Materials Today: Proceedings 78 (2023) 656–661

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Materials Today: Proceedings

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An explanatory study on defects in plastic molding parts caused by

machine parameters in injection molding process
Ankush Mourya, Arshit Nanda, Kartik Parashar, Sushant, Rajender Kumar ⇑
Department of Mechanical Engineering, FET, MRIIRS, Faridabad 121003, India

a r t i c l e i n f o a b s t r a c t

Article history: In the Injection Molding process, the output product quality is dependence on various attributes such as
Available online 19 December 2022 product geometry, the material used for manufacturing, and the machining parameters (process param-
eters). Here it is an exaggeration to say that the parameters associated with the molding process play a
Keywords: crucial role in the production of high-quality products. In the present study, the causal approach is used
Injection Molding to recognize the problems associated with the injection molding components to cause defects such as
Defects shrinkage, flow lines, sink marks, burn marks, short shots, warpage, etc. This study aims to reveal the
Process Parameter
basic understanding of the injection molding process and the importance of machining parameters in
Optimization
moldings. This study will brief the type of defects and their causing machining parameters to the indus-
trial practitioners/researchers. In addition, the study will suggest the parameters to set out on the
machine so that the final product will be free from any defect.
Copyright Ó 2023 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the 3rd Biennial International Conference on Future
Learning Aspects of Mechanical Engineering.

1. Introduction defects such as shot molding, warpage, shrinkage, etc. are depen-
dent on attributes such as machining parameters such as the tem-
As the population is growing exponentially worldwide, there is perature of heating elements, timings for injection and holding
also an exponential rise in the demand for products made up of pressure, cooling channels temperature, etc. The earlier studies
Plastic Material especially molded by the Injection Process. This reported that the selection of the raw material plays an important
process is named as Injection Molding Process and is preferred role as it helps in defining the machining (mold machine) param-
for the production of a wide range of products with variations in eters such as the temperature of the barrel, injection pressure,
specification such as shape and size etc. [44] Even, the raw material and injection timing, etc. [31] The machining parameters if not suit
range also varies according to the functions/services to be per- the material to inject further lead to defects like shot-molding,
formed by the end products. burn-out, and shrinkage, etc. The earlier studies available report
In the Injection Molding Process, the raw material in the form of that the defects occurred in injection moldings because of the
pallets/granules is melted in the barrel and then injected into the parameters used for the molding process [4]. As an example, a
mold of desired geometry. The molded part is cooled within the small rise in injection temperature can cause the viscosity of the
mold itself to avoid any defect through cooling channels. Fig. 1 melt and ultimately causes the quality of the end product. On
below shows the injection molding machine and important parts the other hand, if the cooling temperature is not appropriate it
of the machine [2]. may affect the molding and cause a shrinkage defect.
Once the moldings are ejected from the mold, it has been In the injection molding operation, the melted polymers are
inspected for quality evaluation. Moreover, in the molding process, injected into the mold with pressure and after solidification, they
it can’t be predicted that all the moldings are free from defects. The get the shape of the mold. It is a complicated process with numer-
ous physical fields and numerous elements which influence each
⇑ Corresponding author at: Mechanical Engineering Department, Faculty of other. Plastic injection molding is a considerably significant tool
Engineering & Technology, Manav Rachna International Institute of Research & in manufacturing. Several components are produced by this pro-
Studies, Sector - 43, Delhi - Surajkund Road, Aravalli Hills, Faridabad, India. cess. For making a component through injection molding different
E-mail addresses: [email protected] (A. Mourya), sushant1.fet@m- process parameters are applied in a controlled manner. Table 1
riu.edu.in ( Sushant), [email protected] (R. Kumar).

https://doi.org/10.1016/j.matpr.2022.12.070
2214-7853/Copyright Ó 2023 Elsevier Ltd. All rights reserved.
Selection and peer-review under responsibility of the 3rd Biennial International Conference on Future Learning Aspects of Mechanical Engineering.
A. Mourya, A. Nanda, K. Parashar et al. Materials Today: Proceedings 78 (2023) 656–661

Fig. 1. Injection Molding Machine.

