A larger processing window will account for the lot to lot changes between materials, without having to make process changes.3 Setting the Beginning Variables • Injection Pressure = Maximum of machine - Should not be pressure limited • Injection Velocity = Maximum of machine - This is for the injection velocity curve starting point - If flashing is an issue start slower and then increase • Injection Cut-Off Time = 15 seconds - This is only a limiting factor, needs to be above 10 seconds for velocity graph • Hold Pressure = 0 - Need to get 95% full part with a hold pressure of 0 • Hold Time = 10-15 seconds - Need to ensure gate is frozen • Screw Speed = 90% of Maximum - Unless shear sensitive material, if shear sensitive, set RPMs to optimum • Cooling Time = 10–15 seconds • Shot Size = 50% of calculated part volume • Decompression = .25" • Transfer Position = High enough to ensure a cushion - Cushion size does not matter but there must be a cushion to keep a constant pressure on the melt during hold time - Typically 0.25" is sufficient • Back Pressure = 800-1000 plastic pressure - 100–150 hydraulic pressure - Unless specified by material data sheet Determining Shot Size The shot size should be determined by calculating the combined volume of the parts and the runner system. If the material is shear-sensitive, consult the material data sheet or processing guide for instructions to set recovery time • The cooling time should only be 1–2 seconds longer than the screw recovery time, unless dictated by dimensional stability or part thickness Minimize Clamp Pressure This step is done to reduce the amount of energy used by the machine Shot Size = 1.00 + .10 = 1.10, Transfer Position = .50 + .10 = .60 Set Safeties This step is to ensure the machine will alarm and alert nearby employees if the machine malfunctions, or if a part gets stuck

Polystrand composite panels are made with continuous fiber reinforced thermoplastic face sheets thermally bonded or adhered to traditional core materials such as honeycomb, foam, aluminum, and nonwovens as reinforcement.

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