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Base Resin ABS PA PBT PC PE PEEK PP PPS Barrel Temperatures °F (°C) Rear Zone 400–475(200–250) 480–540 (248–282) 480–520 (250–270) 480–570 (250–300) 400–445 (200–230) 660–700 (350–475) 400–440 (200–225) 520–600 (270–300) Center Zone 410–480(205–253) 490–550 (254–287) 485–525 (251–273) 500–580 (260–305) 410–455 (207–237) 670–710 (357–385) 410–450 (205–230) 550–610 (285–310) Front Zone 420–490(210–257) 500–560 (260–293) 490–530 (254–276) 515–590 (267–310) 420–465 (213–243) 680–720 (363–400) 420–455 (215–235) 570–620 (300–320) Nozzle 425–500(215–260) 510–570 (265–298) 490–540 (254–282) 530–600 (275–315) 430–475 (220–250) 700–730 (370–395) 430–460 (220–240) 610–620 (320–325) Melt Temperature 425–515(215–270) 510–570 (265–298) 490–540 (254–282) 530–615 (275–325) 430–495 (220–260) 700–725 (370–385) 430–475 (220–250) 610–635 (320–335) Mold Temperature 140–200(60–90) 150–300 (65–148) 140–280 (60–137) 160–240 (70–115) 80–140 (25–60) 300–400 (150–200) 80–140 (25–60) 190–300 (90–150) Drying Parameters 190 (90) 2–4 Hours 0 .01%–0 .15% 180 (82) 4–5 Hours 0 .10%–0 .20% 275 (135) 3–4 Hours 0 .02%–0 .04% 250 (125) 3–4 Hours 0 .02% 160 (70) 2 Hours 300 (150) 3–4 Hours 0 .10% 160 (70) 2 Hours 280 (135) 2–3 Hours 0 .01%–0 .20% Nozzle Type General Purpose Nylon or Reverse Taper General Purpose General Purpose General Purpose General Purpose General Purpose General Purpose Injection Velocity1 2–5 in/sec; 50–127 mm/sec Injection Pressure 1,000–2,000 psi; 7–14 Mpa Back Pressure 50–100 psi; 0 .3–0 .7 Mpa Screw Speed 25–75 RPM Cushion 0 .125–0 .250 in; 3–6 mm Screw Compression Ratio2 2 .0:1–2 .5:1 Comments 1 . Venting Guidelines by Resin • PC: .001"–.002" depth & .250" width • PC/PSU: .002"–.003" depth & .250" width • PES: .003"–.004" depth & .250" width • PEI: .001"–.003" depth & .250" width • PP: .001"–.002" depth & .250" width • ABS: .0015"–.0025" depth & .250" width • PEEK: .002"–.004" depth & .250" width FIGURE 40 - Venting Guidelines Vent Groove Vent Land Vent FIGURE 44 - Venting guidelines FIGURE 43 - Venting areas 20 Gravi-Tech CHAPTER 5 | PROCESS OPTIMIZATION Process optimization ensures a quality process and minimizes cycle time. It is better to fill out the part at slower speeds in-order to let any compressed air escape, and to get the best surface finish on the part.3 • Using all of the previous settings, record the Transfer Pressure, Fill Time, and Injection speed • Reduce the injection velocity by 10% and record the same values Transfer Pressure (psi) Fill Time (sec) Injection Velocity (in/sec) Relative Shear Rate Relative Viscosity 1238 0 .20 8 .00 5 .00 247 .60 1125 0 .22 7 .00 4 .55 247 .50 1058 0 .25 6 .00 4 .00 264 .50 960 0 .35 5 .00 2 .86 336 .12 870 0 .45 4 .00 2 .22 391 .65 780 0 .58 3 .00 1 .72 452 .59 690 0 .85 2 .00 1 .18 586 .78 600 1 .35 1 .00 0 .74 810 .45 510 2 .50 0 .75 0 .40 1275 .83 420 5 .23 0 .50 0 .19 2198 .34 330 9 .56 0 .25 0 .10 3157 .99 240 15 .26 0 .10 0 .07 3667 .49 FIGURE 47 - Injection Speed 22 Gravi-Tech • Keep reducing the injection velocity until a fill time of 10-15 seconds is reached • Calculate the Relative Viscosity for each of the Injection Speeds using the equation above (Transfer Pressure * Fill Time) • Calculate the Relative Shear Rate for each of the injection speeds using the equation (1/Fill Time) • Plot the points on a graph and find the optimum velocity • The optimum velocity will be where the curve starts to level out In figure 48 above, the optimum velocity is where the plotted line crosses the black trend line; therefore the optimum velocity would be about 1 .00 in/sec .

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