below lists the parameters essential in the injection molding Here, the process parameters play an important role and can be
process: controlled by the machinist based on predictor values [10].
The present study is based on an explanation of the literature Prediction of the values of a process parameter is the toughest
available regarding the essentialness of the parameters and their task and requires a large amount of data on the product character-
contribution to defect-free production. The present study aims to istics that need to be satisfied. The parameters thus require the
explore the defects that occur in moldings and the factors that adjustment of varying the product characteristics such as material;
are causing the defects. In addition, the study includes the reveal- shape and size; mechanical strength etc. The process parameters
ing of process parameters’ impact on product characteristics. also help in predicting the dynamic quality characteristics of the
product [12].
The literature available on the injection molding process and
products reveals the impact of the parameter. The operational
2. Literature review
parameters not only influence the product quality but also influ-
ence the mechanical properties such as tensile, compression,
The manufacturing sector contributes around 15–20 % of the
strength, etc. [19] The cavity pressure and temperature within
nation’s economy [38]. Out of this contribution, the production of
the mold for each injection cycle has a direct impact on the quality
plastic components contributes a lot and fulfills the daily needs
of the product [41]. The study on process parameters of Injection
of the consumers as well as the demands of other sectors’ prod-
Molding components made up of polycarbonate material reports
ucts/services. In the plastic manufacturing, the Injection molding
that the melting, as well as mold temperature, has a significant
operation contributes the majority of the stake because of its util-
influence on the mechanical properties of the end product [9]. As
ity and suitability of all job, batch and continuous scale production.
the temperature increase annealing results in increased yield stress
The characteristic such as versatility and recyclability make the of
and cause failure. Further, the moldings made up of ABS material
thermoplastic materials prevalent for products manufacturing
by the injection molding operation are having a huge scope in
especially through Injection molding. In the Injection Molding,
the automobile sector. Shrinkage is the most common defect
the material enters at the room temperature or in few cases at pre-
reported on the plastic moldings of ABS material. The studies on
heated conditions (based on the requirements of the moldings)
shrinkage defect elimination reported that the melt temperature
passes through the barrel where it gets melted. The number of hea-
has an important concern. The experimentation analysis was also
ters in sequential manner are incorporated on the barrel outer
reported by considering the three heating zones (different in
body and controlled by thermos-couples. The heat generated
temp.) with manageable variables such as melt temperature, injec-
through the heaters then passes to the material inside the barrel
tion pressure, packing pressure, and cooling time [35]. Another
and molten the material. This hot material inside the barrel
study reports the minimization of warpage can be obtained by
pushed/injected into the mold with by developing the high pres-
working on the packing pressure profile and process parameters
sure through ram/screw-type plungers mounted inside the barrel.
[16].
The molten material once injected into the mold filled into the cav-
The process parameter not only plays an important role while
ities of the mold and then the pressure for Injection is reversed. The
the operation happens, but it is also important and considered
application of water outside the mold body extracts the heat from
while designing and framing the injection molding process. The
the melted material filled inside the cavities and help in solidifica-
selection of material, mold specification and cooling channel are
tion. The solidify part then extracted from the mold with the ejec-
also crucial to finalize especially in the multi-cavity molds. The
tor pins and then finished through machining operation (if
geometric parameters of the molding are of important concern.
required) for final packaging.
These parameters further lead to defining the process parameters
The Injection Machining Operation (known as Injection Mold-
and ultimately dictate the quality of the product [26]. Further, in
ing) is also having he applications in manufacturing the complex
the mold specification, the part thickness is the factor that can
shape products as it is having the non-linearity in the structures.
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A. Mourya, A. Nanda, K. Parashar et al. Materials Today: Proceedings 78 (2023) 656–661

Table 1
Essential parameters for Injection Molding.

