Let's just for a moment picture this, a single mold has made manufacturing or production quite simple and straightforward. While this is a win for both clients and manufacturers, the plastic injection molding process is not easy; it has its fair share of problems as well.

For every stage of the production process, you'll need a troubleshooter to mitigate all these issues. Most of the problems with plastic injection molding projects are that most engineers and technicians have not familiarized themselves with the technology being used.

Plastic injection molders at times lack the technical know-how, the knowledge nor the experience to handle some of these modern machines. Some are not even trained properly, the result is the end-product will have defects and not be up to the industry standards and regulations.

Some of the most common problems that come with plastic injection molding and a brief explanation as to what causes this:

Mold warpage

Injection molding warpage can only happen when the original shape is gnarled especially during cooling. We are talking about defective parts of the mold that can twist, bow, fold, or bend.

Some of the most common causes of warpage include:

• Inadequate Injection Pressure or Time: this mostly occurs from the past production cycle; it arises mainly to the data beingused on the computer to handle the particular operation or task is not the proper one.
• Inadequate Residence Time: the molten plastic stays for long periods or short period inside the mold which makes the end-product look warped or crooked.
• Low Barrel Temperature: the barrel used for delivering the molten plastic is not appropriately heated.
• Mold Temperature Too Low: the mold is too cold to receive the molten plastic.
• No ejection uniformity: The rapid tooling machine doesn't eject the final material the way it should.
• Part Geometry: All of the finished and final parts look uneven.

Mold burns

In any plastic injection molding project, there are bound to be mold burns. They are distinct as they are black discolorations appearing on the final part and product, they can also appear rusty or brownish.

The burn marks visible on any injected molded parts get there at the end of the flow track, as a result of air being trapped. Some of the most common reasons for burn marks include:

• Injection speed is quite high: The molding machine is working at a faster rate than it should.
• Varying resin temperature: Its either too low or too high, if that's the case it will cause burns if it's not done with the right temperature.
• Lack of venting: Lack of proper airflow will be a problem for the finished parts, when this happens the burns become more visible
• Inadequate gate size: the gates which allow the flow of molten materials do no have the correct size and specs.
• Inadequate nozzle size: The nozzle does not deliver the molten material as it doesn't have the correct size or specs.