Molding Process
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PSU Wall Thickness Lower Limit and Flow Length Ratio
Problem Phenomenon
[Problem Phenomenon] PSU thin-wall designed parts are incompletely filled; short shots persist after structural adjustment
Cause Analysis
PSU melt has poor flowability; the ratio of flow length to wall thickness is only about 80; wall thickness must not be less than 1.5mm, mostly above 2mm; below the lower limit, no process can fill completely
Solution
Design wall thickness ≥1.5mm and check against the 80:1 flow length ratio; for thin-wall requirements, use multiple gates to shorten flow length; evaluate switching to materials with better flowability; after adjustment, continuously sample to verify the effect, and resume mass production only after confirming stability
Key Takeaway
PSU wall thickness 1.5mm is a design red line; flow length ratio 80 determines gate layout; After confirming effectiveness, solidify the parameters and practices into the work instructions to prevent recurrence
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