PBT Crastin Dupont
PET Rynite Dupont
Polyimides have excellent physical properties and are used in applications where parts are exposed to harsh environments
Polyimide is used for Aircraft Engine Cooling Tube

Polyamide-imide polymers find application in hydraulic bushings and seals, mechanical parts for electronics, and engine comp
The polymer in solution has application as a laminating resin for spacecraft, a decorative finish for kitchen equipment, and as w
enamel.
PC can replace ferrous or glass products
PC alone is widely used as vacuum cleaner housings, household appliance housings, and power tools. These are arenas where
impact strength, heat resistance, durability, and high-quality finish justify its expense.
PC is also used in safety helmets, riot shields, aircraft canopies, traffic light lens housings, and automotive battery cases.
The headlight lens is made from polycarbonate. PC gives excellent transparency with impact resistance which helps to avoid b
headlight. Polycarbonate plastic is used because of its tensile strength and the ability to be manufactured to conform to the fr
styling of a vehicle. Although it's a very hard plastic, it's also very porous so during manufacturing a protective silicone hard co
applied to the headlight lens. This silicone hard coat is supposed to protect the headlight lens from intense sun, heat, road che
bugs, humidity and acid rain, etc.
The Speedosystem Bearing block material Zinc die casting is replaced by SAN 20% GF
Nylon 6,6 is used as an engineering resin in a variety of molding applications such as gears, bearings, rollers, and door latches
its good abrasion resistance and self-lubricating tendencies.
The PPS also provided better corrosion resistance against aggressive fuels than the previously used die-cast aluminum.
PET, Polycarbonate is used for blow mould the water bottle.
LCPs are typically selected for connectors because of their high thermal performance, ease of mold filling in thin cross section
dimensional stability
Ask the Expert.mht
PolyAcetal (POM) is used for tank units where the material is going to immersed in petrol, For this application PBT is also used
Polyester Resin is used for nylon

Polystyrene is used for manufacture CD Case.
LDPE is used for manufacture Carrier bag.
Corterra (Polytrimethylene Terephthalate – PTT, Brand name of cell chemicals)
is used in the textile and carpet industries, which take advantage of its stain resistance, wearability as a result of high resilienc
elastic recovery, color fastness, and soft hand
Polyetherimide is used in a variety of applications. Electrical applications include printed circuit substrates and burn-in sockets
automotive industry, PEI is used for under-the-hood temperature sensors and lamp sockets. PEI sheet has also been used to fo
aircraft cargo vent. The dimensional stability of this polymer allows its use for large flat parts such in hard disks for computers
Polyurethanes find application in many areas. They can be used as impact modifiers for other plastics. Other applications inclu
or wheels, exterior body parts, drive belts, and hydraulic seals.Polyurethanes can be used in film applications such as textile la
for clothing and protective coatings for hospital beds. They are also used in tubing and hose in both unreinforced and reinforc
because of their low-temperature properties and toughness. Their abrasion resistance allows them to be used in applications
athletic shoe soles and ski boots. Polyurethanes are also used as coatings for wire and cable.
PU is used for Shoe soles.

Plastics are Visco-elastic materials (With respect to Strain rate)
Plastics are Brittle-Ductile materials (With respect to Temperature)
The simplest polyolefin is polyethylene (PE).
By volume, plastics production exceeds steel production.
Phenolic plastics and epoxy resins are thermosets
Weld Lines
The hairline grooves on the surface of a molded part where flow fronts join during filling, called weld lines or knit lines, cause
cosmetic flaws and reduced mechanical performance (see figure 2-8). Because few polymer chains cross the boundary when t
fronts butt, the tensile and impact strength in the weld-line area is reduced. The resulting notches on the weld line also act as
concentrators, further reducing impact strength.
Additionally, if the flow fronts are covered with a film from additives or a layer of impurities, they may not
bind properly, which again can reduce impact and tensile strength. Weld-line strength in thermoplastics
varies with specific resin and processing parameters, such as flow-front temperature, distance from the gate, filling pressure,
of packing. For instance, Makrolon polycarbonate resins usually have exceptional weld-line tensile strength, typically over 95%
strength without weld lines. Other resins can suffer
over 50% loss of tensile strength at the weld line.
86 pages, Bayer, engineering polymers, material selection, thermo plastics & plouterthanes, a design guide MaterialSelection_
1995,pdf, page 19
117 pages, design_of_plastic_products, triangle, book.pdf, Page 57
CALCITE FILLED POLYPROPYLENE 30% 53.97

CELCON (BLACK) M270 133.80
CELCON NATURAL 98.36
DELRIN (NATURAL) 83.40
NORYL 20% GF, (GFN2) 234.73
NORYL BLACK N110-701 234.73
NYLON 66, 33% GF NATURAL 159.36
NYLON 6, 30% GF BLACK 108.37
NYLON 6, 30% GF NATURAL 119.46
NYLON 6, COLOUR BLACK 98.84
NYLON 6 NATURAL 108.14
PC AMBER 245.35
PC BLACK 224.10
PC BLACK NOVAREX 423.79
PC BLUE 277.22
PC CLEAR LEXAN - 143 R 181.61
PC CLEAR NOVAREX IMPORTED 423.79
PC CLEAR PANLITE IMPORTED 195.04
PC GREEN 245.65
PC MILKY WHITE IMPORTED 397.57
PC MILKY WHITE 923R 277.22
PC RED IMPORTED 423.79
PC RED 245.35
PC SHEET 0.5 MM PER SQ. METER IMPORTED 237.08
PC SHEET 0.5 MM PER SQ. METER INDEGENIOUS 297.10
PBT 30% GF NATURAL 147.75
PBT 40% GF NATURAL IMPORTED 492.15
PBT NATURAL; DURANEX PB5 7400W IMPORTED 334.93
PBT NATURAL GR DURANEX 2002 IMPORTED 262.40
POLYACETAL CELCON BLACK – GRINDING 133.80
POLYACETAL DURACON NATURAL GR M90 106.06
POLAMIDE FILM, 125 MICRONS, IMPORTED 11321.83
POLYCARBONATE CLEAR CALIBRE 303-15 181.61
POLYCARBONATE CLEAR MAKROLON 2805 181.61
POLYCARBONATE CLEAR MAKROLON 2407 181.61
POM
“warm to the touch” feel
988 pages, Book, plastics materials & processes, a concise encyclopedia Plastics Materials and Processes.pdf, Page No. 34
612 pages, Book, Handbook of Plastics Technologies110.pdf, page no. 1.17

The Remainder of the energy generated from the frictional heat generated by the mechanical motion of the screw ; this mech
called `Viscous dissipation’.
Nylon has a very sharp melting point and low melt viscosity, which is advantageous in injection molding but causes difficulty in
and blow molding.
Anisotropic shrinkage of fiber-reinforced polymers can be attributed to the fact that the fibers become oriented in the flow-sh
during injection molding. The shrinkage anisotropy, defined as the difference between the shrinkage parallel and perpendicula
flow.
Thermal expansion of a Lexan® 121, an unfilled polycarbonate, showing equivalent expansion in both in-flow and cross-flow d
(Courtesy of GE Plastics.)
The glass transition temperature, Tg, is the temperature where the polymer chains have enough energy to slip easily past thei
neighboring chains. At temperatures well above Tg, the polymer has sufficient mobility to flow under processing stresses.
Unlike the homopolymer, copolymers can be processed by many methods, including extrusion, blow molding, and injection m
Acrylic fibers have good abrasion resistance, flex life, and toughness, and high strength. They have good resistance to stains an
moisture.
Polyamide-imides can be used from cryogenic temperatures to nearly 260°C. They have the temperature resistance of the pol
but better mechanical properties, including good stiffness and creep resistance.
PAI polymers are inherently flame retardant, with little smoke produced when they are burned. The polymer has good chemic
resistance, but at high temperatures it can be affected by strong acids, bases, and steam. PAI has a heat deflection temperatu
280°C, along with good wear and friction properties. Polyamide-imides also have good radiation resistance and are more stab
standard nylons under different humidity conditions. The polymer has one of the highest glass transition temperatures, in the
270 to 285°C.
Adding carbon black leads to UV resistance
Carbon Fillers are added to increase the thermal conductivity of thermoplastics
PC can replace ferrous or glass products

Polyethylene (PE) is the highest-volume polymer in the world.
Polyimides will burn, but they have self-extinguishing properties.
Printed circuit boards are also fabricated with polyimides.

What is the plastic material you will be used at 90°C and subjected to continuous creep (Continuous Tensile load) ? Design hea
automotive
He told `Delrin’.
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
What is the difference between PA6 & Nylon6 ? Sr. Person in design – IFB automotive
PA6 - A particular Plastic Material Name

Nylon6 - Brand name of the Plastic material
I made an example of Polycarbonate (PC) with Lexan
Addition Polymerization
Involves a simple addition of monomer molecules to each other without the loss of any atoms from the original molecule
Condensation Polymerization
Involves a reaction between bifunctional reactants in which a small molecule is eliminated during each step of the polymer bu
reaction
introduction EBB 220, 42 pages.ppt, page 11 & 12
Homopolymer
Polymer consisting of multiples of the same repeating units as Polyethylene
Example : Delrin [homopolymer of Poly Acetal (POM)]
Copolymer
Resulted products from two different monomers (e,g A and B) polymerized together
Example : Celcon, Duracon, Lucel [Copolymer of Poly Acetal (POM)], ABS
Terpolymers
Polymers obtained from three different monomers (e.g. A, B and C)
Example : ACS
introduction EBB 220, 42 pages.ppt, page 14

Monomer
The basic chemical unit of polymer, is called a monomer (beads in necklace)
Eg. Vinyl chloride, ethylene glycol, lactic acid, amino acids, glucose etc.,
Molecule with minimum functionality of two that reacts to form the structural units of the polymer.
Oligomer
These are compounds having a few (unlike “many” in case of Polymers) monomers joined together by covalent bonds (usually
50 repeating units).
Eg. Oligonucleotides, peptides etc.,
Short chain synthesized from reaction of several monomers.

Eg. Dimmer, trimer, tetramer
Macromolecules
Refers to very large molecules. Since polymers are generally composed of thousands of monomers, each polymer molecule is
Thus polymers are also termed as macromolecules
Sometimes polymers are called "macromolecules" - "macro" means "large" à polymers must be very large molecules
Polymer
Macromolecule generated through sequential reaction of a small number of elementary units.
Introduction to Polymers chemcical - chapter1, 49 pages.pdf, page 5, 6

introduction EBB 220, 42 pages.ppt, page 8
Polystyrene - Good for vacuum forming
Even though ABS plastics are used largely for mechanical purposes, they also have good electrical properties that are fairly con
over a wide range of frequencies. These properties are little affected by temperature and atmospheric humidity in the accepta
operating range of temperatures. The final properties will be influenced to some extent by the conditions under which the ma
processed to the final product; for example, molding at a high temperature improves the gloss and heat resistance of the prod
whereas the highest impact resistance and strength are obtained by molding at low temperature.
PTFE (Teflon) is added as a internal lubrication material in Delrin

CFRP - carbon fibre reinforced plastics
GFRP - Glass fibre reinforced plastics
TFPP - Talc filled polypropelene
Delrin, the world’s first acetal resin, is a highly versatile engineering plastic with metal-like properties.
Reference : dupont delrin acetal resin 230323c, 65 pages.pdf, Page 5
DFMEA OUTPUTS
RPN: Risk Assessment Number
Identification of Critical and Significant Characteristics
The type of nylon (nylon 6, nylon 10, etc.) is indicative of the number of carbon atoms
in the repeat unit. Many different types of nylons can be prepared, depending on the starting
monomers used. The type of nylon is determined by the number of carbon atoms in the
monomers used in the polymerization. The number of carbon atoms between the amide
linkages also controls the properties of the polymer. When only one monomer is used (lactam
or amino acid), the nylon is identified with only one number (nylon 6, nylon 12).
When two monomers are used in the preparation, the nylon will be identified using two
numbers (nylon 6,6, nylon 6,12).91 This is shown in Fig. 2.9. The first number refers to the
number of carbon atoms in the diamine used (a) and the second number refers to the number
of carbon atoms in the diacid monomer (b + 2), due to the two carbons in the carbonyl
group.92
The amide groups are polar groups and significantly affect the polymer properties. The
presence of these groups allows for hydrogen bonding between chains, improving the interchain
attraction. This gives nylon polymers good mechanical properties. The polar nature
of nylons also improves the bondability of the materials, while the flexible aliphatic
carbon groups give nylons low melt viscosity for easy processing.93 This structure also
gives polymers that are tough above their glass transition temperature.94
612 pages, Book, Handbook of Plastics Technologies110.pdf

Page 65 of 612
Glass fiber-reinforced thermoplastics

(FRTPs) help to simplify these problems. For instance, 40 percent glass fiberreinforced
nylon outperforms its unreinforced version by exhibiting 2-1 2 times
greater tensile and Izod impact strengths, 4 times greater flexural modulus and only
1/5 of the tensile creep.
Glass Transition Temperature (Tg)

Polymers come in many forms, including plastics, rubber, and fibers. Plastics are stiffer
than rubber yet have reduced low-temperature properties. Generally, a plastic differs from
a rubbery material due to the location of its glass transition temperature (Tg). A plastic has
a Tg above room temperature, while a rubber has a Tg below room temperature. Tg is most
clearly defined by evaluating the classic relationship of elastic modulus to temperature for
polymers as presented in Fig. 1.5.

page 12 of 612
Consider a molecular liquid which is slowly cooling down. At a certain temperature, the average kinetic energy of molecules n
exceeds the binding energy between neighboring molecules and growth of organized solid crystal begins. Formation of an ord
system takes certain amount of time since molecules must move from their current location to energetically preferred point a
nodes. As temperature falls, molecular motion slows further down and, if cooling rate is fast enough, molecules never reach t
destination — the substance enters into dynamic arrest and a disordered, glassy solid (or supercooled liquid) forms. In fact Ka
has argued that if such an arrest did not happen at still lower temperatues a thermodynamically paradoxical situation would a
where the undercooled liquid would have to be denser and of a lower enthalpy than the crystalline phase. Such arrest appare
place at certain temperature, which is called the glass transition temperature, Tg.
A full discussion of Tg requires an understanding of mechanical loss mechanisms (vibrational and resonance modes) of specific
common in a given material) functional groups and molecular arrangements. Factors such as heat treatment and molecular re
arrangement, vacancies, induced strain and other factors affecting the condition of a material may have an effect on Tg rangin
the subtle to the dramatic. Tg is dependent on the viscoelastic materials properties, and so varies with rate of applied load. Th
silly putty is a good example of this: pull slowly and it flows; hit it with a hammer and it shatters.
In contrast to the melting points of crystalline materials the glass transition temperature is therefore somewhat dependent on
scale of the imposed change. To some extent time and temperature are interchangeable quantities when dealing with glasses
often expressed in the time-temperature superposition prrinciple. An alternative way to discuss the same issue is to say that a
transition temperature is only truly a point on the temperature scale if the change is imposed at one particular frequency. Thi
the ability to modulate the temperature in a DSC experiment has made determining Tg considerably more precise. Since Tg is
rate (or frequency) dependent as the glass is formed, the glass transition is not considered a true thermodynamic phase trans
many in the field. They reserve this epithet rather for a transition that is sharp and history-independent.
In polymers, Tg is often expressed as the temperature at which the Gibbs free energy is such that the activation energy for the
cooperative movement of 50 or so elements of the polymer is exceeded. This allows molecular chains to slide past each other
force is applied. From this definition, we can see that the introduction of relatively stiff chemical groups (such as benzene ring
interfere with the flowing process and hence increase Tg. With thermoplastics, the stiffness of the material will drop due to th
This is shown in the figure below. It can be seen that when the glass temperature has been reached, the stiffness stays the sam
while, till the material melts. This region is called the rubber plateau.
Image:Rubberplateau.jpg
Tg can be significantly decreased by addition of plasticizers into the polymer matrix. Smaller molecules of plasticizer embed th
between the polymer chains, increasing the spacing and free volume, and allowing them to move past one another even at lo
temperatures. The "new-car smell" is due to the initial outgassing of volatile small-molecule plasticizers used to modify interio
(e.g., dashboards) to keep them from cracking in the cold, winter weather. The addition of nonreactive side groups to a polym
also make the chains stand off from one another, reducing Tg. If a plastic with some desirable properties has a Tg which is too
Acetal is the most important of all plastics. It offers long term dimensional stability and excellent lubricity. It is often used in ge
office equipment, irrigation equipment, autos, appliances, clocks and meters.
PBT produces extremely smooth surfaces in molding and is often used in housing.
Nylon offers toughness and wears well against other plastics. They are often used in worm gears and housings.
PPS offers high stiffness, dimensional stability and extended fatigue life.
LPC works well in small, precision gears under light loads, such as watch gears.
Plastic gear materials