Sr. No. Parameters Details taken from

1 Melt Temperature: It is the temperature at which the plastic materials melted to flow the material smoothly and are injected into the [3,15]
mold. The melting of the material is done inside the barrel through the electrical heaters. The thermocouples are employed to control the
constant melting temp in the barrel. To speed up the melting operation, in fewer cases preheating of the material is done using dryers.
2 Mold Temperature: The temperature of the mold is kept low as compared to the barrel temperature to let the plastic cool. It became [23][5]
essential to maintain the appropriate temperature and evenly distributed it within the mold to avoid the defects like shrinkage, warpage,
etc. Even, the mold temperature must be controlled to regulate the cooling rate of the plastic material.
3 Holding Time: The time taken by the machines in filling the melted material inside the mold through the injection pressure is known as [40][27]
Holding time. Generally, in an automatic injection molding machine, the limit switch or pressure build signals were given to the injection
screw to push forward and inject the molten plastic into a closed mold. The holding time is controlled by a timer and based on attributes
like shape and size of molding, no. of cavities to be filled, material, and the injection pressure, etc.
4 Injection Pressure: The pressure is applied on the mold to remain closed until the molten material gets injected into the mold. The [13][40]
injection pressure for filling the mold is very crucial and also depends on factors like the material to be injected, state of the melt (viscous
more or less), no. of cavities to be filled in a mold etc.
5 Holding Pressure: It is kept about half of injection pressure to get the mold gates to freeze. Normally, it is set under 5 min and depends [39,1]
on basically the mold geometrical specifications such as gate size, runner length, sprue, etc. The objective behind setting this holding
pressure is to ensure that the material gets filled in the cavities and the gates are frozen to avoid any material backout action due to
suction.
6 Cooling Time: The objective of the cooling is to reduce the temperature of the plastic material which is inside the mold up to its [8,32]
solidification. The time taken to solidify the moldings within the mold is termed the cooling time. Even, this extra amount of time allows
the moldings to become rigid enough to withstand the ejection process. Normally, a water-cooled arrangement installed within the mold
is used for this purpose. The cooling time is mainly dependent on the material to be molded, the molding design and specifications, etc.
Normally, it is kept in the range of 40–60 % of the total cycle time.
7 Injection Speed: In the injection molding operation, the speed at which melt is being injected by the injection nozzle into the mold [24] [42]
cavity. The material first passes through sprue then runner and finally through gate into required mold cavity. This injection speed is also
an important concern to avoid any kind of defective production run. Generally, the injection speed is kept moderate one because it has
the dependency on both material characteristics and molding machine parameters. Higher the injection speed has the probability to fill
the excess material and chances of flash becomes higher whereas the slow speed may cause the shot-moldings.

be impacted by the process parameters especially when ultra-thin increments also contribute considerably for reduction in short
moldings are manufactured. The thin-walled components are shots defect.
preferable in injection moldings because of having direct impacts b. Sink-marks: The hollow bubbles trapped on the end product
on material consumption, and operational cost [34]. Still, the are generally found on moldings especially having thick wall thick-
defects like warpage and shrinkage are reported especially on the ness. Mostly, the sinks result from the operations where the cush-
thin wall components [25] A study on thin-walled components ion among no. of cycles is varying. Even, varying injection pressure,
made up of PP reveals that the filling time/injection time after that lesser mold clamping, and cooling timing cause the development of
pressure holding time can contribute to defective production if not the sink-marks on the final moldings [40]. It is important to con-
provided with the proper parameter specifications. Even, the inte- sider shrinkage in molding design because it has also linkages with
gration of cooling channels helps the injection molding process in the sink marks defects especially in the moldings with thicker
the reduction of cycle time. In general, four types of cooling chan- geometry. To eliminate the sink mark defect, it becomes necessary
nels are used i.e. T-type, L—Type, Spiral, and Zigzag. A study to to slight increase the holding pressure and time. This will help in
reveal the impact of cooling time on product characteristics getting the part’s surface to cool. In addition, the increase in cool-
reported there are least requirements of cooling in spiral channels ing time also leads to limit the shrinkages.
when compared with the other three types. Among the four c. Weld lines: Is referring to the lines that occur on final compo-
designs, the spiral cooling channel was the better option compared nents because of the joining of material within the molds during
to the Inline-T cooling channel [28]. the molding operation. In most of the products, the low melting
point is the main cause behind these lines. Even the high injection
pressure flow speed is also having a direct impact on generating
3. Defects in injection molding such lines on the products. Moreover, this defect is observed in
the moldings manufactured with two or more different materials
Despite the good quality products resulting from the injection due to variation in temperature range between two materials.
molding operation, there are many kinds of defects are also While the manufacturing operation i.e. injection molding, it
observed in the moldings. A few common defects observed in becomes necessary to maintain the temperature otherwise both
moldings are as follows: can solidify partially which will cause to bonding in between them.
a. Short-shot: The short-shot is the uncompleted part produced. This defect further causes the strength of the product [20]. To elim-
In general, if the mold cavity is not filled due to any reason is called inate this defect, the material temperature requirements need to
the short shot. This is mainly happening, when the new part pro- be addressed first. The increased material temperature help in pre-
duction begins on the machine. The material flow in the molds is venting the end product from the partial solidification of the mold-
the important remedy and resulting short-shot. The material flow ing. Further, the slight increase in injection speed and pressure can
has a dependency on the process parameter such as the barrel tem- also lead to limit the cooling rate and especially before the material
perature, injection pressure, injection timing, etc. Even, it has been has filled the mold.
also revealed from the literature that the flow rate in low melting d. War page: In the injection molding operation, once the com-
and molding temperature cause in developing the air vents and ponent is ejected from the mold, there is a war page. It is known as
lead to result in short-shot [18]. The short shot defect can also be the deviation of the peri-pheri of the component. The reasons for
observed in narrow/blocked gate opening moulds. To eliminate the warpage are part is ejected when it is too hot, the design of
this defect, the increase in injection pressure and injection speed the ejection system is poor, inadequate injection pressure or time,
will result in complete moulding. Even, the mould temperature improper flow rates, and cooling in the mold is not uniform [30].

