Molding Process
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PC/ABS Warpage
Problem Phenomenon
PC/ABS large flat parts warp, and assembly gaps are out of tolerance.
Cause Analysis
Uneven cooling produces differential shrinkage; excessive holding pressure freezes residual stress; abrupt wall thickness changes and asymmetric rib layout amplify deformation; the shrinkage difference of the two components also participates.
Solution
①Make the core and cavity temperatures as consistent as possible to reduce differential shrinkage; ②Extend cooling time to fully shape the product; ③Reduce excessive holding pressure to reduce frozen stress; ④Optimize wall thickness uniformity to reduce differential shrinkage; ⑤Anneal when necessary to eliminate residual stress.
Key Takeaway
PC/ABS large flat part warpage = 'cooling balance + holding restraint': as an amorphous blend, stress management is the main line; large parts especially need the mold temperature field made uniform.
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