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Eastman™ polymersProcessing and mold design guidelines

10A typical bubbler configuration is shown in Figure 6. A bubbler is very similar to a baffle, except water is supplied to the end of the core with a bu

11NOTE:• Reynolds number must be calculated for each area of the mold having different cooling line diameters.• A water line in parallel should have

12Why corners are critical cooling areasFigure 7 illustrates that there is approximately 3 times the steel mass on the outside of a corner than on the

13Figure 10 Sprue designSprue coolingIn Figure 11, upper and lower cooling line circuits are shown around the sprue to aid in cooling. The sprue bus

14Figure 13 High-conductivity sprue bushingMold/sprue cooling exampleFigure 14 shows a part with inadequate cooling. Notice the long sprue, with low

15Runner cross sectionRemember that flow efficiency in runners increases as the cross section approaches a circular shape. The most efficient runner is a

16It is good practice to gate into areas where the flow path is continuous and smooth, rather than into notches or ribs. Streamlining the flow path hel

3Edge gate A gate land of 1.0–1.5 mm (0.040–0.060 in.) is suggested. A generous radius at the edge of the gate will yield improved flow characteristics

18Hot runner systemsDesign guidelinesHot runner systems are common in applications using polyester materials. When properly designed, these systems ca

19Hot probeMeltCooling lineCooling lineLandPartExcellent thermal control at the tip of the hot drop is critical to proper operation of this type of sy

Proper mold design and machine setup are essential parts of a quality molding operation. This publication is intended to assist you in the design or c

20It is important to maintain suggested tool temperatures at the interface with the part. An independent cooling circuit in close proximity as shown i

21Venting problems can also be attributed to improper location of vents. Venting problems can sometimes be solved by relocating the gate so that the l

22Family molds Family molds contain two or more cavities that mold different parts. Eastman™ polymers are being used successfully in family molds. Lik

23Using zero draftZero draft is not recommended. It can cause the mold to lock up during ejection. It can also increase the cost of the mold significan

24Nicklon™ coatingThis alloy is 10.5% phosphorous-dissolved nickel with 25% PTFE suspended in solution. It is applied using electroless co-deposition.

25Clamping forceRequired clamping pressure can be calculated from a mold filling analysis where wall thickness, flow length, specific material, melt te

26Good temperature control of the nozzle is important. If a thermocouple at the threaded end of a long nozzle is controlling a heater band or bands at

27Tray dryers. These dryers can be used only if they are supplied with air dried by a good desiccant bed system. Tray dryers with heating only (and no

28Drying time. Pellets to be dried need to be in the hopper at the conditions shown on the data sheets for each specific polymer. If the dryer is turne

29Moisture measurementDew point meters measure only the dryness of the air, not the dryness of the plastic pellets in the hopper. Use of the dew point

ContentsEastman™ polymers—Processing and mold design guidelines . . . . . . . 6Part I Mold design . . . . . . . . . . . . . .

30Dryer troubleshooting guideFor more detailed information, see the “Troubleshooting guide” on page 39.Problem Possible cause Corrective actionHigh d

31Injection moldingProper conditions and machine operations for molding Eastman™ polymers are discussed in this section. It includes sections on start

32of the screw at the end of the shot indicates a leaking check valve. A leaking check valve will prevent a cushion from being maintained and can caus

33Production moldingProduction start-upThe processing window needs to be defined to establish a controlled molding process. The starting point for a p

34Part III Secondary operationsParts made of Eastman™ polymers can be assembled using a wide variety of joining techniques. Solvent bonding, UV-cura

35Ultrasonic weldingUltrasonic welding can be performed successfully using shear-type joints. Shear joints produce strong, hermetic bonds. Shear joint

36Ultrasonic stakingUltrasonic staking is an assembly method in which the controlled melting and reforming of a plastic stud is used to capture or lo

37Other fastening techniquesBosses, snap fits, and locating features that take advantage of the ductility and toughness of these polymers should be des

38Splay is an appearance defect in the surface of the part, usually appearing as trapped gas bubbles being smeared across the surface as the flow fron

39Suggested remediesDo 1 first, 2, 3, etc.1 means increase 2 means decreasePROBLEMSShortshotsBrittlepartsVoidsorsinks1Bubbles1SurfacesplayGatesplaySpru

Hot drops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Valve gates .

40“Reading” parts as they are moldedOften some very small marks and other visible features of a part can tell much about improvements needed in the mo

41PRETRIAL PREPARATION Company______________________ Date Sch.____________ Material ____________________ Location______________________ Time Sch

42Form 2MOLDING CONDITIONS RECORD Company__________________________________________ Company Representative __________________________ Date/Time___

43Form 3Identifying problems that are causing scrap

Eastman Chemical CompanyCorporate HeadquartersP.O. Box 431Kingsport, TN 37662-5280 U.S.A.Telephone:U.S.A. and Canada, 800-EASTMAN (800-327-8626)Other

Dryer troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Injection molding. . . .

6Part I Mold designDesign for moldabilityMoldability as well as product performance can be enhanced by proper part design features. Good design for m

Stress concentration factorsStress concentrations are areas that, by the nature of their design, tend to concentrate or magnify the stress level withi

8Ribs are generally spaced at a distance at least twice the wall thickness to allow enough steel between the ribs for adequate cooling. A draft angle

3Mold shrinkage and warpageKey factors in minimizing warpage include:• Uniform wall thickness• Consistent mold temperaturesA uniform wall:• Promotes e