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What impact does material viscosity have on injection molding machine performance?

2024/12/11 By Topstar

Material Viscosity in Injection Molding(1)

The viscosity of the materials used in injection molding refers to the fluid’s resistance to flow, which can impact how the material behaves in an injection molding machine. The type of material being injected (whether it is a thermoplastic, thermoset, or elastomer) directly affects the viscosity, affecting the overall performance of the injection molding machine. Material flow, fill speed, cycle time, and product quality are all affected by viscosity. This article will explore the impact of material viscosity on an injection molding machine’s performance and how Topstar’s machines are designed to handle a wide range of material viscosities effectively.

How does viscosity affect material flow in an injection molding machine?

The most obvious effect of material viscosity is its effect on how easily the material flows through the injection molding machine. Materials with higher viscosities, such as thick plastics or highly filled compounds, tend to flow more slowly and require you to apply more force and pressure to inject them into the mold, which can increase cycle time. Conversely, materials with lower viscosities, such as certain elastomers or resins, flow more easily and require less pressure, resulting in faster injection speeds. An injection molding machine that does not match the material viscosity may experience problems such as incomplete mold filling, uneven cooling, or long cycle times, affecting product quality and production efficiency.

The impact of high-viscosity materials on injection molding machine performance

High-viscosity materials require more pressure to pass through the injection molding system. These materials are generally more difficult to flow, so the injection molding machine must generate higher pressure to overcome this resistance. Manufacturers using high-viscosity materials must ensure that their injection molding machines provide enough pressure and heating for smooth and consistent flow. Topstar equips its injection molding machines with powerful servo motors, high-quality precision PVD three small parts, double-shot transfer cylinders, and uniform force on the shooting platform. These machines feature fast injection speed, electroplated screw design, and an upgraded nozzle configuration to ensure smooth flow of high-viscosity materials, thereby shortening cycle time and improving efficiency.

TM II injection molding machine

The impact of low-viscosity materials

Low-viscosity materials can also cause problems in the injection molding process. Low-viscosity materials flow too fast, which can cause overfilling, excessive overflow, or insufficient injection in the mold cavity, especially when you do not properly adjust the pressure and speed of the injection molding machine. Topstar uses the double-shot transfer cylinders to make the shooting platform move with uniform force, and the linear guide rails make the injection more stable. You use proportional back pressure control in the pre-plasticization stage, which is easy to operate and achieves multi-stage back pressure settings to improve plasticization quality. You address these issues by controlling injection speed and pressure, enabling manufacturers to fine-tune their processes to handle low-viscosity materials and ensure even material distribution effectively.

Linear Guides1
Linear Guides

Temperature Control and Viscosity

The viscosity of most materials is temperature dependent, meaning that the material’s flow characteristics will change depending on the temperature it is heated to during the injection molding process. If the material is warm, it will be more viscous, resulting in better flow and mold filling. On the other hand, if you overheat the material, it may degrade, affecting the quality of the final product. Topstar equips its range of injection molding machines with advanced temperature control systems to ensure you heat the material to the optimal injection temperature. They feature precise heating elements and cooling systems that allow manufacturers to maintain consistent material temperatures throughout the injection cycle. Temperature control at the feed port allows for more efficient production and more precise, higher-quality parts, and it reduces the likelihood of molding defects caused by inconsistent material flow.

Optimizing Material Flow for Different Viscosities in Injection Molding

Optimizing material flow for different viscosities is critical to maximizing injection molding performance. The key is to balance factors such as injection pressure, injection speed, barrel temperature, and mold temperature to ensure the material flows smoothly into the mold cavity without causing defects.

Topstar’s injection molding machines are all equipped with electroplated screw configurations and self-developed control systems as standard, allowing manufacturers to optimize the flow of materials at any viscosity level. You can customize the precise screw design according to the characteristics of specific materials to ensure optimal flow and consistency. For example, customers who use PC materials to make light guide plates require injection pressures above 1800kgf/cm², and we generally use chrome-plated screws or bimetallic screws. In addition, Topstar also provides a computer operation interface that allows users to fine-tune the injection process for each specific material viscosity. This helps manufacturers obtain consistent, high-quality parts.

Injection molding electroplating screw

Control material viscosity to improve injection molding performance

Material viscosity is a key factor in injection molding and significantly impacts machine performance, production efficiency, and final product quality. Whether using high-viscosity or low-viscosity materials, it is necessary to ensure that its injection molding machine can effectively handle these materials. The injection molding machines provided by Topstar are designed to handle materials of various viscosities through advanced features such as precision temperature control, adjustable injection speed, and customized screw design. Enable manufacturers to optimize material flow, shorten cycle time, and maintain consistent product quality.

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