Comprehensive Guide to PC Molding: Challenges and Solutions #
Course Overview #
Date and Time: 2025/08/05, 09:00–16:00
Duration: 6 hours
This physical course is designed to address the prevention and solution of appearance and structural problems in PC (polycarbonate) molding. The curriculum covers the following technical topics:
- PC material characteristics
- Molding principles
- Key considerations during molding
- Common molding problems and case analysis
- Systematic approaches to molding
- Appearance and structural issues in molded products
Fundamental Aspects of PC #
- Molecular Chain Composition and Material Properties
Understanding how the molecular structure of PC influences its physical properties. - Polyester Polar Materials
Characteristics and implications for processing. - Common PC Types
- General
- Flame retardant
- Halogen-free flame retardant
- High transparency (RF)
- Diffusion grade
- High toughness
- High rigidity
- High flow
- Low temperature resistance
- High impact resistance
- Chemical resistance
- UV resistance and high weather resistance
- Bisphenol A (BPA) Release and Impact
Considerations regarding BPA in PC materials. - Material Comparisons
Comparative analysis of PC with transparent ABS, PMMA, PETG, PES, PA12, and transparent PP. - Alloy Plastics
Overview of PC-based alloy plastics and their applications.
Principles of Injection Molding #
- PC Viscosity and Non-Newtonian Fluid Behavior
How PC’s flow characteristics affect molding. - Flow Layers in Molding
- Core layer
- Shear layer
- Cured skin layer
- Plastic Flow Characteristics
Key behaviors during the molding process.
Five Key Considerations for PC Molding #
- Product Design Precautions
- Flow length ratio
- Variations in wall thickness
- Design of transparent parts
- Raw Material Molding Characteristics
- Flame resistance
- Effects of additives
- Use of secondary materials
- Material temperature management
- Mold Structure Inspection Focus
- Template structure strength
- Exhaust design
- Gate type selection
- Machinery and Equipment Selection
- Differences between PC-specific and general material pipes
- Drying conditions for PC
- Molding Parameter Settings
- Influence of the molding curve
- Injection pressure and speed
- Pressure holding
- Mold temperature
Common PC Molding Problems and Case Analysis #
- Parameter Adjustment for Burrs and Shrinkage
How mold design and settings influence these defects. - Internal Stress Issues
Identifying and mitigating internal stress during molding. - Vacuum Bubble Formation
Causes and solutions for bubble defects. - Material Pipe-Induced Defects
Addressing black spots, black lines, and color inconsistencies. - Gate Trace Issues
How injection rate affects visible traces at the gate. - Post-Processing Defects
Challenges in painting, printing, electroplating, thermal transfer, and UV printing on PC parts.
Contact Information:
- Phone: +886-4-2436-0995
- Mobile: +886-983588477
- Fax: +886-4-2436-1547
- Address: No. 11-11, Jingzhong Ln., Beitun Dist., Taichung City 406001, Taiwan
- Email: heryow@heryow.com
For more information about our OEM/ODM Service, Capabilities, Applications, or Company Profile, please visit the respective pages.