1. WINWARD TECHNOLOGIES, LLC
Systematic Molding
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WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

2. WINWARD TECHNOLOGIES, LLC
MOLDING:
Art or Science?
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

3. Injection Molding Approaches
Traditional Molding (Art)
Decoupled Molding (Science)
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

4. WINWARD TECHNOLOGIES, LLC
Traditional Molding
Fill & Pack on first stage
Use only enough first stage pressure to pack the mold
Subject to large shot to shot variation
Shorts, flash, warp, dimensional issues
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

5. WINWARD TECHNOLOGIES, LLC
thin
As speed increases, the plastic gets thinner and easier to push
viscosity
thick
flow rate
slow
fast
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

6. WINWARD TECHNOLOGIES, LLC
thin
High sensitivity to fill speed variation
viscosity
Low sensitivity to fill speed variation
thick
flow rate
slow
fast
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

7. A method of process control that minimizes variation in parts by:
Decoupled Molding
A method of process control that minimizes variation in parts by:
separating the filling stage from pack & hold
Utilizing the machine controls to manage fill, pack & hold
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

8. WINWARD TECHNOLOGIES, LLC
Decoupled Molding
Set first stage hydraulic pressure control “high”
Allow machine to provide whatever pressure needed to deliver constant fill speed
Set first stage velocity for constant and fast fill speed
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

9. WINWARD TECHNOLOGIES, LLC
Decoupled Molding
Separate the filling (velocity) phase from packing phase
Transfer to pack at ~ 95% of full shot (by position)
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

10. Benefits of Decoupled Molding
Fast fill at constant speed
Reduce part variations due to material viscosity variations
Won’t flash
Pack consistently
Gives the most robust, repeatable process
Reduces cycle time, improves quality
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

11. Systematic Decoupled Molding
Philosophy of molding from the plastics point of view
Non-Newtonian
Flow rate, temperature, pressure, cooling rate
Use optimum constant flow rate
Separates fill from pack and hold
Cavity pressure controls process
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

12. WINWARD TECHNOLOGIES, LLC
Total Process Control
EXTERNAL VARIATION
PROCESS VARIABLES
Flow Rate
Temperature
Pressure
Cooling Rate
Material Viscosity
Your whole business is a process to be controlled.
But our core manufacturing process is molding.
So lets not forget that your molding processes must be robust, capable and in control.
How many of you are familiar with RJG systematic decoupled molding?
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

13. Process Optimization Systematic Decoupled Molding
Rigorous methodology to launch a new part
Arrives at the optimum process
Drives the set-up sheet
Should be done at prototype
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003

14. WINWARD TECHNOLOGIES, LLC
Total Process Control
Correlates: PART CHARACTERISTICS
Dimensions
Surface
Structure
To: PROCESS PARAMETERS
Your whole business is a process to be controlled.
But our core manufacturing process is molding.
So lets not forget that your molding processes must be robust, capable and in control.
How many of you are familiar with RJG systematic decoupled molding?
WINWARD TECHNOLOGIES, LLC
Oct. 18, 2003