Use the optimum velocity from the previous step and once again, fill the part to 95% full • Add just enough hold pressure to fill out the part, until it is just full - There should be sinks in the part; it should not look like a final part • Increase the hold pressure until the part slightly flashes, around the parting line of the part • Once these two values have been found, take the average of them, and this is the hold pressure to be used when processing - If sinks are found in the part at the new hold pressure, increase it until the sinks disappear or flashing occurs. Design Guide 29 Mold too hot Wrong screw configuration Residence time too low Clean mold surface Stop using mold spray Check mold for condensation Make sure material is thoroughly mixed Check for contamination Increase melt Increase mold Delamination Root cause: Either contamination or extremely high degree of orientation. 30 Gravi-Tech Mold temperature too Venting plugged Cycle too short Check ring slippage New lot of material Under-packing Check for proper venting Increase pack pressure Increase melt Reduce mold Reduce transfer position Dimension—Small • A DOE should be run to conclude which processing parameters have the greatest influence on part size Design Guide 31 Mold temperature too cold Hot runner too hot Running out of material New lot of material Over-packing Check for proper venting Reduce hold pressure Reduce hold time Increase mold Increase transfer position Dimension—Large • A DOE should be run to conclude which processing parameters have the greatest influence on part size 32 Gravi-Tech Tooling damage Rolled parting lines Bent cores Plating worn off Broken ejector pin Running out of material Barrel malfunction Melt temperature too Over- or under-packed Cooling time too high or low Escessive back pressure Reduce ejection velocity Check for mold damage Use mold release Reduce mold finish Check for heaters overriding Dry material Increase/decrease hold pressure Reduce hold time Increase/decrease mold Distortion/Deformation Root cause: Various causes—parts too hot to eject/packing/poor ejection design/tooling damage/ high polish. Very difficult to resolve through processing Root cause: Nominal wall thickness is not maintained or uneven cooling. 42 Gravi-Tech Uneven cooling Damaged ejection Leaking check ring New lot Melt temperature Cooling time too low Hold pressure too high Hold time too low Transfer too high Plate with lower friction coating Maintain constant wall thickness Maintain constant cooling Reduce sharp corners Gate from thick to thin Increase/decrease cooling time Reduce mold Warpage • Parts will warp to the hotter half of the mold Root cause: Internal stresses caused by uneven shrinkage.

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