Plastics – A General Review - Plastics, 66 pages.doc
35/99
The Advantages of Delrin®
• Most frequently used polymer for gears
• Superior dimensional stability and low water absorption
• Superior strength, modulus, flexural fatigue endurance, and high surface hardness
• Lower coefficient of friction against steel
• Available in a variety of lubricated compositions for improved friction and wear performance
The Advantages of Zytel®

• Performs at higher service temperatures
• Resin of choice for worm gears
• Used as a dissimilar material against Delrin® to reduce gear wear and noise
• Lower surface hardness and modulus which reduces mesh noise against steel
• Better resistance to mild acids and bases
• Provides more forgiving, tougher gear teeth
The most commonly used compositions of Delrin® and Zytel® for gears are provided in
Delrin Vs. nylon Comparision Chart

Dupont - Engineering Polymers for High Performance Gears - Gear_Brochure_11_06, 26 pages.pdf
7/26
HDT is also called DTUL (deflection temperature under load)

Page 11/22
Brittleness is the opposite of toughness. As a rule,

reinforced thermoplastics show higher stiffness and
lower impact properties,or more brittleness than
unfilled plastics.
Honeywell Plastics Design Solutions Guide plastic, 92 pages.pdf
82/92
Glass Transition Temperature

At the glass transition temperature, Tg, a material undergoes a significant change in properties. Generally, below the glass tra
temperature, the material has a stiff, glassy, brittle response to loads, while above the Tg, it has a more ductile, rubbery respo
31/84
>Tg Plastic = ductile, rubbery

< Tg Plastic = Stiff, glossy, brittle
< Stiff, glossy, brittle to > ductile, rubbery
Vicat Softening Point
This is the temperature at which a small, circular, heated, lightly loaded probe penetrates a specific distance into a thermopla
specimen. Figure 4.01 shows a typical test apparatus. This test is useful for crystalline materials, but is of somewhat limited va
amorphous thermoplastics, which tend to creep during the test. This test indicates the ability of
a thermoplastic to withstand a short-term contact with a heated surface.
31/84
Nonuniform mold shrinkage behavior is an undesirable phenomenon in injection molding since it can lead to the following:
• Distortions of the finished part (warpage)
• Difficulties in hitting the target dimensions
• Higher internal stress levels
Shrinkage and Warpage, 8 pages

5/8
Plastic is Brittle Ductile with respect to Temperature material i.e., if temperature is less means than it will be Brittle, if tempera
more means than it will be Brittle,
page 11 of 72
Relationships between Polymer Properties and Morphology

4/22

Page 4/22
Table 2. Relationships between Polymer Properties and Morphology

Property Crystalline Amorphous
Light transmission High None to low
Solvent resistance High Low
Lubricity High Low
Dimensional stability High Low
Mold shrinkage High Low
Resistance to dynamic fatigue High Low
Facility to form high strength fibers High None
Thermal expansion coefficient High Low
Melting temperature Sharp Absent
Dependence of properties on temperature High Low
Crystalline Polymers vs. Amorphous Polymers

Plastic & Thermoplastic Elastomer Materials 05_Plastic-Thermoplastic, 7 pages.pdf
4/7
Crystalline Polymers vs. Amorphous Polymers

14/84
Designer Check List

Hanser The Complete Part Design 20060608_26681914-85_3-446-40309-4_Leseprobe01, 12 pages.pdf
6/12
Design checklist
Ticona, DesignChecklistres72dpi, 1 pages.pdf
Goodfellow Polymer properties, Tab303a, 24 pages.pdf
Plastics various charts - Electric, chemical, mechincal, physical & thermal properties,
Thermoplastics Vs. various chemical compoounds resistance chart
Plastic & Thermoplastic Elastomer Materials 05_Plastic-Thermoplastic, 7 pages
6/7
Chemical resistance of various materials by chemical classes

41/84
Chemical Resistance of Engineering Thermoplastics

19/22
Approximate,* in Dollars per Cubic Inch of Plastics - price - cost - rupee
117 pages, design_of_plastic_products, triangle, book.pdf
page 16 of 117
Price cosr rupees Chart for Various Plastics:

41/99
Approximate,* in Dollars per Cubic Inch of Plastics - cost, price

8.16 - 16/117
engineering thermoplastics high performance thermoplastics price cost ruppes chart

Page 16/22
Material properties list

Price Ruppe cost
Plastic Materials Guide - pm_guide, 6 pages.pdf
Commonly used Polymers in Injection Molding - properties - with cost rupee price
Injection Molding Basics mfg-injection-molding, 50 pages.pdf
4/50
Injection Molding Costs.ppt

Parameters of the Molding Process-m142_c12-param, 31 pages.ppt
31/31
Cost, Price, rupee chart
plastic raw materials.xls
SOLID PROPERTIES OF POLYMERS - definitions

Good for Theoritical definitions - all plastics
page 12 of 612
86 pages, Bayer, engineering polymers, material selection, thermo plastics & plouterthanes, a des.pdf
lot of definitions
UNDERSTANDING ENGINEERING PLASTICS 6/86
MECHANICAL BEHAVIOR OF PLASTICS 13/86
Various definitions
8.21 - 21/117
Physical Properties and Terminology - definitions

82/92
Definitions
ides-Getting the Most Out of Your Data - By Michael Sepesepe, 29 pages.pdf
all pages
definitions
Mechanical Property of Plastics, 7 pages.doc
Properties & Definitions
15/84
Definitions Melting point & Glass transiiton temp. gdt

Week 1 Visco-elasticity, 71 pages.ppt
9/71
Glass Transition temperature (Definition inside flextural modulus definition 10/29)

all pages
various fasteners to join plastics

page 60 of 72
Mechanical fasteners
136 pages, General Design Principles for DuPont Engineering Polymers H76838
page 70 of 136
Guidelines for self-tapping fasteners:

48/92
Bolt assembly, stress problems and solutions

76/84
Structural Design Formulae

Structural Design Formulae-L12565_4, 24 pages.pdf
13/24
ADVANTAGES AND LIMITATIONS OF self tapping screw FASTENERS

Honeywell, Smart Structure and Integrated System, Reinforced Nylon and Aluminum Self-Tapping
Scre.doc.pdf
2/21
Effect of Glass fiber filler in Poly carbonate

all pages
Detail of rectangular edge gates & another gates

LNP_Injection_Molding.pdf
11 of 36
Various gate
51 pages, A Troubleshooting Forum & Workshop on Injection Molded Parts-Presentation_ITP 09.pdf
page 10 of 51
Schematic of different gating systems

page 10 of 51
Types of gate :
Sprue, Pin, Edge, Ring, Diaphram, Fan, Film & tab
612 pages, Book, Handbook of Plastics Technologies110.pdf, page no. 32
Three-plate runner system guidelines.- gate design

170 pages, Part and Mold Design Guide,.pdf
139/170
Plastic gear materials

35/99
Delrin Vs. nylon Gear Comparision Chart

Dupont - Engineering Polymers for High Performance Gears - Gear_Brochure_11_06, 26 pages.pdf
7/26
For detailed diagram of injection moulding machine

lecture 16 plastics 3.pdf
page 1 of 5
For detailed diagram of injection moulding machine

8 & 9 of 36
Equipment factor chart

20 of 36
Multi-shot injection molding213Compatible

page 17 of 72
Co-injection Molded Parts

page 18 of 72
Gas Assist Injection Molding

page 19 of 72
“Metal” Injection Molding (MIM)

page 20 of 72
Part Cooling calculations

page 36 of 72
Sidewall openings molded without any special mold action

page 50 of 72
Approximate Clamp forces for injection shot capabilities

170 pages, Troble shooting in plastic injection molding machines-njit-etd1993-013, book.pdf
page 50 of 170
Liquid injection moulding
page 74 of 170
Aspects of gas-injection moulding

Gas-Injection Moulding with DuPont engineering polymers - GasInj_e, 8 pages
page 8 of 8
Rotational molding
page 103 of 117
Typical processing conditions for glass reinforced compounds

page 4 of 36
polyamide-imide TORLON_Molding_Guide, 16 pages.pdf

Traingle
page 2 of 16
Injection Molding Guidelines for Unfilled Materials

612 pages, Book, Handbook of Plastics Technologies110
page 33 of 612
Bonding for Thermoplastic Combinations in Multicomponent Injection Molding

page 39 of 612
Coinjection moulding – sandwhich moulding Page no. 36

117 pages, design_of_plastic_products, triangle, book.pdf, page 33
Suggested Drying Conditions for Generic Thermoplastic Resins

Harper Ch. A., Petrie E. M. - Plastics Materials and Processes. A Concise Encyclopedia(2003)(974),
handbook.pdf
page 175 of 988
HOT-RUNNER SYSTEMS
148/170
Hot runners
Product and mould design - completed product__mold_design, 19 pages.pdf
11/19
Hot runner technology
ATI Hot Runner Technology Today-Systems, Developments, Trends, hot_runner, 12 pages.pdf
Hot runner systems
Realize the potential, feel the difference, Injection moulding guide, im, 33 pages.pdf
17/33
injection-molding-processing-guide.pdf
page 6 of 14
page 4 of 36
mde_injection_molding_troubleshooting_guide.pdf
2 of 11

page 12 of 51 super
Various molding defects

page 28 of 72
Processing steps via a fishbone diagram.

complete injection molding process, 27 pages.pdf
page 18 of 27
Dupont Hytrel thermoplastic polyester elastomer Injection Molding Guide H81091, 37 pages.pdf
page 26 of 37
Troubleshooting Tips for Injection Blow Molding.pdf

Equistar - Troubleshooting Tips for Injection Blow Molding - Troubleshooting Injection Blow, 3 pa.pdf
NYLON RESINS - CORRECTING MOLDING PROBLEMS - A TROUBLE SHOOTING GUIDE

firestone - nylon resins correcting molding problems a trouble shooting guide-Injection Molding, .pdf
firestone - nylon resins correcting molding problems a trouble shooting guide-Injection Molding, .pdf
page 5 of 12
Injection molding trouble shooting guide for LNP* engineering compounds
page 4 of 36
Torlon Polyamide imide Trouble shooting guide

polyamide-imide TORLON_Molding_Guide, 16 pages.pdf
page 10 of 16
L12565_2.pdf
page 2 of 4
Injection moulding truble shooting
Udel Polysupone Injection moulding truble shooting - Indication Chart
Solvay-polysulpone-Udel_Design_Guide, 80 pages.pdf
65/80
Injection moulding troubl shooting - Indication Chart
BASF-Injection Molding-Trouble Shooting Guidelines-injmoldtroubleshooting, 1 pages.pdf
GE Injection moulding mini guide - Shwon with photo
GE Injection moulding mini guide 8654, 43 pages.pdf
injection moulding Troubleshooting - with photo
GE plastics injection moulding mini guide - injection process design aids, 41 pages.pdf
23/41
injection moulding Troubleshooting with photo
Huntsman-Processing Parameters-Injection molding-Injection_Molding110705, 10 pages.pdf
8/10
injection moulding Troubleshooting - Indication Chart
injection moulding trouble shooting chart- molding troubleshooting, 1 pages.pdf
injection moulding Troubleshooting - Indication Chart
Injection_Troubleshooting_Guide, 1 pages.pdf
injection moulding Troubleshooting
mde_injection_molding_troubleshooting_guide, 11 pages.pdf
2/11
Injection Moulding Trouble Shooting Guide

Performance Plastics Injection Moulding Trouble Shooting Guide - trouble_shooting_guide, 3 pages.pdf
Injection Molding Troubleshooting

Realize the potential, feel the difference, Injection moulding guide, im, 33 pages.pdf
29/33
Injection Molding Troubleshooting - Indication Chart

RTP Company Trouble-Shooting Guide - trouble, 1 pages.pdf
1/1
Injection Molding Troubleshooting - Indication Chart
Injection Molding Troubleshooting Guide - inject1, 1 pages
Advanced composites Material Processing Guidelines and Troubleshooting Guide ACP Material Process
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`Troubleshooting' search by windows F3

D:\Engineering\Engineering 1\plastic design\www.ides.com\experts\ides-experts plastic processing-bob
hatch
This is for free lance reading and exploring from free time

Inj molding, 12 pages.doc
7/12
Trouble shooting of injection moulding-korea engg. plastics-kh-m-04-0, 7 pages

injection moulding trouble shooting guide for Eastar polymers - PPD407, 29 pages.pdf
Cannot be copied, to be converted to ms wordand to be done., To be incorporated
For Drafts, Ribs, bosses & gussets diagram

page 6 of 36
Rib Design
page 55 of 117
Boss Design
page 60 of 117
Part Design for Insert Molding

page 18 of 136
Delrin Gear Design

page 51 of 136
Self tapping Screw & Plastic part Boss

38 pages, engg plastics, Joining Guide.pdf
Page no. 9 of 38, Refer Figure 5
Rib Design Guideline

25/170
Boss Design Guideline

26/170
Stuctural design, beam bending formulas

62/170
Designing for Uniform Walls

Designing for Ribbed Walls
Designing without Stress Concentration
Gate Location
Designing for Assembly
Designing with Clearance on Threads
Dupont plastic part design list H81079, 6 pages.pdf

All pages
Various srructural formulas

20/92
insert guide lines, 9 pages.doc
Section properties for some common cross-sections

45/84
Design of bosses
63/84
Boss Design
plastics part design and mouldability -pdc1, 23 pages.pdf
20/23
Rib, Gusset, Boss design
Product and mould design - completed product__mold_design, 19 pages.pdf
4/19
Boss design (For self tapping screws & ultrasonic welding)

76/80
GE plastics - injection moulding design guideline - completed GE GUIDELINE, 15 pages.pdf
Guidelines for Machining Engineering Plastics.pdf
Guidelines for Machining Engineering Plastics, 2 pages.pdf
Plastic Numbering (bottle)
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4/7
Scientists who discovered the plastic materials with years:

List of Acronyms for plastics:
3/66
Properties chart
MechanicalPropertiesofPlastics.pdf
all pages / 4 pages
Higher mold temperature chart

17 of 36
Polypropelene properties
page 135 of 170
Typical properties of PC Lexan 141R

234 pages, shrinkage and ejection forces in injection moulded products AJPONTES_thesis.pdf
page 100 of 234
Coefficients of Linear Thermal Expansion (CLTE) for Common Materials

86 pages, Bayer, engineering polymers, material selection, thermo plastics & plouterthanes, a des.PDF
PAGE 42 OF 86
Property Vs. Recommended Materials

page 14 of 117
Celcon™Acetal M90 Copolymer—Typical Properties

page 20 of 117
THERMOPLASTIC PROPERTIES
plastics_properties_2.pdf
Nylon grades properties comparison chart
nylon (PA)\NYLON PLASTIC.mht
Comparative Properties of Thermoplastics
page 15 of 612
Thermoforming Process Temperatures for Selected Materials
page 47 of 612
Properties of Reinforced Nylon 6,6

page 338 of 612
WATER ABSORPTION chart
water-absorption-plastics.pdf
Brittle Temperature chart of plastics

handbook.pdf
page 96 of 988
Mechanical Engineers' Handbook (www.eBookByte.com) Ch-08.pdf

super properties of various materials
Important Properties of Plastics and Listing of Plastics Suppliers

handbook.pdf
page 645 of 988
Delrin Data sheet

Acetal products quadrant bearingAndWear2, 2 pages.pdf
Plastics propeties comparision chart
Curbell - Product and comparision chart - Curbell_Plastics_Properties_Chart, 2 pages.pdf
Plastics Available for Processes chart
8.41 - 41/117
Coefficients of Table 3-8 Linear Thermal Expansion (CLTE) for Common Materials
79/170
Producers and Trade Names of Engineering Thermoplastics

Page 6/22
Property Comparison for Selected Plastics

Hanser The Complete Part Design 20060608_26681914-85_3-446-40309-4_Leseprobe01, 12 pages.pdf
5/12
Thermal Conductivities of Solids, Liquids and Gases with Temperature

60/92
plastic - Material properties - 330-333, 4 pages.pdf
all pages
plastic & elastomers identification chart - New ID chart, 1 pages
Properties of PEEK
21/22
Approximate drilling speed and feed rate for 1/4 – 3/8 in. hole in various thermoplastics
81/84
Typical Properties* of Udel Polysulfone (U.S. Units)

