Molds & Tooling
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Warpage deformation of PP thin-wall parts
Problem Phenomenon
Thin-wall shells warp out of tolerance after demolding, assembly is difficult, and multiple corners are not in the same plane.
Cause Analysis
Uneven shrinkage, uneven orientation, and uneven cooling are the three major causes; the longer the flow distance, the greater the internal stress, and a single gate also causes twisting deformation.; during on-site investigation, verify item by item according to this mechanism to avoid blindly adjusting the machine based only on experience
Solution
①Switch to multiple pin-point gates to shorten the flow distance; ②balance the cooling system and minimize the temperature difference between cavity and core; ③adjust the cooling time and holding pressure curve; ④adopt multi-stage injection control.
Key Takeaway
Thin-wall part warpage must be systematically treated from the three aspects of gate, cooling, and process; multi-point gates and balanced cooling are the two fastest-effective measures.; after confirming effectiveness, solidify the parameters and practices into the work instruction to prevent recurrence
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