https://www.avient.com/sites/default/files/2023-06/AVIENT_TPEs and LSR eBook.pdf
Materials with lower specific gravity will fill more volume and therefore yield more parts per pound. By factoring specific gravity along with price per pound, you can identify the cost for the amount of material you need to fill a given volume, as in your mold cavity. Use this simple calculation: SPECIFIC GRAVITY X PRICE PER POUND = POUND/VOLUME COST Consider the example below.
https://www.avient.com/sites/default/files/2021-11/artisan-ar7300-pre-colored-formulation-processing-guide.pdf
Sink Marks Melt too hot Insufficient material volume • Increase shot size • Increase packing pressure Part geometry too thick • Reduce wall thickness • Reduce rib thickness Flash Injection pressure too high • Decrease injection pressure • Increase clamp pressure • Increase transfer position Excess material volume • Decrease pack pressure • Decrease shot size Melt and/or mold temperature too hot Loose clamp • Reset mold height • Increase clamp tonnage Shrink Too much shrink • Increase cooling time Too little shrink • Decrease cooling time Burning • Reduce decompression • Clean, widen and increase number of vents • Increase gate size to reduce shear Wet material • Verify material is dried at proper condition Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature • Decrease back pressure • Increase screw decompression • Verify material has been dried at proper conditions Incorrect nozzle • Use reverse taper tip Weld Lines Melt front temperatures are too low • Increase pack and hold pressure • Increase gate size • Identify end of fill pattern and verify proper vent location • Add vents or increase vent width • Move gate location Warp • Reduce injection speed • Increase pack pressure • Increase pack time • Increase cool time Mold design • Non-uniform mold cooling Part design • Non-uniform wall thickness Thermolator incorrect temperature • Check settings • Inspect thermocouple Sticking in Mold Overfilled cavity • Decrease injection rate and pressure • Decrease hold pressure • Decrease cooling time Part too hot • Decrease barrel temperature • Increase cooling time • Increase draft angle • Polish cores in direction of ejection Black Specks Contamination • Purge machine Degradation • Reduce melt temperature • Reduce screw speed • Reduce back pressure Machine related • Check for wear on screw, barrel or check ring Delamination • Purge barrel to eliminate material contamination • Reduce sharp corners in material flow path • Increase venting Discoloration Oversheared material • Decrease melt temperature • Reduce residence time Mold design • Increase gate sizing Dry material • Check moisture of material to ensure it is within the recommended moisture percentage for molding 1.844.4AVIENT www.avient.com Copyright © 2021, Avient Corporation.
https://www.avient.com/sites/default/files/2024-09/Complet OnForce LFT Overview _ Brand Brochure.pdf
Adapted from Composites Part A: Applied Science and Manufacturing, Volume 33, Issue 12, J.L. OnForce™ LGF/PP Long glass fiber reinforced polypropylene widely used in higher volume applications.
https://www.avient.com/sites/default/files/2020-10/2020-gravi-tech-processing-guide.pdf
Wear generally occurs around the gate; thus inserts are recommended for large-volume production. Decrease nozzle and barrel temperatures Insufficient Material Volume 1. Increase transfer position Excess Material Volume 1.
https://www.avient.com/sites/default/files/2024-10/Replacing Aluminum with Long Fiber Thermoplastics _LFT_ Application Bulletin.pdf
This can lead to higher tooling costs for high-volume programs. However, metals may be preferred for applications with high-temperature requirements or where production volume, assembly steps, or secondary processing needs don’t warrant tooling change or investment in new equipment.