Solvay-polysulpone-Udel_Design_Guide, 80 pages
11/80
Material properties list
Rutland plastics - Material Properties and Applications - materials summary table, 2 pages
PROPERTIES OF PLASTIC MATERIALS
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Material Properties and Applications
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thermoplastic selection guide
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Torlon PAI Material properties
Torlon_Design_Guide, 53 pages.pdf
9/53
Material name Abbreviation Trade names Description Applications

Inj Molding (detailed), 25 pages.doc
12/25
Injection Molding Parameters-Melt Temperature

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6/31
Plastic properties
Typical Property Data to Compare Types of Plastics, pages.mht
Snap fits
page 76 of 136
Snap fit design

84/170
Snap fit design

Hanser Designing with Plastics 20060105_261515524-85_3-446-22590-0_Leseprobe_2, 15 pages.pdf
4/15
Snap fit design

20/92
Snap fit design

66/84
Test Type Vs. Standard

8.27 - 27/117
Properties, Units and Standard Methods of Measurement of Engineering Thermoplastics
Page 10/22
ISO and ASTM Test Methods

88/92
Approximate Part Size Ranges for the Principal Processes

page 42 of 117
Suggested Wall Thicknesses for Thermoplastic Molding Materials

page 97 of 117
Approximate Part Size Ranges for the Principal Processes

8.42 - 42/117
Typical Nominal Thickness for Various Thermoplastics

Design Considerations For Injection Molded Parts, Designing_In_Plastics_Part_1_02_339res72dpi, 6 .pdf
2/6
Typical Nominal Thickness for Various Classes of Thermoplastics

58/84
Tolerance Guide for Plastic Profile Extrusions

page 93 of 117
Tolerance Guidelines
Plastics APSI-Ext-design-tolerance-guidelines, 2 pages.pdf
Process Vs. Part diemnsion vs. Tolearnce chart
Injection Molding Basics mfg-injection-molding, 50 pages.pdf
34/50
Traingle diagram 8.13 - 13/117
traingle chart
How to choose plastic, 11 plastic.ppt
8 of 11
Triangle chart
Plastic & Thermoplastic Elastomer Materials 05_Plastic-Thermoplastic, 7 pages.pdf
3/7
Traingle chart
quadrant engineering plastic products, 13395_FACTSHEET_EPP_engl, 4 pages, triangle chart.pdf
2/4
Traingle chart
NylonApplicationsCPE, 49 pages, triangle.pdf
1/49
Triangle chart
2/80
Triangle chart
Classification of Plastics triangle, techinfop3, 1 pages
1/1
Traingle chart
thermoplastics_selection_guide, 1 pages, triangle.pdf
A guide to tool surface enhancements commonly used in the plastics processing industry
9 of 36
Polyethylene Shrinkage Changes from Part and Process Changes

page 6 of 27
The Effect of a Variety of Pigments on the Linear Shrinkage of PBT

page 12 of 27
Plastics Available for Processes

page 41 of 117
Blow modeling design

page 81 of 117
Weld profile
page 92 of 136
Formula for thermally induced stress

38 pages, engg plastics, Joining Guide.pdf,
page 13 of 38
Slots in inclined walls without side core

72 pages,2003NMW_Design_with_Plastics.pdf, Page 50
Also refer : 136 pages, General Design Principles for DuPont Engineering Polymers H76838.pdf, Page 13
170 pages, Part and Mold Design Guide.pdf, Page 35
Guidelines on Part Design for Plastic Processing Methods

Harper Ch. A., Petrie E. M. - Plastics Materials and Processes. A Concise Encyclopedia(2003)(974).pdf
page 23 of 988
Properties of Glass Fibers

handbook.pdf
page 261 of 988
Hot Plate Temperatures to Weld Plastics and Plastic Films
handbook.pdf
page 280 of 988
Film Selection Chart

988 pages, Book, plastics materials & processes, a concise encyclopedia Plastics Materials and Pr.pdf
page 15 of 988
A good file for polymer chemistry study

polymer basics, allison calhoun, 0392sampbk1, 6 pages
WWW Sites Containing Data Sheets of Engineering Thermoplastics
Page 15/22
Why Plastics Fail
WhyPlasticsFail, 2 pages.pdf
Troubleshooting Tips for Injection Blow Molding

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2/3
Advantages of Engineering Plastics versus Metals

NylonApplicationsCPE, 49 pages, triangle.pdf
3/49
ExxonMobil™ Polypropylene Resins (Unfilled)
Typical Processing Conditions
Know Your Material, machine & Mold
Amorphous vs.
Semicryastalline
Amorphous vs.
Semicryastalline
Amorphous vs.
Semicryastalline
Amorphous vs.
Semicryastalline
Amorphous vs.
Semicryastalline
check list
check list
Chemical
Chemical
Chemical
Chemical
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Cost
Definitions
Definitions
Definitions
Definitions
Definitions
Definitions
Definitions
Definitions
Definitions
Fastener
Fastener
Fastener
Fastener
Fastener
Fastener
Filler
Gate Design
Gate Design
Gate Design
Gate Design
Gate Design
Gear Design
Gear Design
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
GIM
Hot Runner
Hot Runner
Hot Runner
Hot Runner
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
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Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
Trouble Shooting
Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
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Injection Moulding
Trouble Shooting
mech design
mech design
mech design
mech design
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Numbering
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Cost
Properties Chart
Properties Chart
Properties Chart
Properties Chart
Snap Fit
Snap Fit
Snap Fit
Snap Fit
Snap Fit
Test Standards
Test Standards
Test Standards
Thickness
Thickness
Thickness
Thickness
Thickness
tolearnce
tolearnce
tolearnce
Triangle Digram
Triangle Digram
Triangle Digram
Triangle Digram
Triangle Digram
Triangle Digram
Triangle Digram
Triangle Digram
Properties Chart
GIM
Defect Cause
Brittleness ---
Wet material
Overheating
Brittleness Molded-in-stresses
Poor part design
Weld-lines
Brittleness --
A. Low melt temperature
B. Polymer degradation due to overheating.
C. Excessive moisture in resin
D. Contamination or excessive
PART BRITTLENESS E. Excessive regrind.
F. Slow injection rate
G. Improper location of gate
H. Gate size too small
1. Moisture in material
2. Excessive melt temperature
3. Melt temperature to low
Brittleness 4. Contamination
5. Excessive amounts of regrind
6. Improper gate size/location
Brittle parts Wet material

Brittleness --
Part temperature differential

Excessive shrinkage
Orientation of material
Poor part design
Warped parts Ejection problem
Cooling is too short, material is too hot, lack of cooling around the tool,
Warping incorrect water temperatures (the parts bow inwards towards the hot side of
the tool)
Anisotropic shrinkage.
WARPED PARTS
High molded-in stress.
Warpage / Disportion ---

A. Low melt temperature
B. Parts ejected too hot
C. Varying wall thickness
D. Non-uniform filling
PART WARPAGE E. Improperly designed knockout system
F. Poor pressure distribution
G. Overpacking
H. Lost contact with cavity surface.
A. Molded-in stresses are too high
due to:
1.
Excessive packing of the cavity
2. Cavities being filled too slowly
3. Melt temperature being too
low or non-homogenous
B. Part is being ejected while still
too hot
C. Ejector mechanism is improperly
designed
D. Part is improperly designed
Warpage or part (non-uniform walls)
E. Gates are improperly located
deformation and/or designed
F. Undercuts, ribs, bosses, threads,
etc., are improperly designed
G. Mold cooling is inadequate
(Capacity of the cooling system
is too low, cooling circuits in the
mold halves are not balanced,
heat transfer is poor)
H. Moveable mold components
(cores) have shifted or become
misaligned
I. Runner system is inadequate
Warpage/ --
part distortion
part
wrong part design
part too heavy
machine
insufficient cooling time
too high injection pressure
Warpage, part mould
distortion wrong gate location:different shrinkage in different flow directions
too big undercuts
inadequate ejector pins
cavity too hot
material
orientation of fillers
wrong material choice
1. Part ejected while too hot

2. Shrinkage differential due to non-uniform shrinkage
3. Melt temperature too low
Warpage 4. Shrinkage differential due to non-uniform wall thickness
5. Insufficient pack and hold times or pressures
6. Ejection system poorly designed
7. Differential mold cooling
Warpage --
Inadequate clamp tonnage

High Injection Pressure
Flashing Misaligned platen
Excessive vent depth
Flashing --
Flash ---
Flashing --
1. Excessive melt/mold temperature

2. Excessive packing of material
3. Injection pressure to high
Flashing 4. Projected area to large for available tonnage
5. Uneven or poor parting line and mating surface
6. Mold clamping pressure not properly adjusted
7. Non- uniform cavity pressure due to unbalanced filling
Flashing/Burr ---
Inadequate clamp tonnage
High Injection Pressure
Flashing Misaligned platen
Excessive vent depth
Too much injection pressure.

Too much material.
Material viscosity too low.
PART FLASHES Tool too loose.
Not enough clamp capacity.
Flashing --
A. Excessive pressure.
B. Temperature excessively high.
C. Overpacking.
D. Injection force greater than available clamping forces.
PART FLASHING E. Clamping pressure too low.
F. Mold deficiencies.
G. Insufficient venting.
H. Foreign matter left in mold.
I. Improper mating of mold surfaces
Boost time too long
Clamp pressure too low
Flash Mold damaged or misaligned
Wet material
A. Injection pressure is too high

B. Too much material is being
C. Material is too hot
D. Clamp end of press is out of adjustment
E. Flash or foreign material is acting as a high spot on
mating surfaces of the mold
F. Mold surfaces, cores and/or cavity inserts are out of register.
Flashing G. Mold or platens are warped
H. Clearance in vents, knockouts, etc., is too great
I. Venting is insufficient or blocked thereby forcing material from the cavity area
J. Injection pressure is unevenly
K. Projected cavity area is too large
for the available clamping clamping pressure.
Pressure
Air trapped in cavity

Barrel or nozzle overheating
Shear heat
Burn marks Contamination
Hang-up in molding machine
Burns Dieseling in the mold
Burn marks --
Burn Marks Tool lacks venting, injection speed is too high
A. High melt temperature

B. Injection rate too rapid
BURN MARKS C. Entrapped air in mold.
D. High moisture content in resin
Air trapped in cavity

Barrel or nozzle overheating
Shear heat
Burn marks Contamination
Hang-up in molding machine
Burn marks --
Vents clogged
Burn marks Insufficient venting
Fill rate too fast
A. Material is too hot
B. Molten resin is exposed to air in
the machine due to starving the
feed section or entraining air in
the screw feed
C. Vents are inadequate or blocked
D. Material is entering the cavities
Burning, charring too rapidly
E.
or black specks Material is hanging up in the
heating cylinder and/or nozzle
(generally indicated by specks or
streaks in the molded item)
F. Regrind is of questionable quality
G. Previous polymer or purge
material has not been completely
removed
Insufficient venting
Weak weld-lines Injection speed or mold temperature too low
Incorrect gate location
Weak weld-lines Injection speed or mold temperature too low
Incorrect gate location
1. Melt temperature too low
2. Mold temperature too low
3. Insufficient pressure at weld line
Weak weld-lines 4. Air trapped in mold
5. Injection rate to slow
6. Flow distance from gate to weld line area excessive
weld-lines --
A. Low melt temperature.

B. Cold mold
POOR WELDS/WELD C. Insufficient pressure
LINES D. Entrapped Air
E. Excessive lubricant/mold release
F. Excessive distance from gate to weld lines
Poor Weld Line ---

Strength
Weld lines (Knit lines) --
Poor venting.
POOR KNIT LINES
Too cool a melt.
Over packing
Sticking in mold Mold design
Over packing
Sticking in mold Mold design

A. Overpacking.
B. Parts too hot.
C. Low nozzle temperature.
D. Insufficient knockout
E. Insufficient mold release
PARTS STICKING IN F. Inadequate sprue puller
MOLD G. Improper mold surface finish
H. Inadequate draft or cavities/sprue
I. Cavity misalignment/core shifting.
J. Cavity pressure non-uniform 1. Redesign runner-gate system for (multi-cavity
mold)
K. Surface imperfections and undercuts in mold.
1. Over packing material in mold

2. Insufficient draft on cavities/sprue
3. Part to hot for ejection
Parts sticking in mold 4. Undercuts to big to allow part release
5. Molded part sticking to stationary half of mold
6. Knockout
Sticking in mold --
Sticking in sprue --
bushing
1. Nozzle orifice is larger then sprue orifice

2. Insufficient taper on sprue bushing
Sprue Sticking 3. Imperfections on inside of sprue
4. Over packing material in sprue
5. Nozzle temperature to low to provide clean break
A. Improperly fitted sprue nozzle interface.

B. Sprue bushing taper insufficient
C. Pitted surfaces
SPRUE STICKING D. Inadequate pull back
E. Overpacking in sprue.
F. Sprue diameter excessive
G. Low nozzle temperature
Surface imperfections Injection speed too low

(frosty surface or Cold melt/cold mold
white marks) Wet material
Glass fibre streaks --

B. Cold mold
C. Slow injection rate.
PART SURFACE D. Insufficient material in mold
IMPERFECTIONS E. Water or condensation on mold
F. Excess lubrication on mold surface
G. Moisture in resin
H. Mold surface defects.

2. Mold temperature to low
3. Insufficient packing of the part
Surface Imperfections 4. Insufficient material in mold
(Glass on surface, 5. Injection rate to slow
mineral bloom) 6. Water on mold surface
7. Excessive build up of lubricant on mold
9. Inadequate venting
Holding pressure or time too low

Sinks or voids Insufficient feed
Gate freezing off or located improperly
Sink marks ---
Voids ---
VOIDS OR SINKS
Voids occur inside the Material shrinkage & insufficient supply of molten material.
part. Sinks pull away Not enough pack pressure during material solidification.
from the mold wall.
1. Improper part design

2. Insufficient pack and hold times
Sinks and Voids 3. Insufficient volume of material
4. Gate freezes off prior to properly packing out part
Sinks or voids --
Sink marks --
Wet material
Gate too small
Runner too small
Runner too long
Injection rate too slow
Internal voids Hold time too short
Hold pressure too low
Resin melt or mold too cold
Jetting
Sink Mark --
A. Insufficient pressure on parts.

B. Insufficient material packed into cavity.
C. High melt temperature.
SINK MARKS D. Premature freezing of gate.
E. Parts ejected too hot.
F. Heavy sections adjacent
Voids (Bubbles) --
Bubbles ---
BUBBLES
Part surface bulges Gas entrapment
above a bubble
Voids ---
A. Excessive moisture in resin
VOIDS/BUBBLES B. High melt temperature.
C. High internal shrinkage due to insufficient material in cavity.

LAMINATION AT THE B. Cold mold
C. Slow injection rate
GATE D. Low holding pressure.
E. Small gate size.
Shot to Shot variation

Dimensional Melt temperature variation
Inadequate packing
inconsistency
Shot-to-shot ---
dimensional change
Dimensions Out of Loss of control of shrinkage

Specification
A. Inconsistent molding conditions.
B. Machine control malfunctions or
inadequate controls, resulting in
DIMENSIONAL temperature variations.
C. Resin feed non-uniform
VARIATIONS D. Non-Uniform cavity pressure due to
unbalanced runner.
E. Poor part design.
F. Material variations.
Dimensional --
inconsistency
1. Non-uniform feeding of material

Dimensional 2. Insufficient packing of part
3. Regrind levels inconsistent
inconsistency 4. Melt pressure variations
5. Unbalanced runner system
A.
Non-uniform feed due to:
1.
Variation in machine operation
2.
Variation in the material
B.
Dimensional Cylinder temperatures are
variations cycling too broadly
C. Cycles are inconsistent
D. Machine capacity is too small
E.
Mold temperatures inadequately
controlled
• Check location of coring.
Inadequate shot size.

Shorts Vents blocked.
Not enough material.
Blockage in flow atthe feed-throat.
PART SHORTS Not enough injection pressure.

