1st. Material preparation

  1.  Confirm the material number/type according to the product drawing.
  2. Confirm the masterbatch number and mixing ratio (if masterbatch is needed)
  3. Check whether the material of the barrel is correct, and there is a material identification plate for the engineering test mold on the barrel
  4. Confirm the proportion of recycled materials, drying temperature and drying time, (according to material properties and product requirements)

2nd. Mold preparation

  1. Confirm the mold number
  2. Check whether the mold has special requirements such as inserts and core pulling
  3. Mold inspection: check whether the appearance of the positioning ring, hot runner interface and other molds is OK
  4. Inspection of mold accessories: check the diameter and length of the water pipe, the length of the pressure plate, the length of the pressure plate bolt, the suspension bridge, etc.
  5. Whether the mold injection nozzle R matches the machine injection nozzle

3rd machine preparation

  1. Confirm whether the mold can be installed on the injection molding machine: the maximum clamping force of the machine, the size of the mold, the mold thickness, the core pulling function, and the air blowing device.
  2. Whether the ejector pin of the machine fits the mold
  3. Check whether the screw has been cleaned
  4. Check whether the mold temperature controller, manipulator, automatic mixing machine, and automatic suction machine can work normally: the manipulator fixture matches the mold
  5. Confirm product drawings/samples (if any), understand important dimensions
  6. Prepare related tools

4th, test steps

  1.  Before loading the mold, clean the machine for 5 seconds, and check whether the appearance of the mold such as the positioning ring, thimble hole, core pulling device, hot runner interface, etc. is OK.
  2.  Install the hoisting ring (the curved hoisting ring is not used). The depth of the hoisting ring screwed into the mold must be greater than 1.5 times the diameter of the hoisting ring. If the hoisting ring surface is not attached to the mould, a gasket must be used to prevent the hoisting ring from bending and breaking. After confirming that there is no problem with the machine, lift the mold
  3. Place the mold between the movable and fixed plates and maintain a certain height, and connect the water pipe and related interfaces (if any) under the mold.
  4. Align the positioning hole, adjust the level, and align the mold into the positioning hole of the machine. After determining the horizontal balance, first slightly tighten the two pressure plates on both sides of the fixed mold to position the mold
  5. Close the operating door, close the mold, and start the automatic mold adjustment
  6. Adjustment of clamping force
  7. After completion, open the operating door and lock the movable and fixed mold pressing plate.
  8. Loosen the rope and remove the suspension bridge
  9. Connect the water pipes and related equipment on both sides of the mold (if any)
  10. Connect the hot runner plug and preheat the mold in advance
  11. Close the operating door and set the mold to preheat the mold at a lower temperature (not directly set to the final molding temperature).
  12. The ejector pin is held tightly by the main holder (the ejector pin must be held tightly when the mold is closed, otherwise, the ejector pin will be prevented from being damaged by the slider when the mold is opened)
  13. Open the mold and check the parting surface
  14. Adjust the position of the thimble to zero, adjust the force and speed of the thimble, and eject this number.
  15. Adjust the mold opening and closing (speed of mold opening and closing, position, position of low voltage protection, monitoring time) to find out the correct speed-fast when closing the mold ==> slow ==> slower, when opening Slow first ==> fast ==> slow down. Select the contact point between the guide post and the guide sleeve for the slow mode switching position. The lower the low pressure protection pressure, the better. The monitoring time is 0.1s longer than the actual clamping time
  16. Check the running status under idling condition and adjust to stable and suitable
  17. Enter the process parameter data, (please adjust within a smaller error range is allowed, generally 5%. It is not necessary to follow the exact same value in the process card. For the temperature setting range of various materials, please refer to the relevant (Reference table for material temperature setting)
  18. Loading: Before loading, verify that the material number of the raw material is correct
  19. Back to the shooting table, spray to prevent mold sticking
  20. The top shooting platform: the top of the turret, the turret returns to zero
  21. For hot runner molds, hot runner injection should be done before this to ensure that the runner is unobstructed. 1) Cardboard must be used between the movable and fixed molds to catch the injected material; 2) The runner can be properly injected before injection. Increase the temperature (, after confirming that it is normal, adjust it back to the normal value
  22. Semi-automatic production, check whether the injection molding condition is normal, and adjust the injection pressure and rate. 1) For smaller parts, cover both sides of the mold to prevent splashing of the parts; 2) Set the maximum injection pressure according to the actual display injection pressure;
  23. Find the switching point of holding pressure, hit the product to 95%~98% full, then add holding pressure
  24. Adjust the back pressure of the melted glue, the screw speed, and the best measurement time is 65% to 75% of the cooling time, and the best is 75%.
  25. Turn on the monitoring and set the counter
  26. Weigh the weight of the product at the conversion point and record the comparison with the weight of the conversion point on the process card. For PPAP, 2 molds must be received, and the 1 mold product must be placed in the mold sample bag, and the 1 mold process engineer shall keep it for future reference
  27. Compare the printed product with the sample. If the mold is changed, the product number must be confirmed
  28. Send QA inspection, send 5 molds to QA for inspection, and provide a total of 300 molds (for reference, different products and different mold requirements can adjust the modulus) samples
  29. After production, the machine can be stopped after collecting the last 1 mould product and putting it into the mould sample bag
  30. During PPAP, the process engineer needs to record the process parameters and fill in the blank “injection process parameter card”, and send the set process parameters from the machine to the server host for the next cal
  31. If the process has been optimized in formal production, the new process parameters need to be sent from the machine to the host as an update.
  32. If the safety door needs to be opened during the production, if the alarm or shutdown is required, return to the turret first to prevent spraying
  33. Material injection is required when restarting. If the hot runner mold needs hot runner injection to prevent mold sticking
  34. Shut down and open the mold for maintenance
  35. Clamp the mold and return to the turret; close the mold temperature controller and hot runner
  36. Turn off the electric heater after cleaning the screw
  37. Loosen the ejector pin, you must loosen the ejector pin when the mold is closed, otherwise the ejector pin may be damaged by the slider
  38. Open the operating door, install the suspension bridge, and suspend the mold tightly. The sling should not be too tight, but it can be slightly shaken
  39. Loosen the pressure plate and remove the mold
  40. Lift the mold and place the lower mold area
  41. Clean up the injection station, and hand over the nozzle material and scrap products to production for recycling.