https://www.avient.com/sites/default/files/2021-07/colormatrix-lcx-for-ebm-product-bulletin.pdf
ColorMatrix LCX dispersions are designed to minimize and eliminate screw slip, streaking and specking, all while generating cost-to-color savings through processing efficiencies that include: • Handling efficiency – bulk distribution, individual feed stations • Inventory reduction – less inventory and required floor space • Process efficiency – improved color change times KEY CHARACTERISTICS • Highly concentrated pigment dispersions specifically for EBM processing • Provides dimensional stability by utilizing more resin instead of fillers • Reduces costs through handling and processing efficiencies • Customization available for design and product handling • Can be formulated in combination with a wide selection of additive technologies to meet performance needs MARKETS AND APPLICATIONS ColorMatrix LCX Liquid Dispersions for EBM processing are well suited for the following: • Monolayer applications • LDR less than 3% • Large volume whites and blacks • Tints 1.844.4AVIENT www.avient.com Copyright © 2021, Avient Corporation.
https://www.avient.com/sites/default/files/resources/Investor%2520Day%2520-%2520May%25202012%2520-%2520Commercial%2520Excellence.pdf
Kahler (16) Page 16 • Shifted sales compensation practices to drive value and margin expansion • Significantly upgraded and added sales, marketing, and From Volume to Value $2,622 $3,060 Sales ($ millions) 2006 2011PFadded sales, marketing, and technical resources • Expanded global cross-selling • Invested in training and tools 3.3% 6.8% Adjusted OI% ($ millions) 2006 2011PF 2006 2011PF Page 17 • Value pricing practices enabled by use of EVE tools • Shifting the basis of competition to specialization 1.5% 8.9% Specialty OI% Specialization Drives Margin Expansion 2006 2011PF 7.2% PPS OI% competition to specialization differentiates PolyOne as a value-added solutions provider • Redirecting our technology and marketing focus to the most attractive segments 2.6% 5.6% 2006 2011 POD OI% 5.5% 7.2% 2006 2011 2006 2011 2006 2011 Page 18 • Global key account management team focused on key markets and strategic OEMs • Drive growth in target markets through application development750 1,120 Total Commercial Employees 2007 – 2011 49% Increase Commercial Excellence – Recent Investments *Includes ColorMatrix through application development • Leverage breadth of solutions across all PolyOne platforms to identify innovative solutions for strategic OEMs and Tier 1 partners * 750 2007 2011 Sales Marketing R&D/Tech Page 19 5% 1% 0% 27% 2% 12% 4% Performance Dashboards Drive Execution 45% 26% 18% 5% 55% Page 20 53% Drivers of Customer Loyalty Customer Experience is Key to Customer Loyalty 53% Building Customer Loyalty n = 4,960 B2B customers of 24 companies Source: Corporate Executive Board Company and Brand Impact Product and Service Delivery Value-to- Price Ratio Customer Experience Page 21 • Continue to redirect our focus to more attractive segments and increase customer loyalty and retention • Leverage new commercial tools and investments to enable disciplined execution and accountability Critical Imperatives to enable disciplined execution and accountability • Position PolyOne as the differentiated value-added specialty solutions provider Drive improved mix in all segments and achieve margin and profitability growth Page 22 Page 23
https://www.avient.com/sites/default/files/2020-09/lubrione-processing-guide.pdf
PROBLEM CAUSE SOLUTION Incomplete Fill Melt and/or mold temperature too cold Shot Size • Increase nozzle and barrel temperatures • Increase mold temperature • Increase injection speed • Increase pack and hold pressure • Increase nozzle tip diameter • Check thermocouples and heater bands • Enlarge or widen vents and increase number of vents • Check that vents are unplugged • Check that gates are unplugged • Enlarge gates and/or runners • Perform short shots to determine fill pattern and verify proper vent location • Increase wall thickness to move gas trap to parting line • Increase cushion Brittleness Melt temperature too low Degraded/Overheated material Gate location and/or size • Increase melt temperature • Increase injection speed • Measure melt temperature with pyrometer • Decrease melt temperature • Decrease back pressure • Use smaller barrel/excessive residence time • Relocate gate to nonstress area • Increase gate size to allow higher flow speed and lower molded-in stress Fibers on Surface (Splay) Melt temperature too low Insufficient packing • Increase