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What are the best practices for optimizing injection speed in manufacturing?

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Injection speed is one of the most important factors that affect the quality and efficiency of injection molding. It determines how fast the molten plastic fills the mold cavity, and influences the pressure, temperature, shrinkage, and cooling time of the final product. However, optimizing injection speed is not a simple task, as it depends on various factors such as material properties, mold design, machine settings, and product specifications. In this article, you will learn some of the best practices for optimizing injection speed in manufacturing, and how to avoid common pitfalls and problems.

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1 Know your material

Different materials have different flow behaviors, viscosity, and thermal characteristics, which affect how they respond to injection speed. For example, some materials are more shear-sensitive, meaning that they become less viscous and more fluid when subjected to high injection speeds. This can result in better filling, but also more flash, warping, and stress. Other materials are more shear-thinning, meaning that they become more viscous and less fluid when subjected to high injection speeds. This can result in better dimensional stability, but also more short shots, sink marks, and weld lines. Therefore, you should always consult the material data sheet and perform trial runs to determine the optimal injection speed for your material.

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David Rodriguez

Operations & Manufacturing | Scientific Injection Molding | Tool Room | Project Engineering | NPI & Industrialization | Maintenance
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La selección del material va en función a las propiedades mecánicas y/o resistencias químicas así como propiedades estéticas y visuales del mismo material y a la necesidad del producto. No siempre la más alta velocidad de inyección es lo ideal para nuestro proceso ya que pudiéramos además de crear defectos en el producto, pudiésemos estar rompiendo la cadena molecular del polímero fomentando la degradación y reduciendo las propiedades del mismo. La forma ideal para determinar la velocidad de inyección óptima es a través de generar la curva reologica y seleccionar la velocidad donde el tiempo de inyección alcanza la región plana en la curva.

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2 Adjust your mold design

Mold design plays a pivotal role in optimizing injection speed. Factors such as the size, shape, location, and number of gates, runners, and vents affect how molten plastic flows into the mold cavity and how air escapes. To optimize injection speed, it's important to have a balanced and uniform filling pattern with minimal pressure loss, turbulence, and hesitation. To achieve this, you should consider using larger and fewer gates to reduce resistance and improve flow rate, tapered and rounded runners to reduce friction and shear stress, adequate venting to allow air to escape and prevent trapped gas and burn marks, as well as thin and consistent wall thicknesses to reduce cooling time and shrinkage.

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3 Fine-tune your machine settings

To optimize injection speed and the quality of the final product, you should adjust machine settings such as injection pressure, holding pressure, back pressure, screw speed, and screw position according to the material properties, mold design, and product specifications. For example, using higher injection pressure can increase the injection speed and fill the mold faster. Lowering holding pressure can reduce the residual stress and warping of the product. Additionally, lower back pressure can reduce the melt temperature and viscosity while higher screw speed can increase the shear rate and reduce the viscosity of the material. Lastly, a lower screw position can reduce the cushion and increase the injection stroke.

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4 Monitor your product quality

Optimizing injection speed in manufacturing is not a one-time process, but rather a continuous one. You should always monitor your product quality and performance, and make adjustments as needed. Weight, dimensions, and appearance are all factors that can indicate whether the injection speed is optimal or not. For instance, if the weight is too low, it means the injection speed is too slow; if the dimensions are too small, it means the injection speed is too fast; and if the appearance is dull or rough, it means that the injection speed is too slow. By following these best practices, you can improve your injection molding process and achieve better results - ultimately leading to improved quality, efficiency, and cost.

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5 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Thomas M.

Former Maintenance Supervisor at Kyodo America
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Use scientific molding techniques to find the best fill rate. You may have to inject slow until the plastic gets thru the gate to prevent splay. Then increase the injection speed to the optimum speed as found by scientific test.

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What are the best practices for optimizing injection speed in manufacturing?

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5

1 Know your material

2 Adjust your mold design

3 Fine-tune your machine settings

4 Monitor your product quality

5 Here’s what else to consider

Manufacturing Engineering

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What are the best practices for optimizing injection speed in manufacturing?

1

2

3

4

5

1 Know your material

2 Adjust your mold design

3 Fine-tune your machine settings

4 Monitor your product quality

5 Here’s what else to consider

Manufacturing Engineering

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