No burn marks Material too high in viscosity.
Short Shuts & poor --
surface finish
Short shot, record --

groove effect
Short shots ---

Short Shots 3. Insufficient material volume
4. Air entrapment causing resistance to fill
5. Restricted flow of material to cavity
Short Shots ---
Short Shot --
Short Shots --
PART SHORTS Gas trapping/ poor

and has burn marks venting.
Progressively Residence time too long

Barrel temperature too high
shorter shots Shot size too small
Inconsistent Shot --
A. low melt temperature.
B. Cold mold.
C. Insufficient pressure on material in cavity pressure.
D. Inadequate feeding of material
SHORT SHOTS E. Entrapped air/resistance to fill
F. Flow to cavity restricted
G. Unbalanced flow (in multicavity mold)
H. Poor part design.
Short shots—at the

start of injection 1) Shortage of material
molding operation— 2) Machine capacity is too small
injection ram is 3) Polymer melt is slipping past the screw (ram)
bottoming
A. Injection time is too short
B. Injection pressure is too low
Short shots—at the C. Cylinder temperature is too low
start of the injection D. Heater bands on the nozzle or cylinder are inoperative
E. Nozzle, sprue or gates are blocked or frozen
molding operation— F. Excessive resistance to flow in
injection ram is not the sprue bushing, runners, vents consistent with machine shot capacity
bottoming and/or gates
G. Material viscosity is too high
(melt index is too low)
A. Check Items D and E in Section II

B. Loss of injection pressure
Short shots—after C. Venting is inadequate (usually accompanied by burned orcharred spots on
a period of successful molded part)
injection D. Shortage of material
molding operations E. Interrupted feed
F. Polymer is sticking in the feed throat
Short shots—
occur periodically A. Cylinder temperature controller is cycling too broadly
during injection B. Cycles are inconsistent
molding operations
1. Contamination in material
2. Heater Band malfunction
3. Contamination from previous run
Black Specks
4. Degraded Polymer
machine
· down time too long
· barrel switched off
over a long period
of time
· poor purging of barrel
· dirty plasticizing unit
· inadequate nozzle
Black specks mould
· dead edges in gate/
runner system
material
· granule impurities
· degradation by other resins
· pick-up of degraded
material from cylinder wall
during cooling
machine
· injection pressure too low
· inadequate functioning of back flow valve
· suck-back too long
· plasticizing too fast
· air trap in the hopper feed
· improper feed
Blisters, bubbles
mould
· volatiles and trapped gas
· mould temperature too low
· thin to thick transition
material
· melt overheating
2. Air Entrapment
Blisters/Bubbles
3. Degraded polymer
Tool or material is too hot, often caused by a lack of cooling around the tool or
Blister a faulty heater
Blister --
1. Burrs or sharp corners at the gate

Burns in gate area 2. Gate size to small
3. Color concentrate shear sensitive
1. Plugged vents
2. Over clamping
Burns at the end of fill 3. Inadequate vents
4. Melt temperature to high
5. Injection rate to fast
1. Contamination
2. Part removal
Cracking/Crazing 3. Packing excessive material into the mold
4. Non-uniform or too cold of a mold temperature
5. Chemical contamination
A. Excessive packing resulting in highly
stressed area at gate.
B. Low mold temperature
CRAZING/CRACKING C. Mold cooling non-uniform
D. Improperly designed knockout system
E. Excessive undercut
F. Draft angles inadequate
Crazing --

2. Material contamination
3. Incompatible color concentrate
Delaminating 4. Injection rate to low
5. Air entrapment in mold
Contamination of the material e.g. PP mixed with ABS, very dangerous if the
Delamination part is being used for a safety critical application as the material has very little
strength when delaminated as the materials cannot bond
Delaminating --
1. Material Overheating
Discoloration 2. Material oxidized by drying at to high temperature
3. Contamination by foreign material
Discoloration/ ---
Burning
Poor dispersion.
NON-UNIFORM
COLOR
Contamination.
Poor concentrate mixing or

Non-Uniform Color dispersion
A. Overheating in cylinder.
MATERIAL B. Material hanging up in cylinder
C. Oxidation/ degradation due to excessive drying temperature.
DISCOLORATION D. Contamination
E. Flow over sharp projections
A. Because of poor mixing . . .

1. In a ram machine
2. In a screw machine
B. Because of the pigment . . .
1.
Particles are too coarse
Poor color 2. Feed is non-uniform
3. Pigment is difficult to disperse
dispersion C. Because of the concentrate . . .
1. Letdown ratio is too great
2. Base polymer is not compatible
with Hytrel
3. Pigment concentration is
too high
1. Poor mold cooling
2. Clamp speeds slow
Excessive Cycle Time 3. Melt and mold temperatures to high
4. Screw recovery time excessive

2. Mold Temperature to low
Flow lines 3. Gate size to small
4. Non- uniform wall thickness

B. Low mold temperature.
FLOW LINES/MARKS C. Injection rate too rapid.
D. Jetting due to improper gate size
FLOW MARKS
Back fills Filling from thin to thick sections.
Surface irregularity.
Shadowing Uneven filling of section.
Folds
Flow marks ---
1. Nozzle temperature to hot

Nozzle Drooling 2. Moisture in material
A. Nozzle temperature too high
B. High melt temperature
C. Excessive moisture in resin
NOZZLE DROOL D. Nozzle orifice too large
E. Excessive cycle time.
F. Lack of lubrication
G. Improper type nozzle
1. Excessive moisture in material

2. Melt temperature to high
Splay (Silver 3. Excessive shear heat
Streaking) 4. Air entrapment
5. Condensation or excessive lubricant on mold surface
6. Moisture condensing in feed section of barrel
Splay ---
Silver streak ---

A. Excessive moisture in resin
B. High melt temperature.
SPLAY/SILVER C. Condensation on mold surface
STREAKING D. Excessive mold release agent on mold surface.
E. Moisture condensing on unmelted resin in feed sections.
F. Melt fracture
Surface Defects Moisture in part.

(Streaks) Possible mold sweating.
SURFACE DEFECTS
Silver streaking or Contaminated material.
splay High shear in the material.
marks
SURFACE DEFECTS High molecular

weight compound in
Uneven shine highly polished
Beach marks mold.
Brown streak & ---

Black spots
Burnt streaks --
(brown)
Streaks --
Moisture streaks --
Jetting
a „snake-like or
spiral-shaped“ --
pattern on the
surface of a molede
part.
Jetting --
Jetting Poor tool design, gate position or runner. Injection speed set too high.
Jetting ---
Shrinkage --
A. Gates not frozen off
B. Effective injection pressure in
the cavities is too low
1. Gates are too small or
improperly designed
2. Runner system is improperly
designed (diameters and
Excessive layout are incorrect)
3. Melt temperature is too low
shrinkage 4. Flow rate of material is too low
5. Nozzle orifice is too small
C. Injection pressure is too low
D. Mold temperature is too high
E. Not enough material in the cavity
F. Dwell time is too short
G. Molding conditions not optimized
Holding time/pressure too low, cooling time too low, with sprueless hot
Sink Marks runners this can also be caused by the gate temperature being set too high
Sinks, shrink A. With the exception of Item B-4, the causes shown for Section VIII generally
marks, voids, apply
bubbles B. Moisture content of the polymer is too high
Sinks ---
Bubbles & Voids --
Voids or Sinks Inadequate amount of material.
Sink Marks --
Ejector marks --
EJECTOR PIN MARKS Parts soft during ejection.
A. Excessive flashing
B. Material too highly packed in the cavity (mainly with large gates)
C. Pieces deform during ejection
(part is too soft)
D. Parts stick to the mold due to
Ejection difficulties highly polished surfaces
E. Mold conditions:
1. Mold surfaces are scratched and marred
2. Draft or taper on cavity walls cores or sprues is not great enough
3. Undercuts are improperly designed
4. Sprue bushing and nozzle orifice are misaligned
Embedded Particles on the tool surface, contaminated material or foreign debris in the
contaminates barrel, or too much shear heat burning the material prior to injection
Contamination --
Scratches --
A. Material is overheated
B. Thermocouple is burned out
C. Temperature controller is
malfunctioning
D. Regrind is of questionable quality
E.
Improper shutdown procedures
were used (over weekends or
periods of interrupted production)
Degradation F. Moisture content of the polymer
is too high
G.
Polymer residing in the barrel
too long
H.
Stagnation of material in the
cylinder, nozzle, or nozzle valve
Polymer degradation Excess water in the granules, excessive temperatures in barrel

a.
Trapped air
b.
Moisture is condensing on
cold pellets when they are
moved into a warm, humid
processing area
c.
Moisture absorbed in the
polymer
D. Delamination due to:
1. Contamination of the material
2. Material being too cold
E. Pigment poorly dispersed
F. Cloudy or hazy surfaces—low
gloss
1. Injection pressure is too low
Surface defects 2. Injection speed is too low
3. Effective injection pressure in
on the molded the cavities is too low
article 4. There is moisture on the mold
and/or pellet surfaces
G. Flow lines (ripple pattern)
1. Gate design and/or location
is not correct
2. Material is too cold
3. Injection speed is too slow
4. Mold is too cold
5. Flow rate of the material is
too low
6. Polymer melt is jetting into
the cavity
7. Polymer melt is non-uniform
H. Weak weld lines due to:
1. Material being too cold at the
point of weld
2. Material flowing too slowly to
the point of weld
A. Nozzle temperature to high.

B. Pressure too low.
NOZZLE FREEZE OFF C. Low mold temperature
D. Nozzle orifice to small.
Injection time too short

Cavity not Gate too small
filling Shot size too small
Injection speed too slow
Wet material
Post blowing Cycle too short
An increase in :
Injection pressure
Injection rate
Holding pressure
Holding-pressure time
Melt temperature
Mold temperature
Clamping pressure
Wall thickness
Melt flow rate
In-Mold Shrinkage Ejection temperature
Cooling time
Gate minimum dimension
Number of gates
Amount of filler
Kind of filler
Mold-open time (operator break)
Room temperature
Humidity
Air movement
machine
injection pressure too low
inadequate functioning of back flow valve
suck-back too long
plasticizing too fast
air trap in the hopper feed
Blisters, bubbles improper feed
mould
volatiles and trapped gas
mould temperature too low
thin to thick transition
material
melt overheating
Blister --
machine
injection speed too slow or too fast
hold pressure too long
mould
inadequate mould cooling
mould too hot around gate
Blush / flow marks mould too cold
gate too small
wrong gate location
gate land length too long
wrong hot runner system
material
melt temperature too low
Injection speeds too slow (the plastic has cooled down too much during
Flow marks injection, injection speeds must be set as fast as you can get away with at all
times)
machine
· injection speed too
slow or too fast
· injection pressure
too low
· hold pressure
too long
mould
Blush / flow marks · inadequate mould cooling
· mould too hot around gate
· mould too cold
· gate too small
· wrong gate location
· gate land length too long
· wrong hot runner system
material
· melt temperature too low
Cold material
Gate blush Melt fracture
Gate Blush ---
machine
problems with back flow valve
injection speed too fast
back pressure too high
Burn marks / diesel mould
effect inadequate venting : entrapped air
frictional burning
check sprue diameter
material
melt too hot or too cold:may create shear
Diesel effect --
machine
injection speed too high
mould
mould too cold
sharp corners in gate area
shear heat caused at sharp corners
Delamination material
melt too hot
poorly melted
incompatible colour dyes
cross contamination with other polymers
too much use of recycled material
machine
injection hold pressure time too short
overall cycle too short
back flow valve cracked
excessive cylinder clearance
Dimensions of part heater bands burned out
mould
too hot
gates too small (related to inadequate pressures)
gating in the wrong place
mould too small
machine
contamination
mould
check sprue diameter
pin-point too small
Discolouration poor venting
material
melt too hot or too low:may create shear
long residence time
instability of polymer/pigments
machine
clamping pressure too low
injection pressure too high
mould
inadequate mould supports
Flash clamping force too low
damaged mould surface: parting line
excessive projected area
material
melt too hot
viscosity too low
Tool damage, too much injection speed/material injected, clamping force too
Flash low. Can also be caused by dirt and contaminants around tooling surfaces
Too much material.
Clamp pressure low.
Flashing Injection pressure too high.
Injection speed too fast.
Flash --
machine
mould
mould too cold
Jetting gates too small
gate land length wrong
wrong gate location
material
melt too cold
JETTING High viscosity flow.
machine
wrong or worn out screw, giving hang-ups
mould
Pitting shear in gating
sharp corners
material
inhomogeneous material
contamination
machine
injection speed too low
mould
Record grooves mould too cold
different texture of mould halves: polished vs coarse grain
material
melt too cold
machine
holding time too long
too much material feed
Sticking in cavity mould
cavity too hot – release is better from hot mould (20°C below HDT)
mould too cold
poor mould finish
material
melt too hot
PART STICKS IN
”A” HALF or Insufficient extraction force.
STATIONARY SIDE
OF THE TOOL
PART STICKS Insufficient ejection force.

DURING EJECTION
machine
mould
Sticking on core core too hot
core bending
creation of vacuum — especially on thin-walled parts
machine
too much material feed
nozzle frozen
nozzle diameter too large for sprue bush
Sticking of sprue inadequate draft angle
drool from nozzle
mould
too hot
ineffective sprue pullers
Short shot Lack of material, injection speed or pressure too low
machine
improper feed
injection speed too low
injection time too short
faulty back flow valve ring
Short shots mould
poor mould venting
mould too cold
material
viscosity too high
machine
injection pressure time too short
short of shot capacity
mould
mould temperature too high: too high shrinkage
Sink marks gate too small: leads to early cooling/freezing at the gate, holding pressure
cannot help anymore to compensate
for the shrinkage
land length too long
wrong dimensions rib vs wall
material
melt too hot
Silver streaks Moisture in the material, usually when hygroscopic resins are dried improperly
Color Streaks ---
Masterbatch isn't mixing properly, or the material has run out and it's starting
Colour Streaks to come through as natural only
machine
degraded material
hot spot in cylinder
material hang-up area at nozzle tips or adaptors
injection pressure too low or too high
injection speed too low or too high
back pressure too low
mould
Splay / streaks frictional burning at gate, in machine nozzle or hot runner
trapped volatiles
material
melt too hot
contamination in resin
excessive moisture
Noryl resin: degradation of material due to too long pre-drying at high
temperatures
Splay Marks Caused by the material (plastic) being damped prior to injection
machine
damaged back flow valve ring
mould
areas of hang-up
hot spots
Streaking material
contamination caused by stock or machine
if steady pattern: machine
if erratic pattern: material pigmentation /
instability of material
Splay ---
machine
injection too fast
mould
Gate splay mould too cold
gate too small
material
melt too cold
machine
back pressure too high
nozzle temperature too high
Stringing mould
wrong sprue
material
insufficient melt strength
Stringiness Nozzle temperature too high. Gate hasn't frozen off

Tiger Striping ---
machine
injection pressure time too short
back pressure too low
mould
Voids mould temperature too low
incorrect material flow
part wall too thick
material
melt too hot
wrong material grade: some Lexan resin types more sensitive
Lack of holding pressure (holding pressure is used to pack out the part during
Voids the holding time). Also mold may be out of registration (when the two halves
don't center properly and part walls are not the same thickness).
part
wrong part design
machine
injection speed too slow
injection time forward too short
Weld lines / knit lines mould
mould too cold
insufficient venting
inaccurate functioning of back flow valve
distance from gate excessive
material
melt too cold
Mold/material temperatures set too low (the material is cold when they meet,
Weld line so they don't bond)
Weld Line ---
Weld Lines --
Weld line --
Unmelted Particles --
Screw Slip --
Screw Stall --
Cold slug --
Tails & Hooks

especially near raised --
engraving etc.
Dark spots --
Cloudy / milky --
transparent parts
Unusually low
maximum service --
temperature
Contamination.
Material degradation.
Off-Color Part or Odor
BURNT SMELL
Parts have a yellow Degraded material.
cast
Gloss Differences ---
Gate smear ---
Wrinkle near gate ---
Pits ---
Remedy
Parts being too brittle can sometimes be seen, but is quite uncommon
with PP/TPO Compounds.
1. Concentrate: Be sure that the concentrate is being added at the
appropriate rate. Too much concentrate can cause the parts to be
very brittle.
2. Melt Temperature: A melt temperature that is very high can degrade
the material to a point where it will become brittle. Be sure that
your melt temperature is within the specified range for your selected
material.
• Review drying procedure

• Reduce barrel/nozzle temperature
• Increase barrel/nozzle temperature
• Eliminate sharp corners
• Increase injection pressure
• Increase melt temperature
1. Pre-dry material.
2. Lower melt temperature and/
or residence time.
3. Raise mould temperature.
4. Reduce amount of regrind
A1. Raise melt temperature.
B1. Lower melt temperature.2. Cylinder residence time excessive,
use smaller capacity machine.
C. 1. Utilize hopper/dryers.
2. Dry material prior to handling.
3. Eliminate moisture pick-up by
improving material handling
procedures.
4. Reduce lag-time between production
and use of regrind material.
D.1. Resin inspection for contamination.
pigment. 2. Review handling and use of regrind
material.
3. Reduce pigment loading.
4. Keep hopper and other possible
exposure points covered.
5. Thoroughly purge injection cylinder.
6. Clean hopper thoroughly when
switching materials.
E.1. Reduce amount of regrind. (Do not
exceed 25-30% regrind as a general
rule).
F.1. Increase inject/first stage pressure.
2. Increase boost time.
G.1. Relocate gate. Keep gate away
from potential stress area.
H.1. Enlarge gate size.
1) Check moisture level of material and dry if needed

2a) Lower melt temperature
2b) Lower nozzle temperature
2c) Decrease back pressure
3d) Check for long residence times in the barrel and lower temperatures if needed
3) Increase melt temperature
4a) Inspect resin for contamination (replace if contaminated)
4b) Purge machine thoroughly
5) Reduce regrind % (general rule- 25-30%)
6a) Increase gate size to obtain optimum filling
6b) Relocate gate away from potential stress areas
Dry the resin

1) Molded in stressed
• Reduce holding pressure
• Reduce injection speed
• Increase cooling time
• Reduce melt temperature (Semicrystalline thermoplastics)
• Increase melt temperature (Amorphous thermoplastics)
• Reduce mold temperature (Semicrystalline thermoplastics)
• Increase mold temperature (Amorphous thermoplastics)
2) Insufficient draft allowance
3) Improper Ejection
• Check mold cooling system

• Increase part packing
• Change gate location
• Add ribs or part thickness to improve stiffness
• Check for uniform wall thickness
• Reduce mold temperature
• Increase ejector pin area
Descriptions
Distorted part
Relocate the gate so flow occurs in only one direction.

