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What defects of injection molding can the all electric injection molding machine solve?

2025/06/25 By Topstar

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Working with hydraulic injection molding machines is prone to injection molding defects such as warpage, material shortages, and dents, which can be reduced by switching to all electric injection molding machines. They are electrically driven and can provide tighter control over every stage of the entire process. At the same time, all electric injection molding machine can also adjust speed curves, employ multi-stage pressure control, and maintain consistent thermal management to address each defect. As well as being able to use servo motors to improve dimensional accuracy, increase injection speed, and reduce energy consumption and improve cycle time.

Eliminate warpage and dimensional variation with all electric injection molding machine.

Parts produced by hydraulic injection molding machines often exhibit warpage and dimensional inaccuracies due to inconsistent clamping forces and temperature fluctuations. All-electric injection molding machines address these issues by delivering precise and repeatable clamping forces through servo control. For example, Topstar’s electric injection molding machines can maintain clamping force within ±0.5% of the target value, ensuring uniform cavity compression; therefore, molded parts are consistently less likely to deform during cooling. Additionally, the rapid servo-driven screw movement stabilizes barrel and mold temperatures more effectively, minimizing heat buildup and preventing local hot spots. By leveraging these features, all electric injection molding machines achieve unprecedented dimensional stability in precision molding applications.

Eliminate warpage and dimensional variation

Preventing Short Shots and Incomplete Fill

The root cause of molten plastic failing to fill the mold cavity completely is insufficient injection speed, insufficient pressure, or cold material. All electric injection molding machines can effectively prevent short shots with their high-speed injection capabilities and multi-stage pressure control. They can utilize electric drive to accelerate quickly, up to 600 mm/s, to overcome viscous resistance in thin-walled or complex molds. Secondly, operators can define a multi-stage injection curve during operation to ramp up pressure precisely at critical fill percentages, preventing premature switching. Additionally, electric servo-driven screw positioning maintains a consistent injection volume, eliminating the fluctuations common in hydraulic systems. When you calibrate the injection peak pressure to within ±1 bar, you guarantee complete mold cavity filling, even with high-glass fiber composites. By deploying these precise speed and pressure controls, they can eliminate short shots in a variety of polymer systems and geometries.

Preventing Short Shots and Incomplete Fill

Reduce sink marks and internal stress with all electric injection molding machine.

Sink marks and internal stress occur when the molten plastic of the injection molding machine cools unevenly or under-packs. With all electric injection molding machines, I can solve these problems by programming precise packing profiles and optimizing cooling times. In addition to high-speed filling, you set the packing pressure to match the cavity pressure profile. This ensures the packing and holding phases counteract material shrinkage, virtually eliminating sink marks in thick sections. In addition, the fast response of electric injection molding machines enables shorter and more frequent packing cycles, which evenly distributes pressure and reduces residual stress. Operators can use real-time cavity pressure feedback during production to dynamically adjust packing time, eliminating stress points from over- or under-packing. By fine-tuning the packing phase with servo precision, all-electric injection molding machines can produce parts with smooth surfaces and minimal internal strain.

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Eliminate flash and over-packing

Flash is caused by the injection molding machine’s uncontrolled injection speed or excessive clamping force. Traditional hydraulic injection molding machines often exceed target pressure, causing flash even with perfect mold alignment. If you use an all electric injection molding machine, you can avoid this situation by strictly controlling the screw movement and immediately cutting off the pressure. The electric drive can record the position and torque in real-time to achieve precise switching between filling and holding pressure.

The ability to set the switching threshold based on the actual cavity pressure feedback allows for immediate stopping of the injection at the exact moment when the mold seal is formed. Additionally, their clamping mechanism applies only the necessary tonnage to maintain the seal without excessively stressing the mold. Fine motion control combined with closed-loop feedback eliminates flash, cutting scrap rates and slashing mold maintenance costs.

Preventing ejection and burn marks

High injection speeds and localized heating can cause ejection and burn marks caused by trapped air. All electric injection molding machines address these defects with customizable injection acceleration profiles and precise exhaust control. For example, operators can program a two-stage acceleration profile, first fast filling, then gate-zone deceleration to stabilize the fluid front. This method prevents ejection pattern formation. Additionally, the electric servo-driven screw back pressure maintains optimal melt uniformity and reduces cavitation, which can cause burn marks. When you equip your mold with appropriately sized vents and synchronize the vent opening time with the injection speed profile, you ensure that trapped air escapes before the melt front passes through. By combining advanced motion control with mold venting strategies, all-electric injection molding machines can produce flawless, high-gloss surfaces.

Reduce defects in production.

With the precision of their servo drives, real-time feedback, and programmable motion trajectories, all electric injection molding machines can solve a range of molding defects, including warpage, underfill, sink marks, flash, ejection, and burning. Additionally, you can utilize multi-stage injection speeds to prevent incomplete filling, calibrate holding pressure to eliminate sink marks, apply precise clamping force to minimize flash and synchronize venting with decelerated filling to prevent ejection. Additionally, they are more energy-efficient and repeatable, which reduces operating costs and improves part quality.

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