Molds & Tooling
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Much Setup Scrap for PEEK First Articles
Problem Phenomenon
Each mold change and startup of PEEK requires dozens of shots to produce qualified parts, high-priced raw material is seriously wasted, and setup cost even exceeds mold cost.
Cause Analysis
PEEK has a narrow process window, and the multiple parameters of temperature, pressure, and speed are strongly coupled, making trial-and-error setup extremely inefficient; without process data accumulation, every setup starts from scratch.
Solution
①Preset the initial process based on Moldflow simulation; ②Establish standard process cards to accumulate historical parameters; ③Sort and recycle setup scrap for downgraded use; ④Use cavity sensing technology to shorten the stabilization time.
Key Takeaway
PEEK setup cost must be hedged with data-based management; process cards and simulation analysis are the core tools for reducing trial and error; every kilogram of scrap is a loss of real money.
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