Increase the process temperature.
Reduce the pack pressure.
Increase the mold temperature
Balance Mold temperature

Increase Hold pressure time
Increase Gate size
Locate gate in thickest area
Check shot volume
Avoid bottlenecks in melt flow
Reduce wall thickness
Maintain uniform wall thickness
A.1Raise melt temperature.
B. 1. Lower melt temperature.
2. Lower mold temperature.
3. Increase mold cooling time.
C. 1. Provide additional cooling to
thickness sections.
3. Operate stationary and moving mold
halves at different temperatures.
4. Redesign part for more uniform
cross-section.
5. Use metal with high conductivity
for the mold sections requiring
greater heat dissipation.
D.1. Increase injection rate.
2. Raise packing pressure.
3. Redesign to provide balanced gates
and runners.
E.1. Redesign for balanced ejection forces
F.1. Gate into heavy section.
G. 1. Lower packing pressure.
H. 1. Increase injection rate.
2. Increase first stage injection pressure
3. Provide adequate venting.
A• Reduce injection pressure.
• Increase venting. Operate without a
shot pad (with the ram bottoming).
If shrinkage is a concern, note sug-
gestions in Section VIII, Item E.
• Increase temperatures of the cylinder
and/or ram speed (boost pressure).
• Increase temperatures of the cylinder
and/or screw speed.
B• Reduce temperature of the mold.
• Increase time of the overall cycle.
• Reduce temperatures of the cylinder.
• Consideruse of shrink or cooling fixtures.
C• Redesign. Use knock-out pins with
larger area or use stripper plates.
D• Redesign. Use walls with a more
uniform thickness or gradual changes
in thickness.
E• Redesign or relocate the gates. Gate
into thickest sections toward longest
flow path.
F• Redesign. Undercuts should be
radiused and no more than 0.8 mm
(0.03 in) deep. Use ribs and bosses of
minimum thickness.
G• Increase capacity of cooling.
• Modify coring to give adequate cooling.
Locate coring closer to to the cavity surface
H• Realign.
I• Redesign.
1. Raise tool temperature,

uniform?
2. Increase gate and runner size.
3. Increase fill speed.
4. Increase injection pressure and
packing time/pressure.
5. Check flow path and relocate
gate position and/or amend part
design.
1. equalize temperature of both mould halves
2. observe mould for uniform part ejection
3. check handling of parts after ejection from mould
4. check part weight: take care with Valox resin
5. increase injection hold time
6. increase cooling time
7. increase or reduce injection pressure
8. increase mould close time
9. increase or reduce mould temperature
10. set differential mould temperatures to counteract warpage due to part
geometry
11. use shrink fixtures and jigs for uniform cooling of the part
12. check gate locations and total number of gates to reduce orientation
13. additional gates may be required to overcome overpacking or underpacking on
large parts
14. increase gate dimensions
15. change gate location if glass-filled, notice fibre orientation
16. redesign part to equalize wall variation in moulded part – heavy and thin walls
in same part create differential
shrinkage stresses
1a) Decrease melt temperature

b) Decrease mold temperature
c) Increase cooling time
d) Cool part in warm water after ejection
e) Use secondary fixture to hold part dimensions
2a) Increase injection rate
b) Increase pack pressure
c) Balance runners and gates
d) Increase runner and gate size
e) Increase/decrease injection time
3 Increase melt temperature to provide better pack out of part
4a) Increase cooling time
b) Redesign part with uniform wall thickness
5 Add pack and hold time or pressure
6 Redesign ejection system for balanced ejection force
7 Balance mold temperature
Machine (Optimization of processing parameters)
• Increase the holding pressure or extend holding
pressure time.
• Increase mold temperature
• Increase back pressure
• Increase amount of cushion
Mold
• Gates or runners too small
• Improper gate location
• Uneven mold temperatures
• Mold design such as a variation of wall
thickness, non-uniform ejection, undercut
(insufficient drafts and incorrectly
positioned), unusal geometry and position of
the cooling channels.
Material
• The melt is inhomogeneous or
thermally damaged
• Granules not correctly melted
• Use a larger machine

• Reduce injection pressure
• Align platen
• Review mold venting
1. Lower material temperature by lowering barrel temperature.

2. Decrease injection pressure.
3. Decrease overall cycle.
4. Decrease plunger forward time.
5. Check mould closure (possible
obstruction on parting line surface).
6. Improve mould venting.
7. Check press platens for parallelism.
8. Move mould to larger (clamp) Press.
Flash is a common problem with injection molding and can often be
remedied very easily.
1. Parting Line: Ensure that the parting line on the injection mold is
properly maintained and is free of any debris.
2. Shot size: Too large of a shot size or too much pack can often flash
around the gate.
3. Clamp Pressure: Insufficient clamp tonnage or pressure can result in
poor shutoff, which will cause the part to flash. The available
tonnage should be sufficient to mold the desired part.
4. Melt Temperature: If melt temperature is too high it can cause the
material to become very watery which could cause the part to flash
more easily
1. Reduce the injection pressure

2. Reduce the injection speed
3. Reduce the melt temperature
4. Increase the size of gate
5. Ensure mold closes and seals satisfactory
6. Ensure machine has sufficient mold lock
1) Reduce melt and mold temperatures

2) Decrease packing pressure
3a) Decrease injection pressure
3b) Decrease boost time
3c) Decrease injection rate
3d) Increase transfer position
4) Switch to larger tonnage machine
5a) Remove mold and carefully inspect and repair parting lines
5b) Repair cavities and cores that do not have a positive shut-off
6a) Increase clamping pressure
6b) Check parting line for obstruction
6c) Check press platens for parallelism
7a) Balance/increase runner and gate sizes to obtain uniform filling
7b) Properly balance cavity layout for maintaining uniform cavity pressure
Decrease Melt temperature

Decrease Injection pressure
Decrease Cycle time
Decrease Clamp pressure
Decrease Screw forward time
Improve molding venting
Check for damage at parting line
Check for worn mold mechanism
• Use a larger machine
• Align platen
• Review mold venting
Reduce injection pressure and time.

Decrease shot size.
Reduce injection speed.
Reduce process temperature.
Machine or dress the parting line.
Use a higher viscosity compound. Increase clamp tonnage.
Reduce thickness of the vents. Move to a larger machine.

• Increase clamping force
• Reduce pressure in the cavity by:
- Reducing the holding pressure
- Reducing the holding pressure time
Mold
• Reduce melt or mold temperature
• Optimizing the injection speed
• Check for mold wear in the area of the flash
A1. Lower injection pressure.

2. Reduce boost time.
3. Reduce injection forward time.
B.1. Lower melt temperature.
C.1. Lower packing pressure.
2. Reduce shot size.
D.1. User larger tonnage machine.
2. Reduce number of cavities.
E.1. Increase clamping pressure.
F.1. Progressively increase gate size from
sprue to obtain uniform filling.
2. Balance cavity layout for maintenance
of uniform pressure in cavity.
G.1. Increase cavity venting.
H.1. Inspect and clean mold thoroughly.
I. 1. Insure mold properly installed.
2. Inspect and repair parting lines.
3. Inspect and repair cavities and cores
not having positive seal and surface
mating.
Shorten boost time
Increase clamp pressure
Resurface or realign mold
Dry the resin
A• Reduce injection pressure.

B• Reduce shot size or run without a pad.
injected into the mold Note Section VII, Item A.
C• Reduce pressure to pack out.
• Reduce temperature of the melt.
D• Reset the toggles and/or increase
clamp pressure.
E• Inspect land areas, etc., of the mold carefully and clean where necessary.
F• Remove mold, overhaul and correct the
cavity inserts are out of register
G• Check and overhaul if necessary.
H• Check clearance and adjust as necessary.
• Clearance should not be more than 0.038 mm (0.0015 in).
I• Inspect the vents and clean if necessary.
• Increase width of the vents. Vents should not be more than 0.038 mm (0.0015
in) in depth.
J• Cavity and runner layout should be
distributed in the mold balanced.
K• Shift to a press with greater available
for the available clamping clamping pressure.
pressure
• Reduce the number of cavities.
• Improve mold venting

• Check heater controls
• Purge barrel
• Clean hopper dryer
• Remove and clean screw
Clean vents.
1. Decrease plunger speed.

3. Improve venting in mould cavity.
4. Change gate location to alter flow pattern.
Descriptions
Black or brown burnt areas on the part located at furthest points from gate
A1. Reduce melt temperature

B.1. Reduce first stage pressure.
C.1. Vent mold cavity at final fill point.
2. Lower injection speed (first stage
pressure and/or boost time)
3. Gate relocation,
D.1. Use hopper/dryers.
2. Dry resin prior to molding.
Improving material handling
procedures.
• Improve mold venting

• Check heater controls
• Purge barrel
• Clean hopper dryer
• Remove and clean screw

• Reduce clamping force to achieve better venting
Mold
• Check vents and clean if necessary
• In the case of entrapped air due to flow front meeting,
change gate position (first, perform a simulated filling)
• Attach additional venting, for example through ejector
Clean vents
Deepen vents
Dry the resin or slow injection speed
A• Reduce temperatures of the cylinder.
• Shorten time of cycle
B• Keep a reserve of resin in the hopper to
avoid starving the feed section.
• Reduce screw speed on the screw
injection molding machines to obtain
melt in the feed section of the screw
before significant compression.
C• Inspect and clean vents.
• Vent at point where polymer is burning.
D• Sufficient venting normally corrects this
problem. If this doesn’t solve the prob-
lem, try reducing the injection ram speed.
(See suggestions Section II, Item B.)
E• Clean the nozzle and cylinder with purge
compound or disassemble. Polymer flow
path should be streamlined with no dead
spots for polymer hang-up.
F• Segregate and check the regrind critically
for contamination, excessive moisture or
degraded polymer. Try virgin material.
G• Purge with Hytrel until the machine is
free of other polymers or remove the
screw and nozzle and clean thoroughly
• Improve cavity venting

• Increase injection rate and tool temperature
• Relocate gate or add overflow tab
• Improve cavity venting

• Increase injection rate and tool temperature
• Relocate gate or add overflow tab
􀂾 Increase melt temperature
􀂾 Increase mold temperature
a) Increase first stage injection pressure
b) Increase boost time
c) Increase pack pressure
d) Increase pack time
e) Increase injection rate/speed
a) Increase vents at weld area
b) Decrease injection speed to allow air removal
c) Decrease clamp pressure to minimum pressure
a) Increase injection speed
c) Increase first stage injection pressure
a) Relocate gate or use multiple gating
b) Utilize overflow tab in mold to increase strength in weld line area
1. Increase injection pressure.

2. Increase packing time/pressure.
4. Raise material temperature.
5. Vent the cavity in the weld
area.
6. Provide an overflow well
adjacent to the weld area.
7. Change gate location to alter
flow pattern.
A.1. Raise melt temperature.

B.1. Increase mold temperature.
C.1. Raise first stage pressure.
3. Increase injection forward time.
4. Raise holding pressure.
D.1. Provide adequate vents.
2. Reduce injection rate
E.1. Clean mold surface thoroughly plugging vents.
F. 1. Relocate gates. 2. Use multiple balanced gates.
Weld line strength is the direct relation to how the two material fronts
come together and melt together to become one.
ACP (2004, 2005) All Rights Reserved Advanced Composites TS Group
1. Melt Temperature: If the two melt fronts are not at a high enough
temperature it could cause the weld line to be weak.
2. Pressure Drop: Insufficient pressure applied to the two melt fronts
can sometimes cause the weld line to be poorly welded together.
3. Venting: Poor venting in the area near the weld line can cause the
material fronts to encounter a restriction, which could cause a poor
weld.
• Increase holding pressure
• Increase injection speed
Mold
• Move weld line by changing the position of the gate
• Insert cascade hot runner
• Push-pull technique
• SCORIM
• Use the simulation program
Material
• Improper flow rate
Cascade Injection Technology

• Hot runner system (valve
controlled)
• Distinct control of melt front
prevents weldline generation
• Application for high flow length
/ thickness ratios, i.e. car
bumpers
Push–Pull Technique
• Pulses melt front by two-component injection molding
• Deformation of formerly “butt” weld
• Increased mechanical strength
SCORIM Technology
• Pulses melt front by twopiston
head
• Deformation of formerly
“butt” weld
• Increased mechanical
strength
Place vents at last place to fill and at converging flow fronts

Increase size of the vents.
Increase the melt and/or mold temperature.

Increase injection speed.

• Check for undercuts
• Inspect ejector system
• Increase draft in tool

• Check for undercuts
• Inspect ejector system
• Increase draft in tool
A.1. Lower first stage injection pressure.
5. Lower holding pressure.
B.1. Increase mold cooling time.
2. Lower melt temperature.
3. Lower mold temperature,
C.1. Raise nozzle temperature.
D.1. Redesign for balanced ejection forces
E.1. Apply mold release agent to cavity.
2. Add external mold release agent or
change to lubricated resin.
F.1. Redesign sprue puller.
G. 1. Draw polish to proper finish.
H. 1. Polish and provide maximum allowable draft.
I.1. Realign cores and cavities.
J.1. Redesign runner-gate system for
(multi-cavity mold) balanced filling of cavaties.
K.1. Repair and polish.
1a) Decrease first stage injection pressure

b) Decrease boost time
c) Decrease injection forward time
d) Decrease packing pressure
e) Increase transfer position
2) Redesign to allow maximum allowable draft
3a) Increase cooling time
b) Decrease melt temperature
c) Decrease mold temperature
4) Redesign or reduce undercut
5a) Redesign sprue puller
b) Increase nozzle temperature
6) Redesign for balanced ejection force

2. Decrease plunger forward time,
3. Increase mould closed time.
4. Lower mould temperature.
5. Decrease barrel and nozzle
temperature.
6. Check mould for undercuts
and/or insufficient draft.
7. Use external lubricants.
2. Decrease plunger forward time,
3. Increase mould closed time.
4. Increase mould temperature at
sprue bushing.
5. Raise nozzle temperature.
6. Check sizes and alignments of
holes in nozzle and sprue bushing
(hole in sprue bushing must
be larger).
7. Provide more effective sprue
puller.
1 Use nozzle that has an orifice at least .010” smaller then the sprue orifice
2 Increase taper on sprue bushing (Minimum of 1.5° over the length of the sprue)
3 Eliminate imperfections and polish surface in direction of draw
4a) Reduce pack and hold time
b) Decrease injection forward time
c) Utilize machine sprue break
5a) Increase nozzle temperature
b) Use reverse taper nozzle
A. 1. Sprue bushing orifice should be larger than the nozzle.

B. 1. Increase taper.
C. 1. Eliminate pits and draw polish surface.
D. 1. Increase undercut and redesign puller.
E. 1. Lower holding pressure
F. 1. Redesign sprue with smaller diameter.
G. 1. Increase nozzle temperature to provide clean break.

• Increase barrel temps/mold temperature
• Review drying procedures
1. Increase injection time

2. Increase mould wall temperature
3. Increase melt temperature
4. Optimise hold pressure time
5. Increase hold pressure
A. 1. Raise melt temperature.
B. 1. Raise mold temperature.
C. 1. Raise first stage injection pressure.
3. Increase injection speed.
D.1. Increase shot size/maintain constant
cushion.
2. Raise second stage injection
pressure.
E.1. Examine and repair any water leaks.
2. Raise mold temperature.
F.1. Wipe mold thoroughly with solvent.
2. Reduce use of mold release agent.
G.1. Use hopper/dryers.
2. Dry material prior to molding.
procedures.
H.1. Examine and remove any defects.
Draw polish surface.

