Molds & Tooling
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HDPE turnover crate weld line cracking
Problem Phenomenon
The turnover crate cracks at the weld lines of the handle and frame during use, and the drop test breaks along the weld lines.
Cause Analysis
The HDPE melt front temperature drops quickly, and the molecular chains at the multi-gate confluence are not fully fused; the gate layout placing the weld line exactly in the stressed area is a design error.
Solution
①Increase melt temperature and mold temperature; ②increase the injection speed at the confluence area; ③adjust the gate position to relocate the weld line; ④set an overflow well at the confluence to improve fusion.; after adjustment, take consecutive samples to verify the effect, and resume mass production only after confirming stability
Key Takeaway
Weld line position and strength must be managed simultaneously; the gate design of stressed parts should keep weld lines away from stress concentration areas.; after confirming effectiveness, fix the parameters and practices into the work instruction to prevent recurrence
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