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A Soft Tooling Process Chain for Injection Molding of a 3D Component with Micro Pillars

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Causes of the Gloss Transition Defect on High-Gloss Injection-Molded Surfaces.

Jinsu Gim¹, Eunsu Han², Byungohk Rhee²

¹Center for Coating Materials and Processing, Engineering Research Center, Seoul National University, 1, Gwanak-ro, Gwanak-gu, Seoul 08826, Korea.

|September 18, 2020

Summary

Gloss transition defects in injection molding reduce product quality. This study identifies surface shrinkage as the cause, with mold surface replication and process conditions like flow front speed and mold temperature being key to improving gloss.

Keywords:

gloss transition defect injection molding mold surface replication shrinkage surface analysis surface defect surface gloss

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Area of Science:

Polymer science and engineering
Materials science
Manufacturing processes

Background:

Gloss transition defects negatively impact the perceived quality of injection-molded products.
Current methods to address these defects are often empirical and require extra equipment.
Systematic analysis of the root causes of low gloss and gloss transitions during molding is lacking.

Purpose of the Study:

To systematically analyze the causes of low-gloss polymer surfaces and gloss transition defects.
To elucidate the relationship between molding conditions and surface gloss.
To provide insights for optimizing mold design and process parameters.

Main Methods:

Analysis of polymer surface changes and gloss using gloss and topography measurements.
Investigating the influence of molding conditions on surface properties.
Correlating surface topography and gloss with process parameters.

Main Results:

Polymer surface shrinkage leads to rough topography and reduced gloss.
Effective replication of a smooth mold surface mitigates shrinkage effects and enhances gloss.
Surface stiffness and melt pressure are critical for mold surface replication.
Flow front speed and mold temperature significantly impact surface gloss by influencing melt pressure and surface stiffness recovery.

Conclusions:

Optimizing mold design and process conditions is essential for uniform gloss.
Controlling flow front speed and mold temperature enhances surface gloss uniformity.
Understanding the interplay between shrinkage, replication, and process parameters is key to defect mitigation.