2) Increase mold temperature
3) Increase pack pressure
4a) Increase shot size and maintain constant cushion
b) Decrease injection transfer position
5a) Increase first stage pressure
c) Increase injection speed
6a) Increase mold temperature
b) Look for water leaks and repair if needed
7a) Clean mold surface
b) Use mold release sparingly
8a) Review material handling procedures
b) Dry material prior to molding
9) Increase number of vents
• Increase hold pressure or time

• Increase shot size
• Check gate dimension and location
Increase Hold pressure
Increase Hold time
Increase Gate, sprue
Increase and runner size
…………………...
(if it is too high)
Decrease Mold temperature
Decrease Cushion
Gate location (near thick wall)

Increase Hold time
Decrease Injection fill rate
Repair leaking back flow valve,
if pad can not be maintained
Locate gate in the thickest area
Increase Size of gates
Maintain Location of gates
Eliminate restrictions in runner or nozzle
Decrease wall thickness.

Increase the pack pressure and time.
Increase the gate size.
Relocate the gate to the thickest section.
Increase the runner size
1) Core out thick wall sections

2) Ensure pack and hold time is sufficient for gate freeze by performing a gate
freeze analysis
3a) Increase shot size to maintain a constant cushion
b) Inspect non-return valve for wear
4a) Increase size of gates and runners
b) Increase size of the nozzle and sprue
2. Increase packing time/pressure.
3. Use maximum ram speed.
4. Raise mould temperature
(voids).
5. Lower mould temperature
(sinks).
6. Decrease cushion.
7. Increase size of sprue and/
or runners and/or gates.
8. Relocate gates nearer thick
sections.
1. Increase injection pressure

2. Optimise holding pressure time
3. Reduce screw speed
4. Reduce nozzle and metering zone temperatures
5. Increase feed zone temperature
6. Adjust back pressure
7. Increase mould temperature
8. Enlarge gates and runners
Dry the resin

Open the gate
Open runner
Relocate gate
Increase rate
Lengthen hold time
Increase hold pressure
Raise temperature
Deepen or add vents
Redesign gate
• Check metering stroke and increase if necessary
• Extend holding pressure time
• Increase cushion
• Reduce melt or mold temperature (sink mark near the sprue)
• Increase melt or mold temperature (sink mark away from the sprue)
• Optimize injection speed
Mold
• Increase gate for better holding pressure transmission
• Avoid material accumulations
• Optimize wall thickness and/or rib ratio
• If the flow distances are too long, the melt may freeze prematurely,
the flow resistance is too high
• Use non-return valve and/or shut-off nozzle
• Check screw for wear
• Use blowing agents
• Sandwich injection molding
A1. Raise first stage injection pressure

2. Raise holding pressure.
B.1. Increase shot/size maintain constant
into cavity. cushion.
C.1. Lower melt temperature
D.1. Increase injection rate.
2. Raise melt temperature.
3. Increase gate size.
E.1. Lower melt temperature.
4. Provide improved mold cooling.
F.1. Redesign part with more uniform wall
thickness.
2. Improve/increase mold cooling at
thick sections.
3. Move gate to heavy section.
4. Include design over sink mark to hide
it from view (when elimination through
part redesign cannot be achieved).
• Extent holding pressure time
• Set larger melt cushion
• Increase metering stroke
• Reduce difference between the melt and mold temperature
Mold
• Improper venting
• Section thickness too great
• Improper runners or gates
Material
• Excessive moisture
Often time’s bubbles can be seen in a plastic part, the following are some
reasons for this occurring.
1. Venting: Insufficient venting could cause the buildup of gas, which
could result in a bubble.
2. Melt Temperature: Too high of a melt temperature could cause the
material to degrade slightly which would cause bubbles.
3. Mold Temperature: A high mold temperature either through the
whole mold or locally could cause bubbles, this needs to be
monitored closely.
Relocate the gate or modify the flow path.

Add a pin in the area to eliminate the gas trap.
Voids are very similar to bubbles, but less noticeable.

1. Venting: Proper venting around the parting line and on ejector pins
and lifters can reduce the amount of gas that is in the mold, this will
help eliminate voids.
2. Melt Temperature: A high melt temperature can cause some material
degradation, which could cause some voids to appear.
3. Packing: Insufficient packing can sometimes cause voids to occur.
This happens because the frozen layer of material stays against the
tool while the part sinks from the inside out.
A. 1. Utilize hopper/dryer.
procedure.
B.1. Lower melt temperature.
2. Decrease overall cycle time.
C.1. Raise holding temperature
4. Minimize thick sections in part
design

B.1. Raise mold temperature.
C.1. Raise first stage pressure.
D.1. Raise holding pressure.
E.1. Increase gate size.
• Maintain adequate cushion

• Check for worn check ring
• Check heater bands/controllers
• Increase hold time
• Enlarge gate to prevent premature freeze-off

Increase Hold time
Increase Gate size
Increase Cylinder temp.
Increase Back pressure
Screw rpm
Maintain Uniform cushion & Uniform cycle
Check leaking back flow valve
Use larger machine or screw
Check hold pressures.

Check melt and mold temperatures.
Check that cushion was maintained.
A1. Duplicate previous molding conditions
B1. Check and recalibrate control instrumentation.
2. Replace inadequate controllers.
C1. Adjust temperature profile to yield
optimum feeding.
2. Adjust shot size for uniform, minimum
cushion.
D. 1. Provide maximum holding pressure.
2. Increase injection rate.
3. Progressively increase gate sizes
from sprue to provide uniform filling.
E.1. Redesign part.
F.1. Improve virgin/regrind blending.
2. Reduce regrind to virgin ratio.
switching materials
1. Set uniform cycle times.

2. Maintain uniform feed and
cushion from cycle to cycle.
3. Fill mould as rapidly as
possible.
4. Check machine hydraulic and
electrical systems for erratic
performance.
6. Balance cavities for uniform
flow.
7. Reduce number of cavities.
1a) Adjust temperature for optimum filling

b) Increase shot size to maintain proper cushion
c) Replace check valve if cushion cannot be maintained
2) Increase injection forward time and pressure to ensure gate freeze off
3a) Review regrind blending procedures
b) Decrease level of regrind
4) Increase fill pressure to maintain the selected velocity of most runs
5a) Increase holding pressure to maximum
b) Increase injection rate
c) Balance runner and gate sizes to provide balanced filling
A• Check operation of the feed mechanism.
• Check pellet size for variations. Check
feed throat for obstructions or sticking
polymer.
B• See suggestions in Section IV, Item A.
C• See suggestions in Section IV, Item B.
D• See suggestions in Section I, Item B.
For consistency of dimensions when
molding polymers of Hytrel, it is sug-
gested that the shot size not exceed
75% of the machine’s plasticizing
capacity.
E• Check coolant for temperature variations.
Install temperature controller if needed
Material blockage at throat - lower feed zone temperature.

Clean vents
Increase shot size, if possible. If not, move to a larger machine.
Reduce rpm and back pressure.

Decrease the barrel temperature in the rear.
Increase injection pressure.
Increase injection rate.

Increase process temperature.
Use a lower viscosity compound.
Increase gate and runner size.
1. Increase feed.
3. Use maximum ram speed.
4. Decrease cushion.
5. Raise material temperature by
raising barrel temperature.
7. Increase overall cycle.
8. Check shot size vs. rated
machine shot capacity; if shot
size exceeds 75% of rated
(styrene) shot capacity, move
to larger machine.
9. Increase size of sprue and/or
runners and/or gates.
1. Adjust feed to minimum consistent cushion

3. Increase injection speed
4. Increase back pressure
5. Increase barrel temperatures
6. Increase mould temperature, particularly for very
thin large area parts
7. Check non-return valve
8. Improve venting
9. Enlarge gates, sprue diameters and runners.
Check feed to barrel and feed from nozzle

Check that flow path ratio is not excessive
Increase Melt temperature
Increase Mold temperature
Increase Injection fill rate
Increase Injection fill pressure
Increase Wall thickness
Increase Balance gate, runner
Increase Spru, runners and/or gate size
Enlarge vent or change vent location
1) Raise melt temperature

2) Raise mold temperature
3a) Increase shot size to maintain a constant cushion
b) Inspect non-return valve for wear
4a) Provide adequate venting
b) Increase number and size of vents
5a) Increase gate size
b) Increase runner size
c) Use larger orifice nozzle
When troubleshooting short shots it is important to look at your shot size,
cushion, decompression, nozzle tip and injection speed and pressure. A
short shot can be as simple as not having a large enough shot size to as
complex as having a blown manifold. It is a problem that should be
evaluated with caution. A few things to check are
1. Shot size: Make sure that your part is roughly 90-95% full before
transferring and that you have an adequate cushion to fill and pack
the rest of the part. You should first determine how full the part is at
transfer by using no pressure for pack and hold. Then use roughly
75% of pressure at transfer to start packing and pack until gate
freeze occurs.
2. Non-return valve: Ensure that your non-return valve is working
properly by watching the screw during injection. If the screw rotates
during injection, the valve may be letting material leak past the
valve. Increasing decompression may allow the valve to seat better
and allow a better shut off condition, but could cause splay or other
cosmetic issues.
3. Injection Rate: If the injection rate is too slow it is very possible that
the gate will freeze before the part is full. Be sure that the gate is
not freezing before proper part packing by monitoring the machine
and ensuring that transfer is achieved.
4. Gate design/location: If the gate(s) are in a poor location or the
improper size it will sometimes not allow the part to fill properly.
You will often see ribs and/or bosses that are not completely full if
this is a problem.
5. Venting: An improperly vented tool will sometimes prohibit the part
from being filled properly and completely.
6. Nozzle seat: Another possible reason for short shots is improper
nozzle seat. Ensure that the nozzle tip orifice is slightly smaller and
of the same radius (slightly smaller) as the sprue bushing on the
mold. This will reduce the possibility of a “cap” on the front of the
barrel.
1. Increase shot size to provide an adequate cushion

2. Increase the injection pressure
3. Increase the injection time
4. Increase the mold temperature
5. Increase the barrel temperature
6. Increase the back pressure
7. Increase the cycle time
8. Ensure the polymer is dry
9. Ensure the screw tip and check ring are functioning
10. Shot weight is not too high for the machine to process
11. Assess nozzle diameter, gates and runners. Is there a restriction?
12. Ensure adequate venting of cavity
1) If there is too little melt in the cylinder
• Increase metering stroke
• Avoid bridging at the hopper
2) If the material is highly viscous, the flow resistances are too high
• Increase injection pressure and speed
Mold
• Increase wall thickness, move gate or provide several gate
• Larger sprue, runners or gates
• Check venting
Material
• Improper flow rate (melt flow rate is too low)
Improve venting and/or relocate to burned area.
Purge and reduce cycle

Reduce barrel temperature
Use a smaller capacity press or add dummy cavity to increase shot size
1. Examine the machine capacity against shot weight ensuring there is a cushion
2. Stabilize the cycle time reducing delays with insert loading by automation
3. Check there is no screw slip
4. Check the nozzle hole for damage or blockage
5. Examine the check ring to ensure its working properly
A. 1. Raise melt temperature.
B. 1. Raise mold temperature.
C. 1. Raise first stage injection
D. 1. Increase shot size (maintain constant cushion)
E. 1. Vent properly
2. Increase number/size of vents.
F. 1. Increase size of nozzle-sprue runner gate system.
G. 1. Increase gate size.
2. Redesign runner system for balanced flow.
H. 1. Redesign part.
1• Check the injection stroke and increase

as necessary.
• Increase hold time or rpm.
• Be sure the feed hopper has sufficient
material and that the shut-off gate is
open.
• Check the feed system for blockage
and bridging.
• See that the air and power supply to
the weigh feeder (if used) are turned
on.
2• If none of the above provides sufficient

feed, it will be necessary to:
(a) place the mold in a larger shot
capacity press; or
(b) block off some of the mold
cavities.
3• Use a non-return screw tip.

• Check the non-return tip and barrel for
excessive wear or a jammed ring
valve.
• Reduce temperature of the polymer
melt.
A• Increase time of injection.
B• If ram is completely stopped before
the end of the injection cycle, increase
injection pressure. Operate at
maximum injection speed (higher
boost pressure).
• Provide sufficient venting for each
mold cavity.
C• If the machine is at maximum injection
pressure, raise the cylinder temperatures.
• Check actual temperature of the melt
with a needle pyrometer.
D.• Check all heater bands for proper operation with a pyrometer or clampon
ammeter.
E.• Check orifices of the nozzle, sprue and
gates for foreign or unplasticized
material.
F• Enlarge these flow paths as necessary and sufficient melt velocity to preclude
premature freezing.
G.• Increase temperature of the melt.
• Use resin with a lower viscosity, if
possible. (See bulletin, “Rheology and
Handling.”)
A• See suggested solutions for Section II,Items D and E.

B• Check hydraulic system for defective pumps or valves.
• Check for low oil level.
• Check for overheated oil supply, possibly due to loss of coolant or plugged heat
exchanger.
C• Check for blockage of vents.
D• See suggested solutions for Section I, Item A.
E• Clear bridging in the feed throat.
F• Increase cooling of the feed throat.
• Reduce temperature of the rear zone.
A• Consult technical service representatives for the temperature controllers used
on the injection molding machines.
• Increase overall cycle time.
B• Check all timers with a stopwatch for
consistent timer control.
• Check time ram is in motion. (Inconsistent
time indicates melt is non-uniform.)
• If on semi-automatic cycle, check for
variations in operator-controlled portion
of the cycle.
• Check hydraulic system for sticking solenoid
valves.
• Check if the ring shut-off valve on the
non-return screw tip is worn or clogged.
1 Replace with new material

2 Check for over run/over heating
3a) Clean screw and barrel
3b) Check for hang up areas in screw and check valve areas
4b) Lower back pressure
4c) Lower screw RPM
1. purge with an appropriate material

in general: Kapronet
for Lexan PC: ground acrylic or regrind Lexan resin
for Ultem resin: regrind Ultem resin or glass-filled Lexan
resin – don’t drop temp. settings while purging;
(for details on purging, see pages 19 to 24)
2. check for impurities: use uncontaminated material,
do proper housekeeping
3. check and adjust melt temperature
4. check for dead edges: nozzle, back flow valve,
gates/runners
5. check for screw wear
1. control holding / injection pressure
2. increase back pressure
3. increase mould temperature
4. check back flow valve
5. allow for adequate venting
6. enlarge gate
7. shorten land length
1) Check moisture levels of material and dry if needed
2a) Check vents and clean if needed

2b) Reduce clamp pressure to minimum amount needed
2c) Increase back pressure

3b) Lower back pressure
3c) Lower Screw RPM
Descriptions
Raised or layered zone on surface of the part
1) Check whether the blistering is due to thermal composition
• Reduce melt temperature
• Reduce screw rotation speed
2) If air is drawn into the plasticising unit
• Reduce and/or decelerate decompression (screw retraction)
Mold
• If the blistering is caused by entrapped air, better mold venting
should be provided, for example in the weld line area or at the end of
the flow part.
Material
• Use of regrind that is too coarse
• Use of highly volatile materials
• Excessive moisture in material
1a) Polish gate area to eliminate rough areas and sharp edges
1b) Decrease gate land length
2) Gate size should be 50-80% of the nominal wall thickness
3) Remove color concentrate and run natural to verify
1) Clean vents
2) Reduce clamp pressure to minimum needed
3) Add vents
4) Reduce melt temperature
5) Decrease injection rate
1a) Change to different lot of material

1b) Eliminate regrind as contamination source
1c) Remove colorant
2a) Redesign knockout system for balanced ejection force
2b) Rework mold and provide adequate draft angles and eliminate excessive
undercuts
3a) Decrease pack pressure
3b) Decrease shot size
3c) Increase transfer point to lower peak injection pressure
3d) Decrease injection time
4b) Supply uniform cooling to cavity
5a) Do not over use mold release
5b) Clean mold
A.1. Lower packing pressure.
B.1. Increase mold temperature.
C.1. Redesign mold cooling system for
uniform cavity cooling.
D. 1. Redesign knockout system to provide
balanced ejection forces.
E. 1. Rework mold.
F. 1. Rework mold.
1) Molded in stressed
• Reduce holding pressure
• Reduce melt temperature (Semi-crystalline
thermoplastics)
• Increase melt temperature (Amorphous
thermoplastics)
• Reduce mold temperature (Semi-crystalline
thermoplastics)
• Increase mold temperature (Amorphous
thermoplastics)
1 Raise melt temperature

2 Check material feed system for contamination
2 Try different lot/box of material
3 Try virgin only run to verify and change color to a compatible concentrate if
needed
4 Increase injection rate
5 Increase venting
6 Increase mold temperature
Descriptions
Thin mica like layers formed in part wall
1. Eliminate contamination
2. Check compatibility of dye / masterbatch
3. Check moisture content
4. Check melt homogeneity and plasticising
performance
5. Reduce injection speed
6. Reduce melt temperature
1a) Decrease melt temperature
b) Decrease screw RPM
c) Decrease back pressure
d) Decrease residence time
e) Check barrel and nozzle heater bands and thermocouples
2) Set drying temperature at manufactures recommended settings
3a) Review material handling procedures
b) Purge injection cylinder
Check residence unit; cylinder, nozzle

Use smaller injection machine
Increasre Back pressure → vent air
Increase back pressure and/or screw rpm.