melt temperature • Increase mold temperature • Increase injection speed • Increase pack and hold pressure, and time Sink Marks Part geometry too thick Melt temperature too hot Insufficient material volume • Reduce wall thickness • Reduce rib thickness • Decrease nozzle and barrel temperatures • Increase shot size • Increase injection rate • Increase packing pressure Flash Injection pressure too high Excess material volume Melt and/or mold temperature too hot • Decrease injection pressure • Increase clamp pressure • Decrease injection speed • Increase transfer position • Decrease pack pressure • Decrease shot size • Decrease injection speed • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease screw speed TROUBLESHOOTING RECOMMENDATIONS PROBLEM CAUSE SOLUTION Excessive Shrink Too much orientation • Increase packing time and pressure • Increase hold pressure • Decrease melt temperature • Decrease mold temperature • Decrease injection speed • Decrease screw rpm • Increase venting • Increase cooling time Not Enough Shrink Too little orientation • Decrease packing pressure and time • Decrease hold pressure • Increase melt temperature • Increase mold temperature • Increase injection speed • Increase screw rpm • Decrease cooling time Burning Melt and/or mold temperature too hot Mold design Moisture • Decrease nozzle and barrel temperatures • Decrease mold temperature • Clean, widen and increase number of vents • Increase gate size or number of gates • Verify material is dried at proper conditions Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature • Decrease back pressure • Increase screw decompression • Verify material has been dried at proper conditions Weld Lines Melt front temperatures too low • Increase pack and hold pressure • Increase melt temperature • Increase vent width and locations • Increase injection speed • Decrease injection speed • Increase gate size • Perform short shots to determine fill pattern and verify proper vent location • Add vents and/or false ejector pin • Move gate location Warp Excessive orientation • Increase cooling time • Increase melt temperature • Decrease injection pressure and injection speed • Increase number of gates Sticking in Mold Cavities are overpacked Part is too hot • Decrease injection speed and pressure • Decrease pack and hold pressure • Decrease nozzle and barrel temperatures • Decrease mold temperature • Increase cooling time • Increase draft angle • Decrease nozzle and barrel temperatures • Decrease mold temperature TROUBLESHOOTING RECOMMENDATIONS Note: These are general processing conditions.
https://www.avient.com/sites/default/files/2020-09/edgetek-processing-guide.pdf
PROBLEM CAUSE SOLUTION Excessive Shrink Too much orientation • Increase packing time and pressure • Increase hold pressure • Decrease melt temperature • Decrease mold temperature • Decrease injection speed • Decrease screw rpm • Increase venting • Increase cooling time Not Enough Shrink Too little orientation • Decrease packing pressure and time • Decrease hold pressure • Increase melt temperature • Increase mold temperature • Increase injection speed • Increase screw rpm • Decrease cooling time Burning Melt and/or mold temperature too hot Mold design Moisture • Decrease nozzle and barrel temperatures • Decrease mold temperature • Clean, widen and increase number of vents • Increase gate size or number of gates • Verify material is dried at proper conditions Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature • Decrease back pressure • Increase screw decompression • Verify material has been dried at proper conditions Weld Lines Melt front temperatures too low • Increase pack and hold pressure • Increase melt temperature • Increase vent width and locations • Increase injection speed • Decrease injection speed • Increase gate size • Perform short shots to determine fill pattern and verify proper vent location • Add vents and/or false ejector pin • Move gate location Warp Excessive orientation • Increase cooling time • Increase melt temperature • Decrease injection pressure and injection speed • Increase number of gates Sticking in Mold Cavities are overpacked Part is too hot • Decrease injection speed and pressure • Decrease pack and hold pressure • Decrease nozzle and barrel temperatures • Decrease mold temperature • Increase cooling time • Increase draft angle • Decrease nozzle and barrel temperatures • Decrease mold temperature TROUBLESHOOTING RECOMMENDATIONS PROBLEM CAUSE SOLUTION Incomplete Fill Melt and/or mold temperature too cold Shot Size • Increase nozzle and