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A. Mourya, A. Nanda, K. Parashar et al. Materials Today: Proceedings 78 (2023) 656–661

The warpage is resulting from the undue stress development in the side the intended flow channel inside the mold. To eliminate the
process and results in bend/twist in the final product geometry. flashing defects, the mold temperature and the injection pressure
The quick cooling mechanism mounted on the molds for increasing needs to be adjusted.
the productivity rate on the machines is the important and major g. Burn-mark: In the plastic components, burn marks are
contributor in the warpage defect. For eliminating such defect, observed especially in the operation when the air is trapped in
the cooling channel must incorporate the mechanism to provide the mold cavity. This trapped air when subjected to high compres-
cooling for longer periods. sion caused by injection pressure within the mold during operation
e. Flow-marks: The undesired patterns on the moldings are overheats the material and it will appear on the final molding as
referred to as the flow marks and impacted the aesthetic of the burn marks. Further, the burn marks on the moldings are also
components. Flow marks are a indication of non-uniformity in appears in the case where melting temperature is too high and
the flow pattern into the mold that occurs around the gate. When the excessive injection speed. The burn marks from the molding
there is a temperature gradient in the melt consequently non- parts can be eliminated by taking the precautionary measures on
uniformity will as a result and sometimes it will result in little dif- the process parameters such as the material temperature (melt)
ferent color tone from the rest of the components. The variations in and the mold temperature. Both the parameters are directly
the cooling speed of the material is the main reported cause for the resulted in overheating of the material and once material get over-
flow marks. It generally reports in the components with variation heated should be injected with lower speed to limit the risk of air-
in wall thickness of the component results in flow marks [33]. trap while injecting the material inside the mold.
For eliminating the flow marks, the precautionary measures to be h. Silver Streaks: The silver streaks are reported on the mold-
taken for the injection time and pressure. During consideration ings mainly when there is moisture, air and gases are present in
such factors, it is must important to consider the situation that the material. For the moisture, the melt (material) temperature
the molding should be completely filled before the cooling hap- plays the crucial role [29]. To eliminate the silver-streaks defect,
pens. The slight change in design especially in straight (square injection speed plays an important role. The control on injection
shaped) corners molding the round corners are suggested which speed along with slight increase in mold cooling can result in
will further help in consistency of material flow inside the mold. reduced silver-streakes on the final product. The Fig. 2 reveals
f. Flashing: The excess material on the outer body of the mold- the defects in Plastic Moulded parts.
ings is referred to as the flash. The moldings developed under high
injection pressure and even, the injections of highly heated mate- 3.1. Analysis
rial, parting line mismatch due to mold cavities are worn out when
the clamping pressure is not enough to resist the force which is In the present era, industries are more prone to perform energy-
developed during the mold filling are the main cause to develop efficient processes to reduce environmental impact. The defective
the flashes [21]. The excess material on moldings also refereed as production will cause and create an impact on industrial perfor-
burrs and reported in the products in which the material flow out- mance in terms of resource wastage. That’s-why, it becomes

Fig. 2. Injection Moluding Defects.