Change the color concentrate carrier to a material with a
lower melt temperature.
Check for clean regrind
Check barrel temperatures.

Check back pressure and screw rpm,
increase if necessary
A.1. Lower melt temperature.
2. Reduce overall cycle.
3. Reduce screw speed.
4. Lower back pressure.
5. Use smaller capacity machine
to reduce cylinder residence time.
B.1. Purge cylinder thoroughly.
or nozzle. 2. Reduce injection rate.
3. Check cylinder for cracks.
4. Remove nozzle and clean.
5. Remove valve and check for ring
wear.
C.1. Reduce drying temperatures.
excessive drying temperature. Recommended range is 170-180degF
77-82degC for hot air dryers. If drying
under vacuum, temperature of 200F/93C may be used.
D. 1. Improve handling of virgin and
regrind.
2. Purge cylinder thoroughly.
3. Keep hopper covered.
switching materials.
E. 1. Check for nicks in nozzle.
2. Check for sharp projections or
defects in mold.
A• Use a dispersion nozzle or premix

before molding. Change to a screw
machine for better mixing.
• Increase the head or back pressure
and/or screw rpm. Use a high shear or
mixing screw or mixing nozzle.
B• Grind the pigment or obtain as a powder.
• Use a color feeder. Preblend pigment
and polymer.
• Use predispersed pigment concentrate.
C• Use a lower ratio, letdowns greater than
25 to 1 are difficult by injection molding.
• Check with the concentrate supplier or
DuPont.UseHytrelas thebase polymer.
• Use a concentrate with a lower level of
pigment at a lower letdown ratio, for
example, 15 to 1 rather than 25 to 1.
1a) Increase mold cooling in hot spots of parts
b) Ensure fast turbulent flow of water through cooling channels
2a) Adjust clamp speed for minimum mold open time
b) Low pressure close time excessive, adjust clamp positions and pressures
3) Decrease melt and mold temperatures to minimum temperatures needed for
proper fill
4a) Check machine throat and hopper for blockage
b) Check for worn screw and barrel

3) Increase gate size
4) Redesign part for more uniform wall thickness to provide for optimum filling

B1. Raise mold temperature.
C1. Lower first stage pressure.
2. Reduce boost tome.
D.1. Increase gate size.
2. Lower injection rate.
3. Raise melt temperature.
Reposition the gate to a thick section.

Radius dimples.
Relocate gate to balance the flow or reduce the runner diameter.
Increase Injection fill speed

Increase Injection pressure
Increase Melt temperature
Gate size
………………..
Maintain Gate location
1a) Decrease nozzle temperature

b) Decrease melt temperature
c) Reduce back pressure
d) Increase screw decompression
2a) Review material handling procedures to eliminate moisture pick up
b) Dry material according to manufactures recommendations
A1. Lower nozzle temperature
B1. Lower cylinder temperatures.
2. Decrease screw speed (screw machine)
3. Lower back pressure (screw machine)
C. 1. Utilize hopper/dryer
2. Dry material prior to molding
3. Eliminate moisture pick-up by improving material handling
procedure.
D. 1. Use nozzle with smaller orifices.
E. 1. Decrease overall cycle time.
F. 1. Use lubricated resin.
G.1. Use positive-seal nozzle
2. Use reverse taper nozzle.
1a) Review material handling procedures to eliminate moisture pick up

b) Dry material according to manufactures recommendations
2a) Decrease barrel temperatures
b) Decrease nozzle temperatures
3a) Reduce screw RPM
b) Increase gate and runner size
c) Decrease injection rate
d) Check nozzle for obstruction
4a) Reduce screw decompression
b) Improve mold venting
b) Clean mold surface
c) Minimize use of mold release
6a) Decrease throat cooling
b) Increase rear zone temperature

Decrease Injection fill rate
Remove contamination
Check residence unit
Dry pellets for 3~4 hrs at 80~90 C

Cylinder temperature
Clean residence unit
A. 1. Utilize hopper/dryers
3. Eliminate moisture pick-up by improving materials handling procedures.
B. 1. Lower melt temperatures.
C. 2. Raise mold temperature.
D.1. Wipe mold surface thoroughly on mold surface with solvent.
2. Use external mold release sparingly
E. 1. Reduce throat cooling. 2. Raise rear zone temperature.
F.1. Increase gate size,
2. Localized gate heating.
Dry material.
Check for contamination.
Raise mold temperature.
Check for moisture (condensation) or dry the material.

Check regrind for contaminants or moisture. Dry if required
Reduce injection speed.
Increase the process temperature.
Increase the gate size.
Change to a lower molecular weight compound.

Texture mold cavity surface (EDM, sandblast, etc.)
Eliminate contamination and clean cylinder

Residence time in cylinder
Check cooling system in rear cylinder

2. Decrease screw speed
3. Increase cylinder temperature
4. Use machine with larger barrel shot size
Color streaks
1) Color streaks due to the pigment are not correctly
dissolved and distributed:
• Increase screw speed and back pressure
• If necessary, use smaller gate
• Use smaller pigment
2) Color streaks due to thermal damage
• Reduce screw speed
• Reduce back pressure
• Reduce hot runner temperature
• Use larger sprue or gate cross-section
3) Color streaks due to contamination
• Clean cylinder – nozzle, hopper and mold
• Check raw material
• Check conveyor system and mixing equipment
Silver streaks
• Dry the material adequately before processing
• Degas melt via the cylinder
• Increase back pressure to achieve better
venting of the melt
• Increase screw speed
• Reduce feed zone temperature of injection unit
(bridging of the granules, entrapped air)
• Shorten screw retraction
• Check mold for venting
•Check raw material
Burnt streaks
• Reduce screw speed
1. Sufficiently pre-dry material, check manufacturers

guidelines
2. Check packaging
3. Check storage of material
4. If possible, feed directly from the dryer in a closed
system

Mold
• Optimize gate location on the mold
• Enlarge (or round off) gate to avoid a high flow speed
1. Reduce injection speed or injection profile (slow –
fast)
3. Impinge gate onto mould wall/surface
4. Smooth transition gate to moulded part
5. Increase gate diameter
6. Relocate gate
Descriptions
Deformed part by turbulent flow of material
Decrease Injection fill speed

Increase Gate size

If a uniform shrinkage outside the tolerance range is present:
• Increase the holding pressure or extend holding pressure time.
• Decrease mold temperature
• Decrease melt temperature
• Decrease shot weight
• Gates or runners too small
• Improper gate location
Mold
• The melt is inhomogeneous or thermally
damaged
• Granules not correctly melted
A• Increase time injection ram is forward.
B1• Increase size of gates and/or shorten
length of lands.
2• Increase size of runners to decrease
resistance to polymer flow. Runners
should be sized so they maintain a
relatively constant shear rate for the
required volume of flow. Gates should
be sized for proper freeze-off.
3• Check actual temperature of the melt
with a needle pyrometer. If necessary,
increase temperatures of the cylinder.
4• Use polymer with a higher melt index,
if possible. (See bulletin, “Rheology and
Handling.”)
5• Use nozzle with a larger orifice.
C• Increase pressure of injection slowly
until borderline flash conditions are
reached. Note suggestions in
Section VII, Item A.
D• Reduce temperature of the mold.
E• Increase size of shot to obtain a very
slight pad. Note suggestions in
Section VII, Item A.
F• Increase time injection ram is forward.
Descriptions
Localized depression (In thicker zones)
A• See suggested solutions for Section VIII.

• Resins with a low flow rate may assist
in minimizing voids in heavy sections of
easy to fill parts. Also, the use of slow
speeds for the injection ram might help
in the control of sinks and voids.
B• Dry the polymer. For suggested drying
procedures see bulletin, “Rheology and
Handling.”
Sinks can be eliminated or decreased with some simple practices. It is
first important to understand if it is a sink or if it is a pull.
1. Proper mold packing: Be sure to do a part weight study to determine
when the gate freezes and to ensure that you are packing the most
amount of material possible into the mold. This will hopefully pack
out the sinks that are seen.
2. Proper gate size: It is very important to have the proper gate size
and location. It can be impossible to pack out a sink if the gate is
too far away or too small. Following our gating guidelines and
speaking with or technical representatives can help you out with
these problems.
3. Rib/Wall ratio: The rib/ boss thickness should not be more than 40%
of the thickness of the nominal wall.
4. Rib/Boss texture: It is common for ribs to have a poor texture on
them, which will cause them to stick in the mold. Sticking ribs in a
mold will often give the appearance of a sink, but is in fact a “pull”.
1. Ensure the TPU is dry

2. Check the screw is feeding regularly
4. Reduce the melt temperature
5. Reduce the screw speed to lessen the shearing effect on the TPU
6. Reduce the injection speed
7. Increase cavity venting
8. Ensure mold has not over heated
Make sure there is a cushion

maintained.
Increase shot size.
Increase pack and hold pressures.
Increase hold time.
1. Increase the injection holding time

2. Increase the injection speed
3. Increase the injection pressure (note: sometimes a reduced injection
pressure will rectify the situation as it may reduce the injection speed as well)
4. Vent cavity in the area of the sink marks
• Check ejector position and length, correct if
necessary
• Use larger ejectors
• Increase the number of ejectors
• Extend cooling time
If ejector marks is raised:
• Reduce holding pressure and holding
pressure time
• Use longer ejector
Increase mold close time.

Reduce mold temperature.
Texture mold surface for better release.
Increase size of pins.
Increase draft on part.
Reduce wall section.
Use a compound with mold release.
Use a harder compound.
A• See suggested solutions for Section V.

B• Reduce injection pressure and/or hold
• Reduce size of the shot pad.
• Reduce time that injection ram is
forward.
C• Increase time of the overall cycle.
• Reduce temperature of the mold.
• Increase diameter and number of
knockout pins.
• Use rubber type sprue puller or sucker
pins with more undercut.
• Incorporate air ejection in conjunction
with mechanical methods.
• Sand blast or vapor-hone mold core
and core pins in the direction of ejection.
D• Check suggestions in Section VI, Item C.
• Use internal or external mold release.
• Use matte finish on the mold cavity
E. Mold conditions:
• Overhaul and polish the mold surfaces.
and marred
• A minimum of 1° (0.017 rad) taper on long cores or cavities is required.
• Undercuts should not have sharp angles but should be tapered to ease ejection.
• Align nozzle and sprue bushing.
Descriptions
Foreign particle (burnt material or other) embedded in the part
• Check whether the melt or the granules are already

contaminated
• Clean plasticizing unit and hopper
• Clean mold and check for deposits
• Check screw for wear or abrasion and chang if
necessary
• Check wheter the contamination originates from
the environment, reduce dust in the environment.
• Improper regrind usage
• Poor housekeeping
• Check the mold for damage

• Check the mold for undercuts
• Check that mold has sufficient drafts
• Check the splits (splits must not scratch the molded part
A• Reduce temperatures of the cylinder.
• Shorten time of cycle.
B• Check all thermocouples for proper
operation.
C• Check for sticking relays.
• Check for sluggish or stuck meter move-
ments in all controllers.
• Calibrate controllers.
• Check for controllers which may be
connected to the wrong heaters.
D• Segregate and check regrind critically for
contamination, excessive moisture or
degraded polymer. Measure the melt
index of each polymer feed component.
(See bulletin, “Rheology and Handling.”)
Try virgin material.
E• Purge machine thoroughly until degrad-
ed (low viscosity) polymer has been
discharged. Rule-of-thumb is that poly-
mer hold-up is four times the maximum
shot capacity of the machine
F• Dry the regrind and polymer. For sugges-
tions on drying, see bulletin,
“Rheology and Handling.”
G• Change to a smaller capacity machine.
Shot should be between 25% and 75%
of the machine capacity. If a smaller
capacity machine is not available, use a
temperature profile with the front zone
and nozzle at the desired melt tempera
ture and all other temperatures as low as
operable.
H)Inspect the cylinder. Eliminate dead spots (streamline) as necessary.
Descriptions
polymer breakdown from hydrolysis, oxidation etc
outer surface of the mold base.
• Check for coolant leaks.
C• Inspect rework material thoroughly.
• Use care in handling materials and
caution in keeping foreign materials
clear of hopper and work area.
• Reduce temperature of rear cylinder.
• Increase back pressure.
• Use a dryer to remove condensed
moisture. Store pellets in the processing
area for a minimum of 4 hr prior to use.
• Dry the resin. Use a hopper dryer.
D• Check the material for foreign matter.
• Increase temperatures of the cylinder.
E• See suggestions in Section XIV, Item A.
• Increase pressure of injection. See
suggestions in Section VII, Items
A-1 and A-2.
F• Increase speed of injection.
See Section X, Item D.
• See suggestions in Section VIII, Item B.
• Dry the resin. See suggestions in
Section XIII, Items B and C.
G• Redesign and/or relocate gate.
• Raise temperatures of the cylinder
and/or mold.
• Increase speed of injection.
• Increase temperature of mold.
• Use polymer with a higher melt index,
if possible. (See bulletin, “Rheology
and Handling.”)
• Decrease speed of injection. Correct
design and/or location of gate.
• Regrind or additives are not well dis-
persed in the virgin polymer
F• Raise temperatures of the cylinder
and/or mold.
A.1. Decrease nozzle temperature.

B.1. Increase injection pressure.
C.1. Raise mold temperature.
D. 1. Use nozzle with larger orifice.
Lengthen boost time

Open gate
Deepen vents
Increase shot
Increase injection speed
Dry the resin
Lengthen mold-closed time
Effect on shrinkage :
Decreases (usually)
May be either (minor effect)
Decreases
Decreases until gate freeze
May be either
Increases
Usually none; may decrease
May be either; usually increases
Decreases
Increases
Decreases
Decreases
Decreases
Decreases
May be either
May be either
Increases
Increases
May be either; usually decreases
1. control holding / injection pressure

2. increase back pressure
4. check back flow valve
6. enlarge gate
7. shorten land length
1. Slow down or reduce decompression
2. Check granule feed
3. Increase back pressure and adjust screw speed
4. Reduce metering stroke
1. adapt injection speed

2. add a large cold slug area
3. add cold wells at the end of runner systems
4. control nozzle heat better: if necessary add beryllium copper tip (not
recommended for FR resins)
5. shorten or eliminate standard sprue bushing:use a hot sprue bushing
6. clean flow must exist from the cylinder, adaptor, nozzle and tip: avoid and
eliminate any dead pockets or
sections
Descriptions
Directionally "off tone" wavy lines or patterns
1. adapt injection speed

2. add a large cold slug area
3. add cold wells at the end of runner systems
4. control nozzle heat better: if necessary add beryllium
copper tip (not recommended for FR resins)
5. shorten or eliminate standard sprue bushing:
use a hot sprue bushing
6. clean flow must exist from the cylinder, adaptor, nozzle and
tip: avoid and eliminate any dead pockets or sections
• Add cold slug well in runner
• Increase gate size
• Add radius to gate
Gate blush is very common in injection molding, more often then not, it
is seen with the use of sub-gates or cashew gates.
1. Packing: An over pack of the part can cause a blush to be seen
around the gate area. If the selected pressure/time is needed to fill
the part out, a larger gate may be needed.
2. Flow rate: A high flow rate can sometimes result in a gate blush,
slowing the injection rate down or making the gate larger can help
eliminate this problem.
1. check venting channels for dirt

2. decrease injection speed
3. decrease injection pressure
4. use programmed injection
5. check for heater malfunctioning
6. reduce screw r.p.m.
7. decrease nozzle temperature
8. reduce melt temperature
9. improve mould cavity venting
add vents to ejector pins
add vents to parting line of part
10. enlarge gate to reduce frictional burning
11. alter position and/or increase gate size
1. Check vents are clear of dirt / debris

2. Reduce clamping force of the machine
4. Ensure vents are deep enough
5. Avoid entrapped air by changing flow profile
1. increase melt temperature

4. eliminate contamination
5. check percentage regrind
6. dry material
7. purge equipment
8. change material
9. radius all sharp corners at gate
1. increase injection pressure
2. increase cooling time
4. maintain uniform cycle time operation
5. check machine for erratic operation
6. check the percentage regrind to virgin material
7. increase gate size
8. reduce gate land length
9. relocate gate if glass-filled compounds
10. balance runner and/or gate system
11. reduce number of cavities to balanced system
1. purge heating cylinder

2. lower material temperature by
reducing cylinder temperature
decreasing screw speed
reducing back pressure
3. lower nozzle temperature
4. check residence time
5. check machinery purging
6. shorten overall cycle
7. check hopper and feed zone for contaminantst
8. check for proper cooling of ram and feed zone
9. provide additional vents in mould
10. move mould to smaller shot size press to reduce residence time
1. reduce injection speed

2. reduce injection pressure and/or booster time
3. increase clamping force
4. check mould for proper mould support and/or parallelism
6. reduce mould temperature
7. check excessive vent depths
8. change to higher clamping machine
Descriptions
Excess material in thin layer exceeding normal part geometry
Check shot size.
Check for dirt on the mold parting line of low hydraulic pressure.
Check injection pressure and speed.
1. Increase clamp force

2. Optimise change-over point
3. Reduce holding pressure
5. Reduce mould temperature
6. Stiffen mould

2. check nozzle heating
6. avoid gating at thick section
7. modify gate location or angle: directly into wall or pin
8. use tab gate or submarine plus pin
Increase process temperature.

