An area of the extruded sheet that appears Straight sharp lines in either cap surface to have bonded to itself. Generally this will or substrate the is visible in the finished appear as a small “bow-tie”. part, probable cause-material hang up in die creating an interruption of the flow of polymer during extrusion process.
GEL/BUMP DIE DROOL
Spherically shaped defect, potentially visible Degraded talc residue the builds up and in both unformed and formed sheet, typically breaks off from die lip. Generally seen on non-contrasting and originates from an un- the backside of sheet. Varies in size melted portion of the resin. Often identified and shape. with a “tail” in the extrusion direction.
CONTAMINATION BREAKOFF - DEGRADING
Incompatible material within the substrate MATERIAL that manifests itself in the formed part as a Appears as a sharp line followed by a protrusion in “A” surface. Typically will see deposit of material that typically looks like a correlating depression in the backside of a small ball or bump. the formed sheet.
ORANGE PEEL APPEARANCE BREAKOFF - COLOR
Typically seen in high gloss surfaces as Swirling appearance of a contrasting color. a wavy pattern of light and dark areas. Depending on the slope of the material, the light is reflected in various directions.
MOTTLING APPEARANCE POCK MARK/DIMPLE
Similar to orange peel, but larger, more Circular depression generally seen on the cloud-like patches. backside surface of the sheet. Depending on sheet thickness/depth of draw minor pock marks may not appear in the “A” surface after forming.
PINHOLE BLACK SPECK
Concave recess in “A” surface of sheet- Typically carbonized or chared material, probable cause-out gassing during forming from either resin pellet or extruder, that is process due to moisture in the generally seen in flat sheet surface. cap resin.
PIT PATTERN WASHOUT
Concave defect circular in shape and Embossed pattern appears very shallow generally void of material in the area or or undefined. poorly dispersed color concentrate. Size varies and can be on both “A” and “B” surfaces. DEFECT DEFINITIONS
PHANTOM LINES GAUGE VARIATION
An interruption or restriction of resin flow Thickness variation across the web width through the die. Obvious weld line on B of the extruded sheet. Variation exceeds surface, typically visible after forming. PMC Standard or specified tolerances determined by the customer.
CAP OPACITY GLOSS
Does not match Master Sheet (not opaque) Gloss evaluation, typically in smooth core color may show through, changing the products, appears to be more or less color appearance. reflective than the target or expected results. This is sometimes referred to as Sheet too opaque > change color appearance more dull or more shiny.
OFF COLOR MOISTURE
Expected color either visually does not Where excessive moisture in the material match the target or the numeric readings evaporates during the extrusion process exceed the customers specified tolerance. and leaves small visual depressions in the surface of the product.
CORE/ANGEL HAIRS OUT OF SPEC- LENGTH,
Thin pieces of plastic or masking from WIDTH the shear process that can be trapped Dimension exceeds specified tolerances between sheets and cause an impression determined by the customer. or remain imbedded.
CORE SHOWING ROLL BOUNCE
Cap or laminate does not cover entire core, An area of the product where the stack leaving core exposed. rolls were opened or the bead forced the stack roll to open. This appears as an semi-irregular line in the tranverse direction of the sheet.
DELAMINATION WARPED MATERIAL
When two components in a product will not Sheet material that bows or lifts from a flat adhere completely to each other. surface beyond the acceptable tolerance.
FLOW LINES DEFECT REFERENCE CARD
An interruption or restriction of resin flow through the die. Less severe than a Phantom line, can’t feel, and typically visible after forming.