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Case Studies
Case Study 1: Side Wall Deformation Control #
Measured correction to eliminate assembly risk before mass production.
#
Defect
Side wall deformation (measured out of tolerance)
Fix
Tooling-level correction + process window tuning
Outcome
Deformation reduced and verified; stable repeatable production
#
Before#
Measured side wall deformation created assembly/tolerance risk. 
After#
Deformation reduced and verified within the target tolerance window.
Measured side wall deformation created assembly/tolerance risk.
Deformation reduced and verified within the target tolerance window.
Issue #
Side wall deformation caused fitment and tolerance risk during assembly.
Root Cause #
Differential shrink + stress release after ejection, amplified by geometry and cooling imbalance.
Fix #
Measured deformation → tooling correction (support/slider/core) + refined packing/cooling window.
#Result: Deformation reduced and verified to meet customer requirement; production stabilized.
#Process note: Use a controlled packing/cooling window and verify repeatability with dimensional check after full cool-down.
Case Study 2: Flash Defect Elimination #
Structural reinforcement + sealing verification to permanently eliminate flash.
#
Defect
Flash at parting line / edge area
Fix
Added support pillars + verified parting-line contact
Outcome
Flash eliminated; stable production and shipment
#
Before#
Flash observed along parting line during sampling. 
Finding#
Large mold deflection risk due to insufficient internal support. 
Fix#
Added pillars + parting line verification to restore sealing. 
Result#
Flash eliminated; production approved and shipped.
Flash observed along parting line during sampling.
Large mold deflection risk due to insufficient internal support.
Added pillars + parting line verification to restore sealing.
Flash eliminated; production approved and shipped.
Issue #
Flash increased trimming/scrap and created sharp edge & cosmetic risk.
Root Cause #
Large mold deflection under injection pressure due to insufficient support pillars.
Fix #
Added support pillars + verified parting-line contact to restore sealing under pressure.
#Result: Flash eliminated and verified; production stabilized and shipped.
#Process note: Keep clamp & packing profile stable; avoid pressure spikes that can reopen weak shut-off regions.
Case Study 3: Internal Bubble Elimination (Thick-Wall Transparent PC) #
Process tuning + fan-gate freeze-time verification to eliminate internal voids in a transparent PC thick-wall area.
#
Defect
Internal bubble / vacuum void (inside thick section)
Fix
Higher mold temp + optimized packing profile (fan gate)
Outcome
Void eliminated, stable repeatable production
#
Geometry#
Thick-wall transparent PC section. Differential cooling risk is high in the thick area. 
Before#
Internal bubble observed in the thick section (surface may look OK, void is inside). 
After#
No internal bubble after thermal + packing optimization (material unchanged). 
Comparison#
Before/after verification: internal bubbles eliminated in thick-wall areas.
Thick-wall transparent PC section. Differential cooling risk is high in the thick area.
Internal bubble observed in the thick section (surface may look OK, void is inside).
No internal bubble after thermal + packing optimization (material unchanged).
Before/after verification: internal bubbles eliminated in thick-wall areas.
Issue #
Internal bubbles appeared during sampling in the thick-wall transparent area, creating optical rejection risk.
Root Cause #
Outer skin froze early while the core continued to shrink; packing window was insufficient for the thick section.
Fix #
Increase mold temperature and optimize packing profile using fan-gate freeze-time verification.
#Result: Internal voids eliminated and production stabilized.
#Process settings (verified on-site): Material PC · Fan gate thickness 3–4mm · Melt 300°C · Mold 110°C · High injection speed · Packing pressure ~100 MPa · Packing time up to 60s (validated)
