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I spent a few years as an IMD specialist for a Tekra and Bayer films. The most helpful advice I can offer is to get all parties involved at the very beginning of the design phase- tooling, moulding, mould supplier, mould printer, mould former/trimmed (if not being done in house). Both the part and all the related tooling need to be designed as a team for a good chance of success- retrofitting for IMD after the fact is almost always a recipe for failure. If at all possible, make sure all partners in the project have IMD/IML background.

Injection Moulding company is a leader among mould makers. Our main focus is creating the highest quality products. Injection Moulding company is an america injection mould company. Our company concentrates on mould design and mould manufacture. The main products are Plastic Injection Mould, Injection Moulding and Custom Moulds.

Although these types of COP typically do not need drying, for optical applications a low temperature -20~-40 dew point air can be circulated to eliminate surface moisture prior to processing. It would be helpful to have information on what exactly you are running in the mould and process. COP's have a higher specific heat and generally compared to PC or PMMA would require a longer cooling time (30%). It depends on what your moulding to determine if lowering temperatures, etc are acceptable. In my application we needed low stress flat parts that were 0.55mm thick and 120mm in length. However, we also had to mould grooves of 1000nm at .072mm track pitch. basically, lowering temps at the nozzle is simple, but I could not maintain groove replication. So the troubleshooting tips should be geared towards your application otherwise its a lot of good posts from an enormous amount of experience.

Underling problem is we all can make a damn good chair. The Wall-marts of the world will not allow it as it would be a chair that 1) last 2) durable 3) recyclable friendly and last 4) will make a chair that will last 15 years. Mould cost would be $20 per chair vs. $5.99. With our current retail market / industry / society and wanting something cheep - forces us all to make a finished product to last minimum time, forcing society to buy again and again. Good for overall economy - well - yes. I went to a golf driving range this past Saturday. Was letting my kids hit some balls. I was sitting in a "PP injection moulded chair". It was brand new - I leaned back - and the entire bottom seat and back legs buckled, I weight 205. Why - this is the highest quality the retail market will allow. I was born in 1961. My Mom was given an iron from her Mom. When I left the house in 1980, my Mom still was using the iron - yes cord was wrapped in electrical tape - but still good iron. We buy a new piece of shit iron every year that cost 500 times than a iron made in 1960. Different world. Now can we make resin for automotive, food grade, pharmaceutical better today than ever? Yes - different market.

"The dark ages", ( or moulding "before sensor technology" and process controls ), all that we could count on, were the known shrinkage rates for each resin as the starting point for your question. With this information, we would have to address "adhesion" with the draft and surface finish of the core and cavity. When we started to mould urethane resins, much of what we knew, ( or thought we knew ;-) ), really went out the window.Sensor technology and advanced process controls have come a long way, and I suspect the information that Duncan provided you is a really great start for you. I will read this information later myself, but do look forward to the responses from other group members.