3/8/2016

EliminateSurfaceDefectsonMoldedParts:PlasticsTechnology
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Troubleshooter
Eliminate Surface Defects on Molded Parts
52

By: Martin Bichler from Demag Plastics Group

From: Plastics Technology
Issue: July 2005

Visible defects on the surface of a molded part appear as dull, glossy, or hazy areas, or
as a rippled surface, called orange peel.
Visible defects on the surface of a molded part appear as
dull, glossy, or hazy areas, or as a rippled surface, called
orange peel. Common points of occurrence include near
the sprue or behind sharp edges in areas away from the
sprue. The mold and the molding process are the best
places to seek out and identify the causes of these effects.

Dull areas on the part

Dull concentric rings can appear around the sprue like a
faint halo. This is most likely to occur when the part is
made from a high-viscosity, poorly flowing material such as
PC, PMMA, or ABS. With this type of polymer there is the
risk of the cooled surface layer near the gate being
displaced by the flow of resin in the core of the part,
leaving a visible defect.
It is frequently assumed that the defect occurs during the
packing and holding-pressure phase of the process. Yet in
fact, dull areas near the sprue invariably occur at the
beginning of the filling cycle. Our experiments have traced
the actual cause of the skin-layer displacement, which can
be attributed to injection speedmore specifically, the
flow-front velocity.

Click Image to Enlarge

Dull halos around the sprue

and downstream of sharp
edges occur when initial
injection speed is too high,
which causes displacement
of cooled surface material.
Gradually increasing fill
speed with a stepped
injection profile can fix the
problem.

Glossy surfaces appear on

this automotive part due to
poor packing and poor mold
surface replication. Higher
melt or mold temperature,
higher holding pressure, or
longer hold time could
help.

Even when injection speed into the mold is constant, flow

velocity changes. Flow velocity is very high in the area of
the gate as it enters the mold, but slows down as the flow
front extends away from the gate and into the cavity on a widening circle. The change
in flow-front velocity can bring about the surface defects.
One way to reduce the changes in speed of the flow front is to tailor the injectionspeed profile. In order to obtain a slow flow-front velocity near the sprue, it is
necessary to inject in several steps, increasing gradually from a relatively low speed to
ones that are faster and faster. The aim is to obtain a flow-front velocity that is
uniform throughout the whole filling phase.
Low melt temperature is another source of a dull surface on the part. Increasing the
barrel temperature and raising the screw backpressure can help reduce the probability
of surface defects. Too low a temperature of the mold wall can also be a reason, so
increasing the mold temperature is another possible solution to surface defects.
There are also design-related issues that can generate a dull area near the sprue. A
sharp transition between the gate and part can be remedied by providing a small
radius between the gate and the part. Also, take a closer look at gate position and
diameter and confirm that they are correct for the application.
Dull areas occur not only near the sprue but are also frequently found downstream of
sharp edges in the molded part. In such a case, the surface finish up to the sharp edge
is typically very good, while behind it the surface is dull and rough. Here again, too
high an injection speed or flow velocity can cause the cooled surface layer to be
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EliminateSurfaceDefectsonMoldedParts:PlasticsTechnology

displaced by melt flowing underneath.

A stepped or graduated injection speed profile is again recommended. The best
approach is to allow flow to speed up only after the flow front has passed the sharp
edge.
A design-related source of trouble involves sharp transitions at edges in the molding
away from the sprue area. A smoother, radiused transition in those areas is the answer.

Fixing gloss variations

Differences in gloss are most conspicuous on textured surfaces. Irregular gloss may
appear on the molded part even though the mold has a uniform surface texture. The
problem is poor replication of the mold surface in some areas of the part.
Pressure on the injected melt decreases with increasing distance from the gate. If the
part is not fully packed at the point farthest from the gate, where the pressure is
lowest, the mold surface texture will not be reproduced exactly, resulting in a glossy
surface. Hence, unwanted gloss is least likely in the areas where cavity pressure is
strongestfrom the gate to about half way along the flow path.
To fix this situation, consider raising the melt or mold temperature or the holding
pressure. Extending the holding-pressure time also may increase the chances for
accurate mold-surface replication.
Part design can also contribute to gloss variations. For example, large changes in wall
thickness can cause melt-flow irregularities and difficulties in mold-surface
replication. Designing more uniform wall sections can alleviate this. Areas of
excessive wall thickness or oversized ribs can also increase the risk of glossy marks.
Another source is insufficient venting at the flow line.

Orange peels origin

Orange peel or a rippled surface defect typically occurs at the end of the flow path
in thick-walled parts molded of high-viscosity materials. During injection at low
velocity, solidification occurs on the surface too quickly. The high resistance to flow
produces uneven frontal flow, and the solidified outer layer will not fully contact the
cavity wall. The result is ripples. These ripples will freeze and holding pressure will no
longer be able to smooth them out. The solution is to raise the melt temperature and
increase the injection speed.

Now retired, Martin Bichler is a former long-time employee of Demag Plastics Group in
Schwaig, Germany. Bichler was formerly head of application engineering and
processing development. Since his retirement, he continues to work closely with
Demag as an application advisor and symposium lecturer. He focuses on the basic
aspects of injection molding and has published a book in English, Guide to Flawless
Injection Moldings. For questions or comments on this article, contact Bob Lewis at
Demag in Strongsville, Ohio. Tel: (440) 876-8960,or e-mail
applicationsgroup@dpg.com.
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