Production & Quality
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Filling Challenges Brought by Rapid LCP Crystallization
Problem Phenomenon
【Problem Phenomenon】Once the LCP melt cools down it solidifies immediately; filling the end of long flow paths is difficult, and the process adjustment margin is small
Cause Analysis
LCP crystallizes extremely fast; as soon as the melt front temperature drops slightly, a solidified layer forms and blocks the flow path; this characteristic brings both the advantage of short cycles and the disadvantage of a narrow filling window; Fictiv lists rapid crystallization as a core feature of LCP processing
Solution
Use the rapid crystallization characteristic with high-speed injection to shorten filling time; take the upper limit of mold temperature to delay front freezing; make runners and gates short and thick to reduce pressure and heat loss
Key Takeaway
Fast crystallization is a double-edged sword: only high-speed filling plus high mold temperature can use its benefit and avoid its harm; after confirming effectiveness, solidify the parameters and practices into the work instruction to prevent recurrence; include this case in the defect archive as a troubleshooting reference for subsequent similar problems
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