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A. Mourya, A. Nanda, K. Parashar et al. Materials Today: Proceedings 78 (2023) 656–661

Table 2
Revealing the various defects caused by parameters.

Molding Defects Causing Parameter’s

Melt (Material) Mold Holding Cooling Time Holding Injection Injection
Temperature Temperature Pressure Time Pressure Speed
Short-shot Increase Increase Increase
Sink-marks Increase Increase Increase
Weld-lines Increase Moderate Increase Increase
War-page Reduce Reduce Moderate
Flow-marks Increase Increase Increase
Flashing Moderate Moderate
Burn-mark Reduce Reduce Moderate Reduce
Silver Streaks Reduce Increase Increase

prominent to work under optimal conditions. The literature on production is the need of the day, still, there are defects in the
injection molding reported that the selection of parameter values manufactured products caused by the process parameters. In the
and implementations plays a critical role. The parameters such as Injection molding components defects are caused by material (to
heating of material/mold, plastification of molten material, and be molded), mold specification (end design of the product) and
the cooling of moldings/molds are mainly considered as the sub- the process parameters (machine parameters). With the advance-
process to the energy-efficient operations. Table 2 below reveals ment of design tools the defects caused by material and the mold
the different defects induced by the various parameters in the design are addressed at the initial stage before the finalizing the
moldings. production. But the process parameters are still to be addressed.
Table 2 reports the defects and their causes related to the pro- In the present study discussed, the parameters have the direct
cess parameters of injection moldings [39,42]. The Table 2 categor- impact on the moldings made by Injection Molding Process. The
ically reports Melt Temperature, Injection Pressure and Injection study advocates that variation in any parametric value may cause
Speed are the main contributors in the defects such as the short- one or more defects in the final moldings. The present study will
shot, weld-lines, flow marks, burn-marks etc. The other parameters help the researchers and practitioners working on the Injection
such as Mold temperature and Cooling Time also contribute in the Molding Process to understand how and why particular defects
defects appropriately. The parameter Holding Pressure and Hold- are occurring and predict future occurrences. Also, provides them
ing Time only contribute in one defect i.e. Sink-Marks. Table-2 fur- with an understanding of parameter selection to run defect-free
ther reveals that the kind of manipulation required during the production. In addition, the study also explored the defects caused
processing of moldings either reduction or increment. by the variations in the parametric value of the molding process
and the various techniques used for optimizing those parameters.
3.2. Discussion The paper concludes the importance of effective and efficient pro-
cess parameters in the injection molding process. This would help
From the present study, it is revealed that the defects in mold- not only the reduction in defects but also to produce the compo-
ings (components) and their occurrence is not only because of the nents with good quality and energy-efficient operations to survive
design considerations but also caused by the process parameters. in the competitive market. The present study emphasizes the opti-
The defects caused by molding process can be easily eliminate or mality of process parameters. The optimization of process param-
reduce using the parametric variation of the machine parameters. eters is required to hinder or revamp the defects in injection
Though these kinds of defects are less costly, still has an impact on molding and enhance the mold characteristics. As far as Industry
the bottom line tremendously. It is also exaggeration to say that 4.0 is concerned, there is a huge demand for an intelligent
the variation beyond the specified values in the process parameters knowledge-based system. for future work, the integration of smart
cause the moldings and manufacture the defective parts [30,37]. technologies to eliminate the defects caused by the process param-
To overcomes from the defects caused by process parameters, eters will be studied.
many of the studies are also reported. The studies report the adop-
tion of advanced techniques for optimizing the process parameters CRediT authorship contribution statement
such as Taguchi Method, Neural Networks, Statistical Analysis,
Genetic Algorithms etc. In addition, the application of Multi- Ankush Mourya: Conceptualization, Methodology.
Criteria Decision-Making tools using fuzzy data are also used.
The objective of applications of these optimization techniques is Data availability
to define only the optimal value of the parameters so-that the
defects can be eliminated [7,44]. The application of such No data was used for the research described in the article.
approached in optimizing the values of the parameters not only
for increasing the performance of the product by eliminating the Declaration of Competing Interest
defects but also help in improving the product quality [6,17].
The authors declare that they have no known competing finan-
4. Conclusion cial interests or personal relationships that could have appeared
to influence the work reported in this paper.
The history of products made up of plastic material using mold-
ing techniques reveals the existence of more than one century. The References
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