What are some common defects that can occur during the injection moulding process for garden tools?

During the injection molding process for garden tools, several common defects can occur. Here are some examples:
Sink marks: Sink marks are depressions or shrinkage marks on the surface of the molded part caused by the uneven cooling of the material. They often occur when thick sections of the garden tool cool at a different rate than the rest of the part, resulting in a visible indentation.
Warping: Warping refers to the distortion or bending of the molded part, leading to an uneven or twisted shape. It can be caused by non-uniform cooling or inadequate part design, such as insufficient wall thickness or poor gate placement.
Flash: Flash occurs when excess material seeps out from the mold parting line, resulting in thin, unwanted protrusions or edges. It can be caused by excessive injection pressure, poor mold alignment, or worn-out mold components.
Short shots: Short shots happen when the injected material does not completely fill the mold cavity, resulting in incomplete parts. It can occur due to insufficient injection pressure, inadequate melt temperature, or improper gate size.
Flow marks: Flow marks, also known as flow lines or weld lines, are visible lines or streaks on the surface of the garden tool caused by the meeting and solidification of molten material during the injection process. They can be caused by low melt temperature, high injection speed, or complex part geometry.
Voids and air traps: Voids are empty spaces or gaps within the molded part, while air traps occur when air gets trapped during the injection process, resulting in pockets of air within the part. Voids and air traps can occur due to inadequate venting, poor mold design, or improper injection parameters.
Splay marks: Splay marks appear as light-colored streaks or discoloration on the surface of the molded part. They are caused by moisture or foreign contaminants present in the resin, which vaporize and leave behind voids or discoloration during the injection process.
Parting line mismatch: Parting line mismatch occurs when the two halves of the mold do not align correctly, resulting in a visible mismatch or step at the parting line of the garden tool. It can be caused by wear on the mold, improper clamping force, or inadequate mold maintenance.
To minimize these defects, it is essential to optimize the injection molding process parameters, ensure proper mold design, use high-quality materials, and regularly maintain and inspect the molds. Adjustments and improvements can be made based on careful analysis and troubleshooting of the specific defect encountered.
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