Increase injection speed.
Decrease gate size.
Change type of gate.
Relocate gate to impinge.
1. get shear down

2. lower back pressure
4. change temperature profile
5. check regrind percentage
6. check shot size vs part
7. check hot-runner: torpedoes
1. increase injection speed
5. check mould textures
1. check cycle time: cooling

3. decrease injection hold time
5. decrease booster time
6. reduce and adjust feed for constant cushion
7. check for poor mould finish or corrosion on mould surface
8. increase mould opening time
9. decrease material temperature by lowering cylinder
10. lower mould temperature
11. adjust the cavity temperature to a 20°C differential between mould valves
12. check mould for undercuts and/or insufficient draft and taper
13. use proper mould release
Sandblast “A” side of tool.

Polish “B” side.
Run “A” side cooler.
Put keepers in “B” half of tool.
Increase draft on part in “A” half of tool.
Increase mold closed time.

Reduce mold temperature.
Reduce pack and hold pressure.
Sandblast “B” side.
Increase size of ejector pins.
Increase number of ejector pins.
Increase draft on part.
Provide air assist.
1. check cycle time: cooling
5. adjust feed for constant cushion
6. decrease mould-closed time
7. increase core temperature
8. decrease cylinder and nozzle temperature
9. check mould for undercuts and/or insufficient draft
10. check mould for bending: rule of thumb is 1:5 for core diameter to core length

4. increase die-closed time
5. decrease mould temperature at sprue bushing
6. leave nozzle against mould: no pull back
7. raise nozzle temperature
8. check incorrect seat between nozzle and sprue: sizes and alignment of holes in
nozzle and sprue bushing
9. sprue bushing hole must be larger: reduce nozzle diameter for sprue bushing
being used
10. check polishing of sprue
11. check proper design of sprue puller pin
12. check cone of sprue: usually 1:20, for difficult jobs 1:15
13. provide more effective sprue puller:
increase sprue puller by increasing taper of sprue puller
polish worn or rough sprue bushing
Descriptions
Non-Fill / Short mold Partial part
1. increase dosage
3. increase booster time forward
4. increase material temperature by increasing cylinder temperatures
5. increase mould temperature, if glass-filled
6. check material flow length vs wall section thickness
7. increase nozzle diameter
8. check restrictions of nozzle, runners and actual gating
9. increase gate size of sprue and runner system
1. increase injection speed to maximum range
2. sometimes lower injection speed: crystalline materials
6. reduce mould temperature
7. check for hot spots: separate water channels in cooling system / add heat pipes
such as thermal pins or
beryllium copper slugs for spot cooling
8. enlarge and/or add vents to mould parting line
9. increase size of sprue and/or runner
10. increase gate size and reduce gate land length
11. relocate gate next to heavy or thicker areas
12. core out heavy wall sections where possible
13. incorporate textured surfaces
Descriptions
Circular pattern around gate caused by hot gas
Color streaks are often a problem when the material has not been
blended at the proper ratio or when the screw is not of a proper design.
1. Material blending: It is critical that the proper material/concentrate
ratio be used. Any deviation from this ratio could cause problems
with color streaks and/or improper color.
2. Material mixing: Proper screw design is critical when molding a
PP/TPO compound. We recommend a distributive mixing screw with
a high shear spiral mixing head on the tip of the screw. Slowing the
screw down to where it gets to its full shot position about 2 seconds
before the cure time has ended is a good practice to follow. We also
ask that you consult with a technical representative before
purchasing a screw to ensure you are purchasing the correct design.
3. Shear Rate: Color can sometimes separate from the material while
flowing through the gate or high shear areas. Slowing the fill down
or reducing the restriction can reduce the shear rate and therefore
reduce color streaking.
Descriptions
Localized change of colour
1. check pre-drying: dry material before use
2. check moisture content after pre-drying
3. check effectiveness of drying equipment: temperature and time
4. lower nozzle temperature
5. lower material temperature by:
lowering cylinder temperature
decreasing screw speed
lowering back pressure
7. raise mould temperature
8. shorten or eliminate screw decompression
9. shorten overall cycle
10. increase back pressure; in case of drooling,reduce back pressure
11. check for drooling
12. check for contamination(e.g. water or oil leaking into mould cavity)
13. barrel purging (hang-ups)
15. open gates
16. move mould to smaller shot-size press
Descriptions
Splash mark / Silver Streaks Circular pattern around gate caused by hot gas
1. check for material contamination by other resins

2. check barrel purging
3. check for cracked or worn back flow valve ring
4. check for worn feed screw
5. check for excessive clearance on screw/barrel dimensions
6. check for overheated cylinder heater bands
7. check for overheated nozzle heater bands
For the sake of argument splay will be included with silver streaking.
They both appear to be the same defect, but some people differentiate
between moisture splay and shear splay, calling shear splay silver
streaking.
1. Proper drying: If the material you are using has talc in it, we
recommend that you dry that material according the process sheet.
Be cautious of over drying the material as this may cause some of the
additives to be cooked out of the material. Polypropylene does not
absorb moisture but the talc will, it is important to drive off that
moisture.
2. Venting: Be sure to have the tool properly vented in all possible
locations. Venting ejector pins and lifters is also suggested.
3. Excess shear: Too high shear can often cause silver streaking or splay.
Controlling and reducing the flow rate through the area where the
splay is seen can eliminate this.
4. Gas trapping: If two or more material flow fronts are converging on
each other it can sometimes cause a gas trap that is eventually moved
from the area and is smeared out across the part. Try to eliminate
the gas trap by changing the material flow in that area.

5. change gate location
1. use suck back: only for crystalline materials

2. lower back pressure
3. lower or increase nozzle temperature
4. use different temperature profile
5. do not use sprue breaks
Descriptions
String like remain from previous shot transfer in new shot
The occurrence of tiger stripes comes when the material sees to high of a
shear rate going through the gate and when the material has to travel a
long distance.
1. Reduce Shear Rate: Opening up the gate(s) or reducing the injection
rate can reduce or eliminate the appearance of tiger stripes.
2. Heat up the grained side of the tool: This will help the material flow
more easily through the tool.
3. Increase Melt Temp: This will help the material flow a little easier
through the gate and possibly help with the appearance of tiger
stripes.
1. decrease injection speed to medium range

2. increase holding time
5. check gate size: too small results in freezing at gate with voids and sinks in other
areas of the part
6. increase gate size and reduce gate land length
7. increase nozzle size and/or runner system
8. redesign part to obtain equal wall sections
Descriptions
Empty space within part (Air pocket)

3. increase injection speed
4. raise melt temperature by increasing cylinder temperatures
5. raise mould temperature
6. check for proper venting of the part
7. vent the cavity in the weld area
8. provide an overflow well next to the weld area
9. change gate location to alter flow pattern
10. increase gate and/or main runner system
11. reduce gate land length
12. spot heat particular area with thermal pins or cartridge heaters
13. use textured surfaces
Descriptions
Knit Line / Meld Line Discolored line where two flow fronts meet
Increase Injection pressure
Increase Holding pressure/time
Increase Melt temperature (not excess)
Adjust injection fill rate
(around 1sec/mm of wall thickness)
Enlarge vents and Vent the cavity
in the weld line
Change vent or gate location
1. Increase the injection pressure

2. Increase the injection speed
3. Increase the temperature of the melt
4. Increase the mold temperature
5. Ensure the TPU is completely dry
6. Ensure the check ring is functioning

4. Increase hold on pressure
5. Check venting
6. Relocate gate to change flow pattern
1. Increase the cycle time to allow the polymer to melt

2. Increase the barrel temperature
4. Preheat the granules
1. Ensure the hopper and feed throat are free from obstructions
3. Reduce screw charging speed
4. Ensure water cooling to hopper feed throat
1. Increase the melt temperature

2. Check for cold areas of barrel
3. Reduce the screw back pressure
1. Increase nozzle temperature
3. Create cold slug well in the mould opposite sprue
bush

4. Avoid sharp transitions, reduce engraving depth
5. Relocate gate
1. Check granule for impurities

2. Clean plasticising unit
3. Reduce barrel temperature
4. Reduce screw speed
5. Reduce back pressure
6. Check hot runner temperature
7. Reduce regrind dose
1. Check for cross contamination with other polymers

in every area of operation.

3. Optimise injection hold position and time
4. Reduce injection pressure
6. Maintain equal mould temperatures on both halves
of mould tool
7. Anneal parts at as high a temperature as possible
Check for contamination.
Reduce the level of regrind.

Reduce the rear zone temperature.
Reduce the residence time.
Add delay to screw recovery.
Purge machine and observe whether problem reoccurs.
Reduce process temperature. (Particularly in rear of machine).
Reduce regrind level.
Reduce residence time.
Purge machine after shutdown.
Move to a smaller machine.
Reduce hot runner system temperatures.
Minimize dead spots in hot runner manifold.
When a difference in gloss is seen, it is important to make a careful

evaluation of the situation, use the following to help determine what the
problem is.
1. Temperature and Pressure: If two melt fronts are coming together
and the temperature is too low or the pressure is too low it will not
allow the area to be packed out properly, causing a higher gloss in
that area.
2. Venting: Be sure to check all vents around parting lines, on ejector
pins, and on lifters. Improper venting can cause gas to come to the
surface of the part and will give it a higher gloss.
3. Flow distance: If the material has traveled a long distance it will
sometimes not be packed out properly far from the gate. This can be
helped with a larger gate or changing the gate location to help pack
that area out better.
Decrease Injection filling rate

Flare gate
Increase Gate size
Maintain Gate location
Control proper hold pressure time

Wrinkle near gate Increase gate size
Increase Injection fill rate

Increase Injection fill pressure
Increase Hold time
Increase Cylinder temperature
Gate size
…………………..
Enlarge vents
File name
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Processing Guidelines and
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Material Process
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NYLON RESINS - CORRECTING
MOLDING PROBLEMS - A TROUBLE
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Torlon Polyamide imide Trouble

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SHOOTING GUIDE
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with photo
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pages.pdf
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shooting guide
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pages.pdf
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polyamide-imide
pages.pdf
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pages.pdf

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Gas-Injection Moulding with DuPont engineering polymers - GasInj_e, 8 pages.pdf
174 pages, Bayer, material science, engineering polymers, part & mold design, adesign guide Part

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Properties Acetal (POM) Copoly Acetal (POM) Homopoly Acrylic (PMMA)

Specific Gravity (g/cm³) 1.37 to 1.43 1.33 to 4.84 1.15 to 1.19

Melt Mass Flow Rate (g/10 min) 1.5 to 27 -- 0.30 to 4.6

Flexural Modulus (psi) 272000 to 428000 359000 to 458000 162000 to 500000

Flexural Modulus (MPa) 1880 to 2950 2480 to 3160 1120 to 3450

Tensile Strength (psi) 6160 to 9460 7620 to 10700 5310 to 11800

Tensile Strength (MPa) 42.5 to 65.2 52.5 to 73.5 36.6 to 81.1

Tensile Elongation (%) 1.0 to 200 3.0 to 71 0.0 to 7.3

Rockwell Hardness 80 to 117 93 to 120 44 to 102

DTUL at 66 psi (0.45 MPa) (°F)

DTUL at 264 psi (1.8 MPa) (°F)

CLTE, Flow (cm/cm/°C)

Melt Mass Flow Rate (g/10 min) 1.5 to 27 -- 0.30 to 4.6

Drying Temperature (°F) 174 to 250 174 to 186 171 to 185

Drying Temperature (°C) 78.9 to 121 78.9 to 85.3 77.0 to 85.0

Drying Time (hr) 2.0 to 4.5 1.9 to 3.5 2.5 to 5.0

Suggested Max Moisture (%) 0.15 to 0.20 0.2 0.097 to 0.30

Suggested Max Regrind (%) 20 to 25 20 to 25 25

Injection Pressure (psi) 7550 to 15700 12000 to 15600 10500 to 16000

Injection Pressure (MPa) 52.0 to 108 82.7 to 108 72.4 to 110

Rear Temperature (°F) 336 to 401 372 to 391 378 to 491

Rear Temperature (°C) 169 to 205 189 to 199 192 to 255

Middle Temperature (°F) 372 to 401 371 to 388 427 to 476

Middle Temperature (°C) 189 to 205 188 to 198 220 to 247

Front Temperature (°F) 369 to 402 371 to 401 438 to 474

Front Temperature (°C) 187 to 206 188 to 205 226 to 246

Nozzle Temperature (°C) 187 to 207 205 to 207 220 to 247

Mold Temperature (°F) 120 to 204 117 to 201 140 to 171

Mold Temperature (°C) 48.9 to 95.8 47.2 to 93.9 59.9 to 77.1

0.40 to 9.1 -- 34 3.0 to 27 1.3 to 36

2.0 to 59 2.7 to 250 55 to 170 0.0 to 120 1.7 to 94

61 to 86 74 to 123 87 to 111 70 to 121 117 to 121

188 167 to 203 162 to 178 269 to 290 254 to 280

86.7 75.0 to 95.0 72.2 to 81.1 132 to 143 123 to 138

-- 0.000062 to 0.00011 7.6E-05 0.000052 to 0.000087 0.000063 to 0.000070

0.40 to 9.1 -- 34 3.0 to 27 1.3 to 36

149 to 180 200 130 to 145 216 to 263 224 to 248

65.0 to 82.2 93.3 54.4 to 62.8 102 to 128 107 to 120

2.0 to 2.1 4 4 2.8 to 4.3 3.5 to 6.0

-- -- -- 0.019 to 0.020 0.0100 to 0.020

15000 12500 -- 1300 to 20400 12500 to 15000

103 86.2 -- 8.96 to 140 86.2 to 103

384 to 391 -- -- 485 to 576 481 to 508

195 to 199 -- -- 252 to 302 249 to 264

395 to 420 -- 350 517 to 593 482 to 520

201 to 216 -- 177 269 to 312 250 to 271

404 to 441 -- 350 539 to 611 491 to 536

207 to 227 -- 177 282 to 321 255 to 280

193 to 227 -- -- 278 to 319 284 to 285

429 to 441 393 395 to 400 540 to 586 499 to 522

221 to 227 200 202 to 204 282 to 308 259 to 272

104 to 116 200 115 175 to 215 138 to 172

40.2 to 46.5 93.3 46.1 79.7 to 102 59.0 to 77.5

1.5 to 15 6.2 to 26 8.0 to 35 3.0 to 22 5.6 to 30 9.2 to 21

3.7 to 11 1.5 to 150 3.0 to 54 2.0 to 150 6.0 to 86 120 to 180

44 to 46 89 to 119 115 to 121 114 to 118 85 to 122 --

1.5 to 15 6.2 to 26 8.0 to 35 3.0 to 22 5.6 to 30 9.2 to 21

-- 0.020 to 0.022 0.019 to 0.020 0.02 0.02 0.03

9000 to 10100 9430 to 15000 14900 to 15100 15000 -- 9500 to 10500