barrel temperatures • Increase mold temperature • Increase injection speed • Increase pack and hold pressure • Increase nozzle tip diameter • Check thermocouples and heater bands • Enlarge or widen vents and increase number of vents • Check that vents are unplugged • Check that gates are unplugged • Enlarge gates and/or runners • Perform short shots to determine fill pattern and verify proper vent location • Increase wall thickness to move gas trap to parting line • Increase cushion Brittleness Melt temperature too low Degraded/Overheated material Gate location and/or size • Increase melt temperature • Increase injection speed • Measure melt temperature with pyrometer • Decrease melt temperature • Decrease back pressure • Use smaller barrel/excessive residence time • Relocate gate to nonstress area • Increase gate size to allow higher flow speed and lower molded-in stress Fibers on Surface (Splay) Melt temperature too low Insufficient packing • Increase melt temperature • Increase mold temperature • Increase injection speed • Increase pack and hold pressure, and time Sink Marks Part geometry too thick Melt temperature too hot Insufficient material volume • Reduce wall thickness • Reduce rib thickness • Decrease nozzle and barrel temperatures • Increase shot size • Increase injection rate • Increase packing pressure Flash Injection pressure too high Excess material volume Melt and/or mold temperature too hot • Decrease injection pressure • Increase clamp pressure • Decrease injection speed • Increase transfer position • Decrease pack pressure • Decrease shot size • Decrease injection speed • Decrease nozzle and barrel temperatures • Decrease mold temperature • Decrease screw speed TROUBLESHOOTING RECOMMENDATIONS www.avient.com Copyright © 2020, Avient Corporation.
https://www.avient.com/sites/default/files/2020-12/artisan-thermoplastics-nylon-processing-guide.pdf
Sink Marks Melt too hot • Decrease nozzle and barrel temperatures Insufficient material volume • Increase shot size • Increase packing pressure Part geometry too thick • Reduce wall thickness • Reduce rib thickness Processing Guide 5 Flash Injection pressure too high • Decrease injection pressure • Increase clamp pressure • Increase transfer position Excess material volume • Adjust transfer position • Decrease pack pressure • Decrease shot size Melt or mold too hot • Decrease nozzle and barrel temperatures • Decrease mold temperature Loose clamp • Reset mold height • Increase clamp tonnage Shrink Too much shrink • Increase cooling time Too little shrink • Decrease cooling time Burning • Reduce decompression Mold design • Clean, widen and increase number of vents • Increase gate size to reduce shear Wet material • Verify material is dried at proper condition Nozzle Drool Nozzle temperature too hot • Decrease nozzle temperature • Decrease back pressure • Increase screw decompression • Verify material has been dried at proper conditions Incorrect nozzle • Use reverse taper tip Weld Lines Melt front temperatures are too low • Increase pack and hold pressure Mold design • Increase gate size • Identify end of fill pattern and verify proper vent location • Add vents or increase vent width • Move gate location 6 Artisan Pre-Colored Thermoplastics Warp • Increase melt temp • Reduce injection speed • Increase pack pressure • Increase pack time • Decrease mold temperature • Increase cool time Mold design • Non-uniform mold cooling Part design • Non-uniform wall thickness Thermolator incorrect temperature • Check settings • Inspect thermocouple Sticking in Mold Overfilled cavity • Decrease injection rate and pressure • Decrease hold pressure • Decrease cooling time Part too hot • Decrease barrel temperature • Decrease mold temperature • Increase cooling time Mold design • Increase draft angle • Polish cores in direction of ejection Black Specks Contamination • Purge machine Degradation • Reduce melt temperature • Reduce screw speed • Reduce back pressure Machine related • Check for wear on screw, barrel or check ring Delamination • Increase melt temperature • Decrease injection speed • Purge barrel to eliminate material contamination Mold design • Reduce sharp corners in material flow path • Increase venting Processing Guide 7 Discoloration Oversheared material • Decrease melt temperature • Decrease injection speed • Reduce residence time Mold design • Increase gate sizing Dry material • Check moisture of material to ensure it is within the recommended moisture percentage for molding 1.844.4AVIENT www.avient.com Copyright © 2020, Avient Corporation.