When increasing the pressure exercise caution to prevent mold damage.Shows if the process pressure is limited.Do not have an ‘acceptable imbalance limit’, example 3% or 5 % or 10%.Study the % imbalance with the cavities almost full.% imbalance can be very deceiving on smaller parts.Helps in achieving better cavity to cavity consistency.Shows the fill balance between all the cavities.Inject as fast as you NEED to and not as fast as you can.Fast injection speeds may cause material degradation and burning.May not be applicable to optical components.May not be applicable to insert molded components.Shows the most consistent region of viscosity.Shows effect of injection speed on viscosity.As always there are always cautions and exceptions to each one of these. Following are the 6-Steps that should be considered. Incorporating this under one umbrella he coined the term 6-Step Study to help optimize the process robustness. The balance of fill between the cavities was also identified as an important step. Suhas Kulkarni identified the MAD as THE most important and critical step for determining the robustness of the molding process. The Molding Area Diagram (MAD) has references in some early texts such as in the ‘Handbook of Injection Molding’ by Rosato, was not always considered. The 6-Step Study: The Viscosity (Rheology) Curve, the Gate Freeze Study and the Pressure Drop Study were the three studies that were done as part of the Scientific Molding Studies.
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